Nissan - Note - Workshop Manual - 2012 - 2012

ACCELERATOR CONTROL SYSTEM B ENGINE SECTION ACC ACCELERATOR CONTROL SYSTEM A ACC C D CONTENTS ACCELERATOR CONTROL SYSTEM ...................... 2 Removal and Installation .......................................... 2 REMOVAL ............................................................. 2 INSTALLATION ..................................................... 2 INSPECTION AFTER INSTALLATION ................. 2 SERVICE DATA AND SPECIFICATIONS (SDS) ........ 3 Tightening Torque ..................................................... 3 E F G H I J K L M ACC-1 ACCELERATOR CONTROL SYSTEM ACCELERATOR CONTROL SYSTEM Removal and Installation PFP:18005 BBS003Z9 PBIC1506E 1. Accelerator pedal assembly 2. Accelerator pedal stopper (Under floor carpet) REMOVAL 1. Remove harness connector. 2. Remove mounting bolts, and remove accelerator assembly. CAUTION: ● Do not disassemble accelerator pedal assembly and remove sensors. ● Handle them carefully without subjecting them to impacts such as dropping. ● Be careful not to get it wet. 3. Fold the floor carpet and remove accelerator pedal stopper. ● Remove pedal stopper by turning it counterclockwise with fingers. INSTALLATION Install in the reverse order of removal. be careful of the following: ● Insert locating pin into vehicle side to position accelerator pedal assembly. Install mounting bolt to accelerator pedal assembly. ● Align the stud bolt on the floor with the thread hole to insert accelerator pedal stopper until it contacts the face. INSPECTION AFTER INSTALLATION ● ● ● ● Check that the accelerator pedal moves smoothly within the whole operation range. Check that the accelerator pedal securely returns to the original position. For the electrical inspection of the accelerator pedal assembly, refer to EC-409, "DTC P2138 APP SENSOR" (CR WITH EURO-OBD), EC-725, "DTC P2138 APP SENSOR" (CR WITHOUT EURO-OBD) and EC-1197, "DTC P2138 APP SENSOR" (HR WITH EURO-OBD), EC-1517, "DTC P2138 APP SENSOR" (HR WITHOUT EURO-OBD) or “Interpretation”, “DIESEL INJECTION” in EC section(K9K). When accelerator electrical connector is disconnected, perform EC-69, "Accelerator Pedal Released Position Learning" (CR WITH EURO-OBD), EC-486, "Accelerator Pedal Released Position Learning" (CR WITHOUT EURO-OBD) and EC-857, "Accelerator Pedal Released Position Learning" (HR WITH EURO-OBD), EC-1278, "Accelerator Pedal Released Position Learning" (HR WITHOUT EURO-OBD). ACC-2 SERVICE DATA AND SPECIFICATIONS (SDS) SERVICE DATA AND SPECIFICATIONS (SDS) Tightening Torque PFP:00030 A BBS003ZA Unit: N·m (kg-m, in-lb) Accelerator pedal assembly 4.3 - 5.9 (0.44 - 0.60, 38 - 52) ACC C D E F G H I J K L M ACC-3 SERVICE DATA AND SPECIFICATIONS (SDS) ACC-4 AUTOMATIC TRANSAXLE C TRANSMISSION/TRANSAXLE SECTION AT AUTOMATIC TRANSAXLE A B AT D E CONTENTS APPLICATION NOTICE .............................................. 6 How to Check Vehicle Type ..................................... 6 INDEX FOR DTC ........................................................ 7 Alphabetical Index .................................................... 7 DTC No. Index (For EURO-OBD models Only) ....... 9 PRECAUTIONS ........................................................ 10 Precautions for Supplemental Restraint System (SRS) “AIR BAG” and “SEAT BELT PRE-TENSIONER” ................................................................ 10 PrecautionsNecessaryforSteeringWheelRotation After Battery Disconnect ........................................ 10 PrecautionsforOnBoardDiagnostic(OBD)System of A/T and Engine (For EURO-OBD models Only)....11 Precautions .............................................................11 Service Notice or Precautions ................................ 12 PREPARATION ......................................................... 14 Special Service Tools ............................................. 14 Commercial Service Tools ...................................... 16 A/T FLUID ................................................................. 18 Checking A/T Fluid ................................................. 18 Changing A/T Fluid ................................................ 19 A/T CONTROL SYSTEM .......................................... 20 Cross-Sectional View ............................................. 20 Shift Mechanism ..................................................... 21 TCM Function ......................................................... 30 Input/Output Signal of TCM .................................... 31 Line Pressure Control ............................................ 32 Shift Control ........................................................... 33 Lock-up Control ...................................................... 34 Engine Brake Control (Overrun Clutch Control) ..... 35 Control Valve .......................................................... 37 Centrifugal Cancel Mechanism .............................. 38 CAN COMMUNICATION .......................................... 39 System Description ................................................ 39 CAN Communication Unit ...................................... 39 TROUBLE DIAGNOSIS ............................................ 40 DTC Inspection Priority Chart ................................ 40 Fail-safe ................................................................. 40 How to Perform Trouble Diagnoses for Quick and Accurate Repair ..................................................... 42 A/T Electrical Parts Location .................................. 50 Circuit Diagram ....................................................... 52 Inspections Before Trouble Diagnosis .................... 53 Road Test ............................................................... 58 Check Before Engine is Started .............................. 58 Check at Idle ........................................................... 59 Cruise Test — Part 1 .............................................. 61 Cruise Test — Part 2 .............................................. 64 Cruise Test — Part 3 .............................................. 65 Vehicle Speed at Which Gear Shifting Occurs ....... 67 Vehicle Speed at Which Lock-up Occurs/Releases... 67 Symptom Chart ....................................................... 68 TCM Terminals and Reference Value ..................... 80 CONSULT-II Function (A/T) .................................... 83 Diagnostic Procedure Without CONSULT-II ........... 94 EURO-OBD ON BOARD DIAGNOSTIC (OBD) SYSTEM ............ 98 Introduction ............................................................. 98 OBD Function for A/T System ................................ 98 One or Two Trip Detection Logic of OBD ............... 98 OBD Diagnostic Trouble Code (DTC) .................... 98 Malfunction Indicator Lamp (MIL) ......................... 101 DTC U1000 CAN COMMUNICATION LINE ............ 102 Description ............................................................ 102 On Board Diagnosis Logic .................................... 102 Possible Cause ..................................................... 102 DTC Confirmation Procedure ............................... 102 Wiring Diagram — AT — CAN .............................. 103 Diagnostic Procedure ........................................... 104 DTC P0705 PARK/NEUTRAL POSITION (PNP) SWITCH .................................................................. 105 Description ............................................................ 105 CONSULT-II Reference Value .............................. 105 On Board Diagnosis Logic .................................... 105 Possible Cause ..................................................... 105 DTC Confirmation Procedure ............................... 105 Wiring Diagram — AT — PNP/SW ....................... 106 AT-1 F G H I J K L M Diagnostic Procedure ........................................... 107 Component Inspection .......................................... 109 DTC P0710 A/T FLUID TEMPERATURE SENSOR CIRCUIT .................................................................. 110 Description ............................................................ 110 CONSULT-II Reference Value .............................. 110 On Board Diagnosis Logic .................................... 110 Possible Cause ..................................................... 110 DTC Confirmation Procedure ............................... 110 Wiring Diagram — AT — FTS ................................111 Diagnostic Procedure ........................................... 112 Component Inspection .......................................... 114 DTC P0720 VEHICLE SPEED SENSOR·A/T (REVOLUTION SENSOR) ............................................... 115 Description ............................................................ 115 CONSULT-II Reference Value .............................. 115 On Board Diagnosis Logic .................................... 115 Possible Cause ..................................................... 115 DTC Confirmation Procedure ............................... 115 Wiring Diagram — AT — VSSA/T ......................... 117 Diagnostic Procedure ........................................... 118 DTC P0725 ENGINE SPEED SIGNAL ................... 121 Description ............................................................ 121 CONSULT-II Reference Value .............................. 121 On Board Diagnosis Logic .................................... 121 Possible Cause ..................................................... 121 DTC Confirmation Procedure ............................... 121 Wiring Diagram — AT — ENGSS ......................... 122 Diagnostic Procedure ........................................... 123 DTC P0731 A/T 1ST GEAR FUNCTION ................. 125 Description ............................................................ 125 On Board Diagnosis Logic .................................... 125 Possible Cause ..................................................... 125 DTC Confirmation Procedure ............................... 126 Diagnostic Procedure ........................................... 127 DTC P0732 A/T 2ND GEAR FUNCTION ................ 129 Description ............................................................ 129 On Board Diagnosis Logic .................................... 129 Possible Cause ..................................................... 129 DTC Confirmation Procedure ............................... 130 Diagnostic Procedure ........................................... 131 DTC P0733 A/T 3RD GEAR FUNCTION ................ 132 Description ............................................................ 132 On Board Diagnosis Logic .................................... 132 Possible Cause ..................................................... 132 DTC Confirmation Procedure ............................... 133 Diagnostic Procedure ........................................... 134 DTC P0734 A/T 4TH GEAR FUNCTION ................ 136 Description ............................................................ 136 CONSULT-II Reference Value .............................. 136 On Board Diagnosis Logic .................................... 136 Possible Cause ..................................................... 136 DTC Confirmation Procedure ............................... 137 Diagnostic Procedure ........................................... 138 DTC P0740 TORQUE CONVERTER CLUTCH SOLENOID VALVE ................................................. 142 Description ............................................................ 142 CONSULT-II Reference Value .............................. 142 On Board Diagnosis Logic .................................... 142 Possible Cause ..................................................... 142 DTC Confirmation Procedure ................................ 142 Wiring Diagram — AT — TCV .............................. 143 Diagnostic Procedure ............................................ 144 Component Inspection ..........................................146 DTC P0744 A/T TCC S/V FUNCTION (LOCK-UP) .147 Description ............................................................ 147 CONSULT-II Reference Value ............................... 147 On Board Diagnosis Logic .................................... 147 Possible Cause ..................................................... 147 DTC Confirmation Procedure ................................ 148 Diagnostic Procedure ............................................ 149 DTC P0745 LINE PRESSURE SOLENOID VALVE.153 Description ............................................................ 153 CONSULT-II Reference Value ............................... 153 On Board Diagnosis Logic .................................... 153 Possible Cause ..................................................... 153 DTC Confirmation Procedure ................................ 153 Wiring Diagram — AT — LPSV ............................ 154 Diagnostic Procedure ............................................ 155 Component Inspection ..........................................158 DTC P0750 SHIFT SOLENOID VALVE A ............... 159 Description ............................................................ 159 CONSULT-II Reference Value ............................... 159 On Board Diagnosis Logic .................................... 159 Possible Cause ..................................................... 159 DTC Confirmation Procedure ................................ 159 Wiring Diagram — AT — SSV/A ........................... 160 Diagnostic Procedure ............................................ 161 Component Inspection ..........................................163 DTC P0755 SHIFT SOLENOID VALVE B ............... 164 Description ............................................................ 164 CONSULT-II Reference Value ............................... 164 On Board Diagnosis Logic .................................... 164 Possible Cause ..................................................... 164 DTC Confirmation Procedure ................................ 164 Wiring Diagram — AT — SSV/B ........................... 165 Diagnostic Procedure ............................................ 166 Component Inspection ..........................................168 DTC P1705 ACCELERATOR PEDAL POSITION (APP) SENSOR ....................................................... 169 Description ............................................................ 169 CONSULT-II Reference Value ............................... 169 On Board Diagnosis Logic .................................... 169 Possible Cause ..................................................... 169 DTC Confirmation Procedure ................................ 169 Diagnostic Procedure ............................................ 170 DTC P1760 OVERRUN CLUTCH SOLENOID VALVE ...................................................................... 171 Description ............................................................ 171 CONSULT-II Reference Value ............................... 171 On Board Diagnosis Logic .................................... 171 Possible Cause ..................................................... 171 DTC Confirmation Procedure ................................ 171 Wiring Diagram — AT — OVRCSV ...................... 172 Diagnostic Procedure ............................................ 173 Component Inspection ..........................................175 DTC VEHICLE SPEED SENSOR MTR ................... 176 Description ............................................................ 176 AT-2 CONSULT-II Reference Value .............................. 176 On Board Diagnosis Logic ................................... 176 Possible Cause .................................................... 176 DTC Confirmation Procedure ............................... 176 Wiring Diagram — AT — VSSMTR ...................... 177 Diagnostic Procedure ........................................... 178 DTC BATT/FLUID TEMP SEN (A/T FLUID TEMP SENSOR CIRCUIT AND TCM POWER SOURCE). 180 Description ........................................................... 180 CONSULT-II Reference Value .............................. 180 On Board Diagnosis Logic ................................... 180 Possible Cause .................................................... 180 DTC Confirmation Procedure ............................... 180 Wiring Diagram — AT — BA/FTS ........................ 181 Diagnostic Procedure ........................................... 182 Component Inspection ......................................... 185 DTC TURBINE REVOLUTION SENSOR ............... 186 Description ........................................................... 186 CONSULT-II Reference Value .............................. 186 On Board Diagnosis Logic ................................... 186 Possible Cause .................................................... 186 DTC Confirmation Procedure ............................... 186 Wiring Diagram — AT — PT/SEN ........................ 187 Diagnostic Procedure ........................................... 188 CONTROL UNIT (RAM), CONTROL UNIT (ROM). 192 Description ........................................................... 192 On Board Diagnosis Logic ................................... 192 Possible Cause .................................................... 192 DTC Confirmation Procedure ............................... 192 Diagnostic Procedure ........................................... 192 MAIN POWER SUPPLY AND GROUND CIRCUIT. 193 Description ........................................................... 193 On Board Diagnosis Logic ................................... 193 Possible Cause .................................................... 193 DTC Confirmation Procedure ............................... 193 Wiring Diagram — AT — MAIN ............................ 194 Diagnostic Procedure ........................................... 195 PNP, OD SWITCH AND CLOSED THROTTLE, WIDE OPEN THROTTLE POSITION SIGNAL CIRCUIT ........................................................................ 197 CONSULT-II Reference Value .............................. 197 TCM Terminals and Reference Value ................... 197 Diagnostic Procedure ........................................... 198 Component Inspection ......................................... 202 EXC.F/EURO-OBD VEHICLE SPEED SENSOR·A/T (REVOLUTION SENSOR) ................................................................ 203 Description ........................................................... 203 CONSULT-II Reference Value .............................. 203 On Board Diagnosis Logic ................................... 203 Possible Cause .................................................... 203 DTC Confirmation Procedure ............................... 203 Wiring Diagram — AT — VSSAT ......................... 205 Diagnostic Procedure ........................................... 206 VEHICLE SPEED SENSOR MTR .......................... 209 Description ........................................................... 209 CONSULT-II Reference Value .............................. 209 On Board Diagnosis Logic .................................... 209 Possible Cause ..................................................... 209 DTC Confirmation Procedure ............................... 209 Wiring Diagram — AT — VSSMTR ...................... 210 Diagnostic Procedure ........................................... 211 ACCELERATOR PEDAL POSITION (APP) SENSOR ......................................................................... 213 Description ............................................................ 213 CONSULT-II Reference Value .............................. 213 On Board Diagnosis Logic .................................... 213 Possible Cause ..................................................... 213 DTC Confirmation Procedure ............................... 213 Diagnostic Procedure ........................................... 214 SHIFT SOLENOID VALVE A .................................. 215 Description ............................................................ 215 CONSULT-II Reference Value .............................. 215 On Board Diagnosis Logic .................................... 215 Possible Cause ..................................................... 215 DTC Confirmation Procedure ............................... 215 Wiring Diagram — AT — SSV/A ........................... 216 Diagnostic Procedure ........................................... 217 Component Inspection .......................................... 219 SHIFT SOLENOID VALVE B .................................. 220 Description ............................................................ 220 CONSULT-II Reference Value .............................. 220 On Board Diagnosis Logic .................................... 220 Possible Cause ..................................................... 220 DTC Confirmation Procedure ............................... 220 Wiring Diagram — AT — SSV/B ........................... 221 Diagnostic Procedure ........................................... 222 Component Inspection .......................................... 224 OVERRUN CLUTCH SOLENOID VALVE ............... 225 Description ............................................................ 225 CONSULT-II Reference Value .............................. 225 On Board Diagnosis Logic .................................... 225 Possible Cause ..................................................... 225 DTC Confirmation Procedure ............................... 225 Wiring Diagram — AT — OVRCSV ...................... 226 Diagnostic Procedure ........................................... 227 Component Inspection .......................................... 229 TORQUE CONVERTER CLUTCH SOLENOID VALVE ..................................................................... 230 Description ............................................................ 230 CONSULT-II Reference Value .............................. 230 On Board Diagnosis Logic .................................... 230 Possible Cause ..................................................... 230 DTC Confirmation Procedure ............................... 230 Wiring Diagram — AT — TCV .............................. 231 Diagnostic Procedure ........................................... 232 Component Inspection .......................................... 234 BATT/FLUID TEMP SEN (A/T FLUID TEMP SENSOR CIRCUIT AND TCM POWER SOURCE) ....... 235 Description ............................................................ 235 CONSULT-II Reference Value .............................. 235 On Board Diagnosis Logic .................................... 235 Possible Cause ..................................................... 235 DTC Confirmation Procedure ............................... 235 Wiring Diagram — AT — BA/FTS ......................... 236 AT-3 A B AT D E F G H I J K L M Diagnostic Procedure ........................................... 237 Component Inspection .......................................... 240 ENGINE SPEED SIGNAL ....................................... 241 Description ............................................................ 241 CONSULT-II Reference Value .............................. 241 On Board Diagnosis Logic .................................... 241 Possible Cause ..................................................... 241 DTC Confirmation Procedure ............................... 241 Wiring Diagram — AT — ENGSS ......................... 242 Diagnostic Procedure ........................................... 243 TURBINE REVOLUTION SENSOR ........................ 245 Description ............................................................ 245 CONSULT-II Reference Value .............................. 245 On Board Diagnosis Logic .................................... 245 Possible Cause ..................................................... 245 DTC Confirmation Procedure ............................... 245 Wiring Diagram — AT — PT/SEN ........................ 246 Diagnostic Procedure ........................................... 247 LINE PRESSURE SOLENOID VALVE ................... 251 Description ............................................................ 251 CONSULT-II Reference Value .............................. 251 On Board Diagnosis Logic .................................... 251 Possible Cause ..................................................... 251 DTC Confirmation Procedure ............................... 251 Wiring Diagram — AT — LPSV ............................ 252 Diagnostic Procedure ........................................... 253 Component Inspection .......................................... 256 CAN COMMUNICATION LINE ................................ 257 Description ............................................................ 257 On Board Diagnosis Logic .................................... 257 Possible Cause ..................................................... 257 DTC Confirmation Procedure ............................... 257 Wiring Diagram — AT — CAN .............................. 258 Diagnostic Procedure ........................................... 259 MAIN POWER SUPPLY AND GROUND CIRCUIT. 260 Description ............................................................ 260 On Board Diagnosis Logic .................................... 260 Possible Cause ..................................................... 260 DTC Confirmation Procedure ............................... 260 Wiring Diagram — AT — MAIN ............................ 261 Diagnostic Procedure ........................................... 262 A/T 1ST GEAR FUNCTION .................................... 264 Description ............................................................ 264 On Board Diagnosis Logic .................................... 264 Possible Cause ..................................................... 264 DTC Confirmation Procedure ............................... 265 Diagnostic Procedure ........................................... 266 A/T 2ND GEAR FUNCTION .................................... 268 Description ............................................................ 268 On Board Diagnosis Logic .................................... 268 Possible Cause ..................................................... 268 DTC Confirmation Procedure ............................... 269 Diagnostic Procedure ........................................... 270 A/T 3RD GEAR FUNCTION .................................... 271 Description ............................................................ 271 On Board Diagnosis Logic .................................... 271 Possible Cause ..................................................... 271 DTC Confirmation Procedure ............................... 272 Diagnostic Procedure ........................................... 273 A/T 4TH GEAR FUNCTION ....................................275 Description ............................................................ 275 On Board Diagnosis Logic .................................... 275 Possible Cause ..................................................... 275 DTC Confirmation Procedure ................................ 276 Diagnostic Procedure ............................................ 277 A/T TCC S/V FUNCTION (LOCK-UP) ..................... 281 Description ............................................................ 281 CONSULT-II Reference Value ............................... 281 On Board Diagnosis Logic .................................... 281 Possible Cause ..................................................... 281 DTC Confirmation Procedure ................................ 282 Diagnostic Procedure ............................................ 283 CONTROL UNIT (RAM), CONTROL UNIT (ROM) .287 Description ............................................................ 287 On Board Diagnosis Logic .................................... 287 Possible Cause ..................................................... 287 DTC Confirmation Procedure ................................ 287 Diagnostic Procedure ............................................ 287 PNP, OD SWITCH AND CLOSED THROTTLE, WIDE OPEN THROTTLE POSITION SIGNAL CIRCUIT ......................................................................... 288 CONSULT-II Reference Value ............................... 288 TCM Terminals and Reference Value ................... 288 Diagnostic Procedure ............................................ 289 Component Inspection ..........................................293 ALL TROUBLE DIAGNOSIS FOR SYMPTOMS ............ 294 Wiring Diagram — AT — NONDTC ...................... 294 EXC.F/EURO-OBD ............................................... 296 OD OFF Indicator Lamp Does Not Come On ....... 299 Engine Cannot Be Started in “P” and “N” Position.301 In“P” Position,VehicleMoves Forwardor Backward When Pushed ....................................................... 302 In “N” Position, Vehicle Moves .............................. 302 Large Shock “N” → “R” Position ........................... 303 Vehicle Does Not Creep Backward in “R” Position.304 Vehicle Does Not Creep Forward in “D”, “2” or “1” Position ................................................................. 306 Vehicle Cannot Be Started from D1 ....................... 307 A/T Does Not Shift: D1 → D2 or Does Not Kickdown: D4 → D2 ................................................................ 309 A/T Does Not Shift: D2 → D3 ................................ 311 A/T Does Not Shift: D3 → D4 ................................ 314 A/T Does Not Perform Lock-up ............................. 316 A/T Does Not Hold Lock-up Condition .................. 317 Lock-up Is Not Released ....................................... 318 Engine Speed Does Not Return to Idle (Light Braking D4 → D3 ) ........................................................ 318 A/T Does Not Shift: D4 → D3 , When OD OFF ..... 320 A/T Does Not Shift: D3 → 22 , When Selector Lever “D” → “2” Position ................................................. 321 A/T Does Not Shift: 22 → 11 , When Selector Lever “2” → “1” Position .................................................. 323 Vehicle Does Not Decelerate by Engine Brake ..... 325 TCM Self-diagnosis Does Not Activate ................. 329 AT-4 TRANSMISSION CONTROL MODULE ................. 330 Removal and Installation (LHD) ........................... 330 Removal and Installation (RHD) ........................... 331 SHIFT CONTROL SYSTEM ................................... 332 Control Device Removal and Installation ............. 332 Control Device Disassembly and Assembly ......... 335 Selector Lever Knob Removal and Installation .... 336 Adjustment of A/T Position ................................... 336 Checking of A/T Position ...................................... 337 A/T SHIFT LOCK SYSTEM .................................... 338 Description ........................................................... 338 Shift Lock System Parts Location ........................ 338 Wiring Diagram — AT — SHIFT ........................... 339 Diagnostic Procedure ........................................... 340 KEY INTERLOCK CABLE ..................................... 342 Removal and Installation ...................................... 342 ON-VEHICLE SERVICE ......................................... 345 Control Valve Assembly and Accumulators .......... 345 Park/Neutral Position (PNP) Switch ..................... 349 Revolution Sensor ................................................ 350 TurbineRevolutionSensor(PowerTrainRevolution Sensor) ................................................................. 351 Differential Side Oil Seal ...................................... 353 AIR BREATHER HOSE .......................................... 355 Removal and Installation ...................................... 355 TRANSAXLE ASSEMBLY ...................................... 356 Removal and Installation ...................................... 356 OVERHAUL ............................................................ 360 Components ......................................................... 360 Oil Channel .......................................................... 366 Locations of Adjusting Shims, Needle Bearings and Thrust Washers .................................................... 367 Locations of Snap Rings ...................................... 368 DISASSEMBLY ....................................................... 369 Disassembly ......................................................... 369 REPAIR FOR COMPONENT PARTS ..................... 384 Manual Shaft ........................................................ 384 Oil Pump .............................................................. 388 Control Valve Assembly ....................................... 392 Control Valve Upper Body .................................... 401 Control Valve Lower Body .................................... 405 Reverse Clutch ..................................................... 408 High Clutch ........................................................... 413 Forward and Overrun Clutches ............................ 419 Low & Reverse Brake ........................................... 426 Rear Internal Gear and Forward Clutch Hub ........ 431 Output Shaft, Output Gear, Idler Gear, Reduction Pinion Gear and Bearing Retainer ........................ 435 Band Servo Piston Assembly ............................... 441 Final Drive ............................................................ 447 ASSEMBLY ............................................................. 452 Assembly (1) ......................................................... 452 Adjustment (1) ...................................................... 453 Assembly (2) ......................................................... 457 Adjustment (2) ...................................................... 462 Assembly (3) ......................................................... 465 SERVICE DATA AND SPECIFICATIONS (SDS) .... 474 General Specifications .......................................... 474 Vehicle Speed at Which Gear Shifting Occurs ..... 474 Vehicle Speed at When Lock-up Occurs/Releases. 474 Stall Speed ........................................................... 474 Line Pressure ....................................................... 474 Adjusting shims, Needle Bearings, Thrust Washers and Snap Rings .................................................... 475 Control Valves ...................................................... 476 Accumulator .......................................................... 476 Clutches and Brakes ............................................ 476 Final Drive ............................................................ 478 Planetary Carrier .................................................. 478 Oil Pump ............................................................... 478 Input Shaft ............................................................ 478 Reduction Pinion Gear ......................................... 478 Band Servo ........................................................... 478 Output Shaft ......................................................... 478 Bearing Retainer ................................................... 479 Total End Play ....................................................... 479 Reverse Clutch End Play ...................................... 479 Removal and Installation ...................................... 479 Shift Solenoid Valves ............................................ 479 Solenoid Valves .................................................... 479 A/T Fluid Temperature Sensor .............................. 479 Revolution Sensor ................................................ 479 Dropping Resistor ................................................. 479 TurbineRevolutionSensor(PowerTrainRevolution Sensor) ................................................................. 479 AT-5 A B AT D E F G H I J K L M APPLICATION NOTICE APPLICATION NOTICE How to Check Vehicle Type PFP:00000 BCS000N5 Check the Euro-OBD (E-OBD) discrimination of the vehicle (refer to GI-45, "IDENTIFICATION INFORMATION" ) to confirm the service information in AT section. AT-6 INDEX FOR DTC INDEX FOR DTC Alphabetical Index PFP:00024 A BCS000N6 NOTE: If DTC “CAN COMM CIRCUIT” is displayed with other DTCs, first perform the trouble diagnosis for DTC “CAN COMM CIRCUIT”. Refer to AT-102 (EURO-OBD models) or AT-257 (Except EURO-OBD models). EURO-OBD MODELS B AT DTC Items (CONSULT-II screen terms) CONSULT-II or GST*1 Reference page D A/T 1ST GR FNCTN P0731 AT-125 A/T 2ND GR FNCTN P0732 AT-129 A/T 3RD GR FNCTN P0733 AT-132 A/T 4TH GR FNCTN P0734 AT-136 A/T TCC S/V FNCTN P0744 AT-147 ATF TEMP SEN/CIRC P0710 AT-110 — AT-180 U1000 AT-102 CONTROL UNIT (RAM) — AT-192 CONTROL UNIT (ROM) — AT-192 ENGINE SPEED SIG P0725 AT-121 LINE PRESSURE S/V P0745 AT-153 OVERRUN CLUTCH S/V P1760 AT-171 PNP SW/CIRC P0705 AT-105 SHIFT SOLENOID/V A*2 P0750 AT-159 SHIFT SOLENOID/V B*2 P0755 AT-164 T/C CLUTCH SOL/V P0740 AT-142 THROTTLE POSI SEN*2 P1705 AT-169 — AT-186 VHCL SPEED SEN-A/T*3 P0720 AT-115 VHCL SPEED SEN-MTR — AT-176 BATT/FLUID TEMP SEN CAN COMM CIRCUIT TURBINE SENSOR *1: This number is prescribed by ISO 15031-5. *2: When the fail-safe operation occurs, the MIL illuminates. *3: The MIL illuminates when both the “Revolution sensor signal” and the “Vehicle speed sensor signal” meet the fail-safe condition at the same time. AT-7 E F G H I J K L M INDEX FOR DTC EXCEPT EURO-OBD MODELS X: Applicable, —: Not applicable TCM self-diagnosis Items (CONSULT-II screen terms) Reference page OD OFF indicator lamp “A/T” with CONSULT-II A/T 1ST GR FNCTN — X AT-264 A/T 2ND GR FNCTN — X AT-268 A/T 3RD GR FNCTN — X AT-271 A/T 4TH GR FNCTN — X AT-275 A/T TCC S/V FNCTN — X AT-281 BATT/FLUID TEMP SEN X X AT-235 CAN COMM CIRCUIT X X AT-257 CONTROL UNIT (RAM) — X AT-287 CONTROL UNIT (ROM) — X AT-287 ENGINE SPEED SIG X X AT-241 LINE PRESSURE S/V X X AT-251 OVERRUN CLUTCH S/V X X AT-225 SHIFT SOLENOID/V A X X AT-215 SHIFT SOLENOID/V B X X AT-220 T/C CLUTCH SOL/V X X AT-230 THROTTLE POSI SEN X X AT-213 TURBINE SENSOR X X AT-245 VHCL SPEED SEN-A/T X X AT-203 VHCL SPEED SEN-MTR X X AT-209 AT-8 INDEX FOR DTC DTC No. Index (For EURO-OBD models Only) BCS000N7 NOTE: If DTC “CAN COMM CIRCUIT” is displayed with other DTCs, first perform the trouble diagnosis for DTC “CAN COMM CIRCUIT”. Refer to AT-102 (EURO-OBD models) or AT-257 (Except EURO-OBD models). DTC CONSULT-II or Items (CONSULT-II screen terms) GST*1 A B Reference page AT P0705 PNP SW/CIRC AT-105 P0710 ATF TEMP SEN/CIRC AT-110 P0720 VHCL SPEED SEN-A/T*3 AT-115 P0725 ENGINE SPEED SIG AT-121 P0731 A/T 1ST GR FNCTN AT-125 P0732 A/T 2ND GR FNCTN AT-129 P0733 A/T 3RD GR FNCTN AT-132 P0734 A/T 4TH GR FNCTN AT-136 P0740 T/C CLUTCH SOL/V AT-142 P0744 A/T TCC S/V FNCTN AT-147 P0745 LINE PRESSURE S/V AT-153 P0750 SHIFT SOLENOID/V A*2 AT-159 P0755 SHIFT SOLENOID/V B*2 AT-164 P1705 THROTTLE POSI SEN*2 AT-169 P1760 OVERRUN CLUTCH S/V AT-171 U1000 CAN COMM CIRCUIT AT-102 — BATT/FLUID TEMP SEN AT-180 — CONTROL UNIT (RAM) AT-192 — CONTROL UNIT (ROM) AT-192 — TURBINE SENSOR AT-186 — VHCL SPEED SEN-MTR AT-176 *1: This number is prescribed by ISO 15031-5. *2: When the fail-safe operation occurs, the MIL illuminates. *3: The MIL illuminates when both the “Revolution sensor signal” and the “Vehicle speed sensor signal” meet the fail-safe condition at the same time. D E F G H I J K L M AT-9 PRECAUTIONS PFP:00001 PRECAUTIONS Precautions for Supplemental Restraint System (SRS) “AIR BAG” and “SEAT BELT PRE-TENSIONER” BCS000N8 The Supplemental Restraint System such as “AIR BAG” and “SEAT BELT PRE-TENSIONER”, used along with a front seat belt, helps to reduce the risk or severity of injury to the driver and front passenger for certain types of collision. Information necessary to service the system safely is included in the SRS and SB section of this Service Manual. WARNING: ● To avoid rendering the SRS inoperative, which could increase the risk of personal injury or death in the event of a collision which would result in air bag inflation, all maintenance must be performed by an authorized NISSAN/INFINITI dealer. ● Improper maintenance, including incorrect removal and installation of the SRS, can lead to personal injury caused by unintentional activation of the system. For removal of Spiral Cable and Air Bag Module, see the SRS section. ● Do not use electrical test equipment on any circuit related to the SRS unless instructed to in this Service Manual. SRS wiring harnesses can be identified by yellow and/or orange harnesses or harness connectors. Precautions Necessary for Steering Wheel Rotation After Battery Disconnect BCS000N9 NOTE: ● This Procedure is applied only to models with Intelligent Key system and NATS (NISSAN ANTI-THEFT SYSTEM). ● Remove and install all control units after disconnecting both battery cables with the ignition knob in the ″LOCK″ position. ● Always use CONSULT-II to perform self-diagnosis as a part of each function inspection after finishing work. If DTC is detected, perform trouble diagnosis according to self-diagnostic results. For models equipped with the Intelligent Key system and NATS, an electrically controlled steering lock mechanism is adopted on the key cylinder. For this reason, if the battery is disconnected or if the battery is discharged, the steering wheel will lock and steering wheel rotation will become impossible. If steering wheel rotation is required when battery power is interrupted, follow the procedure below before starting the repair operation. OPERATION PROCEDURE 1. 2. 3. 4. 5. 6. Connect both battery cables. NOTE: Supply power using jumper cables if battery is discharged. Use the Intelligent Key or mechanical key to turn the ignition switch to the ″ACC″ position. At this time, the steering lock will be released. Disconnect both battery cables. The steering lock will remain released and the steering wheel can be rotated. Perform the necessary repair operation. When the repair work is completed, return the ignition switch to the ″LOCK″ position before connecting the battery cables. (At this time, the steering lock mechanism will engage.) Perform a self-diagnosis check of all control units using CONSULT-II. AT-10 PRECAUTIONS Precautions for On Board Diagnostic (OBD) System of A/T and Engine (For EURO-OBD models Only) BCS000NA A The ECM has an on board diagnostic system. It will light up the malfunction indicator lamp (MIL) to warn the driver of a malfunction causing emission deterioration. B CAUTION: ● Be sure to turn the ignition switch OFF and disconnect battery negative cable from battery negative terminal before any repair or inspection work. The open/short circuit of related switches, senAT sors, solenoid valves, etc. will cause the MIL to light up. ● Be sure to connect and lock the connectors securely after work. A loose (unlocked) connector will cause the MIL to light up due to an open circuit. (Be sure the connectors are free from water, grease, dirt, bent terminals, etc.) D ● Be sure to route and secure the harnesses properly after work. Interference of the harness with a bracket, etc. may cause the MIL to light up due to a short circuit. ● Be sure to erase the unnecessary malfunction information (repairs completed) from the TCM and E ECM before returning the vehicle to the customer. Precautions ● BCS000NB F Before connecting or disconnecting the TCM harness connector, turn ignition switch OFF and disconnect the battery cable from the negative terminal. Failure to do so may damage the TCM. Because battery voltage is applied to TCM even if ignition switch is turned off. G H I SEF289H ● When connecting or disconnecting pin connectors into or from TCM, take care not to damage pin terminals (bend or break). Make sure that there are not any bends or breaks on TCM pin terminal, when connecting pin connectors. J K L AAT470A ● ● ● ● ● ● Before replacing TCM, perform TCM input/output signal inspection and make sure whether TCM functions properly or not. (See page AT-80, "TCM Terminals and Reference Value".) After performing each TROUBLE DIAGNOSIS, perform “DTC (Diagnostic Trouble Code) Confirmation Procedure”. The DTC should not be displayed in the “DTC Confirmation Procedure” if the repair is completed. Before proceeding with disassembly, thoroughly clean the outside of the transaxle. It is important to prevent the internal parts MEF040DA from becoming contaminated by dirt or other foreign matter. Disassembly should be done in a clean work area. Use lint-free cloth or towels for wiping parts clean. Common shop rags can leave fibers that could interfere with the operation of the A/T. Place disassembled parts in order for easier and proper assembly. AT-11 M PRECAUTIONS ● ● ● ● ● ● ● ● ● All parts should be carefully cleaned with a general purpose, non-flammable solvent before inspection or reassembly. Gaskets, seals and O-rings should be replaced any time the A/T is disassembled. It is very important to perform functional tests whenever they are indicated. The valve body contains precision parts and requires extreme care when parts are removed and serviced. Place disassembled valve body parts in order for easier and proper assembly. Care will also prevent springs and small parts from becoming scattered or lost. Properly installed valves, sleeves, plugs, etc. will slide along bores in valve body under their own weight. Before assembly, apply a coat of recommended ATF to all parts. Apply petroleum jelly to protect O-rings and seals, or hold bearings and washers in place during assembly. Do not use grease. Extreme care should be taken to avoid damage to O-rings, seals and gaskets when assembling. After overhaul, refill the A/T with new ATF. When the A/T drain plug is removed, only some of the fluid is drained. Old A/T fluid will remain in torque converter and ATF cooling system. Always follow the procedures under “Changing A/T Fluid” in the AT section when changing A/T fluid. Refer to AT-19, "Changing A/T Fluid" , AT-18, "Checking A/T Fluid" . Service Notice or Precautions BCS000NC TORQUE CONVERTER SERVICE The torque converter should be replaced under any of the following conditions: ● External leaks in the hub weld area. ● Converter hub is scored or damaged. ● Converter pilot is broken, damaged or fits poorly into crankshaft. ● Steel particles are found after flushing the cooler and cooler lines. ● Pump is damaged or steel particles are found in the converter. ● Vehicle has TCC shudder and/or no TCC apply. Replace only after all hydraulic and electrical diagnoses have been made. (Converter clutch material may be glazed.) ● Converter is contaminated with engine coolant containing antifreeze. ● Internal malfunction of stator roller clutch. ● Heavy clutch debris due to overheating (blue converter). ● Steel particles or clutch lining material found in fluid filter or on magnet when no internal parts in unit are worn or damaged — indicates that lining material came from converter. The torque converter should not be replaced if: ● The fluid has an odor, is discolored, and there is no evidence of metal or clutch facing particles. ● The threads in one or more of the converter bolt holes are damaged. ● A/T malfunction did not display evidence of damaged or worn internal parts, steel particles or clutch plate lining material in unit and inside the fluid filter. ● Vehicle has been exposed to high mileage (only). The exception may be where the torque converter clutch dampener plate lining has seen excess wear by vehicles operated in heavy and/or constant traffic, such as taxi, delivery or police use. AT-12 PRECAUTIONS OBD SELF-DIAGNOSIS (FOR EURO-OBD MODELS ONLY) A/T self-diagnosis is performed by the TCM in combination with the ECM. The results can be read through A the blinking pattern of the OD OFF indicator lamp or the malfunction indicator lamp (MIL). Refer to the table on AT-95, "Judgement of Self-diagnosis Code" for the indicator used to display each self-diagnostic result. B ● The self-diagnostic results indicated by the MIL are automatically stored in both the ECM and TCM memories. Always perform the procedure “HOW TO ERASE DTC” on AT-99, "HOW TO ERASE DTC" to com- AT plete the repair and avoid unnecessary blinking of the MIL. ● The following self-diagnostic items can be detected using ECM self-diagnostic results mode* only when the OD OFF indicator lamp does not indicate any malfunctions. D – PNP switch – A/T 1st, 2nd, 3rd, or 4th gear function *: For details of OBD, refer to AT-98, "ON BOARD DIAGNOSTIC (OBD) SYSTEM" . E ● F G H I J K L M AT-13 PREPARATION PREPARATION Special Service Tools PFP:00100 BCS000NE Tool number Tool name Description ST2505S001 Oil pressure gauge set Measuring line pressure 1. ST25051001 Oil pressure gauge 2. ST25052000 Hose 3. ST25053000 Joint pipe 4. ST25054000 Adapter NT097 5. ST25055000 Adapter ST35325000 Drift a: 215 mm (8.46 in) b: 25 mm (0.98 in) dia. c: M12 X 1.5P Installing LH differential side oil seal (Use with KV31103000) SCIA7102E KV31103000 Drift a: 59 mm (2.32 in) dia. b: 49 mm (1.93 in) dia. Installing LH differential side oil seal (Use with ST35325000) SCIA7103E ST27180001 Puller a: 100 mm (3.94 in) b: 110 mm (4.33 in) c: M8 X 1.25P ● Removing idler gear ● Removing output gear ● Removing and installing clutch spring retainer assembly ● Removing and installing cancel cover ● Removing and installing retaining pin of manual plate ● Installing retaining pin of manual shaft ● Installing retaining pin of parking rod plate NT424 KV31103200 Clutch spring compressor a: 179 mm (7.05 in) b: 76 mm (2.99 in) dia. c: 174 mm (6.85 in) SCIA7104E ST23540000 Pin punch a: 2.3 mm (0.091 in) dia. b: 4 mm (0.16 in) dia. NT442 AT-14 PREPARATION Tool number Tool name Description KV32101000 Pin punch a: 4 mm (0.16 in) dia. A Removing and installing lock pin of pinion mate shaft B AT NT410 ST33400001 Drift a: 60 mm (2.36 in) dia. b: 47 mm (1.85 in) dia. ● Installing oil pump housing oil seal ● Installing output gear bearing outer race D E NT086 KV381054S0 Puller a: 250 mm (9.84 in) b: 160 mm (6.30 in) ● Removing output shaft bearing outer race ● Removing output gear bearing outer race ● Removing idler gear bearing outer race F G NT414 ST30031000 Puller a: 90 mm (3.54 in) dia. b: 50 mm (1.97 in) dia. Removing reduction pinion gear bearing inner race H I J NT411 ST35272000 Drift a: 72 mm (2.83 in) dia. b: 40 mm (1.57 in) dia. c: 35.5 mm (1.398 in) dia. ● Installing reduction pinion gear bearing inner race ● Installing idler gear bearing inner race ● Installing output gear bearing inner race K L NT107 ST37830000 Drift a: 61.9 mm (2.437 in) dia. b: 39 mm (1.54 in) dia. Installing idler gear bearing outer race M NT084 KV40104840 Drift a: 49 mm (1.93 in) dia. b: 42 mm (1.65 in) dia. Installing output shaft bearing outer race NT108 AT-15 PREPARATION Tool number Tool name Description ST33200000 Drift a: 60 mm (2.36 in) dia. b: 44.5 mm (1.752 in) dia. Installing differential side bearings NT091 ST35271000 Drift a: 72 mm (2.83 in) dia. b: 63 mm (2.48 in) dia. ● Installing idler gear ● Installing output gear ● Measuring turning torque of reduction pinion gear ● Measuring turning torque of output shaft NT115 ST3127S000 Preload gauge 1. GG9103000 Torque wrench 2. HT62940000 Socket adapter 3. HT62900000 Socket adapter NT124 Commercial Service Tools BCS000NF Tool name Description Drift a: 22 mm (0.87 in) dia. Installing manual shaft oil seal SCIA7105E Drift a: 54 mm (2.13 in) dia. b: 47 mm (1.85 in) dia. Installing RH differential side oil seal NT115 Drift a: 70 mm (2.76 in) dia. b: 40 mm (1.57 in) dia. c: 31 mm (1.22 in) dia. Removing and installing output shaft bearing inner race NT107 Puller NT077 AT-16 ● Removing output gear bearing inner race ● Removing idler gear bearing inner race ● Removing and installing band servo piston snap ring ● Removing differential side bearings PREPARATION Tool name Description Drift a: 33 mm (1.30 in) dia. Removing output gear bearing inner race A B AT SCIA7105E Drift a: 34 mm (1.34 in) dia. Removing idler gear bearing inner race D E SCIA7105E Drift a: 38 mm (1.50 in) dia. Removing differential side bearings F G SCIA7105E Puller Removing differential side bearing H I SCIA7106E Pin punch a: 2 mm (0.08 in) dia. Aligning groove of manual shaft and hole of transaxle case J K NT410 L M AT-17 A/T FLUID A/T FLUID Checking A/T Fluid 1. 2. 3. a. b. c. PFP:KLE40 BCS000NG Warm up engine. Check for A/T fluid leakage. Before driving, A/T fluid level can be checked at A/T fluid temperatures of 30 to 50°C (86 to 122°F) using “COLD” range on A/ T fluid level gauge. Park vehicle on level surface and set parking brake. Start engine and move selector lever through each gear position. Leave selector lever in “P” position. Check A/T fluid level with engine idling. SCIA3451E d. e. f. 4. 5. 6. 7. Remove A/T fluid level gauge and wipe clean with lint-free cloth. CAUTION: When wiping away the A/T fluid level gauge, always use lint-free cloth, not a cloth one. Re-insert A/T fluid level gauge into A/T fluid charging pipe as far as it will go. CAUTION: Firmly fix the A/T fluid level gauge to the A/T fluid charging pipe using a stopper attached. Remove A/T fluid level gauge and note reading. If reading is at SMA051D low side of range, add ATF to the A/T fluid charging pipe. CAUTION: Do not overfill. Drive vehicle for approximately 5 minutes in urban areas. Re-check A/T fluid level at A/T fluid temperatures of 50 to 80°C (122 to 176°F) using “HOT” range on A/T fluid level gauge. CAUTION: ● When wiping away the A/T fluid level gauge, always use lint-free cloth, not cloth one. ● Firmly fix the A/T fluid level gauge to the A/T fluid charging pipe using a stopper attached. Check A/T fluid condition: ● If ATF is very dark or smells burned, check operation of A/T and repair if necessary. Flush cooling system after repair of A/T. ● If ATF contains frictional material (clutches, bands, etc.), replace radiator and flush cooler line using cleaning solvent and compressed air after repair of A/T. Refer to CO-12, "RADIATOR" . Install the removed A/T fluid level gauge into the A/T fluid charging pipe. CAUTION: Firmly fix the A/T fluid level gauge to the A/T fluid charging pipe using a stopper attached. AT-18 A/T FLUID Changing A/T Fluid 1. 2. 3. 4. 5. BCS000NH Warm up ATF. Stop engine. Drain ATF from drain hole and refill with new ATF. Always refill same volume with drained fluid. CAUTION: Do not reuse drain plug gasket. Fluid grade: Nissan Genuine ATF Matic D or equivalent Refer to MA-24, "RECOMMENDED FLUIDS AND LUBRICANTS" . Fluid capacity: Approx. 7.7 Drain plug: Refer to AT-360, "Components" . (6-3/4 Imp qt) Run engine at idle speed for 5 minutes. Check A/T fluid level and condition. Refer to AT-18, "Checking A/T Fluid" . If ATF is still dirty, repeat steps 2 through 5. A B AT D E F G H I J K L M AT-19 A/T CONTROL SYSTEM A/T CONTROL SYSTEM Cross-Sectional View PFP:31036 BCS000NI SCIA6171J 1. Converter housing 2. Oil pump 3. 4. Reverse clutch 5. High clutch 6. Brake band Front planetary gear 7. Low one-way clutch 8. Rear planetary gear 9. Forward clutch 10. Overrun clutch 11. Low & reverse brake 12. Output gear 13. Band servo piston 14. Reverse clutch drum 15. Side cover 16. Idler gear 17. Forward one-way clutch 18. Transaxle case 19. Reduction pinion gear 20. Final gear 21. Differential case 22. Input shaft 23. Torque converter AT-20 A/T CONTROL SYSTEM Shift Mechanism BCS000NJ A CONSTRUCTION B AT D E F SAT998I 1. Torque converter 2. Oil pump 3. 4. Brake band 5. Reverse clutch 6. High clutch 7. Front sun gear 8. Front pinion gear 9. Front internal gear 10. Front planetary carrier 11. Rear sun gear 12. Rear pinion gear 13. Rear internal gear 14. Rear planetary carrier 15. Forward clutch 16. Forward one-way clutch 17. Overrun clutch 18. Low one-way clutch 19. Low & reverse brake 20. Parking pawl 21. Parking gear 22. Output shaft 23. Idle gear 24. Output gear Abbr. I Function 5 Reverse clutch R/C To transmit input power to front sun gear 7 . 6 High clutch H/C To transmit input power to front planetary carrier 10 . 15 Forward clutch F/C To connect front planetary carrier 10 with forward one-way clutch 16 . 17 Overrun clutch O/C To connect front planetary carrier 10 with rear internal gear 13 . Brake band B/B To lock front sun gear 7 . 16 Forward one-way clutch F/O.C When forward clutch 15 is engaged, to stop rear internal gear 13 from rotating in opposite direction against engine revolution. 18 Low one-way clutch L/O.C To stop front planetary carrier 10 from rotating in opposite direction against engine revolution. 19 Low & reverse brake L & R/B To lock front planetary carrier 10 . 4 H J FUNCTION OF CLUTCH AND BRAKE Clutch and brake components G Input shaft AT-21 K L M A/T CONTROL SYSTEM CLUTCH AND BAND CHART Band servo Shift position R/C 5 H/C 6 F/C 15 O/C 17 2nd apply 3rd release 4th apply F/O.C 16 L/O.C 18 L&R/B 19 Lockup P PARK POSITION R REVERSE POSITION N NEUTRAL POSITION 1st *1D B 2nd *1A B 3rd *1A B Automatic shift D*4 4th 2 C *2C C *3C C B 1st B 2nd B 3rd 1 Remarks *2C C B 2nd B *2C C 1⇔2⇔3 ⇔4 B Automatic shift 1⇔2⇐3 B 1st 3rd *1 B B Locks (held stationary) in 1st speed 1⇐2⇐3 ● *1: Operates when OD OFF. (OD OFF indicator lamp is on.) ● *2: Oil pressure is applied to both 2nd “apply” side and 3rd “release” side of band servo piston. However, brake band does not contract because oil pressure area on the “release” side is greater than that on the “apply” side. ● *3: Oil pressure is applied to 4th “apply” side on condition *2 above, and brake band contracts. ● *4: A/T will not shift to 4th when OD OFF. (OD OFF indicator lamp is on.) ● : Operates. ● A: Operates when throttle opening is less than specification**, activating engine brake. ● B: Operates during “progressive” acceleration. ● C: Operates but does not affect power transmission. ● D: Operates when throttle opening is less than specification**, but does not affect engine brake. – **: Overrun clutch remains in engaged condition when throttle opening is less than 1/16. AT-22 A/T CONTROL SYSTEM POWER TRANSMISSION “N” and “P” Positions ● ● A “N” position Power from the input shaft is not transmitted to the output shaft because the clutches do not operate. “P” position Similar to the “N” position, the clutches do not operate. The parking pawl engages with the parking gear to mechanically hold the output shaft so that the power train is locked. B AT D E F G H SAT991I I J K L M AT-23 A/T CONTROL SYSTEM “11 ” Position ● Forward clutch ● Forward one-way clutch ● Overrun clutch ● Low & reverse brake Engine brake As overrun clutch engages, rear internal gear is locked by the operation of low and reverse brake. This is different from that of D1 and 21 . Overrun clutch always engages, therefore engine brake can be obtained when decelerating. SCIA1816E AT-24 A/T CONTROL SYSTEM “D1 ” and “21 ” Positions ● Forward one-way clutch ● Forward clutch ● Low one-way clutch Overrun clutch engagement conditions (Engine brake) *: Rear internal gear is locked to rotate counterclockwise because of the functioning of these three clutches. A B D1 : OD OFF (OD OFF indicator lamp is on) and throttle opening is less than specification* 21 : Always engaged At D1 and 21 positions, engine brake is not activated due to free turning of low one- way clutch. AT Overrun clutch remains in engaged condition when throttle opening is less than 1/16. D E F G H I J K L SAT377J M AT-25 A/T CONTROL SYSTEM “D2 ”, “22 ” and “12 ” Positions ● Forward clutch ● Forward one-way clutch ● Brake band Overrun clutch engagement conditions *: Rear sun gear drives rear planetary carrier and combined front internal gear. Front internal gear now rotates around front sun gear accompanying front planetary carrier. As front planetary carrier transfers the power to rear internal gear through forward clutch and forward oneway clutch, this rotation of rear internal gear increases the speed of rear planetary carrier compared with that of the 1st speed. D2 : OD OFF (OD OFF indicator lamp is on) and throttle opening is less than specification* 22 and 12 : Always engaged Overrun clutch remains in engaged condition when throttle opening is less than 1/16. SAT378J AT-26 A/T CONTROL SYSTEM “D3 ”, “23 ” and “13 ” Positions ● High clutch ● Forward clutch ● Forward one-way clutch Overrun clutch engagement conditions *: Input power is transmitted to front planetary carrier through high clutch. And front planetary carrier is connected to rear internal gear by operation of forward clutch and forward one-way clutch. This rear internal gear rotation and another input (the rear sun gear) accompany rear planetary carrier to turn at the same speed. A B D3 : OD OFF (OD OFF indicator lamp is on) and throttle opening is less than specification* 23 and 13 : Always engaged AT Overrun clutch remains in engaged condition when throttle opening is less than 1/16. D E F G H I J K L SAT379J M AT-27 A/T CONTROL SYSTEM “D4 ” (OD) Position ● High clutch ● Brake band ● Forward clutch (Does not affect power transmission) Engine brake Input power is transmitted to front carrier through high clutch. This front carrier turns around the sun gear which is fixed by brake band and makes front internal gear (output) turn faster. At D4 position, there is no one-way clutch in the power transaxle line and engine brake can be obtained when decelerating. SAT380J AT-28 A/T CONTROL SYSTEM “R” Position ● Reverse clutch ● Low & reverse brake Engine brake Front planetary carrier is stationary because of the operation of low and reverse brake. Input power is transmitted to front sun gear through reverse clutch, which drives front internal gear in the opposite direction. As there is no one-way clutch in the power transaxle line, engine brake can be obtained when decelerating. A B AT D E F G H I J K SAT381J L M AT-29 A/T CONTROL SYSTEM TCM Function BCS000NK The function of the TCM is to: ● Receive input signals sent from various switches and sensors. ● Determine required line pressure, shifting point, lock-up operation, and engine brake operation. ● Send required output signals to the respective solenoids. CONTROL SYSTEM OUTLINE The automatic transaxle senses vehicle operating conditions through various sensors or signals. It always controls the optimum shift position and reduces shifting and lock-up shocks. SWITCHES & SENSORS TCM ACTUATORS PNP switch Accelerator pedal position signal Closed throttle position signal Wide open throttle position signal Engine speed signal A/T fluid temperature sensor Revolution sensor Turbine revolution sensor (Power train revolution sensor) Vehicle speed sensor Overdrive control switch signal Stop lamp switch signal Shift control Line pressure control Lock-up control Overrun clutch control Fail-safe control Self-diagnosis CONSULT-II communication line control Shift solenoid valve A Shift solenoid valve B Overrun clutch solenoid valve Torque converter clutch solenoid valve Line pressure solenoid valve OD OFF indicator lamp Þ Þ CONTROL SYSTEM DIAGRAM SCIA7112E AT-30 A/T CONTROL SYSTEM Input/Output Signal of TCM BCS000NL A Line pressure control Vehicle speed control Shift control Lock-up control Engine brake control Fail-safe function Self-diagnostics function Accelerator pedal position signal(*5) X X X X X (*3) X X Vehicle speed sensor·A/T (Revolution sensor) X X X X (*3) X X Vehicle speed sensor·MTR (*1) X (*1) X (*1) X (*1) X X Closed throttle position signal(*5) (*2) X (*2) X X (*4) X Wide open throttle position signal(*5) (*2) X (*2) X X X Control item Input Turbine revolution sensor (Power train revolution sensor) AT (*4) X X Engine speed signal PNP switch X X Overdrive control switch signal(*5) TCM power supply voltage signal Output X X X X X X X X X X X X (*3) X D X E (*4) X (*4) X F X X (*4) X X Shift solenoid valve A/B Line pressure solenoid X X Stop lamp switch signal(*5) A/T fluid temperature sensors B G X X X Torque converter clutch solenoid valve X Overrun clutch solenoid valve X OD OFF indicator lamp(*6) X X (*3) X X (*3) X X (*3) X X (*3) X X *1: Spare for vehicle speed sensor·A/T (revolution sensor) *2: Spare for accelerator pedal position signal *3: If these input and output signals are different, the TCM triggers the fail-safe function. *4: Used as a condition for starting self-diagnostics; if self-diagnosis are not started, it is judged that there is some kind of error. *5: Input by CAN communications. *6: Output by CAN communications. H I X J K L M AT-31 A/T CONTROL SYSTEM Line Pressure Control ● ● ● BCS000NM TCM has various line pressure control characteristics to match the driving conditions. An ON-OFF duty signal is sent to the line pressure solenoid valve based on TCM characteristics. Hydraulic pressure on the clutch and brake is electronically controlled through the line pressure solenoid valve to accommodate engine torque. This results in smooth shift operation. NORMAL CONTROL The characteristic of the line pressure to the throttle opening is set for suitable clutch operation. SAT003J BACK-UP CONTROL (ENGINE BRAKE) If the selector lever is shifted to “2” position while driving in D4 or D3, great driving force is applied to the clutch inside the transaxle. Clutch operating pressure (line pressure) must be increased to deal with this driving force. SAT004J DURING SHIFT CHANGE The line pressure is temporarily reduced corresponding to a change in engine torque when shifting gears (that is, when the shift solenoid valve is switched for clutch operation) to reduce shifting shock. SCIA4828E AT-32 A/T CONTROL SYSTEM AT LOW FLUID TEMPERATURE ● ● A/T fluid viscosity and frictional characteristics of the clutch facing change with A/T fluid temperature. Clutch engaging or band-contacting pressure is compensated for, according to A/T fluid temperature, to stabilize shifting quality. The line pressure is reduced below 60°C (140°F) to prevent shifting shock due to high viscosity of A/T fluid when temperature is low. A B AT D SCIA4829E ● Line pressure is increased to a maximum irrespective of the throttle opening when A/T fluid temperature drops to −10°C (14°F). This pressure rise is adopted to prevent a delay in clutch and brake operation due to extreme drop of A/T fluid viscosity at low temperature. E F G H SCIA4830E Shift Control BCS000NN The shift is regulated entirely by electronic control to accommodate vehicle speed and varying engine operations. This is accomplished by electrical signals transmitted by the revolution sensor and the ECM (accelerator pedal position sensor). This results in improved acceleration performance and fuel economy. I J CONTROL OF SHIFT SOLENOID VALVES A AND B The TCM activates shift solenoid valves A and B according to signals from the accelerator pedal position sensor and revolution sensor to select the optimum gear position on the basis of the shift schedule memorized in the TCM. The shift solenoid valve performs simple ON-OFF operation. When set to “ON”, the drain circuit closes and pilot pressure is applied to the shift valve. K L M SAT008J RELATION BETWEEN SHIFT SOLENOID VALVES A AND B AND GEAR POSITIONS Gear position 1 2 3 4 Shift solenoid valve A ON (Closed) OFF (Open) OFF (Open) ON (Closed) Shift solenoid valve B ON (Closed) ON (Closed) OFF (Open) OFF (Open) AT-33 A/T CONTROL SYSTEM CONTROL OF SHIFT VALVES A AND B SAT009J Pilot pressure generated by the operation of shift solenoid valves A and B is applied to the end face of shift valves A and B. The figure above shows the operation of shift valve B. When the shift solenoid valve is “ON”, pilot pressure applied to the end face of the shift valve overcomes spring force, moving the valve upward. Lock-up Control BCS000NO The torque converter clutch piston in the torque converter is locked to eliminate torque converter slip and to increase power transmission efficiency. The solenoid valve is controlled by an ON-OFF duty signal sent from the TCM. The signal is converted to an oil pressure signal which controls the torque converter clutch piston. CONDITIONS FOR LOCK-UP OPERATION When vehicle is driven in 3rd and 4th gear positions, vehicle speed and throttle opening are detected. If the detected values fall within the lock-up zone memorized in the TCM, lock-up is performed. OD ON Selector lever Gear position OFF “D” position D3 D4 Vehicle speed sensor More than set value Throttle position sensor Less than set opening Closed throttle position switch OFF A/T fluid temperature sensor More than 40°C (104°F) TORQUE CONVERTER CLUTCH SOLENOID VALVE CONTROL Lock-up Control System Diagram SCIA5623E AT-34 A/T CONTROL SYSTEM Lock-up Released In the lock-up released state, the torque converter clutch control valve is set into the unlocked state by draining the torque converter clutch piston applying pressure and the torque converter clutch piston release pressure is generated. In this way, the torque converter clutch piston is not coupled. A B Lock-up Applied In the lock-up applied state, the torque converter clutch control valve is set into the locked state by generating the torque converter clutch piston applying pressure and the torque converter clutch piston release pressure is AT drained. In this way, the torque converter clutch piston is pressed and coupled. D SMOOTH LOCK-UP CONTROL When shifting from the lock-up released state to the lock-up applied state, the current output to the torque converter clutch solenoid is controlled with the TCM. In this way, when shifting to the lock-up applied state, the torque converter clutch is temporarily set to the half-clutched state to reduce the shock. E Half-clutched State The current output from the TCM to the torque converter clutch solenoid is varied to steadily increase the torque converter clutch solenoid pressure. In this way, the lock-up applying pressure gradually rises and while the torque converter clutch piston is put into half-clutched status, the torque converter clutch piston applying pressure is increased and the coupling is completed smoothly. Engine Brake Control (Overrun Clutch Control) F G BCS000NP Forward one-way clutch is used to reduce shifting shocks in downshifting operations. This clutch transmits engine torque to the wheels. However, drive force from the wheels is not transmitted to the engine because the one-way clutch rotates idle. This means the engine brake is not effective. The overrun clutch operates when the engine brake is needed. H I OVERRUN CLUTCH OPERATING CONDITIONS J K L M SCIA7186E AT-35 A/T CONTROL SYSTEM OVERRUN CLUTCH SOLENOID VALVE CONTROL The overrun clutch solenoid valve is operated by an ON-OFF signal transmitted by the TCM to provide overrun clutch control (engine brake control). When this solenoid valve is “ON”, the pilot pressure drain port closes. When it is “OFF”, the drain port opens. During the solenoid valve “ON” pilot pressure is applied to the end face of the overrun clutch control valve. SAT015J OVERRUN CLUTCH CONTROL VALVE OPERATION When the solenoid valve is “ON”, pilot pressure is applied to the overrun clutch control valve. This pushes up the overrun clutch control valve. The line pressure is then shut off so that the clutch does not engage. Only in “1” position, however, 1 range pressure is applied to overrun clutch control valve, resulting in valve moving downward and clutch engaged. When the solenoid valve is “OFF”, pilot pressure is not generated. At this point, the overrun clutch control valve moves downward by spring force. As a result, overrun clutch operation pressure is provided by the overrun clutch reducing valve. At overrun clutch reducing valve in “D” position, the hydraulic pressure is reduced to a level that balances the spring force. This is sent to overrun clutch control valve and becomes the operating pressure of overrun clutch which is engaged at all times. In “2” position and “1” position, overrun clutch reducing valve is pushed down by 2 range pressure. Line pressure is directly sent to overrun clutch control valve and becomes the operating pressure of overrun clutch which is engaged at all times. SCIA7172E AT-36 A/T CONTROL SYSTEM Control Valve BCS000NQ A FUNCTION OF CONTROL VALVES Valve name Function Pressure regulator valve, plug and sleeve plug Regulates oil discharged from the oil pump to provide optimum line pressure for all driving conditions. Pressure modifier valve and sleeve Used as a signal supplementary valve to the pressure regulator valve. Regulates pressure-modifier pressure (signal pressure) which controls optimum line pressure for all driving conditions. B AT Pilot valve Regulates line pressure to maintain a constant pilot pressure level which controls lock-up mechanism, overrun clutch, shift timing. Accumulator control valve Regulates accumulator back-pressure to pressure suited to driving conditions. Manual valve Directs line pressure to oil circuits corresponding to select positions. Hydraulic pressure drains when the shift lever is in Neutral. Shift valve A Simultaneously switches three oil circuits using output pressure of shift solenoid valve A to meet driving conditions (vehicle speed, throttle opening, etc.). Provides automatic downshifting and upshifting (1st → 2nd → 3rd → 4th gears/4th → 3rd → 2nd → 1st gears) in combination with shift valve B. Shift valve B Simultaneously switches two oil circuits using output pressure of shift solenoid valve B in relation to driving conditions (vehicle speed, throttle opening, etc.). Provides automatic downshifting and upshifting (1st → 2nd → 3rd → 4th gears/4th → 3rd → 2nd → 1st gears) in combination with shift valve A. G Switches hydraulic circuits to prevent engagement of the overrun clutch simultaneously with application of the brake band in D4 . (Interlocking occurs if the overrun clutch engages during D4 .) H Overrun clutch control valve D E F 1st reducing valve Reduces low & reverse brake pressure to dampen engine-brake shock when downshifting from the 1st position 12 to 11 . Overrun clutch reducing valve Reduces oil pressure directed to the overrun clutch and prevents engine-brake shock. In the 1st and 2nd positions, line pressure acts on the overrun clutch reducing valve to increase the pressure-regulating point, with resultant engine brake capability. I Torque converter relief valve Prevents an excessive rise in torque converter pressure. J Torque converter clutch control valve, plug and sleeve Activates or inactivates the lock-up function. Also provides smooth lock-up through transient application and release of the lock-up system. 1-2 accumulator valve and piston Lessens the shock find when the 2nd gear band servo contracts, and provides smooth shifting. 3-2 timing valve Switches the pace that oil pressure is released depending on vehicle speed; maximizes the high clutch release timing, and allows for soft downshifting. Shuttle valve Determines if the overrun clutch solenoid valve should control the 3-2 timing valve or the overrun clutch control valve and switches between the two. Cooler check valve At low speeds and with a small load when a little heat is generated, saves the volume of cooler flow, and stores the oil pressure for lock-up. AT-37 K L M A/T CONTROL SYSTEM Centrifugal Cancel Mechanism BCS000NR FUNCTION The centrifugal cancel mechanism is a mechanism to cancel the centrifugal hydraulic pressure instead of the conventional check balls. It cancels the centrifugal hydraulic pressure which is generated as high clutch drum rotates, and it allows for preventing high clutch from dragging and for providing stable high clutch piston pressing force in all revolution speeds. STRUCTURE/OPERATION A centrifugal cancel housing is provided to cancel the clutch housing pressure. The centrifugal cancel housing is always filled with ATF from the dedicated fluid passage of oil pump. SCIA6832E When Clutch Pressure Is Not Applied As high clutch drum rotates, a centrifugal force applies to the remaining ATF in clutch housing to push high clutch piston. However, on the other hand, the centrifugal force also applies to ATF filled in centrifugal cancel housing, resulting in a force that pushes high clutch piston back. Consequently the high clutch piston does not move because both forces cancel each other, and thus high clutch is prevented from dragging. When Clutch Pressure Is Applied Clutch pressure that applies to clutch housing overcomes the fluid pressure and spring force of the opposing centrifugal housing to push high clutch piston, and high clutch is engaged. At this time, the centrifugal force caused by the revolution speed of high clutch drum has no impact any more since the centrifugal force that applies to the clutch pressure of clutch housing is canceled by the centrifugal force that applies to centrifugal cancel housing. As a result, high clutch piston pressing force is always stable in all revolution speeds, and thus smooth shifting characteristics are achieved. SCIA6833E AT-38 CAN COMMUNICATION CAN COMMUNICATION System Description PFP:23710 A BCS000NS CAN (Controller Area Network) is a serial communication line for real time application. It is an on-vehicle multiplex communication line with high data communication speed and excellent error detection ability. Many elec- B tronic control units are equipped onto a vehicle, and each control unit shares information and links with other control units during operation (not independent). In CAN communication, control units are connected with 2 communication lines (CAN H line, CAN L line) allowing a high rate of information transmission with less wiring. AT Each control unit transmits/receives data but selectively reads required data only. CAN Communication Unit BCS000NT D Refer to LAN-27, "CAN Communication Unit" . E F G H I J K L M AT-39 TROUBLE DIAGNOSIS TROUBLE DIAGNOSIS DTC Inspection Priority Chart PFP:00004 BCS000NU If some DTCs are displayed at the same time, perform inspections one by one based on the following priority chart. NOTE: If DTC “CAN COMM CIRCUIT” is displayed with other DTCs, first perform the trouble diagnosis for DTC “CAN COMM CIRCUIT”. Refer to AT-102 (EURO-OBD models) or AT-257 (Except EURO-OBD models). Priority Detected items 1 CAN communication line 2 Except above Fail-safe BCS000NV The TCM has an electronic Fail-safe mode. This allows the vehicle to be driven even if a major electrical input/ output device circuit is damaged. Under Fail-Safe, the vehicle always runs in third gear, even with a shift lever position of “1”, “2” or “D”. The customer may complain of sluggish or poor acceleration. Always follow the “AT-43, "WORK FLOW" ”. The SELF-DIAGNOSIS results will be as follows: ● The first SELF-DIAGNOSIS will indicate damage to the vehicle speed sensor or the revolution sensor. ● During the next SELF-DIAGNOSIS, performed after checking the sensor, no damages will be indicated. FAIL-SAFE FUNCTION The following fail-safe functions allow vehicles to be driven even when sensor, switch or solenoid malfunction occurs. Vehicle Speed Sensor·A/T (Revolution Sensor) Vehicle speed sensor·MTR signal is input from combination meter. Accelerator Pedal Position Sensor Signal and Throttle Position Sensor Signal TCM controls the throttle opening angle to a predetermined fixed position to enable driving if a malfunctioning signal is input to TCM. PNP Switch When the multiple PNP switch signals are input to TCM, the priority of selector lever position becomes “D”, “N”, “R”, “2” and “1” in order by internal TCM determination. The use of 4th gear is inhibited until normal operation resumes. Because the hydraulic circuit of the control valve is switched by manual valve according to the selector lever position, however, actual operating condition of vehicle becomes as follows. Actual lever position PNP switch input signal Running status “P” “P” position and other position signals P “R” “R” position and other position signals R “N” “N” position and other position signals N “D” “D” position and other position signals D1 ⇔D2 ⇔D3 ⇔D4 “2” position and other position signals (Except “1” position) 21 ⇔22 ⇔23 “2” position and “1” position signals 21 ⇔22 “1” position and other position signals (Except “2” position) 11 ⇔12 ⇔13 “1” position and “2” position signals 11 ⇔12 “2” “1” AT-40 TROUBLE DIAGNOSIS Shift Solenoid Valve A and B If non-standard solenoid signal is sent to TCM, use of certain gears is limited. Refer to chart shown below. Malfunction in solenoid valve A Normal Shift position “D” position “2” position “1” position A B Gear A B ● ● 1st – × ● 2nd × × ● ● A B ●→× ●→× – ●→× 3rd – × 4th ● B – – – × – – – x × – – – – x ●→× – – – 1st – ●→× ●→× – – – ● 2nd – ●→× × × 3rd – ● ● 1st × ● × × 3rd Gear Malfunction in solenoid valves A and B A × Gear Malfunction in solenoid valve B 3rd A × – – – x × – – – – ●→× ●→× – – – 2nd – ●→× × – – – 3rd – x × – – – Gear B AT D 3rd ●: Solenoid ON ×: Solenoid OFF –: Non-standard condition E F G Line Pressure Solenoid Valve If non-standard solenoid signal is sent to TCM, line pressure solenoid valve is turned OFF to achieve maximum oil pressure. H Torque Converter Clutch Solenoid Valve If non-standard solenoid signal is sent to TCM, torque converter clutch solenoid valve is turned OFF to release lock-up. I Overrun Clutch Solenoid Valve If non-standard solenoid signal is sent to TCM, overrun clutch solenoid valve is turned OFF to engage overrun clutch. This will result in more effective engine brake during deceleration. J K L M AT-41 TROUBLE DIAGNOSIS How to Perform Trouble Diagnoses for Quick and Accurate Repair BCS000NW INTRODUCTION The TCM receives a signal from the vehicle speed sensor, accelerator pedal position sensor or PNP switch and provides shift control or lock-up control via A/T solenoid valves. Input and output signals must always be correct and stable in the operation of the A/T system. The A/T system must be in good operating condition and be free of valve seizure, solenoid valve malfunction, etc. It is much more difficult to diagnose a malfunction that occurs intermittently rather than continuously. Most intermittent malfunctions are caused by poor electric connections or improper wiring. In this case, careful checking of suspected circuits may help prevent the replacement of good parts. A visual check only, may not find the cause of the malfunctions. A road test with CONSULT-II or a circuit tester connected should be performed. Follow the AT-43, "WORK FLOW" . Before undertaking actual checks, take a few minutes to talk with a customer who approaches with a driveability complaint. The customer can supply good information about such malfunctions, especially intermittent ones. Find out what symptoms are present and under what conditions they occur. A “DIAGNOSTIC WORKSHEET” like the example (AT-45, "DIAGNOSTIC WORKSHEET" ) should be used. Start your diagnosis by looking for “conventional” malfunctions first. This will help troubleshoot driveability malfunctions on an electronically controlled engine vehicle. Also check related Service bulletins for information. SAT631IA SAT632I SEF234G AT-42 TROUBLE DIAGNOSIS WORK FLOW A good understanding of the malfunction conditions can make troubleshooting faster and more accurate. In general, each customer feels differently about a malfunction. It is important to fully understand the symptoms or conditions for a customer complaint. Make good use of the two sheets provided, AT-45, "Information from Customer" and AT-46, "Diagnostic Worksheet Chart" , to perform the best troubleshooting possible. A B Work Flow Chart AT For EURO-OBD models D E F G H I J K L M SCIA7146E *1 AT-45 *2 AT-46 *3 AT-40 *4 AT-53 *5 AT-53, AT-56 *6 AT-58 *7 AT-85 *8 AT-98 *9 AT-40 *10 AT-115 *11 AT-192 *12 AT-294 AT-43 TROUBLE DIAGNOSIS *13 AT-68 *14 AT-87 *16 AT-193 *17 EC-48 *15 AT-115 For Except EURO-OBD models SCIA7147E *1 AT-45 *2 AT-46 *3 AT-40 *4 AT-53 *5 AT-53, AT-56 *6 AT-58 *7 AT-85 *8 AT-94 *9 AT-203 *10 AT-287 *11 AT-294 *12 AT-68 *13 AT-87 *14 AT-97 *15 AT-203 *16 AT-287 AT-44 TROUBLE DIAGNOSIS DIAGNOSTIC WORKSHEET Information from Customer A KEY POINTS ● WHAT..... Vehicle & A/T model ● WHEN..... Date, Frequencies ● WHERE..... Road conditions ● HOW..... Operating conditions, Symptoms Customer name MR./MS B AT Model & Year VIN Trans. model Engine Mileage Incident Date Manuf. Date In Service Date Frequency ❏ Continuous Symptoms ❏ Vehicle does not move. ❏ No up-shift ❏ Intermittent ( ❏ No down-shift times a day) (❏ Any position (❏ 1st → 2nd D ❏ 2nd → 3rd (❏ 4th → 3rd ❏ Particular position) E ❏ 3rd → 4th) ❏ 3rd → 2nd ❏ 2nd → 1st) F ❏ Lock-up malfunction ❏ Shift point too high or too low. ❏ Shift shock or slip (❏ N → D ❏ Lock-up ❏ Any drive position) G ❏ Noise or vibration ❏ No kick down H ❏ No pattern select ❏ Others ( ) I J K L M AT-45 TROUBLE DIAGNOSIS Diagnostic Worksheet Chart EURO-OBD models 1. ❏ Read the Fail-safe and listen to customer complaints. AT-40, AT-45 2. ❏ Check A/T fluid AT-18 ❏ Leakage (Follow specified procedure) ❏ Fluid condition ❏ Fluid level 3. ❏ Perform “STALL TEST” and “LINE PRESSURE TEST”. ❏ “STALL TEST” — Mark possible damaged components/others. ❏ Torque converter one-way clutch ❏ Reverse clutch ❏ Forward clutch ❏ Overrun clutch ❏ Forward one-way clutch AT-53, AT-56 ❏ Low & reverse brake ❏ Low one-way clutch ❏ Engine ❏ Line pressure is low ❏ Clutches and brakes except high clutch and brake band are OK ❏ “LINE PRESSURE TEST” — Suspected parts: 4. ❏ Perform “Road Test”. AT-58 4-1. AT-58 “Check Before Engine is Started” ❏ AT-299, "OD OFF Indicator Lamp Does Not Come On" ❏ Perform self-diagnosis. Enter checks for detected items. AT-85 , AT-94 . ❏ AT-102, "DTC U1000 CAN COMMUNICATION LINE" . ❏ AT-105, "DTC P0705 PARK/NEUTRAL POSITION (PNP) SWITCH" . ❏ AT-110, "DTC P0710 A/T FLUID TEMPERATURE SENSOR CIRCUIT" . ❏ AT-115, "DTC P0720 VEHICLE SPEED SENSOR·A/T (REVOLUTION SENSOR)" . ❏ AT-121, "DTC P0725 ENGINE SPEED SIGNAL" . ❏ AT-125, "DTC P0731 A/T 1ST GEAR FUNCTION" ❏ AT-129, "DTC P0732 A/T 2ND GEAR FUNCTION" . ❏ AT-132, "DTC P0733 A/T 3RD GEAR FUNCTION" . ❏ AT-136, "DTC P0734 A/T 4TH GEAR FUNCTION" . ❏ AT-142, "DTC P0740 TORQUE CONVERTER CLUTCH SOLENOID VALVE" . ❏ AT-147, "DTC P0744 A/T TCC S/V FUNCTION (LOCK-UP)" . ❏ AT-153, "DTC P0745 LINE PRESSURE SOLENOID VALVE" . ❏ AT-159, "DTC P0750 SHIFT SOLENOID VALVE A" . ❏ AT-164, "DTC P0755 SHIFT SOLENOID VALVE B" . ❏ AT-169, "DTC P1705 ACCELERATOR PEDAL POSITION (APP) SENSOR" . ❏ AT-171, "DTC P1760 OVERRUN CLUTCH SOLENOID VALVE" . ❏ AT-176, "DTC VEHICLE SPEED SENSOR MTR" . ❏ AT-180, "DTC BATT/FLUID TEMP SEN (A/T FLUID TEMP SENSOR CIRCUIT AND TCM POWER SOURCE)" . ❏ AT-186, "DTC TURBINE REVOLUTION SENSOR" . ❏ AT-192, "CONTROL UNIT (RAM), CONTROL UNIT (ROM)" . ❏ AT-193, "MAIN POWER SUPPLY AND GROUND CIRCUIT" . AT-46 TROUBLE DIAGNOSIS 4. 4-2. “Check at Idle” AT-59 A ❏ AT-301, "Engine Cannot Be Started in “P” and “N” Position" . ❏ AT-302, "In “P” Position, Vehicle Moves Forward or Backward When Pushed" . ❏ AT-302, "In “N” Position, Vehicle Moves" . ❏ AT-303, "Large Shock “N” → “R” Position" . ❏ AT-304, "Vehicle Does Not Creep Backward in “R” Position" . ❏ AT-306, "Vehicle Does Not Creep Forward in “D”, “2” or “1” Position" . 4-3. “Cruise Test” B AT-61 AT Part 1 ❏ AT-307, "Vehicle Cannot Be Started from D1" . ❏ AT-309, "A/T Does Not Shift: D1 → D2 or Does Not Kickdown: D4 → D2" . ❏ AT-311, "A/T Does Not Shift: D2 → D3" . ❏ AT-314, "A/T Does Not Shift: D3 → D4" . ❏ AT-316, "A/T Does Not Perform Lock-up" . ❏ AT-317, "A/T Does Not Hold Lock-up Condition" . ❏ AT-318, "Lock-up Is Not Released" . ❏ AT-318, "Engine Speed Does Not Return to Idle (Light Braking D4 → D3 )" . Part 2 D E AT-64 ❏ AT-307, "Vehicle Cannot Be Started from D1" . ❏ AT-309, "A/T Does Not Shift: D1 → D2 or Does Not Kickdown: D4 → D2" . ❏ AT-311, "A/T Does Not Shift: D2 → D3" . ❏ AT-314, "A/T Does Not Shift: D3 → D4" . Part 3 F G AT-65 ❏ AT-320, "A/T Does Not Shift: D4 → D3 , When OD OFF" . ❏ AT-321, "A/T Does Not Shift: D3 → 22 , When Selector Lever “D” → “2” Position" . ❏ AT-323, "A/T Does Not Shift: 22 → 11 , When Selector Lever “2” → “1” Position" . ❏ AT-325, "Vehicle Does Not Decelerate by Engine Brake" . ❏ Perform self-diagnosis. Enter checks for detected items. AT-85 , AT-94 . H I ❏ AT-102, "DTC U1000 CAN COMMUNICATION LINE" . ❏ AT-105, "DTC P0705 PARK/NEUTRAL POSITION (PNP) SWITCH" . ❏ AT-110, "DTC P0710 A/T FLUID TEMPERATURE SENSOR CIRCUIT" . ❏ AT-115, "DTC P0720 VEHICLE SPEED SENSOR·A/T (REVOLUTION SENSOR)" . ❏ AT-121, "DTC P0725 ENGINE SPEED SIGNAL" . ❏ AT-125, "DTC P0731 A/T 1ST GEAR FUNCTION" ❏ AT-129, "DTC P0732 A/T 2ND GEAR FUNCTION" . ❏ AT-132, "DTC P0733 A/T 3RD GEAR FUNCTION" . ❏ AT-136, "DTC P0734 A/T 4TH GEAR FUNCTION" . ❏ AT-142, "DTC P0740 TORQUE CONVERTER CLUTCH SOLENOID VALVE" . ❏ AT-147, "DTC P0744 A/T TCC S/V FUNCTION (LOCK-UP)" . ❏ AT-153, "DTC P0745 LINE PRESSURE SOLENOID VALVE" . ❏ AT-159, "DTC P0750 SHIFT SOLENOID VALVE A" . ❏ AT-164, "DTC P0755 SHIFT SOLENOID VALVE B" . ❏ AT-169, "DTC P1705 ACCELERATOR PEDAL POSITION (APP) SENSOR" . ❏ AT-171, "DTC P1760 OVERRUN CLUTCH SOLENOID VALVE" . ❏ AT-176, "DTC VEHICLE SPEED SENSOR MTR" . ❏ AT-180, "DTC BATT/FLUID TEMP SEN (A/T FLUID TEMP SENSOR CIRCUIT AND TCM POWER SOURCE)" . ❏ AT-186, "DTC TURBINE REVOLUTION SENSOR" . ❏ AT-192, "CONTROL UNIT (RAM), CONTROL UNIT (ROM)" . ❏ AT-193, "MAIN POWER SUPPLY AND GROUND CIRCUIT" . J K L M 5. ❏ For self-diagnosis NG items, inspect each component. Repair or replace the damaged parts. AT-85, AT-95 6. ❏ Perform “Road Test”. AT-58 7. ❏ Perform the Diagnostic Procedures for all remaining items marked NG. Repair or replace the damaged parts. Refer to the Symptom Chart when you perform the procedures. (The chart also shows some other possible symptoms and the component inspection orders.) AT-68 8. ❏ Erase DTC from TCM and ECM memories. AT-87, AT-97 AT-47 TROUBLE DIAGNOSIS Except EURO-OBD models 1. ❏ Read the Fail-safe and listen to customer complaints. AT-40, AT-45 2. ❏ Check A/T fluid AT-18 ❏ Leakage (Follow specified procedure) ❏ Fluid condition ❏ Fluid level 3. ❏ Perform “STALL TEST” and “LINE PRESSURE TEST”. ❏ “STALL TEST” — Mark possible damaged components/others. AT-53, AT-56 ❏ Low & reverse brake ❏ Low one-way clutch ❏ Engine ❏ Line pressure is low ❏ Clutches and brakes except high clutch and brake band are OK ❏ Torque converter one-way clutch ❏ Reverse clutch ❏ Forward clutch ❏ Overrun clutch ❏ Forward one-way clutch ❏ “LINE PRESSURE TEST” — Suspected parts: 4. ❏ Perform “Road Test”. AT-58 4-1. AT-58 “Check Before Engine is Started” ❏ AT-299, "OD OFF Indicator Lamp Does Not Come On" ❏ Perform self-diagnosis. Enter checks for detected items. AT-85 , AT-94 . ❏ AT-257, "CAN COMMUNICATION LINE" . ❏ AT-203, "VEHICLE SPEED SENSOR·A/T (REVOLUTION SENSOR)" . ❏ AT-209, "VEHICLE SPEED SENSOR MTR" . ❏ AT-245, "TURBINE REVOLUTION SENSOR" . ❏ AT-213, "ACCELERATOR PEDAL POSITION (APP) SENSOR" . ❏ AT-215, "SHIFT SOLENOID VALVE A" . ❏ AT-220, "SHIFT SOLENOID VALVE B" . ❏ AT-225, "OVERRUN CLUTCH SOLENOID VALVE" . ❏ AT-230, "TORQUE CONVERTER CLUTCH SOLENOID VALVE" . ❏ AT-235, "BATT/FLUID TEMP SEN (A/T FLUID TEMP SENSOR CIRCUIT AND TCM POWER SOURCE)" . ❏ AT-241, "ENGINE SPEED SIGNAL" . ❏ AT-264, "A/T 1ST GEAR FUNCTION" . ❏ AT-268, "A/T 2ND GEAR FUNCTION" . ❏ AT-271, "A/T 3RD GEAR FUNCTION" . ❏ AT-275, "A/T 4TH GEAR FUNCTION" . ❏ AT-281, "A/T TCC S/V FUNCTION (LOCK-UP)" . ❏ AT-251, "LINE PRESSURE SOLENOID VALVE" . ❏ AT-287, "CONTROL UNIT (RAM), CONTROL UNIT (ROM)" . AT-48 TROUBLE DIAGNOSIS 4. 4-2. “Check at Idle” AT-59 A ❏ AT-301, "Engine Cannot Be Started in “P” and “N” Position" . ❏ AT-302, "In “P” Position, Vehicle Moves Forward or Backward When Pushed" . ❏ AT-302, "In “N” Position, Vehicle Moves" . ❏ AT-303, "Large Shock “N” → “R” Position" . ❏ AT-304, "Vehicle Does Not Creep Backward in “R” Position" . ❏ AT-306, "Vehicle Does Not Creep Forward in “D”, “2” or “1” Position" . 4-3. “Cruise Test” B AT-61 AT Part 1 ❏ AT-307, "Vehicle Cannot Be Started from D1" . ❏ AT-309, "A/T Does Not Shift: D1 → D2 or Does Not Kickdown: D4 → D2" . ❏ AT-311, "A/T Does Not Shift: D2 → D3" . ❏ AT-314, "A/T Does Not Shift: D3 → D4" . ❏ AT-316, "A/T Does Not Perform Lock-up" . ❏ AT-317, "A/T Does Not Hold Lock-up Condition" . ❏ AT-318, "Lock-up Is Not Released" . ❏ AT-318, "Engine Speed Does Not Return to Idle (Light Braking D4 → D3 )" . Part 2 D E AT-64 ❏ AT-307, "Vehicle Cannot Be Started from D1" . ❏ AT-309, "A/T Does Not Shift: D1 → D2 or Does Not Kickdown: D4 → D2" . ❏ AT-311, "A/T Does Not Shift: D2 → D3" . ❏ AT-314, "A/T Does Not Shift: D3 → D4" . Part 3 F G AT-65 ❏ AT-320, "A/T Does Not Shift: D4 → D3 , When OD OFF" . ❏ AT-321, "A/T Does Not Shift: D3 → 22 , When Selector Lever “D” → “2” Position" . ❏ AT-323, "A/T Does Not Shift: 22 → 11 , When Selector Lever “2” → “1” Position" . ❏ AT-325, "Vehicle Does Not Decelerate by Engine Brake" . ❏ Perform self-diagnosis. Enter checks for detected items. AT-85 , AT-94 . H I ❏ AT-257, "CAN COMMUNICATION LINE" . ❏ AT-203, "VEHICLE SPEED SENSOR·A/T (REVOLUTION SENSOR)" . ❏ AT-209, "VEHICLE SPEED SENSOR MTR" . ❏ AT-245, "TURBINE REVOLUTION SENSOR" . ❏ AT-213, "ACCELERATOR PEDAL POSITION (APP) SENSOR" . ❏ AT-215, "SHIFT SOLENOID VALVE A" . ❏ AT-220, "SHIFT SOLENOID VALVE B" . ❏ AT-225, "OVERRUN CLUTCH SOLENOID VALVE" . ❏ AT-230, "TORQUE CONVERTER CLUTCH SOLENOID VALVE" . ❏ AT-235, "BATT/FLUID TEMP SEN (A/T FLUID TEMP SENSOR CIRCUIT AND TCM POWER SOURCE)" . ❏ AT-241, "ENGINE SPEED SIGNAL" . ❏ AT-264, "A/T 1ST GEAR FUNCTION" . ❏ AT-268, "A/T 2ND GEAR FUNCTION" . ❏ AT-271, "A/T 3RD GEAR FUNCTION" . ❏ AT-275, "A/T 4TH GEAR FUNCTION" . ❏ AT-281, "A/T TCC S/V FUNCTION (LOCK-UP)" . ❏ AT-251, "LINE PRESSURE SOLENOID VALVE" . ❏ AT-287, "CONTROL UNIT (RAM), CONTROL UNIT (ROM)" . J K L M 5. ❏ For self-diagnosis NG items, inspect each component. Repair or replace the damaged parts. AT-85, AT-95 6. ❏ Perform “Road Test”. AT-58 7. ❏ Perform the Diagnostic Procedures for all remaining items marked NG. Repair or replace the damaged parts. Refer to the Symptom Chart when you perform the procedures. (The chart also shows some other possible symptoms and the component inspection orders.) AT-68 8. ❏ Erase DTC from TCM and ECM memories. AT-87, AT-97 AT-49 TROUBLE DIAGNOSIS A/T Electrical Parts Location BCS000NX MCIB0179E AT-50 TROUBLE DIAGNOSIS 1. O/D OFF indicator lamp 2. A/T position indicator 3. Over drive control switch 4. Accelerator pedal position (APP) sensor 5. Turbine revolution sensor (Power train revolution sensor) 6. PNP switch 7. Terminal body (Terminal cord assembly connector) 8. Revolution sensor 9. TCM A B 10. Dropping resistor AT D E F G H I J K L M AT-51 TROUBLE DIAGNOSIS Circuit Diagram BCS000NY MCWA0240E AT-52 TROUBLE DIAGNOSIS Inspections Before Trouble Diagnosis BCS000NZ A A/T FLUID CHECK Fluid Leakage and Fluid Level Check Check fluid leakage and check the fluid level. Refer to AT-18, "Checking A/T Fluid" . B Fluid Condition Check Check the A/T fluid condition. Fluid status Conceivable Cause AT Required Operation Varnished (viscous varnish state) Clutch, brake scorched Replace the ATF and check the A/T main unit and the vehicle for malfunctions (wire harnesses, cooler pipes, etc.) Milky white or cloudy Water in the ATF Replace the ATF and check for places where water is getting in. Large amount of metal powder mixed in Unusual wear of sliding parts within A/T Replace the ATF and check for improper operation of the A/T. D E SAT638A F STALL TEST Stall Test Procedure 1. 2. G Check ATF and engine oil levels. If necessary, add ATF and engine oil. Drive vehicle for approximately 10 minutes or until ATF and engine oil reach operating temperature. ATF operating temperature: H 50 - 80°C (122 - 176°F) I SAT647B 3. 4. Set parking brake and block wheels. Install a tachometer where it can be seen by driver during test. ● It is good practice to mark the point of specified engine rpm on indicator. J K L M SAT513G 5. Start engine, apply foot brake, and place selector lever in “D” position. SAT775B AT-53 TROUBLE DIAGNOSIS 6. 7. Accelerate to wide open throttle gradually while applying foot brake. Quickly note the engine stall revolution and immediately release throttle. CAUTION: Do not hold down the accelerator pedal for more than 5 seconds during this test. Stall revolution : 2,250 - 2,700 rpm SAT514G 8. 9. Move selector lever to “N” position. Cool off ATF. CAUTION: Run the engine at idle for at least 1 minute. 10. Repeat steps 6 through 9 with selector lever in “2”, “1” and “R” positions. SAT771B Judgement of Stall Test The test result and possible damaged components relating to each result are shown in the illustrations on next page. In order to pinpoint the possible damaged components, refer to AT-43, "Work Flow Chart" . NOTE: Stall revolution is too high in “D”, “2”, or “1” position: ● Slippage occurs in 1st gear but not in 2nd and 3rd gears. ..... Low one-way clutch slippage ● Slippage occurs in the following gears: 1st through 3rd gears in “D” position and engine brake functions with OD OFF. (OD OFF indicator lamp is on.) 1st and 2nd gears in “2” position and engine brake functions with accelerator pedal released (fully closed throttle)...... Forward clutch or forward one-way clutch slippage Stall revolution is too high in “R” position: ● Engine brake does not function in “1” position. ..... Low & reverse brake slippage ● Engine brake functions in “1” position. ..... Reverse clutch slippage Stall revolution within specifications: ● Vehicle does not achieve speed of more than 80 km/h (50 MPH). ..... One-way clutch seizure in torque converter housing CAUTION: Be careful because automatic fluid temperature increases abnormally: ● Slippage occurs in 3rd and 4th gears in “D” position. ..... High clutch slippage ● Slippage occurs in 2nd and 4th gears in “D” position. ..... Brake band slippage ● Engine brake does not function in 2nd and 3rd gears in “D” position, 2nd gear in “2” position, and 1st gear in “1” position with OD OFF. (OD OFF indicator lamp is on.) ..... Overrun clutch slippage Stall revolution less than specifications: ● Poor acceleration during starts. ..... One-way clutch seizure in torque converter AT-54 TROUBLE DIAGNOSIS A B AT D E F G H I J K L M SCIA7113E AT-55 TROUBLE DIAGNOSIS LINE PRESSURE TEST Line Pressure Test Ports Location of line pressure test ports are shown in the figure. ● Always replace pressure plugs as they are self-sealing bolts. SCIA7187E Line Pressure Test Procedure 1. 2. Check ATF and engine oil levels. If necessary, add ATF or engine oil. Drive vehicle for approx. 10 minutes or until engine oil and ATF reach operating temperature. ATF operating temperature: 50 - 80°C (122 -176°F) SAT647B 3. Install oil pressure gauge to corresponding line pressure test port. SCIA6528J 4. Set parking brake and block wheels. SAT513G AT-56 TROUBLE DIAGNOSIS 5. Start engine and measure line pressure at idle and stall speed. CAUTION: ● Keep the brake pedal pressed all the way down during measurement. ● When measuring the line pressure at the stall speed, refer to AT-53, "STALL TEST" . A B AT SAT493G D Line Pressure Line pressure [kPa (bar, kg/cm2 , psi)] Engine speed D, 2nd and 1st positions R position Idle speed 500 (5.0, 5.1, 73) 778 (7.8, 7.9, 113) Stall speed 1,159 (11.6, 11.8, 168) 1,803 (18.0, 18.4, 262) E F Judgement of Line Pressure Test Judgement Line pressure is low in all positions. Line pressure is low in particular position. Suspected parts ● Oil pump wear ● Control piston damage ● Pressure regulator valve or plug sticking ● Spring for pressure regulator valve damaged ● Fluid pressure leakage between oil strainer and pressure regulator valve ● Clogged strainer ● Fluid pressure leakage between manual valve and particular clutch ● For example, line pressure is: − Low in “R” and “1” positions, but − Normal in “D”, and “2” positions. Therefore, fluid leakage exists at or around low and reverse brake circuit. Refer to AT-22, "CLUTCH AND BAND CHART" . At idle Line pressure is high. Line pressure is low. At stall speed ● Accelerator pedal position signal malfunction ● A/T fluid temperature sensor damaged ● Line pressure solenoid valve sticking ● Short circuit of line pressure solenoid valve circuit ● Pressure modifier valve sticking ● Pressure regulator valve or plug sticking ● Open in dropping resistor circuit ● Accelerator pedal position signal malfunction ● Line pressure solenoid valve sticking ● Short circuit of line pressure solenoid valve circuit ● Pressure regulator valve or plug sticking ● Pressure modifier valve sticking ● Pilot valve sticking AT-57 G H I J K L M TROUBLE DIAGNOSIS Road Test BCS000O0 DESCRIPTION ● ● 1. 2. 3. The purpose of the test is to determine overall performance of A/ T and analyze causes of malfunctions. The road test consists of the following three parts: Check before engine is started. Refer to AT-58 . Check at idle. Refer to AT-59 . Cruise test ● Inspection all the item from Part 1 to Part 3. Refer to AT-61 , AT-64 and AT-65 . SAT786A ● ● Before road test, familiarize yourself with all test procedures and items to check. Perform tests on all items until specified symptom is found. Troubleshoot the items which are checked out to be no good after road test. Refer to AT-83, "CONSULT-II Function (A/T)" , AT-94, "Diagnostic Procedure Without CONSULT-II" and AT294, "TROUBLE DIAGNOSIS FOR SYMPTOMS" . SAT496G Check Before Engine is Started BCS000O1 1. CHECK OD OFF INDICATOR LAMP 1. 2. 3. Park vehicle on flat surface. Move selector lever to “P” position. Turn ignition switch OFF. Wait at least 5 seconds. SAT772B 4. Turn ignition switch ON. (Do not start engine.) Does OD OFF indicator lamp (1) come on for about 2 seconds? YES >> 1. Turn ignition switch OFF. 2. Perform self-diagnosis and note NG items. Refer to AT-85, "SELF-DIAGNOSTIC RESULT MODE" , AT-94, "Diagnostic Procedure Without CONSULT-II" . 3. Go to AT-59, "Check at Idle" . NO >> Stop “Road Test”. Go to AT-299, "OD OFF Indicator Lamp Does Not Come On" . AT-58 MCIB0175E TROUBLE DIAGNOSIS Check at Idle BCS000O2 1. CHECK ENGINE START A 1. Park vehicle on flat surface. 2. Turn ignition switch ON. (Do not start engine.) 3. Move selector lever to “P” or “N” position. 4. Turn ignition switch to “START” position. Is engine started? YES >> GO TO 2. NO >> ● Stop “Road Test”. Mark the box on the AT-45, "DIAGNOSTIC WORKSHEET" . ● GO TO AT-301, "Engine Cannot Be Started in “P” and “N” Position" . B AT D E SAT769B 2. CHECK ENGINE START F 1. Turn ignition switch ON. (Do not start engine.) 2. Move selector lever to “R”, “D”, “2” or “1” position. 3. Turn ignition switch to “START” position. Is engine started? YES >> ● Stop “Road Test”. Mark the box on the AT-45, "DIAGNOSTIC WORKSHEET" . ● GO TO AT-301, "Engine Cannot Be Started in “P” and “N” Position" . ● Continue “Road Test”. NO >> GO TO 3. G H I SAT770B J 3. CHECK VEHICLE MOVE 1. 2. 3. K Move selector lever to “P” position. Turn ignition switch OFF. Release parking brake. L M SAT768B 4. Push vehicle forward or backward. Does vehicle move when it is pushed forward or backyard? YES >> ● Mark the box on the AT-45, "DIAGNOSTIC WORKSHEET" . ● GO TO AT-302, "In “P” Position, Vehicle Moves Forward or Backward When Pushed" . ● Continue “Road Test”. NO >> GO TO 4. SAT796A AT-59 TROUBLE DIAGNOSIS 4. CHECK VEHICLE MOVE 1. Apply parking brake. 2. Start engine. 3. Move selector lever to “N” position. 4. Release parking brake. Does vehicle move forward or backward? YES >> ● Mark the box on the AT-45, "DIAGNOSTIC WORKSHEET" . ● GO TO AT-302, "In “N” Position, Vehicle Moves" . ● Continue “Road Test”. NO >> GO TO 5. SAT771B 5. CHECK SHIFT SHOCK 1. Apply foot brake. SAT797A 2. Move selector lever to “R” position. Is there large shock when changing from “N” to “R” position? YES >> ● Mark the box on the AT-45, "DIAGNOSTIC WORKSHEET" . ● GO TO AT-303, "Large Shock “N” → “R” Position" . ● Continue “Road Test”. NO >> GO TO 6. SAT772B 6. CHECK VEHICLE MOVE Release foot brake for several seconds. Does vehicle creep backward when foot brake is released? YES >> GO TO 7. NO >> ● Mark the box on the AT-45, "DIAGNOSTIC WORKSHEET" . ● GO TO AT-304, "Vehicle Does Not Creep Backward in “R” Position" . ● Continue “Road Test”. SAT799A AT-60 TROUBLE DIAGNOSIS 7. CHECK VEHICLE MOVE A Move selector lever to “D”, “2” and “1” positions and check if vehicle creeps forward. Does vehicle creep forward in all three positions? YES >> GO TO AT-61, "Cruise Test — Part 1" . NO >> ● Mark the box on the AT-45, "DIAGNOSTIC WORKSHEET" . ● GO TO AT-306, "Vehicle Does Not Creep Forward in “D”, “2” or “1” Position" . ● Continue “Road Test”. B AT D SAT773B Cruise Test — Part 1 BCS000O3 1. CHECK STARTING GEAR (D1 ) POSITION 1. Drive vehicle for approximately 10 minutes to warm engine oil and ATF up to operating temperature. ATF operating temperature: 2. 3. 4. 5. E F 50 - 80°C (122 - 176°F) Park vehicle on flat surface. Push overdrive control switch. (OD OFF indicator lamp is off.) Move selector lever to “P” position. Start engine. G H I J SCIA5472E 6. Move selector lever to “D” position. K L M SAT775B 7. Accelerate vehicle by constantly depressing accelerator pedal half-way. Read gear position. Refer to AT-88, "DATA MONITOR MODE" . Does vehicle start from D1 ? YES >> GO TO 2. NO >> ● Mark the box on the AT-45, "DIAGNOSTIC WORKSHEET" . ● GO TO AT-307, "Vehicle Cannot Be Started from D1" . ● Continue “Road Test”. AT-61 SAT495G TROUBLE DIAGNOSIS 2. CHECK SHIFT-UP (D1 TO D2 ) Check shift-up (D1 to D2 ). Specified speed when shifting from D1 to D2. Refer to AT-67, "Vehicle Speed at Which Gear Shifting Occurs" . Read gear position, throttle opening and vehicle speed. Refer to AT-88, "DATA MONITOR MODE" . Does A/T shift from D1 to D2 at the specified speed? YES >> GO TO 3. NO >> ● Mark the box on the AT-45, "DIAGNOSTIC WORKSHEET" . ● GO TO AT-309, "A/T Does Not Shift: D1 → D2 or Does Not Kickdown: D4 → D2" . ● Continue “Road Test”. SCIA7188E 3. CHECK SHIFT-UP (D2 TO D3 ) Check shift-up (D2 to D3 ). Specified speed when shifting from D2 to D3. Refer to AT-67, "Vehicle Speed at Which Gear Shifting Occurs" . Read gear position, throttle opening and vehicle speed. Refer to AT-88, "DATA MONITOR MODE" . Does A/T shift from D2 to D3 at the specified speed? YES >> GO TO 4. NO >> ● Mark the box on the AT-45, "DIAGNOSTIC WORKSHEET" . ● GO TO AT-311, "A/T Does Not Shift: D2 → D3" . ● Continue “Road Test”. SCIA7189E 4. CHECK SHIFT-UP (D3 TO D4 ) Check shift-up (D3 to D4 ). Specified speed when shifting from D3 to D4. Refer to AT-67, "Vehicle Speed at Which Gear Shifting Occurs" . Read gear position, throttle opening and vehicle speed. Refer to AT-88, "DATA MONITOR MODE" . Does A/T shift from D3 to D4 at the specified speed? YES >> GO TO 5. NO >> ● Mark the box on the AT-45, "DIAGNOSTIC WORKSHEET" . ● GO TO AT-314, "A/T Does Not Shift: D3 → D4" . ● Continue “Road Test”. SCIA7190E AT-62 TROUBLE DIAGNOSIS 5. CHECK LOCK-UP (D4 TO D4 L/U) A Check lock-up (D4 to D4 L/U). Specified speed when lock-up occurs. Refer to AT-67, "Vehicle Speed at Which Lock-up Occurs/Releases" . Read vehicle speed, throttle opening when lock-up duty becomes 94%. Refer to AT-88, "DATA MONITOR MODE" . Does A/T perform lock-up at the specified speed? YES >> GO TO 6. NO >> ● Mark the box on the AT-45, "DIAGNOSTIC WORKSHEET" . ● GO TO AT-316, "A/T Does Not Perform Lock-up" . ● Continue “Road Test”. SCIA7191E B AT D E 6. CHECK LOCK-UP HOLD F Check lock-up hold. When lock-up duty becomes 94%. Refer to AT-88, "DATA MONITOR MODE" . Does A/T hold lock-up condition for more than 30 seconds? YES >> GO TO 7. NO >> ● Mark the box on the AT-45, "DIAGNOSTIC WORKSHEET" . ● GO TO AT-317, "A/T Does Not Hold Lock-up Condition" . ● Continue “Road Test”. G H 7. CHECK SHIFT-DOWN (D4 L/U TO D4 ) I Release accelerator pedal. When lock-up duty becomes 4%. Refer to AT-88, "DATA MONITOR MODE" . Is lock-up released when accelerator pedal is released? YES >> GO TO 8. NO >> ● Mark the box on the AT-45, "DIAGNOSTIC WORKSHEET" . ● GO TO AT-318, "Lock-up Is Not Released" . ● Continue “Road Test”. 8. CHECK SHIFT-DOWN (D4 J K L TO D3 ) Decelerate vehicle by applying foot brake lightly. Read gear position and engine speed. Refer to AT-88, "DATA MONITOR MODE" . Does engine speed return to idle smoothly when A/T is shifted from D4 to D3 ? YES >> 1. Stop vehicle. 2. Go to AT-64, "Cruise Test — Part 2" . NO >> ● Mark the box on the AT-45, "DIAGNOSTIC WORKSHEET" . ● GO TO AT-318, "Engine Speed Does Not Return to Idle (Light Braking D4 → D3 )" . ● Continue “Road Test”. AT-63 M SAT959I TROUBLE DIAGNOSIS Cruise Test — Part 2 BCS000O4 1. CHECK STARTING GEAR (D1 ) POSITION 1. 2. 3. Push overdrive control switch. (OD OFF indicator lamp is off.) Move selector lever to “D” position. Accelerate vehicle by half throttle again. Read gear position. Refer to AT-88, "DATA MONITOR MODE" . Does vehicle start from D1 ? YES >> GO TO 2. NO >> ● Mark the box on the AT-45, "DIAGNOSTIC WORKSHEET" . ● GO TO AT-307, "Vehicle Cannot Be Started from D1" . ● Continue “Road Test”. SAT495G 2. CHECK SHIFT-UP AND SHIFT-DOWN (D3 1. 2. TO D4 TO D2 ) Accelerate vehicle to 80 km/h (50 MPH) as shown in the figure. Release accelerator pedal and then quickly depress it fully. Read gear position and throttle opening. Refer to AT-88, "DATA MONITOR MODE" . Does A/T shift from D4 to D2 as soon as accelerator pedal is depressed fully? YES >> GO TO 3. NO >> ● Mark the box on the AT-45, "DIAGNOSTIC WORKSHEET" . ● GO TO AT-309, "A/T Does Not Shift: D1 → D2 or Does Not Kickdown: D4 → D2" . ● Continue “Road Test”. 3. CHECK SHIFT-UP (D2 SCIA7192E TO D3 ) Check shift-up (D2 to D3 ) Specified speed when shifting from D2 to D3 . Refer to AT-67, "Vehicle Speed at Which Gear Shifting Occurs" . Read gear position, throttle opening and vehicle speed. Refer to AT-88, "DATA MONITOR MODE" . Does A/T shift from D2 to D3 at the specified speed? YES >> GO TO 4. NO >> ● Mark the box on the AT-45, "DIAGNOSTIC WORKSHEET" . ● GO TO AT-311, "A/T Does Not Shift: D2 → D3" . ● Continue “Road Test”. SAT960I AT-64 TROUBLE DIAGNOSIS 4. CHECK SHIFT-UP (D3 TO D4 ) AND ENGINE BRAKE Release accelerator pedal after shifting from D2 to D3 . Read gear position, throttle opening and vehicle speed. Refer to AT-88, "DATA MONITOR MODE" . Does A/T shift from D3 to D4 and does vehicle decelerate by engine brake? YES >> 1. Stop vehicle. 2. Go to AT-65, "Cruise Test — Part 3" . NO >> ● Mark the box on the AT-45, "DIAGNOSTIC WORKSHEET" . ● GO TO AT-314, "A/T Does Not Shift: D3 → D4" . ● Continue “Road Test”. Cruise Test — Part 3 A B AT D SAT405H E BCS000O5 1. CHECK SHIFT-DOWN (D4 TO D3 ) (WITH OVERDRIVE CONTROL SWITCH) F 1. 2. 3. Push overdrive control switch. (OD OFF indicator lamp is off.) Move selector lever to “D” position. Accelerate vehicle using half throttle to D4 . G H I SAT812A 4. J Release accelerator pedal. K L M SAT813A 5. Push overdrive control switch. (OD OFF indicator lamp is on.) Read gear position and vehicle speed. Refer to AT-88, "DATA MONITOR MODE" . Does A/T shift from D4 to D3 (OD OFF)? YES >> GO TO 2. NO >> ● Mark the box on the AT-45, "DIAGNOSTIC WORKSHEET" . ● GO TO AT-320, "A/T Does Not Shift: D4 → D3 , When OD OFF" . ● Continue “Road Test”. AT-65 SCIA5469E TROUBLE DIAGNOSIS 2. CHECK ENGINE BRAKE Check engine brake. Does vehicle decelerate by engine brake? YES >> GO TO 3. NO >> ● Mark the box on the AT-45, "DIAGNOSTIC WORKSHEET" . ● GO TO AT-325, "Vehicle Does Not Decelerate by Engine Brake" . ● Continue “Road Test”. SCIA5469E 3. CHECK SHIFT-DOWN (D3 TO 22 ) Move selector lever from “D” to “2” position while driving in D3 (OD OFF). Read gear position. Refer to AT-88, "DATA MONITOR MODE" . Does A/T shift from D3 (OD OFF) to 22 ? YES >> GO TO 4. NO >> ● Mark the box on the AT-45, "DIAGNOSTIC WORKSHEET" . ● GO TO AT-321, "A/T Does Not Shift: D3 → 22 , When Selector Lever “D” → “2” Position" . ● Continue “Road Test”. SAT791GA 4. CHECK ENGINE BRAKE Check engine brake. Does vehicle decelerate by engine brake? YES >> GO TO 5. NO >> ● Mark the box on the AT-45, "DIAGNOSTIC WORKSHEET" . ● GO TO AT-325, "Vehicle Does Not Decelerate by Engine Brake" . ● Continue “Road Test”. SAT791GA 5. CHECK SHIFT-DOWN (22 TO 11 ) Move selector lever from “2” to “1” position while driving in 22 . Read gear position. Refer to AT-88, "DATA MONITOR MODE" . Does A/T shift from 22 to 11 position? YES >> GO TO 6. NO >> ● Mark the box on the AT-45, "DIAGNOSTIC WORKSHEET" . ● GO TO AT-323, "A/T Does Not Shift: 22 → 11 , When Selector Lever “2” → “1” Position" . ● Continue “Road Test”. AT-66 SAT778B TROUBLE DIAGNOSIS 6. CHECK ENGINE BRAKE A Check engine brake. Does vehicle decelerate by engine brake? YES >> 1. Stop vehicle. 2. Perform self-diagnosis. Refer to AT-85, "SELF-DIAGNOSTIC RESULT MODE" , AT-94, "Diagnostic Procedure Without CONSULT-II" . NO >> ● Mark the box on the AT-45, "DIAGNOSTIC WORKSHEET" . ● GO TO AT-325, "Vehicle Does Not Decelerate by Engine Brake" . ● Stop “Road Test”. B AT D SAT778B E Vehicle Speed at Which Gear Shifting Occurs BCS000O6 Vehicle speed [km/h (MPH)] Throttle position ● D1 → D2 D2 → D3 D3 → D4 D4 → D3 D3 → D2 D2 → D1 Full throttle 51 - 59 (32 - 37) 97 - 105 (60 - 65) 154 - 162 (96 - 101) 150 - 158 (93 - 98) 87 - 95 (54 - 59) 41 - 49 (25 - 30) Half throttle 31 - 39 (19 - 24) 60 - 68 (37 - 42) 122 - 130 (76 - 81) 63 - 71 (39 - 44) 36 - 44 (22 - 27) 5 - 13 (3 - 8) At half throttle, the accelerator opening is 4/8 of the full opening. 2.0 / 8 BCS000O7 Vehicle speed [km/h (MPH)] Selector lever position G H Vehicle Speed at Which Lock-up Occurs/Releases Throttle position F Lock-up “ON” Lock-up “OFF” D position 76 - 84 (47 - 52) 56 - 64 (35 - 40) D position (OD OFF) 86 - 94 (53 - 58) 83 - 91 (52 - 57) I J K L M AT-67 TROUBLE DIAGNOSIS Symptom Chart BCS000O8 Numbers are arranged in order of inspection. Perform inspections starting with number one and work up. Items Symptom Condition Torque converter is not locked up. ON vehicle OFF vehicle No Lock-up Engagement/TCC Inoperative Torque converter clutch piston slip. ON vehicle OFF vehicle Lock-up point is extremely high or low. ON vehicle Diagnostic item Reference page 1. Accelerator pedal position sensor AT-169 (*1), AT-213 (*2) 2. Vehicle speed sensor·A/T (Revolution sensor) and vehicle speed sensor·MTR AT-115 and AT-176 (*1), AT-203 and AT-209 (*2) 3. Engine speed signal AT-121 (*1), AT-241 (*2) 4. A/T fluid temperature sensor AT-110 (*1), AT-235 (*2) 5. Line pressure test AT-56 6. Torque converter clutch solenoid valve AT-142 (*1), AT-230 (*2) 7. Control valve assembly AT-345 8. Torque converter AT-369 1. A/T fluid level AT-18 2. Accelerator pedal position sensor AT-169 (*1), AT-213 (*2) 3. Line pressure test AT-56 4. Torque converter clutch solenoid valve AT-142 (*1), AT-230 (*2) 5. Line pressure solenoid valve AT-153 (*1), AT-251 (*2) 6. Control valve assembly AT-345 7. Torque converter AT-369 1. Accelerator pedal position sensor AT-169 (*1), AT-213 (*2) 2. Vehicle speed sensor·A/T (Revolution sensor) and vehicle speed sensor·MTR AT-115 and AT-176 (*1), AT-203 and AT-209 (*2) 3. Torque converter clutch solenoid valve AT-142 (*1), AT-230 (*2) 4. Control valve assembly AT-345 AT-68 TROUBLE DIAGNOSIS Items Symptom Sharp shock in shifting from “N” to “D” position. Condition ON vehicle OFF vehicle Too sharp a shock in changing from D1 to D2 . Diagnostic item 1. Engine idling speed EC-69 (*1), EC-486 (*2) 2. Accelerator pedal position sensor AT-169 (*1), AT-213 (*2) 3. Line pressure test AT-56 4. A/T fluid temperature sensor AT-110 (*1), AT-235 (*2) 5. Engine speed signal AT-121 (*1), AT-241 (*2) 6. Line pressure solenoid valve AT-153 (*1), AT-251 (*2) 7. Control valve assembly AT-345 8. Accumulator N-D AT-345 9. Forward clutch AT-419 1. Accelerator pedal position sensor AT-169 (*1), AT-213 (*2) 2. Line pressure test AT-56 3. Accumulator servo release AT-345 4. Control valve assembly AT-345 5. A/T fluid temperature sensor AT-110 (*1), AT-235 (*2) 6. Brake band AT-441 1. Accelerator pedal position sensor AT-169 (*1), AT-213 (*2) 2. Line pressure test AT-56 3. Control valve assembly AT-345 4. High clutch AT-413 5. Brake band AT-441 1. Accelerator pedal position sensor AT-169 (*1), AT-213 (*2) 2. Line pressure test AT-56 3. Control valve assembly AT-345 4. Brake band AT-441 5. Overrun clutch AT-419 6. Forward one-way clutch AT-431 1. Accelerator pedal position sensor AT-169 (*1), AT-213 (*2) 2. Line pressure test AT-56 3. Overrun clutch solenoid valve AT-171 (*1), AT-225 (*2) 4. Control valve assembly AT-345 ON vehicle 1. Control valve assembly AT-345 OFF vehicle 2. Low & reverse brake AT-426 ON vehicle OFF vehicle Shift Shock Too sharp a shock in changing from D2 to D3 . ON vehicle OFF vehicle ON vehicle Too sharp a shock in changing from D3 to D4 . OFF vehicle Gear change shock during deceleration by releasing accelerator pedal. Large shock in changing from 12 to 11 in “1” position. Reference page ON vehicle AT-69 A B AT D E F G H I J K L M TROUBLE DIAGNOSIS Items Symptom Too high a gear change point from D1 to D2 , from D2 to D3 , from D3 to D4 . Gear change directly from D1 to D3 occurs. Too high a change point from D4 to D3 , from D3 to D 2 , from D2 to D1 . Improper Shift Timing Kickdown does not operate when depressing accelerator pedal in D4 within kickdown vehicle speed. Kickdown operates or engine overruns when depressing accelerator pedal in D4 beyond kickdown vehicle speed limit. Gear change from 22 to 23 in “2” position. Gear change from 11 to 12 in “1” position. Condition Diagnostic item 1. Accelerator pedal position sensor AT-169 (*1), AT-213 (*2) 2. Vehicle speed sensor·A/T (Revolution sensor) and vehicle speed sensor·MTR AT-115 and AT-176 (*1), AT-203 and AT-209 (*2) 3. Shift solenoid valve A AT-159 (*1), AT-215 (*2) 4. Shift solenoid valve B AT-164 (*1), AT-220 (*2) 1. A/T fluid level AT-18 2. Accumulator servo release AT-345 3. Brake band AT-441 1. Accelerator pedal position sensor AT-169 (*1), AT-213 (*2) 2. Vehicle speed sensor·A/T (Revolution sensor) and vehicle speed sensor·MTR AT-115 and AT-176 (*1), AT-203 and AT-209 (*2) 1. Accelerator pedal position sensor AT-169 (*1), AT-213 (*2) 2. Vehicle speed sensor·A/T (Revolution sensor) and vehicle speed sensor·MTR AT-115 and AT-176 (*1), AT-203 and AT-209 (*2) 3. Shift solenoid valve A AT-159 (*1), AT-215 (*2) 4. Shift solenoid valve B AT-164 (*1), AT-220 (*2) 1. Vehicle speed sensor·A/T (Revolution sensor) and vehicle speed sensor·MTR AT-115 and AT-176 (*1), AT-203 and AT-209 (*2) 2. Accelerator pedal position sensor AT-169 (*1), AT-213 (*2) 3. Shift solenoid valve A AT-159 (*1), AT-215 (*2) 4. Shift solenoid valve B AT-164 (*1), AT-220 (*2) 1. PNP switch adjustment AT-350 2. Control cable adjustment AT-336 1. PNP switch adjustment AT-350 2. Control cable adjustment AT-336 ON vehicle ON vehicle OFF vehicle ON vehicle ON vehicle ON vehicle ON vehicle ON vehicle Reference page AT-70 TROUBLE DIAGNOSIS Items Symptom Condition Diagnostic item 1. A/T fluid level AT-18 2. Accelerator pedal position sensor AT-169 (*1), AT-213 (*2) 3. Overrun clutch solenoid valve AT-171 (*1), AT-225 (*2) 4. Shift solenoid valve A AT-159 (*1), AT-215 (*2) 5. Line pressure solenoid valve AT-153 (*1), AT-251 (*2) 6. Control valve assembly AT-345 7. Brake band AT-441 8. Overrun clutch AT-419 1. A/T fluid level AT-18 2. Accelerator pedal position sensor AT-169 (*1), AT-213 (*2) 3. Shift solenoid valve A AT-159 (*1), AT-215 (*2) 4. Shift solenoid valve B AT-164 (*1), AT-220 (*2) 5. Control valve assembly AT-345 6. High clutch AT-413 7. Brake band AT-441 1. A/T fluid level AT-18 2. Accelerator pedal position sensor AT-169 (*1), AT-213 (*2) 3. Shift solenoid valve A AT-159 (*1), AT-215 (*2) 4. Shift solenoid valve B AT-164 (*1), AT-220 (*2) 5. Control valve assembly AT-345 6. Low one-way clutch AT-369 7. High clutch AT-413 ON vehicle Failure to change gear from D4 to D3 . OFF vehicle Failure to change gear from D3 to D2 or from D4 to D2 . ON vehicle No Down Shift OFF vehicle ON vehicle Failure to change gear from D2 to D1 or from D3 to D1 . OFF vehicle Failure to change from D3 to 22 when shifting selector lever into “2” position. AT-321 ON vehicle OFF vehicle Reference page 8. Brake band AT-441 1. Accelerator pedal position sensor AT-169 (*1), AT-213 (*2) 2. Shift solenoid valve B AT-164 (*1), AT-220 (*2) 3. Control valve assembly AT-345 4. Control cable adjustment AT-336 5. Brake band AT-441 AT-71 A B AT D E F G H I J K L M TROUBLE DIAGNOSIS Items No Down Shift Symptom Does not change from 12 to 11 in 1st position. Condition AT-350 2. Vehicle speed sensor·A/T (Revolution sensor) and vehicle speed sensor·MTR AT-115 and AT-176 (*1), AT-203 and AT-209 (*2) 3. Shift solenoid valve A AT-159 (*1), AT-215 (*2) 4. Control valve assembly AT-345 5. Overrun clutch solenoid valve AT-171 (*1), AT-225 (*2) 6. Overrun clutch AT-419 7. Low & reverse brake AT-426 1. Control cable adjustment AT-336 2. Shift solenoid valve A AT-159 (*1), AT-215 (*2) 3. Control valve assembly AT-345 4. Vehicle speed sensor·A/T (Revolution sensor) and vehicle speed sensor·MTR AT-115 and AT-176 (*1), AT-203 and AT-209 (*2) 5. Accelerator pedal position sensor AT-169 (*1), AT-213 (*2) 6. Brake band AT-441 1. Control cable adjustment AT-336 2. Shift solenoid valve B AT-164 (*1), AT-220 (*2) 3. Control valve assembly AT-345 4. Vehicle speed sensor·A/T (Revolution sensor) and vehicle speed sensor·MTR AT-115 and AT-176 (*1), AT-203 and AT-209 (*2) 5. Accelerator pedal position sensor AT-169 (*1), AT-213 (*2) 6. High clutch AT-413 7. Brake band AT-441 1. PNP switch adjustment AT-350 2. Overdrive control switch AT-197 (*1), AT-288 (*2) 3. Control cable adjustment AT-336 4. Shift solenoid valve A AT-159 (*1), AT-215 (*2) 5. Vehicle speed sensor·A/T (Revolution sensor) and vehicle speed sensor·MTR AT-115 and AT-176 (*1), AT-203 and AT-209 (*2) 6. A/T fluid temperature sensor AT-110 (*1), AT-235 (*2) 7. Brake band AT-441 ON vehicle OFF vehicle ON vehicle No Up Shift Failure to change gear from D2 to D3 . OFF vehicle Failure to change gear from D3 to D4 . ON vehicle OFF vehicle Reference page 1. PNP switch adjustment ON vehicle OFF vehicle Failure to change gear from D1 to D2 . Diagnostic item AT-72 TROUBLE DIAGNOSIS Items No Up Shift Symptom A/T does not shift to D4 when driving with OD ON. (OD OFF indicator lamp is off.) Condition Slips/Will Not Engage AT-169 (*1), AT-213 (*2) 2. PNP switch adjustment AT-350 3. Overdrive control switch AT-197 (*1), AT-288 (*2) 4. Vehicle speed sensor·A/T (Revolution sensor) and vehicle speed sensor·MTR AT-115 and AT-176 (*1), AT-203 and AT-209 (*2) 5. Shift solenoid valve A AT-159 (*1), AT-215 (*2) 6. Overrun clutch solenoid valve AT-171 (*1), AT-225 (*2) 7. Control valve assembly AT-345 8. A/T fluid temperature sensor AT-110 (*1), AT-235 (*2) 9. Line pressure solenoid valve AT-153 (*1), AT-251 (*2) 10. Brake band AT-441 11. Overrun clutch AT-419 1. Control cable adjustment AT-336 2. Stall test AT-53 3. Line pressure test AT-56 4. Line pressure solenoid valve AT-153 (*1), AT-251 (*2) 5. Control valve assembly AT-345 6. Reverse clutch AT-408 7. High clutch AT-413 8. Forward clutch AT-419 9. Overrun clutch AT-419 10. Low & reverse brake AT-426 ON vehicle 1. Control cable adjustment AT-336 OFF vehicle 2. Low one-way clutch AT-369 ON vehicle ON vehicle OFF vehicle Vehicle will not run in “D” and “2” positions (but runs in “1” and “R” positions). Reference page 1. Accelerator pedal position sensor OFF vehicle Vehicle will not run in “R” position (but runs in “D”, “2” and “1” positions). Clutch slips. Very poor acceleration. Diagnostic item A B AT D E F G H I J K L M AT-73 TROUBLE DIAGNOSIS Items Symptom Condition Diagnostic item 1. A/T fluid level AT-18 2. Stall test AT-53 3. Line pressure test AT-56 4. Line pressure solenoid valve AT-153 (*1), AT-251 (*2) 5. Control valve assembly AT-345 6. Accumulator N-D AT-345 7. Reverse clutch AT-408 8. High clutch AT-413 9. Forward clutch AT-419 10. Forward one-way clutch AT-431 ON vehicle Vehicle will not run in “D”, “1”, “2” positions (but runs in R position). Clutch slips. Very poor acceleration. OFF vehicle ON vehicle Slips/Will Not Engage Clutches or brakes slip somewhat in starting. OFF vehicle ON vehicle No creep at all. AT-304, AT-306 OFF vehicle Almost no shock or clutches slipping in change from D1 to D2 . ON vehicle OFF vehicle Reference page 11. Low one-way clutch AT-369 1. A/T fluid level AT-18 2. Control cable adjustment AT-336 3. Accelerator pedal position sensor AT-169 (*1), AT-213 (*2) 4. Line pressure test AT-56 5. Line pressure solenoid valve AT-153 (*1), AT-251 (*2) 6. Control valve assembly AT-345 7. Accumulator N-D AT-345 8. Forward clutch AT-419 9. Reverse clutch AT-408 10. Low & reverse brake AT-426 11. Oil pump AT-388 12. Torque converter AT-369 1. A/T fluid level AT-18 2. Line pressure test AT-56 3. Control valve assembly AT-345 4. Forward clutch AT-419 5. Oil pump AT-388 6. Torque converter AT-369 1. A/T fluid level AT-18 2. Accelerator pedal position sensor AT-169 (*1), AT-213 (*2) 3. Line pressure test AT-56 4. Accumulator servo release AT-345 5. Control valve assembly AT-345 6. Brake band AT-441 AT-74 TROUBLE DIAGNOSIS Items Symptom Almost no shock or slipping in changing from D2 to D3 . Condition ON vehicle OFF vehicle Almost no shock or slipping in changing from D3 to D4 . Slips/Will Not Engage ON vehicle OFF vehicle Races extremely fast or slips in changing from D4 to D2 when depressing accelerator pedal. ON vehicle OFF vehicle Reference page 1. A/T fluid level AT-18 2. Accelerator pedal position sensor AT-169 (*1), AT-213 (*2) 3. Line pressure test AT-56 4. Control valve assembly AT-345 5. High clutch AT-413 6. Forward clutch AT-419 1. A/T fluid level AT-18 2. Accelerator pedal position sensor AT-169 (*1), AT-213 (*2) 3. Line pressure test AT-56 4. Control valve assembly AT-345 5. Brake band AT-441 1. A/T fluid level AT-18 2. Accelerator pedal position sensor AT-169 (*1), AT-213 (*2) 3. Line pressure test AT-56 4. Line pressure solenoid valve AT-153 (*1), AT-251 (*2) 5. Shift solenoid valve A AT-159 (*1), AT-215 (*2) 6. Control valve assembly AT-345 7. Brake band AT-441 8. Forward clutch AT-419 1. A/T fluid level AT-18 2. Accelerator pedal position sensor AT-169 (*1), AT-213 (*2) 3. Line pressure test AT-56 4. Line pressure solenoid valve AT-153 (*1), AT-251 (*2) 5. Shift solenoid valve A AT-159 (*1), AT-215 (*2) 6. Shift solenoid valve B AT-164 (*1), AT-220 (*2) 7. Control valve assembly AT-345 8. Brake band AT-441 9. Forward clutch AT-419 ON vehicle OFF vehicle Races extremely fast or slips in changing from D4 to D3 when depressing accelerator pedal. Diagnostic item AT-75 A B AT D E F G H I J K L M TROUBLE DIAGNOSIS Items Symptom Races extremely fast or slips in changing from D3 to D2 when depressing accelerator pedal. Condition ON vehicle OFF vehicle Slips/Will Not Engage Races extremely fast or slips in changing from D4 or D3 to D 1 when depressing accelerator pedal. ON vehicle OFF vehicle ON vehicle Vehicle will not run in any position. OFF vehicle Others Engine cannot be started in “P” and “N” positions. AT-301 ON vehicle Engine starts in positions other than “P” and “N”. ON vehicle Diagnostic item Reference page 1. A/T fluid level AT-18 2. Accelerator pedal position sensor AT-169 (*1), AT-213 (*2) 3. Line pressure test AT-56 4. Line pressure solenoid valve AT-153 (*1), AT-251 (*2) 5. Shift solenoid valve B AT-164 (*1), AT-220 (*2) 6. Control valve assembly AT-345 7. Brake band AT-441 8. High clutch AT-413 1. A/T fluid level AT-18 2. Accelerator pedal position sensor AT-169 (*1), AT-213 (*2) 3. Line pressure test AT-56 4. Line pressure solenoid valve AT-153 (*1), AT-251 (*2) 5. Shift solenoid valve A AT-159 (*1), AT-215 (*2) 6. Shift solenoid valve B AT-164 (*1), AT-220 (*2) 7. Control valve assembly AT-345 8. Forward clutch AT-419 9. Forward one-way clutch AT-431 10. Low one-way clutch AT-369 1. A/T fluid level AT-18 2. Control cable adjustment AT-336 3. Line pressure test AT-56 4. Line pressure solenoid valve AT-153 (*1), AT-251 (*2) 5. Oil pump AT-388 6. High clutch AT-413 7. Brake band AT-441 8. Low & reverse brake AT-426 9. Torque converter AT-369 10. Parking components AT-360 1. Ignition switch and starter PG-4, SC-45 2. Control cable adjustment AT-336 3. PNP switch adjustment AT-350 1. Control cable adjustment AT-336 2. PNP switch adjustment AT-350 AT-76 TROUBLE DIAGNOSIS Items Symptom Condition Diagnostic item OFF vehicle Vehicle moves when changing into “P” position or parking gear does not disengage when shifted out of “P” position. Vehicle runs in “N” position. AT-302 ON vehicle AT-18 2. Line pressure test AT-56 3. Accelerator pedal position sensor AT-169 (*1), AT-213 (*2) B 4. Vehicle speed sensor·A/T (Revolution sensor) and vehicle speed sensor·MTR AT-115 and AT-176 (*1), AT-203 and AT-209 (*2) AT 5. Oil pump AT-388 6. Torque converter AT-369 1. Control cable adjustment AT-336 OFF vehicle 2. Parking components AT-360 ON vehicle 1. Control cable adjustment AT-336 2. Forward clutch AT-419 3. Reverse clutch AT-408 4. Overrun clutch AT-419 1. A/T fluid level AT-18 2. Control cable adjustment AT-336 3. Line pressure test AT-56 4. Line pressure solenoid valve AT-153 (*1), AT-251 (*2) 5. Control valve assembly AT-345 6. High clutch AT-413 7. Brake band AT-441 8. Forward clutch AT-419 9. Overrun clutch AT-419 1. Engine idling speed EC-69 (*1), EC-486 (*2) 1. Engine idling speed EC-69 (*1), EC-486 (*2) 2. A/T fluid level AT-18 3. Torque converter clutch solenoid valve AT-142 (*1), AT-230 (*2) 4. Control valve assembly AT-345 OFF vehicle 5. Torque converter AT-369 ON vehicle 1. A/T fluid level AT-18 2. Reverse clutch AT-408 3. Low & reverse brake AT-426 4. High clutch AT-413 5. Low one-way clutch AT-369 ON vehicle 1. A/T fluid level AT-18 OFF vehicle 2. Brake band AT-441 F OFF vehicle Vehicle braked when shifting into “R” position. OFF vehicle Excessive creep. Engine stops when shifting lever into “R”, “D”, “2” and “1” positions. Vehicle braked by gear change from D1 to D2 . Vehicle braked by gear change from D2 to D3 . D E ON vehicle Others A 1. A/T fluid level ON vehicle Transaxle noise in“ P” and “N” positions. Reference page ON vehicle ON vehicle OFF vehicle AT-77 G H I J K L M TROUBLE DIAGNOSIS Items Symptom Condition ON vehicle Vehicle braked by gear change from D3 to D4 . AT-18 2. Overrun clutch AT-419 3. Forward one-way clutch AT-431 4. Reverse clutch AT-408 1. A/T fluid level AT-18 2. PNP switch adjustment AT-349 3. Overdrive control switch AT-197 (*1), AT-288 (*2) 4. Accelerator pedal position sensor AT-169 (*1), AT-213 (*2) 5. Vehicle speed sensor·A/T (Revolution sensor) and vehicle speed sensor·MTR AT-115 and AT-176 (*1), AT-203 and AT-209 (*2) 6. Shift solenoid valve A AT-159 (*1), AT-215 (*2) 7. Shift solenoid valve B AT-164 (*1), AT-220 (*2) 8. Control valve assembly AT-345 9. Reverse clutch AT-408 10. High clutch AT-413 11. Brake band AT-441 12. Low & reverse brake AT-426 13. Oil pump AT-388 14. Torque converter AT-369 ON vehicle 1. A/T fluid level AT-18 OFF vehicle 2. Torque converter AT-369 1. PNP switch adjustment AT-349 2. Control cable adjustment AT-336 3. Vehicle speed sensor·A/T (Revolution sensor) and vehicle speed sensor·MTR AT-115 and AT-176 (*1), AT-203 and AT-209 (*2) 4. Control valve assembly AT-345 5. Overrun clutch solenoid valve AT-171 (*1), AT-225 (*2) 6. Overrun clutch AT-419 7. Low & reverse brake AT-426 OFF vehicle Maximum speed not attained. Poor acceleration. Others OFF vehicle Engine brake does not operate in “1” position. Reference page 1. A/T fluid level ON vehicle Transaxle noise in “D”, “2”, “1” and “R” positions. Diagnostic item ON vehicle OFF vehicle AT-78 TROUBLE DIAGNOSIS Items Symptom Condition Diagnostic item 1. A/T fluid level AT-18 2. Engine idling speed EC-69 (*1), EC-486 (*2) 3. Accelerator pedal position sensor AT-169 (*1), AT-213 (*2) 4. Line pressure test AT-56 5. Line pressure solenoid valve AT-153 (*1), AT-251 (*2) 6. Control valve assembly AT-345 7. Oil pump AT-388 8. Reverse clutch AT-408 9. High clutch AT-413 10. Brake band AT-441 11. Forward clutch AT-419 12. Overrun clutch AT-419 13. Low & reverse brake AT-426 14. Torque converter AT-369 1. A/T fluid level AT-18 2. Reverse clutch AT-408 3. High clutch AT-413 4. Brake band AT-441 5. Forward clutch AT-419 6. Overrun clutch AT-419 7. Low & reverse brake AT-426 1. A/T fluid level AT-18 2. Torque converter AT-369 3. Oil pump AT-388 4. Reverse clutch AT-408 5. High clutch AT-413 6. Brake band AT-441 7. Forward clutch AT-419 8. Overrun clutch AT-419 9. Low & reverse brake AT-426 ON vehicle Transaxle overheats. OFF vehicle Others ON vehicle ATF shoots out during operation. White smoke emitted from exhaust pipe during operation. OFF vehicle ON vehicle Unusual smell at A/T fluid charging pipe. OFF vehicle Reference page *1: For EURO-OBD models *2: Except for EURO-OBD models AT-79 A B AT D E F G H I J K L M TROUBLE DIAGNOSIS TCM Terminals and Reference Value BCS000O9 TCM CONNECTOR TERMINAL LAYOUT SCIA0495E TCM INSPECTION TABLE TCM terminal data are reference values, measured between each terminal and ground. Terminal Wire color Item Condition When releasing accelerator pedal after warming up engine. 1 2 3 P V O Line pressure solenoid valve When depressing accelerator pedal fully after warming up engine. When releasing accelerator pedal after warming up engine. Line pressure solenoid valve (with dropping resistor) Torque converter clutch solenoid valve Judgement standard (Approx.) 1.5 - 3.0V 0V 4 - 14V When depressing accelerator pedal fully after warming up engine. 0V When A/T performs lock-up. 8 - 15V When A/T does not perform lockup. 0V 5 L CAN H — — 6 Y CAN L — — 10 R 11 12 19 R SB R Power supply When turning ignition switch to “ON”. Battery voltage When turning ignition switch to “OFF”. 0V Shift solenoid valve A Shift solenoid valve B Power supply When shift solenoid valve A operates. (When driving in “D1 ” or “D4 ”.) Battery voltage When shift solenoid valve A does not operate. (When driving in “D2 ” or “D3 ”.) 0V When shift solenoid valve B operates. (When driving in “D1 ” or “D2 ”.) Battery voltage When shift solenoid valve B does not operate. (When driving in “D3 ” or “D4 ”.) 0V When turning ignition switch to “ON”. Battery voltage When turning ignition switch to “OFF”. 0V AT-80 TROUBLE DIAGNOSIS Terminal 20 25 26 Wire color LG B Y Item Condition Overrun clutch solenoid valve Ground When overrun clutch solenoid valve operates. (When overrun clutch disengaged. Refer to AT-22 .) Battery voltage When overrun clutch solenoid valve does not operate. (When overrun clutch engaged. Refer to AT-22 .) 0V Always 0V When setting selector lever to “1” position. PNP switch “1” position When setting selector lever to other positions. and 27 L PNP switch “2” position Judgement standard (Approx.) When setting selector lever to “2” position. When setting selector lever to other positions. 28 LG Power supply (memory back-up) Always 29 V Revolution sensor When driving at 20 km/h (12 MPH) A B AT D Battery voltage 0V E Battery voltage F 0V Battery voltage G 150 Hz H 30*1 L CONSULT- II (RX) — — 31*1 BR CONSULT- II (TX) — — When setting selector lever to “D” position. 34 35 LG L PNP switch “D” position When setting selector lever to other positions. When setting selector lever to “R” position. PNP switch “R” position and 36 R 38 LG 39*2 L When setting selector lever to other positions. When setting selector lever to “N” or “P” position. PNP switch “N” or “P” position When setting selector lever to other positions. Turbine revolution sensor (power train revolution sensor) When driving at 20 km/h (12 MPH) Engine speed signal Refer to EC-95 *3 or EC-512 *4 . Battery voltage 0V Battery voltage 40 R Vehicle speed sensor 42 B Sensor ground Always 47 48 BR B A/T fluid temperature sensor and Ground Battery voltage *1 : These terminals are connected to the data link connector. AT-81 K L 0V M 360 Hz Voltage varies between less than 0V and more than 4.5V 0V When A/T fluid temperature is 20°C (68°F). 1.5V When A/T fluid temperature is 80°C (176°F). 0.5V Always J 0V and When driving vehicle at 2 to 3 km/h (1 to 2 MPH) for 1 m (3 ft) or more. I 0V TROUBLE DIAGNOSIS *2 : This terminal is connected to the ECM. *3 : For EURO-OBD models *4 : Except for EURO-OBD models AT-82 TROUBLE DIAGNOSIS CONSULT-II Function (A/T) BCS000OA A CONSULT-II can display each diagnostic item using the diagnostic test models shown following. FUNCTION Diagnostic test mode Function Reference page Work support This mode enables a technician to adjust some devices faster and more accurately by following the indications on CONSULT-II. — Self-diagnostic results Self-diagnostic results can be read and erased quickly. AT-85 Data monitor Input/Output data in the TCM can be read. AT-88 CAN diagnostic support monitor The results of transmit/receive diagnosis of CAN communication can be read. AT-90 Function test Performed by CONSULT-II instead of a technician to determine whether each system is “OK” or “NG”. DTC work support Select the operating condition to confirm Diagnostic Trouble Codes. TCM part number TCM part number can be read. AT-90 Condition Released accelerator pedal. 0.0/8 Fully depressed accelerator pedal. 8.0/8 When A/T fluid temperature is 20°C (68°F). 1.5V When A/T fluid temperature is 80°C (176°F). 0.5V BATTERY VOLT When turning ignition switch to “ON”. Battery voltage ENGINE SPEED Engine running Approximately matches the tachometer reading. TURBINE REV During driving (lock-up ON) Approximately matches the engine speed. When overdrive control switch is depressed. ON When overdrive control switch is released. OFF When setting selector lever to “N” or “P” position. ON When setting selector lever to other positions. OFF When setting selector lever to “R” position. ON When setting selector lever to other positions. OFF When setting selector lever to “D” position. ON When setting selector lever to other positions. OFF PN POSI SW R POSITION SW D POSITION SW H I J K During driving OVERDRIVE SW G Display value (Approx.) Approximately matches the speedometer reading. FLUID TEMP SE E F VHCL/S SE-A/T THROTTLE POSI D — NOTICE: 1. The CONSULT-II electrically displays shift timing and lock-up timing (that is, operation timing of each solenoid). Check for time difference between actual shift timing and the CONSULT-II display. If the difference is noticeable, mechanical parts (except solenoids, sensors, etc.) may be malfunctioning. Check mechanical parts using applicable diagnostic procedures. 2. Shift schedule (which implies gear position) displayed on CONSULT-II and that indicated in Service Manual may differ slightly. This occurs because of the following reasons: – Actual shift schedule has more or less tolerance or allowance, – Shift schedule indicated in Service Manual refers to the point where shifts start, and – Gear position displayed on CONSULT-II indicates the point where shifts are completed. 3. Shift solenoid valve “A” or “B” is displayed on CONSULT-II at the start of shifting. Gear position is displayed upon completion of shifting (which is computed by TCM). VHCL/S SE-MTR AT — CONSULT-II REFERENCE VALUE Item name B AT-83 L M TROUBLE DIAGNOSIS Item name 2 POSITION SW 1 POSITION SW CLOSED THL/SW Condition Display value (Approx.) When setting selector lever to “2” position. ON When setting selector lever to other positions. OFF When setting selector lever to “1” position. ON When setting selector lever to other positions. OFF Released accelerator pedal. ON Depressed accelerator pedal. OFF Fully depressed accelerator pedal. ON Released accelerator pedal. OFF When shift solenoid valve A operates. (When driving in “D1 ” or “D4 ”.) ON When shift solenoid valve A does not operate. (When driving in “D2 ” or “D3 ”.) OFF When shift solenoid valve B operates. (When driving in “D1 ” or “D2 ”.) ON When shift solenoid valve B does not operate. (When driving in “D3 ” or “D4 ”.) OFF When overrun clutch solenoid valve operates. (When overrun clutch disengaged. Refer to AT22 .) ON When overrun clutch solenoid valve does not operate. (When overrun clutch engaged. Refer to AT-22 .) OFF Depressed brake pedal. ON Released brake pedal. OFF During driving 1, 2, 3, 4 When setting selector lever to “N” or “P” positions. N·P When setting selector lever to “R” position. R When setting selector lever to “D” position. D When setting selector lever to “2” position. 2 When setting selector lever to “1” position. 1 VEHICLE SPEED During driving Approximately matches the speedometer reading. LINE PRES DTY Line pressure low ⇔ Line pressure high 0% ⇔ 94% TCC S/V DUTY Lock-up OFF ⇔ Lock-up ON 4% ⇔ 94% W/O THRL/P-SW SHIFT S/V A SHIFT S/V B OVERRUN/C S/V BRAKE SW GEAR SLCT LVR POSI AT-84 TROUBLE DIAGNOSIS CONSULT-II START PROCEDURE A Refer to GI-36, "CONSULT-II Start Procedure" . SELF-DIAGNOSTIC RESULT MODE After performing AT-94, "Diagnostic Procedure Without CONSULT-II" , place check marks for results on the AT-45, "DIAGNOSTIC WORKSHEET" . Reference pages are provided following the items. B Operation Procedure 1. 2. Perform "CONSULT-II start procedure". Refer to GI-36, "CONSULT-II Start Procedure"GI-36 . Touch “SELF-DIAG RESULTS”. Display shows malfunction experienced since the last erasing operation. AT D E BCIA0031E F Display Items List (For EURO-OBD models) OBD (DTC) Items (CONSULT-II screen terms) CAN COMM CIRCUIT Malfunction is detected when... MIL indicator lamp*1, “ENGINE” with CONSULT-II or GST G Reference page H ● When malfunction is detected in CAN communication line. U1000 AT-102 ● TCM does not receive the correct voltage signal (based on the gear position) from the switch. P0705 AT-105 ATF TEMP SEN/CIRC ● TCM receives an excessively low or high voltage from the sensor. P0710 AT-110 VHCL SPEED SEN-A/T ● TCM does not receive the proper voltage signal from the sensor. P0720 AT-115 ENGINE SPEED SIG ● TCM does not receive the proper voltage signal from the ECM. P0725 AT-121 ● A/T cannot be shifted to the 1st gear position even if electrical circuit is good. P0731*2 AT-125 ● A/T cannot be shifted to the 2nd gear position even if electrical circuit is good. P0732*2 AT-129 ● A/T cannot be shifted to the 3rd gear position even if electrical circuit is good. P0733*2 AT-132 ● A/T cannot be shifted to the 4th gear position even if electrical circuit is good. P0734*2 AT-136 ● TCM detects an improper voltage drop when it tries to operate the solenoid valve. P0740 AT-142 ● A/T cannot perform lock-up even if electrical circuit is good. P0744*2 AT-147 ● TCM detects an improper voltage drop when it tries to operate the solenoid valve. P0745 AT-153 ● TCM detects an improper voltage drop when it tries to operate the solenoid valve. P0750 AT-159 ● TCM detects an improper voltage drop when it tries to operate the solenoid valve. P0755 AT-164 THROTTLE POSI SEN ● TCM receives an excessively low or high voltage from this sensor. P1705 AT-169 OVERRUN CLUTCH S/ V ● TCM detects an improper voltage drop when it tries to operate the solenoid valve. P1760 AT-171 ● TCM does not receive the proper voltage signal from the sensor. — AT-176 PNP SW/CIRC A/T 1ST GR FNCTN A/T 2ND GR FNCTN A/T 3RD GR FNCTN A/T 4TH GR FNCTN T/C CLUTCH SOL/V A/T TCC S/V FNCTN LINE PRESSURE S/V SHIFT SOLENOID/V A SHIFT SOLENOID/V B VHCL SPEED SENMTR AT-85 I J K L M TROUBLE DIAGNOSIS OBD (DTC) Items (CONSULT-II screen terms) Malfunction is detected when... MIL indicator lamp*1, “ENGINE” with CONSULT-II or GST Reference page BATT/FLUID TEMP SEN ● TCM receives an excessively low or high voltage from the sensor. — AT-180 TURBINE SENSOR ● TCM does not receive proper voltage signal from sensor. — AT-186 CONTROL UNIT (RAM) ● TCM memory (RAM) is malfunctioning. — AT-192 CONTROL UNIT (ROM) ● TCM memory (ROM) is malfunctioning. — AT-192 ● This is not a malfunction message (Whenever shutting off a power supply to the TCM, this message appears on the screen). Refer to AT-193, "MAIN POWER SUPPLY AND GROUND CIRCUIT" . — AT-193 No failure has been detected. — — INITIAL START No failure (NO SELF DIAGNOSTIC FAILURE INDICATED FURTHER TESTING MAY BE REQUIRED) ● *1: Refer to AT-101, "Malfunction Indicator Lamp (MIL)" . *2: These malfunctions cannot be displayed MIL if another malfunction is assigned to MIL. Display Items List (Except for EURO-OBD models) Items (CONSULT-II screen terms) Malfunction is detected when... Reference page VHCL SPEED SEN-A/T ● TCM does not receive the proper voltage signal from the sensor. AT-203 VHCL SPEED SEN-MTR ● TCM does not receive the proper voltage signal from the sensor. AT-209 THROTTLE POSI SEN ● TCM receives an excessively low or high voltage from this sensor. AT-213 ● TCM detects an improper voltage drop when it tries to operate the solenoid valve. AT-215 ● TCM detects an improper voltage drop when it tries to operate the solenoid valve. AT-220 ● TCM detects an improper voltage drop when it tries to operate the solenoid valve. AT-225 ● TCM detects an improper voltage drop when it tries to operate the solenoid valve. AT-230 BATT/FLUID TEMP SEN ● TCM receives an excessively low or high voltage from the sensor. AT-235 ENGINE SPEED SIG ● TCM does not receive the proper voltage signal from the ECM. AT-241 TURBINE SENSOR ● TCM does not receive proper voltage signal from sensor. AT-245 ● TCM detects an improper voltage drop when it tries to operate the solenoid valve. AT-251 ● When malfunction is detected in CAN communication line. AT-257 ● A/T cannot be shifted to the 1st gear position even if electrical circuit is good. AT-264 ● A/T cannot be shifted to the 2nd gear position even if electrical circuit is good. AT-268 ● A/T cannot be shifted to the 3rd gear position even if electrical circuit is good. AT-271 ● A/T cannot be shifted to the 4th gear position even if electrical circuit is good. AT-275 A/T TCC S/V FNCTN ● A/T cannot perform lock-up even if electrical circuit is good. AT-281 CONTROL UNIT (RAM) ● TCM memory (RAM) is malfunctioning. AT-287 CONTROL UNIT (ROM) ● TCM memory (ROM) is malfunctioning. AT-287 SHIFT SOLENOID/V A SHIFT SOLENOID/V B OVERRUN CLUTCH S/V T/C CLUTCH SOL/V LINE PRESSURE S/V CAN COMM CIRCUIT A/T 1ST GR FNCTN A/T 2ND GR FNCTN A/T 3RD GR FNCTN A/T 4TH GR FNCTN AT-86 TROUBLE DIAGNOSIS Items (CONSULT-II screen terms) Malfunction is detected when... ● INITIAL START No failure (NO SELF DIAGNOSTIC FAILURE INDICATED FURTHER TESTING MAY BE REQUIRED) This is not a malfunction message (Whenever shutting off a power supply to the TCM, this message appears on the screen). Refer to AT-260, "MAIN POWER SUPPLY AND GROUND CIRCUIT" . Reference page A AT-260 B ● No failure has been detected. — AT How to Erase Self-diagnostic Results 1. 2. Perform "CONSULT-II start procedure". Refer to GI-36, "CONSULT-II Start Procedure" . Touch “SELF-DIAG RESULTS”. D E F BCIA0031E 3. G Touch “ERASE”. (The self-diagnostic results will be erased.) H I J SCIA4849E K L M AT-87 TROUBLE DIAGNOSIS DATA MONITOR MODE Operation Procedure 1. 2. Perform "CONSULT-II start procedure". Refer to GI-36, "CONSULT-II Start Procedure" . Touch “DATA MONITOR”. NOTE: When malfunction is detected, CONSULT-II performs “REAL-TIME DIAGNOSIS”. Also, any malfunction detected while in this mode will be displayed in real time. BCIA0031E Display Items List X: Standard, —: Not applicable, : Option Monitor Item Selection Monitored item (Unit) VHCL/S SE-A/T (km/h) SELECTION FROM MENU Remarks TCM INPUT SIGNALS MAIN SIGNALS X — Revolution sensor Vehicle speed display may not be accurate under approx. 10 km/h (6 mph). It may not indicate 0 km/h (0 mph) when vehicle is stationary. VHCL/S SE-MTR (km/h) X — THRTL POS SEN (V) X — FLUID TEMP SE (V) X — BATTERY VOLT (V) X — ENGINE SPEED (rpm) X X TURBINE REV (rpm) X — OVERDRIVE SW (ON/OFF) X — PN POSI SW (ON/OFF) X — R POSITION SW (ON/OFF) X — D POSITION SW (ON/OFF) X — 2 POSITION SW (ON/OFF) X — 1 POSITION SW (ON/OFF) X — ASCD-CRUISE (ON/OFF) X — ASCD-OD CUT (ON/OFF) X — KICKDOWN SW (ON/OFF) X — POWERSHIFT SW (ON/OFF) X — CLOSED THL/SW (ON/OFF) X — W/O THRL/P-SW (ON/OFF) X — *SHIFT S/V A (ON/OFF) — — *SHIFT S/V B (ON/OFF) — — *OVRRUN/C S/V (ON/OFF) — — Signal input with CAN communication. Not mounted but displayed. Signal input with CAN communication. AT-88 Displays status of check signal (reinput signal) for TCM control signal output. Remains unchanged when solenoid valves are open or shorted. TROUBLE DIAGNOSIS Monitor Item Selection Monitored item (Unit) SELECTION FROM MENU A Remarks TCM INPUT SIGNALS MAIN SIGNALS HOLD SW (ON/OFF) X — Not mounted but displayed. BRAKE SW (ON/OFF) X — Stop lamp switch GEAR — X Gear position recognized by the TCM updated after gear-shifting SLCT LVR POSI — X Selector lever position is recognized by the TCM. For fail-safe operation, the specific value used for control is displayed. VEHICLE SPEED (km/h) — X Vehicle speed recognized by the TCM. X Degree of opening for accelerator recognized by the TCM For fail-safe operation, the specific value used for control is displayed. THROTTLE POSI (0.0/8) — LINE PRES DTY (%) — X TCC S/V DUTY (%) — X SHIFT S/V A (ON/OFF) — X SHIFT S/V B (ON/OFF) — X OVERRUN/C S/V (ON/OFF) — X SELF-D DP LMP (ON/OFF) — X TC SLIP RATIO (0.000) — — TC SLIP SPEED (rpm) — — Difference between engine speed and torque converter input shaft speed Voltage (V) — — Displays the value measured by the voltage probe. Frequency (Hz) — — DUTY-HI (high) (%) — — DUTY-LOW (low) (%) — — PLS WIDTH-HI (ms) — — PLS WIDTH-LOW (ms) — — AT-89 B AT D E F G H I J K The value measured by the pulse probe is displayed. L M TROUBLE DIAGNOSIS CAN DIAGNOSTIC SUPPORT MONITOR MODE Operation Procedure 1. 2. Perform "CONSULT-II start procedure". Refer to GI-36, "CONSULT-II Start Procedure" . Touch “CAN DAIG SUPPORT MNTR”. BCIA0031E DTC WORK SUPPORT MODE WITH CONSULT-II Operation Procedure 1. 2. Perform "CONSULT-II start procedure". Refer to GI-36, "CONSULT-II Start Procedure" . Touch “DTC WORK SUPPORT”. BCIA0031E 3. Touch select item menu (1ST, 2ND, etc.). SAT018K 4. Touch “START”. SAT589J AT-90 TROUBLE DIAGNOSIS 5. Perform driving test according to “DTC CONFIRMATION PROCEDURE” in “TROUBLE DIAGNOSIS FOR DTC”. A B AT SAT019K D ● When testing conditions are satisfied, CONSULT-II screen changes from “OUT OF CONDITION” to “TESTING”. E F G SAT591J 6. Stop vehicle. H I J SAT592J ● If “NG” appears on the screen, malfunction may exist. Go to “Diagnostic Procedure”. K L M SAT593J AT-91 TROUBLE DIAGNOSIS 7. Perform test drive to check gear shift feeling in accordance with the instructions displayed. SAT594J 8. Touch “YES” or “NO”. SAT595J 9. CONSULT-II procedure ended. SAT596J ● If “NG” appears on the screen, malfunction may exist. Go to “Diagnostic Procedure”. SAT593J AT-92 TROUBLE DIAGNOSIS Display Items List DTC work support item Description Following items for “A/T 1st gear function (P0731)” can be confirmed. 1ST GR FNCTN P0731 ● ● Self-diagnosis status (whether the diagnosis is being performed or not) Self-diagnostic results (OK or NG) Following items for “A/T 2nd gear function (P0732)” can be confirmed. 2ND GR FNCTN P0732 Shift solenoid valve B ● Each clutch ● Hydraulic control circuit B AT Shift solenoid valve B Each clutch ● Hydraulic control circuit D ● Shift solenoid valve A E ● Each clutch ● Hydraulic control circuit ● Shift solenoid valve A ● Shift solenoid valve B ● Overrun clutch solenoid valve ● Line pressure solenoid valve ● Each clutch ● Hydraulic control circuit Following items for “A/T TCC S/V function (lock-up) (P0744)” can be confirmed. ● Torque converter clutch solenoid valve Self-diagnosis status (whether the diagnosis is being performed or not) ● Each clutch ● Hydraulic control circuit ● Self-diagnostic results (OK or NG) ● Self-diagnosis status (whether the diagnosis is being performed or not) ● Self-diagnostic results (OK or NG) ● ● TCC S/V FNCTN P0744 Shift solenoid valve A ● ● Self-diagnosis status (whether the diagnosis is being performed or not) Following items for “A/T 4th gear function (P0734)” can be confirmed. 4TH GR FNCTN P0734 ● A ● ● Following items for “A/T 3rd gear function (P0733)” can be confirmed. 3RD GR FNCTN P0733 Check item ● ● Self-diagnosis status (whether the diagnosis is being performed or not) Self-diagnostic results (OK or NG) Self-diagnostic results (OK or NG) F G H I J K L M AT-93 TROUBLE DIAGNOSIS Diagnostic Procedure Without CONSULT-II BCS000OB TCM SELF-DIAGNOSTIC PROCEDURE Description If a malfunction occurs in electrical system, turning ignition switch ON will illuminate OD OFF indicator lamp for 2 seconds. To detect a malfunction, entering a self-diagnosis start signal retrieves information on malfunctions from memory and indicates malfunction by blinking OD OFF indicator lamp. Diagnostic Procedure 1. CHECK OD OFF INDICATOR LAMP 1. 2. 3. Park vehicle on flat surface. Move selector lever to “P” position. Turn ignition switch OFF. Wait at least 5 seconds. SCIA5472E 4. Turn ignition switch ON. (Do not start engine.) Does OD OFF indicator lamp (1) come on about 2 seconds? YES >> GO TO 2. NO >> Stop procedure. Perform AT-299, "OD OFF Indicator Lamp Does Not Come On" before proceeding. MCIB0175E 2. JUDGEMENT PROCEDURE STEP 1 1. 2. 3. 4. 5. Turn ignition switch OFF. Keep pressing shift lock release button. Move selector lever from “P” to “D” position. Turn ignition switch ON. (Do not start engine.) Keep pressing overdrive control switch while OD OFF indicator lamp is lighting up for 2 seconds. (OD OFF indicator lamp is on.) 6. Keep pressing overdrive control switch and shift selector lever to the “2” position. (OD OFF indicator lamp is on.) 7. Stop pressing overdrive control switch. (OD OFF indicator lamp is on.) 8. Shift selector lever to the “1” position. (OD OFF indicator lamp is on.) 9. Keep pressing overdrive control switch. (OD OFF indicator lamp is off.) 10. Depress accelerator pedal fully while pressing overdrive control switch. >> GO TO 3. AT-94 TROUBLE DIAGNOSIS 3. CHECK SELF-DIAGNOSIS CODE A Check OD OFF indicator lamp. Refer to AT-95, "Judgement of Self-diagnosis Code" . B >> DIAGNOSIS END Judgement of Self-diagnosis Code OD OFF indicator lamp All judgement flickers are the same. AT 1st judgement flicker is longer than others. D E F SCIA7161E SCIA5591E All circuits that can be confirmed by self-diagnosis are OK. Revolution sensor circuit is short-circuited or disconnected. Þ Go to AT-115, "DTC P0720 VEHICLE SPEED SENSOR·A/T (REVOLUTION SENSOR)" (*1), AT-203, "VEHICLE SPEED SENSOR·A/T (REVOLUTION SENSOR)" (*2). 2nd judgement flicker is longer than others. 3rd judgement flicker is longer than others. G H I J K SCIA5592E SCIA5593E Vehicle speed sensor circuit is short-circuited or disconnected. Þ Go to AT-176, "DTC VEHICLE SPEED SENSOR MTR" (*1), AT-209, "VEHICLE SPEED SENSOR MTR" (*2). Accelerator pedal position (APP) sensor circuit is short-circuited or disconnected. Þ Go to AT-169, "DTC P1705 ACCELERATOR PEDAL POSITION (APP) SENSOR" (*1), AT-213, "ACCELERATOR PEDAL POSITION (APP) SENSOR" (*2). 4th judgement flicker is longer than others. 5th judgement flicker is longer than others. SCIA5594E M SCIA5595E Shift solenoid valve A circuit is short-circuited or disconnected. Þ Go to AT-159, "DTC P0750 SHIFT SOLENOID VALVE A" (*1), AT-215, "SHIFT SOLENOID VALVE A" (*2). Shift solenoid valve B circuit is short-circuited or disconnected. Þ Go to AT-164, "DTC P0755 SHIFT SOLENOID VALVE B" (*1), AT-220, "SHIFT SOLENOID VALVE B" (*2). AT-95 L TROUBLE DIAGNOSIS OD OFF indicator lamp 6th judgement flicker is longer than others. 7th judgement flicker is longer than others. SCIA5596E SCIA5597E Overrun clutch solenoid valve circuit is short-circuited or disconnected. Þ Go to AT-171, "DTC P1760 OVERRUN CLUTCH SOLENOID VALVE" (*1), AT-225, "OVERRUN CLUTCH SOLENOID VALVE" (*2). Torque converter clutch solenoid valve circuit is short-circuited or disconnected. Þ Go to AT-142, "DTC P0740 TORQUE CONVERTER CLUTCH SOLENOID VALVE" (*1), AT-230, "TORQUE CONVERTER CLUTCH SOLENOID VALVE" (*2). 8th judgement flicker is longer than others. 9th judgement flicker is longer than others. SCIA5598E SCIA5599E A/T fluid temperature sensor is disconnected or TCM power supply circuit is damaged. Þ Go to AT-180, "DTC BATT/FLUID TEMP SEN (A/T FLUID TEMP SENSOR CIRCUIT AND TCM POWER SOURCE)" (*1), AT-235, "BATT/FLUID TEMP SEN (A/T FLUID TEMP SENSOR CIRCUIT AND TCM POWER SOURCE)" (*2). Engine speed signal circuit is short-circuited or disconnected. Þ Go to AT-121, "DTC P0725 ENGINE SPEED SIGNAL" (*1), AT-241, "ENGINE SPEED SIGNAL" (*2). 10th judgement flicker is longer than others. 11th judgement flicker is longer than others. SCIA7082E SCIA7083E Turbine revolution sensor (power train revolution sensor) circuit is short-circuited or disconnected. Þ Go to AT-186, "DTC TURBINE REVOLUTION SENSOR" (*1), AT-245, "TURBINE REVOLUTION SENSOR" (*2). Line pressure solenoid valve circuit is short-circuited or disconnected. Þ Go to AT-153, "DTC P0745 LINE PRESSURE SOLENOID VALVE" (*1), AT-251, "LINE PRESSURE SOLENOID VALVE" (*2). AT-96 TROUBLE DIAGNOSIS OD OFF indicator lamp 12th judgement flicker is longer than others. A Lamp turns off. B AT D SCIA7085E SCIA4674E CAN communication line is damaged. Þ Go to AT-102, "DTC U1000 CAN COMMUNICATION LINE" (*1), AT-257, "CAN COMMUNICATION LINE" (*2). Park/neutral position (PNP) switch, overdrive control switch, closed throttle position signal or wide open throttle position signal circuit is disconnected or TCM is damaged. (Because overdrive control switch signal, closed throttle position signal and wide open throttle position signal are input via CAN communication line malfunction may continue after self-diagnosis.) Þ Go to AT-329, "TCM Self-diagnosis Does Not Activate" . Flickers as shown below. E F G H I J SCIA4675E Battery power is low. Battery has been disconnected for a long time. Battery is connected reversely. (When reconnecting TCM connectors.—This is not a malfunction.) Þ Go to AT-193, "MAIN POWER SUPPLY AND GROUND CIRCUIT" (*1), AT-260, "MAIN POWER SUPPLY AND GROUND CIRCUIT" (*2). t1 = 2.5 seconds t2 = 2.0 seconds *1: For EURO-OBD models *2: Except for EURO-OBD models t3 = 1.0 second 2. 3. L t4 = 1.0 second M How to Erase Self-diagnostic Results 1. K If the ignition switch stays ON after repair work, be sure to turn ignition switch OFF once. Wait for at least 5 seconds and then turn it ON again. Perform AT-94, "Diagnostic Procedure Without CONSULT-II" . Turn ignition switch OFF. (The self-diagnostic results will be erased.) AT-97 ON BOARD DIAGNOSTIC (OBD) SYSTEM [EURO-OBD] ON BOARD DIAGNOSTIC (OBD) SYSTEM Introduction [EURO-OBD] PFP:00028 BCS000OC A/T system has two self-diagnostic systems. The first is emission-related on board diagnostic system (OBD) performed by the TCM in combination with the ECM. The malfunction is indicated by the MIL (malfunction indicator lamp) and is stored as a DTC in the ECM memory but not the TCM memory. The second is the TCM original self-diagnosis indicated by the OD OFF indicator lamp. The malfunction is stored in the TCM memory. The detected items are overlapped with OBD self-diagnostic items. For detail, refer to AT-85, "SELF-DIAGNOSTIC RESULT MODE" . OBD Function for A/T System BCS000OD The ECM provides emission-related on board diagnostic (OBD) functions for the A/T system. One function is to receive a signal from the TCM used with OBD-related parts of the A/T system. The signal is sent to the ECM when a malfunction occurs in the corresponding OBD-related part. The other function is to indicate a diagnostic result by means of the MIL (malfunction indicator lamp) on the instrument panel. Sensors, switches and solenoid valves are used as sensing elements. The MIL automatically illuminates in One or Two Trip Detection Logic when a malfunction is sensed in relation to A/T system parts. One or Two Trip Detection Logic of OBD BCS000OE ONE TRIP DETECTION LOGIC If a malfunction is sensed during the first test drive, the MIL will illuminate and the malfunction will be stored in the ECM memory as a DTC. The TCM is not provided with such a memory function. TWO TRIP DETECTION LOGIC When a malfunction is sensed during the first test drive, it is stored in the ECM memory as a 1st trip DTC (diagnostic trouble code) or 1st trip freeze frame data. At this point, the MIL will not illuminate. — 1st trip If the same malfunction as that experienced during the first test drive is sensed during the second test drive, the MIL will illuminate. — 2nd trip The “trip” in the “One or Two Trip Detection Logic” means a driving mode in which self-diagnosis is performed during vehicle operation. OBD Diagnostic Trouble Code (DTC) BCS000OF HOW TO READ DTC AND 1ST TRIP DTC DTC and 1st trip DTC can be read by the following methods. ( with CONSULT-II or GST) CONSULT-II or GST (Generic Scan Tool) Examples: P0705, P0720 etc. These DTC are prescribed by SAE J2012. (CONSULT-II also displays the malfunctioning component or system.) ● 1st trip DTC No. is the same as DTC No. ● Output of the diagnostic trouble code indicates that the indicated circuit has a malfunction. However, in case of the Mode II and GST, they do not indicate whether the malfunction is still occurring or occurred in the past and returned to normal. CONSULT-II can identify them as shown below, therefore, CONSULT-II (if available) is recommended. A sample of CONSULT-II display for DTC and 1st trip DTC is shown on the next page. DTC or 1st trip DTC of a malfunction is displayed in SELF-DIAGNOSTIC RESULTS mode for “ENGINE” with CONSULT-II. Time data indicates how many times the vehicle was driven after the last detection of a DTC. SAT014K AT-98 ON BOARD DIAGNOSTIC (OBD) SYSTEM [EURO-OBD] If the DTC is being detected currently, the time data will be “0”. A B AT SAT015K D If a 1st trip DTC is stored in the ECM, the time data will be “1t”. E F G SAT016K Freeze Frame Data and 1st Trip Freeze Frame Data The ECM has a memory function, which stores the driving condition such as fuel system status, calculated load value, engine coolant temperature, short term fuel trim, long term fuel trim, engine speed and vehicle speed at the moment the ECM detects a malfunction. Data which are stored in the ECM memory, along with the 1st trip DTC, are called 1st trip freeze frame data, and the data, stored together with the DTC data, are called freeze frame data and displayed on CONSULT-II or GST. The 1st trip freeze frame data can only be displayed on the CONSULT-II screen, not on the GST. For detail, refer to EC-102, "CONSULT-II Function (ENGINE)" . Only one set of freeze frame data (either 1st trip freeze frame data of freeze frame data) can be stored in the ECM. 1st trip freeze frame data is stored in the ECM memory along with the 1st trip DTC. There is no priority for 1st trip freeze frame data and it is updated each time a different 1st trip DTC is detected. However, once freeze frame data (2nd trip detection/MIL on) is stored in the ECM memory, 1st trip freeze frame data is no longer stored. Remember, only one set of freeze frame data can be stored in the ECM. The ECM has the following priorities to update the data. Priority 1 Items Freeze frame data 2 3 Misfire — DTC: P0300 - P0306 Fuel Injection System Function — DTC: P0171, P0172, P0174, P0175 Except the above items (Includes A/T related items) 1st trip freeze frame data Both 1st trip freeze frame data and freeze frame data (along with the DTC) are cleared when the ECM memory is erased. HOW TO ERASE DTC The diagnostic trouble code can be erased by CONSULT-II, GST or ECM DIAGNOSTIC TEST MODE as described following. ● If the battery cable is disconnected, the diagnostic trouble code will be cleared within 24 hours. ● When you erase the DTC, using CONSULT-II or GST is easier and quicker than switching the mode selector on the ECM. The following emission-related diagnostic information is cleared from the ECM memory when erasing DTC related to OBD. For details, refer to EC-48, "Emission-related Diagnostic Information" . ● Diagnostic trouble codes (DTC) ● 1st trip diagnostic trouble codes (1st trip DTC) ● Freeze frame data AT-99 H I J K L M ON BOARD DIAGNOSTIC (OBD) SYSTEM [EURO-OBD] ● ● ● 1st trip freeze frame data System readiness test (SRT) codes Test values HOW TO ERASE DTC (WITH CONSULT-II) ● 1. 2. 3. 4. 5. 6. 7. If a DTC is displayed for both ECM and TCM, it is necessary to be erased for both ECM and TCM. If the ignition switch stays ON after repair work, be sure to turn ignition switch OFF once. Wait at least 10 seconds and then turn it ON (engine stopped) again. Turn CONSULT-II “ON” and touch “A/T”. Touch “SELF-DIAG RESULTS”. Touch “ERASE”. (The DTC in the TCM will be erased.) Then touch “BACK” twice. Touch “ENGINE”. Touch “SELF-DIAG RESULTS”. Touch “ERASE”. (The DTC in the ECM will be erased.) SCIA7155E HOW TO ERASE DTC (WITH GST) 1. 2. 3. If the ignition switch stays ON after repair work, be sure to turn ignition switch OFF once. Wait at least 10 seconds and then turn it ON (engine stopped) again. Perform “TCM SELF-DIAGNOSTIC PROCEDURE (No Tools)”. Refer to AT-94, "Diagnostic Procedure Without CONSULT-II" . (The engine warm-up step can be skipped when performing the diagnosis only to erase the DTC.) Select Mode 4 with Generic Scan Tool (GST). For details, refer to EC-111, "Generic Scan Tool (GST) Function" . AT-100 ON BOARD DIAGNOSTIC (OBD) SYSTEM [EURO-OBD] HOW TO ERASE DTC (NO TOOLS) A The OD OFF indicator lamp is located on the combination meter. 1. If the ignition switch stays ON after repair work, be sure to turn ignition switch OFF once. Wait at least 10 seconds and then turn it ON (engine stopped) again. B 2. Perform “TCM SELF-DIAGNOSTIC PROCEDURE (No Tools)”. Refer to AT-94, "Diagnostic Procedure Without CONSULT-II" . (The engine warm-up step can be skipped when performing the diagnosis only to erase the DTC.) AT 3. Perform “OBD SELF-DIAGNOSTIC PROCEDURE (No tools)”. Refer to EC-57, "How to Erase DTC" . Malfunction Indicator Lamp (MIL) BCS000OG DESCRIPTION D The MIL is located on the instrument panel. 1. The MIL will light up when the ignition switch is turned ON without the engine running. This is a bulb check. ● If the MIL does not light up, refer to DI-32, "WARNING LAMPS" , or see EC-448, "MI & DATA LINK CONNECTORS" . 2. When the engine is started, the MIL should go off. ● If the MIL remains on, the on board diagnostic system has detected an engine system malfunction. E F G SAT652J H I J K L M AT-101 DTC U1000 CAN COMMUNICATION LINE [EURO-OBD] DTC U1000 CAN COMMUNICATION LINE Description PFP:31940 BCS000OH CAN (Controller Area Network) is a serial communication line for real time application. It is an on-vehicle multiplex communication line with high data communication speed and excellent malfunction detection ability. Many electronic control units are equipped onto a vehicle, and each control unit shares information and links with other control units during operation (not independent). In CAN communication, control units are connected with 2 communication lines (CAN H line, CAN L line) allowing a high rate of information transmission with less wiring. Each control unit transmits/receives data but selectively reads required data only. On Board Diagnosis Logic ● ● BCS000OI This is an OBD self-diagnostic item. Diagnostic trouble code “U1000 CAN COMM CIRCUIT” with CONSULT-II or 12th judgement flicker without CONSULT-II is detected when TCM cannot communicate to other control units. Possible Cause BCS000OJ Harness or connector (CAN communication line is open or shorted.) DTC Confirmation Procedure BCS000OK CAUTION: If performing this “DTC Confirmation Procedure” again, always turn ignition switch OFF and wait at least 10 seconds before continuing. After the repair, perform the following procedure to confirm the malfunction is eliminated. WITH CONSULT-II 1. 2. 3. 4. 5. Turn ignition switch ON. Select “DATA MONITOR” mode for “A/T” with CONSULT-II. Touch “START”. Wait at least 6 seconds or start engine and wait for at least 6 seconds. If DTC is detected, go to AT-104, "Diagnostic Procedure" . BCIA0031E WITH GST Follow the procedure “WITH CONSULT-II”. WITHOUT CONSULT-II 1. 2. 3. 4. Turn ignition switch ON. Wait at least 6 seconds or start engine and wait at least 6 seconds. Perform self-diagnosis. Refer to AT-94, "Diagnostic Procedure Without CONSULT-II" . If DTC is detected, go to AT-104, "Diagnostic Procedure" . AT-102 DTC U1000 CAN COMMUNICATION LINE [EURO-OBD] Wiring Diagram — AT — CAN BCS000OL A B AT D E F G H I J K L M MCWA0241E AT-103 DTC U1000 CAN COMMUNICATION LINE [EURO-OBD] TCM terminal data are reference values, measured between each terminal and ground. Terminal Wire color Item Condition Judgement standard (Approx.) 5 L CAN H — — 6 Y CAN L — — Diagnostic Procedure BCS000OM 1. CHECK CAN COMMUNICATION CIRCUIT With CONSULT-II 1. Turn ignition switch ON and start engine. 2. Select “SELF-DIAG RESULTS” mode for “A/T” with CONSULTII. Is any malfunction of the “U1000 CAN COMM CIRCUIT” indicated? YES >> Print out CONSULT-II screen, GO TO LAN section. Refer to LAN-3, "Precautions When Using CONSULT-II" . NO >> INSPECTION END SCIA7135E AT-104 DTC P0705 PARK/NEUTRAL POSITION (PNP) SWITCH [EURO-OBD] DTC P0705 PARK/NEUTRAL POSITION (PNP) SWITCH Description PFP:32006 A BCS000ON The PNP switch assembly includes a transaxle range switch. The transaxle range switch detects the selector lever position and sends a signal to the TCM. ● ● CONSULT-II Reference Value BCS000OO Remarks: Specification data are reference values. Item name Condition PN POSI SW R POSITION SW D POSITION SW 2 POSITION SW 1 POSITION SW ● When setting selector lever to “N” or “P” position. ON When setting selector lever to other positions. OFF When setting selector lever to “R” position. ON When setting selector lever to other positions. OFF When setting selector lever to “D” position. ON When setting selector lever to other positions. OFF When setting selector lever to “2” position. ON When setting selector lever to other positions. OFF When setting selector lever to “1” position. ON When setting selector lever to other positions. OFF ● D E F G BCS000OP This is an OBD self-diagnostic item. Diagnostic trouble code “P0705 PNP SW/CIRC” with CONSULT-II is detected when TCM does not receive the correct voltage signal from the switch based on the gear position. BCS000OQ Harness or connectors [The PNP switch circuit is open or shorted.] PNP switch J DTC Confirmation Procedure BCS000OR CAUTION: ● Always drive vehicle at a safe speed. ● If performing this “DTC Confirmation Procedure” again, always turn ignition switch OFF and wait at least 10 seconds before continuing. After the repair, perform the following procedure to confirm the malfunction is eliminated. WITH CONSULT-II 1. 2. 3. 4. 5. H I Possible Cause ● AT Display value On Board Diagnosis Logic ● B K L M Turn ignition switch ON. (Do not start engine.) Select “DATA MONITOR” mode for “A/T” with CONSULT-II. Touch “START”. Start engine and maintain the following conditions for at least 5 consecutive seconds. VEHICLE SPEED: 10 km/h (6 MPH) or more THROTTLE POSI: More than 1.0/8 SLCT LVR POSI: “D” position If the check result is NG, go to AT-107, "Diagnostic Procedure" . BCIA0031E WITH GST Follow the procedure “WITH CONSULT-II”. AT-105 DTC P0705 PARK/NEUTRAL POSITION (PNP) SWITCH [EURO-OBD] Wiring Diagram — AT — PNP/SW BCS000OS MCWA0242E AT-106 DTC P0705 PARK/NEUTRAL POSITION (PNP) SWITCH [EURO-OBD] TCM terminal data are reference values, measured between each terminal and ground. Wire color Item Battery voltage Y PNP switch “1” position When setting selector lever to “1” position. 26 When setting selector lever to other positions. 0V Battery voltage L PNP switch “2” position When setting selector lever to “2” position. 27 When setting selector lever to other positions. 0V When setting selector lever to “D” position. Battery voltage LG PNP switch “D” position 34 35 L PNP switch “R” position 36 R PNP switch “N” or “P” position Condition Judgement standard (Approx.) Terminal and B AT When setting selector lever to other positions. 0V When setting selector lever to “R” position. Battery voltage When setting selector lever to other positions. 0V When setting selector lever to “N” or “P” position. Battery voltage When setting selector lever to other positions. 0V Diagnostic Procedure A D E BCS000OT F 1. CHECK INPUT SIGNAL G With CONSULT-II 1. Turn ignition switch ON. (Do not start engine.) 2. Select “TCM INPUT SIGNALS” in “DATA MONITOR” mode for “A/T” with CONSULT-II. 3. Read out “P·N”, “R”, “D”, “2” and “1” position switches moving selector lever to each position. H I Item name Condition Display value ON PN POSI SW When setting selector lever to “N” or “P” position. When setting selector lever to other positions. OFF When setting selector lever to “R” position. ON When setting selector lever to other positions. OFF When setting selector lever to “D” positions. ON When setting selector lever to other positions. OFF When setting selector lever to “2” position. ON When setting selector lever to other positions. OFF When setting selector lever to “1” position. ON When setting selector lever to other positions. OFF R POSITION SW D POSITION SW 2 POSITION SW 1 POSITION SW J SAT701J OK or NG OK >> GO TO 6. NG >> GO TO 3. AT-107 K L M DTC P0705 PARK/NEUTRAL POSITION (PNP) SWITCH [EURO-OBD] 2. CHECK INPUT SIGNAL Without CONSULT-II 1. Turn ignition switch ON. (Do not start engine.) 2. Check voltage between TCM connector terminals and ground while moving selector lever through each position. Terminal Selector lever position 36 35 34 27 26 P, N B 0 0 0 0 R 0 B 0 0 0 D 0 0 B 0 0 2 0 0 0 B 0 1 0 0 0 0 B B: Battery voltage 0: 0V OK or NG OK >> GO TO 6. NG >> GO TO 3. SCIA7162E 3. CHECK PNP SWITCH 1. 2. 3. Turn ignition switch OFF. Disconnect PNP switch harness connector. Check continuity between PNP switch harness connector terminals. Selector lever position Terminal Continuity P 1 - 2, 3 - 7 R 3-8 Yes *Continuity should not exist in positions other than the specified positions. N Connector F12 1 - 2, 3 - 9 D 3-6 2 3-5 1 3-4 SCIA3553E OK or NG OK >> GO TO 5. NG >> GO TO 4. 4. CHECK CONTROL CABLE ADJUSTMENT Check PNP switch again with control cable disconnected from manual shaft of A/T assembly. Refer to test group 3. OK or NG OK >> Adjust control cable. Refer to AT-336, "Adjustment of A/T Position" . NG >> Repair or replace PNP switch. Refer to AT-349, "Park/Neutral Position (PNP) Switch" . AT-108 DTC P0705 PARK/NEUTRAL POSITION (PNP) SWITCH [EURO-OBD] 5. DETECT MALFUNCTIONING ITEM A Check the following items: ● Harness for short or open between ignition switch and PNP switch. ● Harness for short or open between PNP switch and TCM. ● Harness for short or open between combination meter and PNP switch. ● Harness for short or open between combination meter and TCM. ● 10A fuse (No.60, located in the IPDM E/R) ● Combination meter. Refer to DI-4, "COMBINATION METERS" . ● Ignition switch. Refer to PG-38, "GROUND" . OK or NG OK >> GO TO 6. NG >> Repair or replace damaged parts. B AT D E 6. CHECK DTC F Perform AT-105, "DTC Confirmation Procedure" . OK or NG OK >> INSPECTION END NG >> GO TO 7. G 7. CHECK TCM H 1. Check TCM input/output signal. Refer to AT-80, "TCM Terminals and Reference Value" . 2. If NG, recheck TCM pin terminals for damage or loose connection with harness connector. OK or NG OK >> INSPECTION END NG >> Repair or replace damaged parts. Component Inspection I BCS000OU J PNP SWITCH 1. Check continuity between PNP switch harness connector terminals. Selector lever position Connector Terminal Continuity “P” 1 - 2, 3 - 7 “R” 3-8 Yes *Continuity should not exist in positions other than the specified positions. “N” “D” 2. 3. 4. 5. 6. 1 - 2, 3 - 9 F12 3-6 “2” 3-5 “1” 3-4 If NG, check again with control cable (2) disconnected from manual shaft of A/T assembly. Refer to step 1. (1): Lock nut (3): Manual shaft If OK on step 2, adjust control cable (2). Refer to AT-336, "Adjustment of A/T Position" . If NG on step 2, remove PNP switch from A/T and check continuity of PNP switch terminals. Refer to step 1. If OK on step 4, adjust PNP switch. Refer to AT-350, "PARK/ NEUTRAL POSITION (PNP) SWITCH ADJUSTMENT" . If NG on step 4, replace PNP switch. Refer to AT-349, "Park/ Neutral Position (PNP) Switch" . AT-109 K L M SCIA5588E SCIA6370J DTC P0710 A/T FLUID TEMPERATURE SENSOR CIRCUIT [EURO-OBD] DTC P0710 A/T FLUID TEMPERATURE SENSOR CIRCUIT Description PFP:31940 BCS000OV The A/T fluid temperature sensor detects the A/T fluid temperature and sends a signal to the TCM. CONSULT-II Reference Value BCS000OW Remarks: Specification data are reference values. Item name Condition FLUID TEMP SE Display value (Approx.) When A/T fluid temperature is 20°C (68°F). 1.5V When A/T fluid temperature is 80°C (176°F). 0.5V On Board Diagnosis Logic ● ● BCS000OX This is an OBD self-diagnostic item. Diagnostic trouble code “P0710 ATF TEMP SEN/CIRC” with CONSULT-II is detected when TCM receives an excessively low or high voltage from the sensor. Possible Cause ● ● BCS000OY Harness or connector (The sensor circuit is open or shorted.) A/T fluid temperature sensor DTC Confirmation Procedure BCS000OZ CAUTION: ● Always drive vehicle at a safe speed. ● If performing this “DTC Confirmation Procedure” again, always turn ignition switch OFF and wait at least 10 seconds before continuing. After the repair, perform the following procedure to confirm the malfunction is eliminated. WITH CONSULT-II 1. 2. 3. 4. Turn ignition switch ON and select “DATA MONITOR” mode for “A/T” with CONSULT-II. Touch “START”. Start engine and maintain the following conditions for at least 10 minutes (Total). (It is not necessary to maintain continuously.) ENGINE SPEED: 450 rpm or more VEHICLE SPEED: 10 km/h (6 MPH) or more THROTTLE POSI: More than 1.0/8 SLCT LVR POSI: “D” position If the check result is NG, go to AT-112, "Diagnostic Procedure" . BCIA0031E WITH GST Follow the procedure “With CONSULT-II”. AT-110 DTC P0710 A/T FLUID TEMPERATURE SENSOR CIRCUIT [EURO-OBD] Wiring Diagram — AT — FTS BCS000P0 A B AT D E F G H I J K L M MCWA0243E AT-111 DTC P0710 A/T FLUID TEMPERATURE SENSOR CIRCUIT [EURO-OBD] TCM terminal data are reference values, measured between each terminal and ground. Terminal Wire color 42 B 47 BR Item Sensor ground A/T fluid temperature sensor Condition Judgement standard (Approx.) Always 0V and When A/T fluid temperature is 20°C (68°F). 1.5V When A/T fluid temperature is 80°C (176°F). 0.5V Diagnostic Procedure BCS000P1 1. CHECK INPUT SIGNAL With CONSULT-II 1. Start engine. 2. Select “TCM INPUT SIGNALS” in “DATA MONITOR” mode for “A/T” with CONSULT-II. 3. Read out the value of “FLUID TEMP SE”. Item name Condition Display value (Approx.) FLUID TEMP SE When A/T fluid temperature is 20°C (68°F). 1.5V When A/T fluid temperature is 80°C (176°F). 0.5V LCIA0090E Without CONSULT-II 1. Start engine. 2. Check voltage TCM connector terminals while warming up A/T. Item A/T fluid temperature sensor Connector E107 Terminal 47 - 42 Condition Judgement standard (Approx.) When A/T fluid temperature is 20°C (68°F). 1.5V When A/T fluid temperature is 80°C (176°F). 0.5V OK or NG OK >> GO TO 7. NG >> GO TO 2. SCIA2658E 2. DETECT MALFUNCTIONING ITEMS Check the following. ● Harness for short or open between TCM, ECM and terminal cord assembly ● Ground circuit for ECM, Refer to EC-128, "POWER SUPPLY AND GROUND CIRCUIT" . OK or NG OK >> GO TO 3. NG >> Repair or replace damaged parts. AT-112 DTC P0710 A/T FLUID TEMPERATURE SENSOR CIRCUIT [EURO-OBD] 3. CHECK FLUID TEMPERATURE SENSOR CIRCUIT 1. 2. 3. Turn ignition switch OFF. Disconnect the TCM connector. Check resistance between TCM connector terminals. Item Connector A/T fluid temperature sensor E107 Terminal A B Temperature [°C (°F)] Resistance (Approx.) 20 (68) 2.5 kΩ 80 (176) 0.3 kΩ AT 47 - 42 D OK or NG OK >> GO TO 7. NG >> GO TO 4. E SCIA2338E 4. 1. 2. 3. CHECK HARNESS BETWEEN TCM AND TERMINAL CORD ASSEMBLY HARNESS CONNECTOR F Turn ignition switch OFF. Disconnect terminal cord assembly harness connector and TCM connector. Check continuity between terminal cord assembly harness connector terminal and TCM connector terminal. G Item TCM Terminal cord assembly harness connector TCM Terminal cord assembly harness connector Connector Terminal E107 42 F13 7 E107 47 F13 6 H Continuity Yes I Yes J SCIA2660E 4. If OK, check harness for short to ground and short to power. 5. If OK, check continuity between ground and transaxle assembly. 6. Reinstall any part removed. OK or NG OK >> GO TO 5. NG >> Repair open circuit or short to ground or short to power in harness or connectors. K L 5. CHECK A/T FLUID TEMPERATURE SENSOR WITH TERMINAL CORD ASSEMBLY 1. 2. 3. M Turn ignition switch OFF. Disconnect terminal cord assembly harness connector in engine room. Check resistance between terminal cord assembly harness connector terminals. Temperature [°C (°F)] Resistance (Approx.) 20 (68) 2.5 kΩ 80 (176) 0.3 kΩ 4. Reinstall any part removed. OK or NG OK >> GO TO 6. NG >> Repair or replace damaged parts. SCIA4948E AT-113 DTC P0710 A/T FLUID TEMPERATURE SENSOR CIRCUIT [EURO-OBD] 6. DETECT MALFUNCTIONING ITEM 1. 2. – • Remove oil pan. Refer to AT-345, "Control Valve Assembly and Accumulators" . Check the following. A/T fluid temperature sensor Check resistance between terminal cord assembly harness connector terminals while changing temperature as shown. Temperature [°C (°F)] Resistance (Approx.) 20 (68) 2.5 kΩ 80 (176) 0.3 kΩ – Harness of terminal cord assembly for short or open OK or NG OK >> GO TO 7. NG >> Repair or replace damaged parts. SAT298F 7. CHECK DTC Perform AT-110, "DTC Confirmation Procedure" . OK or NG OK >> INSPECTION END NG >> GO TO 8. 8. CHECK TCM 1. Check TCM input/output signal. Refer to AT-80, "TCM Terminals and Reference Value" . 2. If NG, recheck TCM pin terminals for damage or loose connection with harness connector. OK or NG OK >> INSPECTION END NG >> Repair or replace damaged parts. Component Inspection BCS000P2 A/T FLUID TEMPERATURE SENSOR ● ● Remove oil pan. Refer to AT-345, "Control Valve Assembly and Accumulators" . Check resistance between terminal cord assembly harness connector terminals while changing temperature as shown. Temperature [°C (°F)] Resistance (Approx.) 20 (68) 2.5 kΩ 80 (176) 0.3 kΩ SAT298F AT-114 DTC P0720 VEHICLE SPEED SENSOR·A/T (REVOLUTION SENSOR) [EURO-OBD] DTC P0720 VEHICLE SPEED SENSOR·A/T (REVOLUTION SENSOR) Description PFP:32702 A BCS000P3 The revolution sensor detects the revolution of the idler gear parking pawl lock gear and emits a pulse signal. The pulse signal is sent to the TCM which converts it into vehicle speed. CONSULT-II Reference Value BCS000P4 Remarks: Specification data are reference values. Item name Condition VHCL/S SE-A/T ● During driving Approximately matches the speedometer reading. BCS000P5 This is an OBD self-diagnostic item. Diagnostic trouble code “P0720 VHCL SPEED SEN-AT” with CONSULT-II or 1st judgement flicker without CONSULT-II is detected when TCM does not receive the proper voltage signal from the sensor. Possible Cause ● ● AT Display value On Board Diagnosis Logic ● B D E BCS000P6 Harness or connector (The sensor circuit is open or shorted.) Revolution sensor F G DTC Confirmation Procedure BCS000P7 CAUTION: ● Always drive vehicle at a safe speed. ● Be careful not to rev engine into the red zone on the tachometer. ● If performing this “DTC Confirmation Procedure” again, always turn ignition switch OFF and wait at least 10 seconds before continuing. After the repair, perform the following procedure to confirm the malfunction is eliminated. H I WITH CONSULT-II 1. 2. 3. 4. 5. 6. 7. Turn ignition switch ON and select “DATA MONITOR” mode for “A/T” with CONSULT-II. Touch “START”. Drive vehicle and check for an increase of “VHCL/S SE-MTR” value. If the check result is NG, go to AT-118, "Diagnostic Procedure" . If the check result is OK, go to following step. Select “DATA MONITOR” mode for “A/T” with CONSULT-II. Touch “START”. Start engine and maintain the following conditions for at least 5 BCIA0031E consecutive seconds. VEHICLE SPEED: 30 km/h (19 MPH) or more THROTTLE POSI: More than 1.0/8 SLCT LVR POSI: “D” position Driving location: Driving the vehicle uphill (increased engine load) will help maintain the driving conditions required for this test. If the check result is NG, go to AT-118, "Diagnostic Procedure" . If the check result is OK, go to following step. Maintain the following conditions for at least 5 consecutive seconds. ENGINE SPEED: 3,500 rpm or more THROTTLE POSI: More than 1.0/8 SLCT LVR POSI: “D” position Driving location: Driving the vehicle uphill (increased engine load) will help maintain the driving conditions required for this test. WITH GST Follow the procedure “WITH CONSULT-II”. AT-115 J K L M DTC P0720 VEHICLE SPEED SENSOR·A/T (REVOLUTION SENSOR) [EURO-OBD] WITHOUT CONSULT-II 1. 2. 3. 4. Start engine. Drive vehicle under the following conditions for more than 5 seconds. Selector lever position: “D” position Vehicle speed: 30 km/h (19 MPH) or more Throttle position: greater than 1.0/8 of the full throttle position Perform self-diagnosis. Refer to AT-94, "Diagnostic Procedure Without CONSULT-II" . If the check result is NG, go to AT-118, "Diagnostic Procedure" . AT-116 DTC P0720 VEHICLE SPEED SENSOR·A/T (REVOLUTION SENSOR) [EURO-OBD] Wiring Diagram — AT — VSSA/T BCS000P8 A B AT D E F G H I J K L M MCWA0245E AT-117 DTC P0720 VEHICLE SPEED SENSOR·A/T (REVOLUTION SENSOR) [EURO-OBD] TCM terminal data are reference values, measured between each terminal and ground. Terminal Wire color Item Condition 29 V Revolution sensor 42 B Sensor ground When driving at 20 km/h (12 MPH) Always Diagnostic Procedure Judgement standard (Approx.) 150 Hz 0V BCS000P9 1. CHECK INPUT SIGNAL With CONSULT-II 1. Start engine. 2. Select “TCM INPUT SIGNALS” in “DATA MONITOR” mode for “A/T” with CONSULT-II. 3. Read out the value of “VHCL/S SE-A/T” while driving. Check the value changes according to driving speed. OK or NG OK >> GO TO 8. NG >> GO TO 2. LCIA0090E 2. CHECK REVOLUTION SENSOR With CONSULT-II 1. Start engine. 2. Check power supply to revolution sensor by voltage between TCM connector terminals. Refer to AT-194, "Wiring Diagram — AT — MAIN" and AT-117, "Wiring Diagram — AT — VSSA/T" . Item Connector Terminal TCM E106, E107 Judgement standard (Approx.) 10 - 42 3. 19 - 42 Battery voltage If OK, check the pulse when vehicle cruises. Item Condition When driving at 20 km/h (12 MPH), use the CONSULT-II pulse frequency measuring function.*1 Revolution sensor CAUTION: Connect the diagnosis data link cable to the data link connector. *1: A circuit tester cannot be used to test this item. Item Connector Terminal Condition Judgement standard (Approx.) TCM E107 29 When driving at 20 km/h (12 MPH) 150 Hz OK or NG OK >> GO TO 8. NG >> GO TO 3. SCIA2344E AT-118 DTC P0720 VEHICLE SPEED SENSOR·A/T (REVOLUTION SENSOR) [EURO-OBD] 3. 1. 2. 3. 4. CHECK POWER AND SENSOR GROUND A Turn ignition switch OFF. Disconnect the revolution sensor harness connector. Turn ignition switch ON. (Do not start engine.) Check voltage between revolution sensor harness connector terminals. B AT Item Connector Terminal Judgement standard (Approx.) Revolution sensor F41 1-3 Battery voltage D E SCIA2614E 5. Item Connector Terminal Judgement standard (Approx.) Revolution sensor F41 1 - ground Battery voltage 6. If OK, check harness for short to ground and short to power. 7. Reinstall any part removed. OK or NG OK >> GO TO 4. NG - 1 >> Battery voltage is not supplied between terminals 1 and 3, terminals 1 and ground: GO TO 6. NG - 2 >> Battery voltage is not supplied between terminals 1 and 3 only: GO TO 7. 4. 1. 2. 3. F Check voltage between revolution sensor harness connector terminal and ground. G H SCIA2615E I J CHECK HARNESS BETWEEN TCM AND REVOLUTION SENSOR K Turn ignition switch OFF. Disconnect the TCM connector and revolution sensor harness connector. Check continuity between TCM connector terminal and revolution sensor harness connector terminal. Item Connector Terminal TCM E107 29 Revolution sensor F41 2 L Continuity M Yes 4. If OK, check harness for short to ground and short to power. 5. Reinstall any part removed. OK or NG OK >> GO TO 5. NG >> Repair open circuit or short to ground or short to power in harness or connectors. 5. CHECK TCM 1. Check TCM input/output signal. Refer to AT-80, "TCM Terminals and Reference Value" . 2. If NG, re-check TCM pin terminals for damage or loose connection with harness connector. OK or NG OK >> GO TO 8. NG >> Repair or replace damaged parts. AT-119 SCIA2616E DTC P0720 VEHICLE SPEED SENSOR·A/T (REVOLUTION SENSOR) [EURO-OBD] 6. 1. 2. 3. CHECK HARNESS BETWEEN TCM AND REVOLUTION SENSOR (POWER) Turn ignition switch OFF. Disconnect the TCM connector and revolution sensor harness connector. Check continuity between TCM connector terminals and revolution sensor harness connector terminal. Refer to AT-52, "Circuit Diagram" and AT-194, "Wiring Diagram — AT — MAIN" . Item Connector Terminal TCM E106 10 Revolution sensor F41 1 TCM E106 19 Revolution sensor F41 1 Continuity Yes Yes 4. If OK, check harness for short to ground and short to power. 5. Reinstall any part removed. OK or NG OK >> 10A fuse (No.38, located in the IPDM E/R) or ignition switch are malfunctioning. NG >> Repair open circuit or short to ground or short to power in harness or connectors. 7. 1. 2. 3. SCIA2617E CHECK HARNESS BETWEEN TCM AND REVOLUTION SENSOR (SENSOR GROUND) Turn ignition switch OFF. Disconnect the TCM connector and revolution sensor harness connector. Check continuity between TCM connector terminal and revolution sensor harness connector terminal. Item Connector Terminal TCM E107 42 Revolution sensor F41 3 Continuity Yes 4. If OK, check harness for short to ground and short to power. 5. Reinstall any part removed. OK or NG OK >> GO TO 5. NG >> Repair open circuit or short to ground or short to power in harness or connectors. 8. CHECK DTC Perform AT-115, "DTC Confirmation Procedure" . OK or NG OK >> INSPECTION END NG >> GO TO 5. AT-120 SCIA2618E DTC P0725 ENGINE SPEED SIGNAL [EURO-OBD] DTC P0725 ENGINE SPEED SIGNAL Description PFP:24825 A BCS000PA The engine speed signal is sent from the ECM to the TCM. B CONSULT-II Reference Value BCS000PB Remarks: Specification data are reference values. Item name Condition ENGINE SPEED Display value Engine running Approximately matches the tachometer reading. On Board Diagnosis Logic ● ● AT BCS000PC This is an OBD self-diagnostic item. Diagnostic trouble code “P0725 ENGINE SPEED SIG” with CONSULT-II or 9th judgement flicker without CONSULT-II is detected when TCM does not receive the proper voltage signal from ECM. Possible Cause D E BCS000PD Harness or connector (Circuit is open or shorted.) F DTC Confirmation Procedure BCS000PE CAUTION: ● Always drive vehicle at a safe speed. ● If performing this “DTC Confirmation Procedure” again, always turn ignition switch OFF and wait at least 10 seconds before continuing. After the repair, perform the following procedure to confirm the malfunction is eliminated. G H WITH CONSULT-II 1. 2. 3. 4. I Turn ignition switch ON and select “DATA MONITOR” mode for “A/T” with CONSULT-II. Touch “START”. Start engine and maintain the following conditions for at least 10 consecutive seconds. VEHICLE SPEED: 10 km/h (6 MPH) or more THROTTLE POSI: More than 1.0/8 SLCT LVR POSI: “D” position If the check result is NG, go to AT-123, "Diagnostic Procedure" . J K BCIA0031E L WITH GST M Follow the procedure “WITH CONSULT-II”. WITHOUT CONSULT-II 1. 2. 3. 4. Start engine. Drive vehicle under the following conditions for more than 10 seconds. Selector lever position: “D” position Vehicle speed: Higher than 10 km/h (6 MPH) Throttle position: Greater than 1.0/8 of the full throttle position Perform self-diagnosis. Refer to AT-94, "Diagnostic Procedure Without CONSULT-II" . If the check result is NG, go to AT-123, "Diagnostic Procedure" . AT-121 DTC P0725 ENGINE SPEED SIGNAL [EURO-OBD] Wiring Diagram — AT — ENGSS BCS000PF MCWA0244E AT-122 DTC P0725 ENGINE SPEED SIGNAL [EURO-OBD] TCM terminal data are reference values, measured between each terminal and ground. Terminal Wire color 39 L Item Condition Judgement standard (Approx.) Refer to EC-95 . Engine speed signal B and Diagnostic Procedure BCS000PG 1. CHECK DTC WITH ECM AT Check DTC with CONSULT-II “ENGINE”. Turn ignition switch ON and select “SELF-DIAGNOSTIC RESULTS” mode for “ENGINE” with CONSULT-II. Refer to EC-102, "CONSULT-II Function (ENGINE)" . OK or NG OK >> GO TO 2. NG >> Check ignition signal circuit for engine control. Refer to EC-433, "IGNITION SIGNAL" . 2. CHECK INPUT SIGNAL 1. 2. 3. A D E F With CONSULT-II Start engine. Select “TCM INPUT SIGNALS” in “DATA MONITOR” mode for “A/T” with CONSULT-II. Read out the value of “ENGINE SPEED”. Check engine speed changes according to throttle position. Item name Condition Display value ENGINE SPEED (rpm) Engine running Approximately matches the tachometer reading. G H I J SCIA4730E K Without CONSULT-II 1. Start engine. 2. Check voltage between TCM harness connector terminal and ground. item Connector Terminal Condition Judgement standard (Approx.) Engine speed signal E107 39 Ground and Refer to EC-95 . L M SCIA3265E OK or NG OK >> GO TO 4. NG >> GO TO 3. AT-123 DTC P0725 ENGINE SPEED SIGNAL [EURO-OBD] 3. CHECK HARNESS BETWEEN TCM AND ECM 1. 2. 3. Turn ignition switch OFF. Disconnect ECM connector and TCM connector. Check continuity between ECM connector and TCM connector. Item Connector Terminal TCM E107 39 ECM F50 13 Continuity Yes 4. 5. If OK, check harness for short to ground and short to power. If OK, check continuity between body ground and transaxle assembly. 6. Reinstall any part removed. OK or NG OK >> GO TO 4. NG >> Repair open circuit or short to ground or short to power in harness or connectors. 4. CHECK DTC Perform AT-121, "DTC Confirmation Procedure" . OK or NG OK >> INSPECTION END NG >> GO TO 5. 5. CHECK TCM 1. Check TCM input/output signal. Refer to AT-80, "TCM Terminals and Reference Value" . 2. If NG, recheck TCM pin terminals for damage or loose connection with harness connector. OK or NG OK >> INSPECTION END NG >> Repair or replace damaged parts. AT-124 SCIA7173E DTC P0731 A/T 1ST GEAR FUNCTION [EURO-OBD] DTC P0731 A/T 1ST GEAR FUNCTION Description ● ● PFP:31940 A BCS000PH This malfunction will not be detected while the OD OFF indicator lamp is indicating another self-diagnosis malfunction. B This malfunction is detected when the A/T does not shift into first gear position as instructed by the TCM. This is not caused by electrical malfunction (circuits open or shorted) but by mechanical malfunction such as control valve sticking, improper solenoid valve operation, etc. AT Gear position 1 2 3 4 Shift solenoid valve A ON (Closed) OFF (Open) OFF (Open) ON (Closed) Shift solenoid valve B ON (Closed) ON (Closed) OFF (Open) OFF (Open) On Board Diagnosis Logic ● ● ● ● BCS000PI This is an OBD self-diagnostic item. Diagnostic trouble code “P0731 A/T 1ST GR FNCTN” with CONSULT-II is detected when A/T cannot be shifted to the 1st gear position even if electrical circuit is good. This diagnosis monitors actual gear position by checking the torque converter slip ratio calculated by TCM as follows: Torque converter slip ratio = A x C/B A: Output shaft revolution signal from revolution sensor B: Engine speed signal from ECM C: Gear ratio determined as gear position which TCM supposes If the actual gear position is higher than the position (1st) supposed by TCM, the slip ratio will be more than normal. In case the ratio exceeds the specified value, TCM judges this diagnosis malfunction. This malfunction will be caused when either shift solenoid valve A is stuck open or shift solenoid valve B is stuck open. Gear positions supposed by TCM are as follows: In case of gear position with no malfunctions: 1 , 2, 3 and 4 positions In case of gear position with shift solenoid valve A stuck open: 2* , 2, 3 and 3 positions In case of gear position with shift solenoid valve B stuck open: 4* , 3, 3 and 4 positions to each gear position above *: “P0731 A/T 1ST GR FNCTN” is detected. Possible Cause ● ● ● ● D BCS000PJ Shift solenoid valve A Shift solenoid valve B Each clutch Hydraulic control circuit E F G H I J K L M AT-125 DTC P0731 A/T 1ST GEAR FUNCTION [EURO-OBD] DTC Confirmation Procedure BCS000PK CAUTION: ● Always drive vehicle at a safe speed. ● If performing this “DTC Confirmation Procedure” again, always turn ignition switch OFF and wait at least 10 seconds before continuing. After the repair, perform the following procedure to confirm the malfunction is eliminated. WITH CONSULT-II 1. 2. 3. 4. 5. – 6. – – 7. 8. Start engine and select “DATA MONITOR” mode for “A/T” with CONSULT-II. Touch “START”. Make sure that output voltage of A/T fluid temperature sensor is within the range below. FLUID TEMP SE: 0.4 - 1.5V If out of range, drive the vehicle to decrease the voltage (warm up the fluid) or stop engine to increase the voltage (cool down the fluid). Select “1ST GR FNCTN P0731” of “DTC WORK SUPPORT” BCIA0031E mode for “A/T” with CONSULT-II and touch “START”. Accelerate vehicle to 20 to 25 km/h (12 to 16 MPH) under the following conditions and release the accelerator pedal completely. THROTTLE POSI: Less than 1.0/8 (at all times during step 4) SLCT LVR POSI: “D” position Make sure that “GEAR” shows “2” after releasing pedal. Depress accelerator pedal to WOT (more than 7.0/8 of “THROTTLE POSI”) quickly from a speed of 20 to 25 km/h (12 to 16 MPH) until “TESTING” changes to “STOP VEHICLE” or “COMPLETED”. (It will take approximately 3 seconds.) If the check result NG appears on CONSULT-II screen, go to AT-127, "Diagnostic Procedure" . If “STOP VEHICLE” appears on CONSULT-II screen, go to the following step. Make sure that “GEAR” shows “1” when depressing accelerator pedal to WOT. If “TESTING” does not appear on CONSULT-II for a long time, select “SELF-DIAG RESULTS” for “A/T”. In case a DTC other than “P0731 A/T 1ST GR FNCTN” is shown, refer to AT-85, "Display Items List (For EURO-OBD models)" . Stop vehicle. Follow the instruction displayed. (Check for normal shifting referring to the table below.) Vehicle condition Gear on actual transmission shift pattern when screen is changed to 1 → 2 → 3 → 4 1→2→3→4 No malfunction exists. 2→2→3→3 Malfunction for “A/T 1ST GR FNCTN ” exists. 9. 4→3→3→4 Make sure that “OK” is displayed. (If “NG” is displayed, refer to “Diagnostic Procedure”.) Refer to AT-127, "Diagnostic Procedure" . Refer to AT-67, "Vehicle Speed at Which Gear Shifting Occurs" . WITH GST Follow the procedure “WITH CONSULT-II”. AT-126 DTC P0731 A/T 1ST GEAR FUNCTION [EURO-OBD] Diagnostic Procedure BCS000PL 1. CHECK VALVE RESISTANCE 1. – – 2. A Remove control valve assembly. Refer to AT-345, "Control Valve Assembly and Accumulators" . Shift solenoid valve A Shift solenoid valve B Check resistance between terminal cord assembly harness connector terminals and ground. Refer to AT-160, "Wiring Diagram — AT — SSV/A" and AT-165, "Wiring Diagram — AT — SSV/B" . Solenoid valve Shift solenoid valve A Shift solenoid valve B Terminal 2 1 Ground B AT D Resistance (Approx.) 20 - 30 Ω E 5 - 20 Ω OK or NG OK >> GO TO 2. NG >> Repair or replace damaged parts. F G H I SCIA3594E 2. CHECK VALVE OPERATION J Remove control valve assembly. Refer to AT-345, "Control Valve Assembly and Accumulators" . – Shift solenoid valve A – Shift solenoid valve B 2. Check solenoid valve by listening for its operating sound while applying battery voltage to the terminals and ground. Refer to AT-160, "Wiring Diagram — AT — SSV/A" and AT-165, "Wiring Diagram — AT — SSV/B" . OK or NG OK >> GO TO 3. NG >> Repair or replace shift solenoid valve assembly. 1. K L M SCIA3595E AT-127 DTC P0731 A/T 1ST GEAR FUNCTION [EURO-OBD] 3. CHECK CONTROL VALVE Disassemble control valve assembly. Refer to AT-392, "Control Valve Assembly" . Check to ensure that: – Valve, sleeve and plug slide along valve bore under their own weight. – Valve, sleeve and plug are free from burrs, dents and scratches. – Control valve springs are free from damage, deformation and fatigue. – Hydraulic line is free from obstacles. OK or NG OK >> GO TO 4. NG >> Repair control valve assembly. 1. 2. 4. CHECK DTC Perform AT-126, "DTC Confirmation Procedure" . OK or NG OK >> INSPECTION END NG >> Check control valve again. If NG, repair or replace control valve assembly. AT-128 DTC P0732 A/T 2ND GEAR FUNCTION [EURO-OBD] DTC P0732 A/T 2ND GEAR FUNCTION Description ● ● PFP:31940 A BCS000PM This malfunction will not be detected while the OD OFF indicator lamp is indicating another self-diagnosis malfunction. B This malfunction is detected when the A/T does not shift into second gear position as instructed by the TCM. This is not caused by electrical malfunction (circuits open or shorted) but by mechanical malfunction such as control valve sticking, improper solenoid valve operation, etc. AT Gear position 1 2 3 4 Shift solenoid valve A ON (Closed) OFF (Open) OFF (Open) ON (Closed) Shift solenoid valve B ON (Closed) ON (Closed) OFF (Open) OFF (Open) On Board Diagnosis Logic ● ● ● ● BCS000PN This is an OBD self-diagnostic item. Diagnostic trouble code “P0732 A/T 2ND GR FNCTN” with CONSULT-II is detected when A/T cannot be shifted to the 2nd gear position even if electrical circuit is good. This diagnosis monitors actual gear position by checking the torque converter slip ratio calculated by TCM as follows: Torque converter slip ratio = A x C/B A: Output shaft revolution signal from revolution sensor B: Engine speed signal from ECM C: Gear ratio determined as gear position which TCM supposes If the actual gear position is higher than the position (2nd) supposed by TCM, the slip ratio will be more than normal. In case the ratio exceeds the specified value, TCM judges this diagnosis malfunction. This malfunction will be caused when shift solenoid valve B is stuck open. Gear positions supposed by TCM are as follows: In case of gear position with no malfunctions: 1, 2 , 3 and 4 positions In case of gear position with shift solenoid valve B stuck open: 4, 3* , 3 and 4 positions to each gear position above *: “P0732 A/T 2ND GR FNCTN” is detected. Possible Cause ● ● ● D E F G H I J BCS000PO Shift solenoid valve B Each clutch Hydraulic control circuit K L M AT-129 DTC P0732 A/T 2ND GEAR FUNCTION [EURO-OBD] DTC Confirmation Procedure BCS000PP CAUTION: ● Always drive vehicle at a safe speed. ● If performing this “DTC Confirmation Procedure” again, always turn ignition switch OFF and wait at least 10 seconds before continuing. After the repair, perform the following procedure to confirm the malfunction is eliminated. WITH CONSULT-II 1. 2. 3. 4. 5. – 6. – – 7. 8. Start engine and select “DATA MONITOR” mode for “A/T” with CONSULT-II. Touch “START”. Make sure that output voltage of A/T fluid temperature sensor is within the range below. FLUID TEMP SE: 0.4 - 1.5V If out of range, drive the vehicle to decrease the voltage (warm up the fluid) or stop engine to increase the voltage (cool down the fluid). Select “2ND GR FNCTN P0732” of “DTC WORK SUPPORT” BCIA0031E mode for “A/T” with CONSULT-II and touch “START”. Accelerate vehicle to 45 to 50 km/h (28 to 31 MPH) under the following conditions and release the accelerator pedal completely. THROTTLE POSI: Less than 1.0/8 SLCT LVR POSI: “D” position Make sure that “GEAR” shows “3” or “4” after releasing pedal. Depress accelerator pedal to WOT (more than 7.0/8 of “THROTTLE POSI”) quickly from a speed of 45 to 50 km/h (28 to 31 MPH) until “TESTING” changes to “STOP VEHICLE” or “COMPLETE”. (It will take approximately 3 seconds.) If the check result NG appears on CONSULT-II screen, go to AT-131, "Diagnostic Procedure" . If “STOP VEHICLE” appears on CONSULT-II screen, go to following step. Make sure that “GEAR” shows “2” when depressing accelerator pedal to WOT. If “TESTING” does not appear on CONSULT-II for a long time, select “SELF-DIAG RESULTS” for “A/T”. In case a DTC other than “P0732 A/T 2ND GR FNCTN” is shown, refer to AT-85, "Display Items List (For EURO-OBD models)" . Stop vehicle. Follow the instruction displayed. (Check for normal shifting referring to the table below.) Vehicle condition Gear on actual transmission shift pattern when screen is changed to 1 → 2 → 3 → 4 No malfunction exists 1→2→3→4 Malfunction for “A/T 2ND GR FNCTN” exists. 4→3→3→4 9. Make sure that “OK” is displayed. (If “NG” is displayed, refer to “Diagnostic Procedure”.) Refer to AT-131, "Diagnostic Procedure" . Refer to AT-67, "Vehicle Speed at Which Gear Shifting Occurs" . WITH GST Follow the procedure “WITH CONSULT-II”. AT-130 DTC P0732 A/T 2ND GEAR FUNCTION [EURO-OBD] Diagnostic Procedure BCS000PQ 1. CHECK VALVE RESISTANCE 1. – 2. A Remove control valve assembly. Refer to AT-345, "Control Valve Assembly and Accumulators" . Shift solenoid valve B Check resistance between terminal cord assembly harness connector terminal and ground. Refer to AT-165, "Wiring Diagram — AT — SSV/B" . Solenoid valve Shift solenoid valve B Terminal 1 Ground B AT Resistance (Approx.) D 5 - 20 Ω OK or NG OK >> GO TO 2. NG >> Repair or replace shift solenoid valve assembly. E SCIA3454E 2. CHECK VALVE OPERATION F Remove control valve assembly. Refer to AT-345, "Control Valve Assembly and Accumulators" . – Shift solenoid valve B 2. Check solenoid valve by listening for its operating sound while applying battery voltage to the terminal and ground. Refer to AT165, "Wiring Diagram — AT — SSV/B" . OK or NG OK >> GO TO 3. NG >> Repair or replace shift solenoid valve assembly. 1. G H I J SCIA2058E 3. CHECK CONTROL VALVE K Disassemble control valve assembly. Refer to AT-392, "Control Valve Assembly" . Check to ensure that: – Valve, sleeve and plug slide along valve bore under their own weight. – Valve, sleeve and plug are free from burrs, dents and scratches. – Control valve springs are free from damage, deformation and fatigue. – Hydraulic line is free from obstacles. OK or NG OK >> GO TO 4. NG >> Repair control valve assembly. 1. 2. 4. CHECK DTC Perform AT-130, "DTC Confirmation Procedure" . OK or NG OK >> INSPECTION END NG >> Check control valve again. If NG, repair or replace control valve assembly. AT-131 L M DTC P0733 A/T 3RD GEAR FUNCTION [EURO-OBD] DTC P0733 A/T 3RD GEAR FUNCTION Description ● ● PFP:31940 BCS000PR This malfunction will not be detected while the OD OFF indicator lamp is indicating another self-diagnosis malfunction. This malfunction is detected when the A/T does not shift into third gear position as instructed by the TCM. This is not caused by electrical malfunction (circuits open or shorted) but by mechanical malfunction such as control valve sticking, improper solenoid valve operation, malfunctioning servo piston or brake band, etc. Gear position 1 2 3 4 Shift solenoid valve A ON (Closed) OFF (Open) OFF (Open) ON (Closed) Shift solenoid valve B ON (Closed) ON (Closed) OFF (Open) OFF (Open) On Board Diagnosis Logic ● ● ● ● BCS000PS This is an OBD self-diagnostic item. Diagnostic trouble code “P0733 A/T 3RD GR FNCTN” with CONSULT-II is detected when A/T cannot be shifted to the 3rd gear position even if electrical circuit is good. This diagnosis monitors actual gear position by checking the torque converter slip ratio calculated by TCM as follows: Torque converter slip ratio = A x C/B A: Output shaft revolution signal from revolution sensor B: Engine speed signal from ECM C: Gear ratio determined as gear position which TCM supposes If the actual gear position is higher than the position (3rd) supposed by TCM, the slip ratio will be more than normal. In case the ratio exceeds the specified value, TCM judges this diagnosis malfunction. This malfunction will be caused when shift solenoid valve A is stuck closed. Gear positions supposed by TCM are as follows. In case of gear position with no malfunctions: 1, 2, 3 and 4 positions In case of gear position with shift solenoid valve A stuck closed: 1, 1, 4* and 4 positions to each gear position above *: “P0733 A/T 3RD GR FNCTN” is detected. Possible Cause ● ● ● BCS000PT Shift solenoid valve A Each clutch Hydraulic control circuit AT-132 DTC P0733 A/T 3RD GEAR FUNCTION [EURO-OBD] DTC Confirmation Procedure BCS000PU CAUTION: ● Always drive vehicle at a safe speed. ● If performing this “DTC Confirmation Procedure” again, always turn ignition switch OFF and wait at least 10 seconds before continuing. After the repair, perform the following procedure to confirm the malfunction is eliminated. WITH CONSULT-II 1. 2. 3. 4. 5. – 6. – – 7. 8. D E F G H I J K L Gear on actual transmission shift pattern when screen is changed to 1 → 2 → 3 → 4 No malfunction exists. 1→2→3→4 Malfunction for “A/T 3RD GR FNCTN” exists. 1→1→4→4 9. B AT Start engine and select “DATA MONITOR” mode for “A/T” with CONSULT-II. Touch “START”. Make sure that output voltage of A/T fluid temperature sensor is within the range below. FLUID TEMP SE: 0.4 - 1.5V If out of range, drive the vehicle to decrease the voltage (warm up the fluid) or stop engine to increase the voltage (cool down the fluid). Select “3RD GR FNCTN P0733” of “DTC WORK SUPPORT” BCIA0031E mode for “A/T” with CONSULT-II and touch “START”. Accelerate vehicle to 60 to 75 km/h (37 to 47 MPH) under the following conditions and release the accelerator pedal completely. THROTTLE POSI: Less than 1.0/8 (at all times during step 4) SLCT LVR POSI: “D” position Make sure that “GEAR” shows “4” after releasing pedal. Depress accelerator pedal steadily with 3.5/8 - 4.5/8 of “THROTTLE POSI” from a speed of 60 to 75 km/h (37 to 47 MPH) until “TESTING” changes to “STOP VEHICLE” or “COMPLETED”. (It will take approximately 3 seconds.) If the check result NG appears on CONSULT-II screen, go to AT-134, "Diagnostic Procedure" . If “STOP VEHICLE” appears on CONSULT-II screen, go to following step. Make sure that “GEAR” shows “3” when depressing accelerator pedal with 3.5/8 - 4.5/8 of “THROTTLE POSI”. If “TESTING” does not appear on CONSULT-II for a long time, select “SELF-DIAG RESULTS” for “A/T”. In case a DTC other than “P0733 A/T 3RD GR FNCTN” is shown, refer to AT-85, "Display Items List (For EURO-OBD models)" . Stop vehicle. Follow the instruction displayed. (Check for normal shifting referring to the table below.) Vehicle condition A Make sure that “OK” is displayed. (If “NG” is displayed, refer to “Diagnostic Procedure”.) Refer to AT-134, "Diagnostic Procedure" . Refer to AT-67, "Vehicle Speed at Which Gear Shifting Occurs" . WITH GST Follow the procedure “WITH CONSULT-II”. AT-133 M DTC P0733 A/T 3RD GEAR FUNCTION [EURO-OBD] Diagnostic Procedure BCS000PV 1. CHECK VALVE RESISTANCE 1. – – 2. Remove control valve assembly. Refer to AT-345, "Control Valve Assembly and Accumulators" . Shift solenoid valve A Shift solenoid valve B Check resistance between terminal cord assembly harness connector terminals and ground. Refer to AT-160, "Wiring Diagram — AT — SSV/A" and AT-165, "Wiring Diagram — AT — SSV/B" . Solenoid valve Shift solenoid valve A Shift solenoid valve B Terminal 2 1 Ground Resistance (Approx.) 20 - 30 Ω 5 - 20 Ω OK or NG OK >> GO TO 2. NG >> Repair or replace shift solenoid valve assembly. SCIA3594E 2. CHECK VALVE OPERATION Remove control valve assembly. Refer to AT-345, "Control Valve Assembly and Accumulators" . – Shift solenoid valve A – Shift solenoid valve B 2. Check solenoid valve by listening for its operating sound while applying battery voltage to the terminals and ground. Refer to AT-160, "Wiring Diagram — AT — SSV/A" and AT-165, "Wiring Diagram — AT — SSV/B" . OK or NG OK >> GO TO 3. NG >> Repair or replace shift solenoid valve assembly. 1. SCIA3595E AT-134 DTC P0733 A/T 3RD GEAR FUNCTION [EURO-OBD] 3. CHECK CONTROL VALVE A Disassemble control valve assembly. Refer to AT-392, "Control Valve Assembly" . Check to ensure that: – Valve, sleeve and plug slide along valve bore under their own weight. – Valve, sleeve and plug are free from burrs, dents and scratches. – Control valve springs are free from damage, deformation and fatigue. – Hydraulic line is free from obstacles. OK or NG OK >> GO TO 4. NG >> Repair control valve assembly. 1. 2. 4. CHECK DTC B AT D E Perform AT-133, "DTC Confirmation Procedure" . OK or NG OK >> INSPECTION END NG >> Check control valve again. If NG, repair or replace control valve assembly. F G H I J K L M AT-135 DTC P0734 A/T 4TH GEAR FUNCTION [EURO-OBD] DTC P0734 A/T 4TH GEAR FUNCTION Description ● ● PFP:31940 BCS000PW This malfunction will not be detected while the OD OFF indicator lamp is indicating another self-diagnosis malfunction. This malfunction is detected when the A/T does not shift into fourth gear position or the torque converter clutch does not lock up as instructed by the TCM. This is not caused by electrical malfunction (circuits open or shorted) but by mechanical malfunction such as control valve sticking, improper solenoid valve operation, malfunctioning oil pump or torque converter clutch, etc. Gear position 1 2 3 4 Shift solenoid valve A ON (Closed) OFF (Open) OFF (Open) ON (Closed) Shift solenoid valve B ON (Closed) ON (Closed) OFF (Open) OFF (Open) CONSULT-II Reference Value BCS000PX Remarks: Specification data are reference values. Item name Condition LINE PRES DTY Display value (Approx.) Small throttle opening (Low line pressure) ⇔ Large throttle opening (High line pressure) On Board Diagnosis Logic ● ● ● ● BCS000PY This is an OBD self-diagnostic item. Diagnostic trouble code “P0734 A/T 4TH GR FNCTN” with CONSULT-II is detected when A/T cannot be shifted to the 4th gear position even if electrical circuit is good. This diagnosis monitors actual gear position by checking the torque converter slip ratio calculated by TCM as follows: Torque converter slip ratio = A x C/B A: Output shaft revolution signal from revolution sensor B: Engine speed signal from ECM C: Gear ratio determined as gear position which TCM supposes If the actual gear position is much lower than the position (4th) supposed by TCM, the slip ratio will be much less than normal. In case the ratio does not reach the specified value, TCM judges this diagnosis malfunction. This malfunction will be caused when shift solenoid valve A is stuck open or shift solenoid valve B is stuck closed. Gear positions supposed by TCM are as follows. In case of gear position with no malfunctions: 1, 2, 3 and 4 positions In case of gear position with shift solenoid valve A stuck open: 2, 2, 3 and 3* positions In case of gear position with shift solenoid valve B stuck closed: 1, 2, 2 and 1* positions to each gear position above *: “P0734 A/T 4TH GR FNCTN” is detected. Possible Cause ● ● ● ● ● 0% ⇔ 94% BCS000PZ Shift solenoid valve A Shift solenoid valve B Line pressure solenoid valve Each clutch Hydraulic control circuit AT-136 DTC P0734 A/T 4TH GEAR FUNCTION [EURO-OBD] DTC Confirmation Procedure BCS000Q0 CAUTION: ● Always drive vehicle at a safe speed. ● If performing this “DTC Confirmation Procedure” again, always turn ignition switch OFF and wait at least 10 seconds before continuing. After the repair, perform the following procedure to confirm the malfunction is eliminated. WITH CONSULT-II 1. 2. 3. 4. 5. – 6. – – 7. 8. D E F G H I J K L Gear on actual transmission shift pattern when screen is changed to 1 → 2 → 3 → 4 1→2→3→4 No malfunction exists 2→2→3→3 Malfunction for “A/T 4TH GR FNCTN” exists. 9. B AT Start engine and select “DATA MONITOR” mode for “A/T” with CONSULT-II. Touch “START”. Make sure that output voltage of A/T fluid temperature sensor is within the range below. FLUID TEMP SE: 0.4 - 1.5V If out of range, drive the vehicle to decrease the voltage (warm up the fluid) or stop engine to increase the voltage (cool down the fluid). Select “4TH GR FNCTN P0734” of “DTC WORK SUPPORT” BCIA0031E mode for “A/T” with CONSULT-II and touch “START”. Accelerate vehicle to 55 to 65 km/h (34 to 40 MPH) under the following conditions and release the accelerator pedal completely. THROTTLE POSI: Less than 5.5/8 (at all times during step 4) SLCT LVR POSI: “D” position Make sure that “GEAR” shows “3” after releasing pedal. Depress accelerator pedal steadily with 1.0/8 - 2.0/8 of “THROTTLE POSI” from a speed of 55 to 65 km/h (34 to 40 MPH) until “TESTING” has turned to “STOP VEHICLE” or “COMPLETED”. (It will take approximately 3 seconds.) If the check result NG appears on CONSULT-II screen, go to AT-138, "Diagnostic Procedure" . If “STOP VEHICLE” appears on CONSULT-II screen, go to following step. Make sure that “GEAR” shows “4” when depressing accelerator pedal with 1.0/8 - 2.0/8 of “THROTTLE POSI”. If “TESTING” does not appear on CONSULT-II for a long time, select “SELF-DIAG RESULTS” for “A/T”. In case a DTC other than “P0734 A/T 4TH GR FNCTN” is shown, refer to AT-85, "Display Items List (For EURO-OBD models)" . Stop vehicle. Follow the instruction displayed. (Check for normal shifting referring to the table below.) Vehicle condition A 1→2→2→1 Make sure that “OK” is displayed. (If “NG” is displayed, refer to “Diagnostic Procedure”.) Refer to AT-138, "Diagnostic Procedure" . Refer to AT-67, "Vehicle Speed at Which Gear Shifting Occurs" . WITH GST Follow the procedure “WITH CONSULT-II”. AT-137 M DTC P0734 A/T 4TH GEAR FUNCTION [EURO-OBD] Diagnostic Procedure 1. CHECK SHIFT-UP (D3 BCS000Q1 TO D4 ) During AT-61, "Cruise Test — Part 1" . Does A/T shift from D3 to D4 at the specified speed? YES >> GO TO 11. NO >> GO TO 2. SCIA7190E 2. CHECK LINE PRESSURE Perform line pressure test. Refer to AT-56, "LINE PRESSURE TEST" . OK or NG OK >> GO TO 3. NG >> GO TO 7. 3. CHECK VALVE RESISTANCE 1. – – 2. Remove control valve assembly. Refer to AT-345, "Control Valve Assembly and Accumulators" . Shift solenoid valve A Shift solenoid valve B Check resistance between terminal cord assembly harness connector terminals and ground. Refer to AT-160, "Wiring Diagram — AT — SSV/A" and AT-165, "Wiring Diagram — AT — SSV/B" . Solenoid valve Shift solenoid valve A Shift solenoid valve B Terminal 2 1 Ground Resistance (Approx.) 20 - 30 Ω 5 - 20 Ω OK or NG OK >> GO TO 4. NG >> Replace solenoid valve assembly. SCIA3594E AT-138 DTC P0734 A/T 4TH GEAR FUNCTION [EURO-OBD] 4. CHECK VALVE OPERATION A Remove control valve assembly. Refer to AT-345, "Control Valve Assembly and Accumulators" . – Shift solenoid valve A – Shift solenoid valve B 2. Check solenoid valve by listening for its operating sound while applying battery voltage to the terminals and ground. Refer to AT-160, "Wiring Diagram — AT — SSV/A" and AT-165, "Wiring Diagram — AT — SSV/B" . OK or NG OK >> GO TO 5. NG >> Replace solenoid valve assembly. 1. B AT D E F G H SCIA3595E I 5. CHECK CONTROL VALVE J Disassemble control valve assembly. Refer to AT-392, "Control Valve Assembly" . Check to ensure that: – Valve, sleeve and plug slide along valve bore under their own weight. – Valve, sleeve and plug are free from burrs, dents and scratches. – Control valve springs are free from damage, deformation and fatigue. – Hydraulic line is free from obstacles. OK or NG OK >> GO TO 6. NG >> Repair control valve. 1. 2. 6. CHECK SHIFT-UP (D3 K L M TO D4 ) During AT-61, "Cruise Test — Part 1" . Does A/T shift from D3 to D4 at the specified speed? YES >> GO TO 11. NO >> Check control valve again. Repair or replace control valve assembly. SCIA7190E AT-139 DTC P0734 A/T 4TH GEAR FUNCTION [EURO-OBD] 7. CHECK VALVE RESISTANCE 1. – 2. Remove control valve assembly. Refer to AT-345, "Control Valve Assembly and Accumulators" . Line pressure solenoid valves Check resistance between terminal cord assembly harness connector terminal and ground. Refer to AT-154, "Wiring Diagram — AT — LPSV" . Solenoid valve Terminal Line pressure solenoid valve 4 Ground Resistance (Approx.) 2.5 - 5 Ω OK or NG OK >> GO TO 8. NG >> Replace solenoid valve assembly. SCIA3457E 8. CHECK VALVE OPERATION Remove control valve assembly. Refer to AT-345, "Control Valve Assembly and Accumulators" . Line pressure solenoid valves 2. Check solenoid valve by listening for its operating sound while applying battery voltage to the terminal and ground. Refer to AT154, "Wiring Diagram — AT — LPSV" . OK or NG OK >> GO TO 9. NG >> Replace solenoid valve assembly. 1. – SCIA3275E 9. CHECK CONTROL VALVE Disassemble control valve assembly. Refer to AT-392, "Control Valve Assembly" . Check line pressure circuit valves for sticking. – Pilot valve – Shift solenoid valve A – Shift solenoid valve B OK or NG OK >> GO TO 10. NG >> Repair control valve. 1. 2. 10. CHECK SHIFT-UP (D3 TO D4 ) During AT-61, "Cruise Test — Part 1" . Does A/T shift from D3 to D4 at the specified speed? YES >> GO TO 11. NO >> Check control valve again. Repair or replace control valve assembly. SCIA7190E AT-140 DTC P0734 A/T 4TH GEAR FUNCTION [EURO-OBD] 11. CHECK DTC A Perform AT-137, "DTC Confirmation Procedure" . OK or NG OK >> INSPECTION END NG >> Perform AT-61, "Cruise Test — Part 1" again and return to the start point of this test group. B AT D E F G H I J K L M AT-141 DTC P0740 TORQUE CONVERTER CLUTCH SOLENOID VALVE [EURO-OBD] DTC P0740 TORQUE CONVERTER CLUTCH SOLENOID VALVE Description PFP:31940 BCS000Q2 The torque converter clutch solenoid valve is activated, with the gear in D4 and D3 , by the TCM in response to signals sent from the vehicle speed sensor and the ECM (throttle opening). Lock-up piston operation will then be controlled. Lock-up operation, however, is prohibited when A/T fluid temperature is too low. When the accelerator pedal is depressed (less than 2/8) on lock-up condition, the engine speed should not change abruptly. If there is an abrupt change in engine speed, there is no lock-up. ● ● ● CONSULT-II Reference Value BCS000Q3 Remarks: Specification data are reference values. Item name Condition TCC S/V DUTY Display value (Approx) Lock-up OFF ⇔ Lock-up ON 4% ⇔ 94% On Board Diagnosis Logic ● ● BCS000Q4 This is an OBD self-diagnostic item. Diagnostic trouble code “P0740 T/C CLUTCH SOL/V” with CONSULT-II or 7th judgement flicker without CONSULT-II is detected when TCM detects an improper voltage drop while it tries to operate solenoid valve. Possible Cause ● ● BCS000Q5 Torque converter clutch solenoid valve Harness or connector (The solenoid circuit is open or shorted.) DTC Confirmation Procedure BCS000Q6 CAUTION: ● Always drive vehicle at a safe speed. ● If performing this “DTC Confirmation Procedure” again, always turn ignition switch OFF and wait at least 10 seconds before continuing. After the repair, perform the following procedure to confirm the malfunction is eliminated. WITH CONSULT-II 1. 2. 3. 4. 5. Turn ignition switch ON. (Do not start engine.) Select “DATA MONITOR” mode for “A/T” with CONSULT-II and wait at least 1 second. Touch “START”. Start engine and maintain the following conditions for at least 5 consecutive seconds. VEHICLE SPEED: 80 km/h (50 MPH) or more THROTTLE POSI: 0.5/8 - 1.0/8 SLCT LVR POSI: “D” position Driving location: Driving the vehicle uphill (increased engine load) will help maintain the driving conditions required for this test. If the check result is NG, go to AT-144, "Diagnostic Procedure" . WITH GST Follow the procedure “WITH CONSULT-II”. WITHOUT CONSULT-II 1. 2. 3. 4. Start engine. Drive vehicle in D1 → D2 → D3 → D4 → D4 lock-up position. Perform self-diagnosis. Refer to AT-94, "Diagnostic Procedure Without CONSULT-II" . If the check result is NG, go to AT-144, "Diagnostic Procedure" . AT-142 BCIA0031E DTC P0740 TORQUE CONVERTER CLUTCH SOLENOID VALVE [EURO-OBD] Wiring Diagram — AT — TCV BCS000Q7 A B AT D E F G H I J K L M MCWA0246E AT-143 DTC P0740 TORQUE CONVERTER CLUTCH SOLENOID VALVE [EURO-OBD] TCM terminal data are reference values, measured between each terminal and ground. Terminal Wire color Item Condition 3 O Torque converter clutch solenoid valve When A/T performs lock-up. When A/T does not perform lock-up. Diagnostic Procedure Judgement standard (Approx.) 8 - 15V 0V BCS000Q8 1. CHECK INPUT SIGNAL With CONSULT-II 1. Start engine. 2. Select “MAIN SIGNALS” in “DATA MONITOR” mode for “A/T” with CONSULT-II. 3. Read out the value of “TCC S/V DUTY” while driving. Check the value changes according to driving speed. Monitor item Condition Display value (Approx) TCC S/V DUTY Lock-up OFF ⇔ Lock-up ON 4% ⇔ 94% SCIA3257E Without CONSULT-II 1. Start engine. 2. Check voltage between TCM connector terminal and ground. Name Torque converter clutch solenoid valve Connector E106 Terminal 3 - Ground Condition Judgement standard (Approx.) When A/T performs lockup. 8 - 15V When A/T does not perform lock-up. 0V OK or NG OK >> GO TO 5. NG >> GO TO 2. SCIA3261E 2. CHECK TORQUE CONVERTER CLUTCH SOLENOID VALVE CIRCUIT 1. 2. 3. Turn ignition switch OFF. Disconnect TCM connector. Check resistance between TCM connector terminal and ground. Solenoid Valve Torque converter clutch solenoid valve Connector Terminal Resistance (Approx.) E106 3 - Ground 5 - 20 Ω OK or NG OK >> GO TO 5. NG >> GO TO 3. SCIA3262E AT-144 DTC P0740 TORQUE CONVERTER CLUTCH SOLENOID VALVE [EURO-OBD] 3. 1. 2. 3. CHECK HARNESS BETWEEN TCM AND TERMINAL CORD ASSEMBLY HARNESS CONNECTOR Turn ignition switch OFF. Disconnect terminal cord assembly harness connector and TCM connector. Check continuity between terminal cord assembly harness connector terminal and TCM connector terminal. Item Connector Terminal TCM E106 3 F13 5 A B Continuity AT Yes Terminal cord assembly harness connector D 4. If OK, check harness for short to ground and short to power. 5. If OK, check continuity between ground and transaxle assembly. 6. Reinstall any part removed. OK or NG OK >> GO TO 4. NG >> Repair open circuit or short to ground or short to power in harness or connectors. SCIA3263E E F 4. CHECK VALVE RESISTANCE 1. 2. 3. G Turn ignition switch OFF. Disconnect terminal cord assembly connector in engine room. Check resistance between terminal cord assembly harness connector terminal and ground. Solenoid valve Connector Terminal Resistance (Approx.) Torque converter clutch solenoid valve F13 5 - Ground 5 - 20 Ω H I OK or NG OK >> GO TO 5. NG >> Repair or replace damaged parts. J SCIA3456E K 5. CHECK DTC L Perform AT-142, "DTC Confirmation Procedure" . OK or NG OK >> INSPECTION END NG >> GO TO 6. M 6. CHECK TCM 1. Check TCM input/output signal. Refer to AT-80, "TCM Terminals and Reference Value" . 2. If NG, recheck TCM pin terminals for damage or loose connection with harness connector. OK or NG OK >> INSPECTION END NG >> Repair or replace damaged parts. AT-145 DTC P0740 TORQUE CONVERTER CLUTCH SOLENOID VALVE [EURO-OBD] Component Inspection BCS000Q9 TORQUE CONVERTER CLUTCH SOLENOID VALVE ● For removal, refer to AT-345, "Control Valve Assembly and Accumulators" . Resistance Check ● Check resistance between terminal and ground. Solenoid valve Torque converter clutch solenoid valve Resistance (Approx.) Terminal 5 Ground 5 - 20 Ω SCIA2063E Operation Check ● Check solenoid valve by listening for its operating sound while applying battery voltage to the terminal and ground. SCIA2066E AT-146 DTC P0744 A/T TCC S/V FUNCTION (LOCK-UP) [EURO-OBD] DTC P0744 A/T TCC S/V FUNCTION (LOCK-UP) Description ● ● PFP:31940 A BCS000QA This malfunction will not be detected while the OD OFF indicator lamp is indicating another self-diagnosis malfunction. B This malfunction is detected when the A/T does not shift into fourth gear position or the torque converter clutch does not lock-up as instructed by the TCM. This is not caused by electrical malfunction (circuits open or shorted) but by mechanical malfunction such as control valve sticking, improper solenoid valve AT operation, malfunctioning oil pump or torque converter clutch, etc. CONSULT-II Reference Value BCS000QB D Remarks: Specification data are reference values. Item name Condition TCC S/V DUTY Display value (Approx) Lock-up OFF ⇔ Lock-up ON 4% ⇔ 94% E On Board Diagnosis Logic ● ● ● ● BCS000QC This is an OBD self-diagnostic item. Diagnostic trouble code “P0744 A/T TCC S/V FNCTN” with CONSULT-II is detected when A/T cannot perform lock-up even if electrical circuit is good. This diagnosis monitors actual gear position by checking the torque converter slip ratio calculated by TCM as follows: Torque converter slip ratio = A x C/B A: Output shaft revolution signal from revolution sensor B: Engine speed signal from ECM C: Gear ratio determined as gear position which TCM supposes If the actual gear position is much lower than the position (4th) supposed by TCM, the slip ratio will be much less than normal. In case the ratio does not reach the specified value, TCM judges this diagnosis malfunction. This malfunction will be caused when shift solenoid valve B is stuck closed. Gear positions supposed by TCM are as follows. In case of gear position with no malfunctions: 1, 2, 3 and 4 positions In case of gear position with shift solenoid valve B stuck closed: 1, 2, 2 and 1* positions to each gear position above *: “P0744 A/T TCC S/V FNCTN” is detected. Possible Cause ● ● ● ● F G H I J K BCS000QD Line pressure solenoid valve Torque converter clutch solenoid valve Each clutch Hydraulic control circuit L M AT-147 DTC P0744 A/T TCC S/V FUNCTION (LOCK-UP) [EURO-OBD] DTC Confirmation Procedure BCS000QE CAUTION: ● Always drive vehicle at a safe speed. ● If performing this “DTC Confirmation Procedure” again, always turn ignition switch OFF and wait at least 10 seconds before continuing. After the repair, perform the following procedure to confirm the malfunction is eliminated. WITH CONSULT-II 1. 2. 3. 4. 5. – – – 6. Start engine and select “DATA MONITOR” mode for “A/T” with CONSULT-II. Touch “START”. Make sure that output voltage of A/T fluid temperature sensor is within the range below. FLUID TEMP SE: 0.4 - 1.5V If out of range, drive vehicle to decrease voltage (warm up the fluid) or stop engine to increase voltage (cool down the fluid). Select “TCC S/V FNCTN P0744” of “DTC WORK SUPPORT” mode for “A/T” with CONSULT-II and touch “START”. BCIA0031E Accelerate vehicle to more than 80 km/h (50 MPH) and maintain the following conditions continuously until “TESTING” has turned to “COMPLETE”. (It will take approximately 30 seconds after “TESTING” shows.) THROTTLE POSI: 1.0/8 - 2.0/8 (at all times during step 4) SLCT LVR POSI: “D” position TCC S/V DUTY: More than 94% VEHICLE SPEED: Constant speed of more than 80 km/h (50 MPH) Make sure that “GEAR” shows “4”. For shift schedule, refer to AT-67, "Vehicle Speed at Which Gear Shifting Occurs" . If “TESTING” does not appear on CONSULT-II for a long time, select “SELF-DIAG RESULTS”. In case a DTC other than “P0744 A/T TCC S/V FNCTN” is shown, refer to AT-85, "Display Items List (For EURO-OBD models)" . Make sure that “OK” is displayed. (If “NG” is displayed, refer to “DIAGNOSTIC PROCEDURE”.) Refer to AT-149, "Diagnostic Procedure" . Refer to AT-67, "Vehicle Speed at Which Lock-up Occurs/Releases" . WITH GST Follow the procedure “WITH CONSULT-II”. AT-148 DTC P0744 A/T TCC S/V FUNCTION (LOCK-UP) [EURO-OBD] Diagnostic Procedure 1. CHECK SHIFT-UP (D3 BCS000QF A TO D4 ) During AT-61, "Cruise Test — Part 1" . Does A/T shift from D3 to D4 at the specified speed? YES >> GO TO 11. NO >> GO TO 2. B AT D SCIA7190E E 2. CHECK LINE PRESSURE Perform line pressure test. Refer to AT-56, "LINE PRESSURE TEST" . OK or NG OK >> GO TO 3. NG >> GO TO 6. F G 3. CHECK CONTROL VALVE Disassemble control valve assembly. Refer to AT-392, "Control Valve Assembly" . Check to ensure that: – Valve, sleeve and plug slide along valve bore under their own weight. – Valve, sleeve and plug are free from burrs, dents and scratches. – Control valve springs are free from damage, deformation and fatigue. – Hydraulic line is free from obstacles. OK or NG OK >> GO TO 4. NG >> Repair control valve. 1. 2. 4. CHECK SHIFT-UP (D3 H I J K TO D4 ) During AT-61, "Cruise Test — Part 1" . Does A/T shift from D3 to D4 at the specified speed? YES >> GO TO 5. NO >> Check control valve again. Repair or replace control valve assembly. L M SCIA7190E 5. CHECK DTC Perform AT-148, "DTC Confirmation Procedure" . OK or NG OK >> INSPECTION END NG >> GO TO 11. Check for proper lock-up. AT-149 DTC P0744 A/T TCC S/V FUNCTION (LOCK-UP) [EURO-OBD] 6. CHECK VALVE RESISTANCE 1. – 2. Remove control valve assembly. Refer to AT-345, "Control Valve Assembly and Accumulators" . Line pressure solenoid valve Check resistance between terminal cord assembly harness connector terminal and ground. Refer to AT-154, "Wiring Diagram — AT — LPSV" . Solenoid valve Line pressure solenoid valve Terminal 4 Ground Resistance (Approx.) 2.5 - 5Ω OK or NG OK >> GO TO 7. NG >> Replace solenoid valve assembly. SCIA3457E 7. CHECK VALVE OPERATION Remove control valve assembly. Refer to AT-345, "Control Valve Assembly and Accumulators" . Line pressure solenoid valve 2. Check solenoid valve by listening for its operating sound while applying battery voltage to the terminal and ground. Refer to AT154, "Wiring Diagram — AT — LPSV" . OK or NG OK >> GO TO 8. NG >> Replace solenoid valve assembly. 1. – SCIA3275E 8. CHECK CONTROL VALVE Disassemble control valve assembly. Refer to AT-392, "Control Valve Assembly" . Check line pressure circuit valves for sticking. – Pressure regulator valve – Pilot valve – Pressure modifier valve OK or NG OK >> GO TO 9. NG >> Repair control valve. 1. 2. 9. CHECK SHIFT-UP (D3 TO D4 ) During AT-61, "Cruise Test — Part 1" . Does A/T shift from D3 to D4 at the specified speed? YES >> GO TO 10. NO >> Check control valve again. Repair or replace control valve assembly. SCIA7190E AT-150 DTC P0744 A/T TCC S/V FUNCTION (LOCK-UP) [EURO-OBD] 10. CHECK DTC A Perform AT-148, "DTC Confirmation Procedure" . OK or NG OK >> INSPECTION END NG >> GO TO 11. Check for proper lock-up. B 11. CHECK LOCK-UP AT During AT-61, "Cruise Test — Part 1" . A/T perform lock-up at the specified speed? YES >> Perform “Cruise test — Part 1” again and return to the start point of this test group. NO >> GO TO 12. D E F SCIA7191E 12. CHECK VALVE RESISTANCE 1. – 2. G Remove control valve assembly. Refer to AT-345, "Control Valve Assembly and Accumulators" . Torque converter clutch solenoid valve Check resistance between terminal cord assembly harness connector terminal and ground. Refer to AT-143, "Wiring Diagram — AT — TCV" . Solenoid valve Torque converter clutch solenoid valve I Resistance (Approx.) Terminal 5 H Ground J 5 - 20 Ω OK or NG OK >> GO TO 13. NG >> Replace solenoid valve assembly. K SCIA2063E 13. CHECK VALVE OPERATION L Remove control valve assembly. Refer to AT-345, "Control Valve Assembly and Accumulators" . – Torque converter clutch solenoid valve 2. Check solenoid valve by listening for its operating sound while applying battery voltage to the terminal and ground. Refer to AT143, "Wiring Diagram — AT — TCV" . OK or NG OK >> GO TO 14. NG >> Replace solenoid valve assembly. 1. M SCIA2066E AT-151 DTC P0744 A/T TCC S/V FUNCTION (LOCK-UP) [EURO-OBD] 14. CHECK CONTROL VALVE Disassemble control valve assembly. Refer to AT-392, "Control Valve Assembly" . Check control valves for sticking. – Torque converter clutch control valve – Torque converter clutch relief valve OK or NG OK >> GO TO 15. NG >> Repair control valve. 1. 2. 15. CHECK LOCK-UP During AT-61, "Cruise Test — Part 1" . A/T perform lock-up at the specified speed? YES >> GO TO 16. NO >> Check control valve again. Repair or replace control valve assembly. SCIA7191E 16. CHECK DTC Perform AT-148, "DTC Confirmation Procedure" . OK or NG OK >> INSPECTION END NG >> Perform “Cruise test — Part 1” again and return to the start point of this test group. AT-152 DTC P0745 LINE PRESSURE SOLENOID VALVE [EURO-OBD] DTC P0745 LINE PRESSURE SOLENOID VALVE Description PFP:31940 A BCS000QG The line pressure solenoid valve regulates the oil pump discharge pressure to suit the driving condition in response to signals sent from the TCM. The line pressure duty cycle value is not constant when the closed throttle position switch is ON. To confirm the line pressure duty cycle at low-pressure, the accelerator (throttle) should be open until the closed throttle position switch is OFF. CONSULT-II Reference Value Display value (Approx.) Small throttle opening (Low line pressure) ⇔ Large throttle opening (High line pressure) ● BCS000QI This is an OBD self-diagnostic item. Diagnostic trouble code “P0745 LINE PRESSURE S/V” with CONSULT-II or 11th judgement flicker without CONSULT-II is detected when TCM detects an improper voltage drop while it tries to operate the solenoid valve. Possible Cause ● ● D 0% ⇔ 94% On Board Diagnosis Logic ● AT BCS000QH Remarks: Specification data are reference values. Item name Condition LINE PRES DTY B BCS000QJ Harness or connector (The solenoid circuit is open or shorted.) Line pressure solenoid valve E F G H DTC Confirmation Procedure BCS000QK CAUTION: If performing this “DTC Confirmation Procedure” again, always turn ignition switch OFF and wait at least 10 seconds before continuing. After the repair, perform the following procedure to confirm the malfunction is eliminated. I J WITH CONSULT-II 1. 2. 3. 4. Turn ignition switch ON and select “DATA MONITOR” mode for “A/T” with CONSULT-II. Touch “START”. Depress accelerator pedal completely and wait at least 1 second. If the check result is NG, go to AT-155, "Diagnostic Procedure" . K L M BCIA0031E WITH GST Follow the procedure “WITH CONSULT-II”. WITHOUT CONSULT-II 1. 2. 3. 4. Start engine. With brake pedal depressed, shift the lever from “P” → “N” → “D” → “N” → “P” positions. Perform self-diagnosis. Refer to AT-94, "Diagnostic Procedure Without CONSULT-II" . If the check result is NG, go to AT-155, "Diagnostic Procedure" . AT-153 DTC P0745 LINE PRESSURE SOLENOID VALVE [EURO-OBD] Wiring Diagram — AT — LPSV BCS000QL MCWA0247E AT-154 DTC P0745 LINE PRESSURE SOLENOID VALVE [EURO-OBD] TCM terminal data are reference values, measured between each terminal and ground. Terminal 1 2 Wire color Item Condition When releasing accelerator pedal after warming up engine. Line pressure solenoid valve P When depressing accelerator pedal fully after warming up engine. When releasing accelerator pedal after warming up engine. Line pressure solenoid valve (with dropping resistor) V When depressing accelerator pedal fully after warming up engine. Diagnostic Procedure Judgement standard (Approx.) 1.5 - 3.0V A B 0V AT 4 - 14V 0V D BCS000QM 1. CHECK INPUT SIGNAL E With CONSULT-II 1. Turn ignition switch ON. (Do not start engine.) 2. Select “MAIN SIGNALS” in “DATA MONITOR” mode for “A/T” with CONSULT-II. 3. Read out the value of “LINE PRES DTY” while driving. Check the value changes according to driving speed. Item name Condition Display value LINE PRES DTY Small throttle opening (Low line pressure) ⇔ Large throttle opening (High line pressure) 0% ⇔ 94% F G H I SCIA3251E J Without CONSULT-II 1. Turn ignition switch ON. (Do not start engine.) 2. Check voltage between TCM connector terminals and ground. Item Line pressure solenoid valve Line pressure solenoid valve (with dropping resistor) Connector E106 E106 Terminal 1 - Ground 2 - Ground K Condition Judgement standard (Approx.) L When releasing accelerator pedal after warming up engine. 1.5 - 3.0V M When depressing accelerator pedal fully after warming up engine. 0V When releasing accelerator pedal after warming up engine. 4 - 14V When depressing accelerator pedal fully after warming up engine. 0V SCIA3267E OK or NG OK >> GO TO 5. NG >> GO TO 2. AT-155 DTC P0745 LINE PRESSURE SOLENOID VALVE [EURO-OBD] 2. CHECK DROPPING RESISTOR 1. 2. 3. Turn ignition switch OFF. Disconnect dropping resistor harness connector in engine room. Check resistance between terminals. Item Dropping resistor Connector Terminal Resistance (Approx.) E58 1-2 12 Ω OK or NG OK >> GO TO 3. NG >> Repair or replace damaged parts. SCIA4950E 3. CHECK VALVE RESISTANCE 1. 2. 3. Turn ignition switch OFF. Disconnect terminal cord assembly connector in engine room. Check resistance between terminal cord assembly harness connector terminal and ground. Solenoid valve Connector Terminal Resistance (Approx.) Line pressure solenoid valve F13 4 - Ground 2.5 - 5.0 Ω OK or NG OK >> GO TO 4. NG >> Repair or replace damaged parts. SCIA3457E AT-156 DTC P0745 LINE PRESSURE SOLENOID VALVE [EURO-OBD] 4. 1. 2. 3. CHECK HARNESS BETWEEN TCM AND TERMINAL CORD ASSEMBLY HARNESS CONNECTOR Turn ignition switch OFF. Disconnect terminal cord assembly harness connector and TCM connector. Check continuity between terminal cord assembly harness connector terminal and TCM connector terminal. Item Connector Terminal TCM E106 1 F13 4 Terminal cord assembly harness connector B Continuity AT Yes D SCIA3272E 4. Check continuity between terminal cord assembly harness connector terminal and dropping resistor harness connector terminal. Item A Connector Terminal Dropping resistor harness connector E58 2 Terminal cord assembly harness connector F13 4 E F Continuity G Yes H SCIA7194E I 5. Check continuity between dropping resistor harness connector terminal and TCM connector terminal. Item Connector Terminal TCM E106 2 E58 1 Dropping resistor harness connector J Continuity Yes 6. If OK, check harness for short to ground and short to power. 7. If OK, check continuity between ground and transaxle assembly. 8. Reinstall any part removed. OK or NG OK >> GO TO 5. NG >> Repair open circuit or short to ground or short to power in harness or connectors. 5. CHECK DTC Perform AT-153, "DTC Confirmation Procedure" . OK or NG OK >> INSPECTION END NG >> GO TO 6. 6. CHECK TCM 1. Check TCM input/output signal. Refer to AT-80, "TCM Terminals and Reference Value" . 2. If NG, recheck TCM pin terminals for damage or loose connection with harness connector. OK or NG OK >> INSPECTION END NG >> Repair or replace damaged parts. AT-157 K L SCIA7195E M DTC P0745 LINE PRESSURE SOLENOID VALVE [EURO-OBD] Component Inspection BCS000QN LINE PRESSURE SOLENOID VALVE ● For removal, refer to AT-345, "Control Valve Assembly and Accumulators" . Resistance Check ● Check resistance between terminal and ground. Solenoid valve Resistance (Approx.) Terminal Line pressure solenoid valve 4 Ground 2.5 - 5 Ω SCIA3457E Operation Check ● Check solenoid valve by listening for its operating sound while applying battery voltage to the terminal and ground. SCIA3275E DROPPING RESISTOR ● Check resistance between terminals. Item Dropping resistor Connector Terminal Resistance (Approx.) E58 1-2 12 Ω SCIA4950E AT-158 DTC P0750 SHIFT SOLENOID VALVE A [EURO-OBD] DTC P0750 SHIFT SOLENOID VALVE A Description PFP:31940 A BCS000QO Shift solenoid valves A and B are turned ON or OFF by the TCM in response to signals sent from the PNP switch, vehicle speed and ECM (throttle opening). Gears will then be shifted to the optimum position. Gear position 1 2 3 4 Shift solenoid valve A ON (Closed) OFF (Open) OFF (Open) ON (Closed) Shift solenoid valve B ON (Closed) ON (Closed) OFF (Open) OFF (Open) CONSULT-II Reference Value D Display value When shift solenoid valve A operates. (When driving in “D1 ” or “D4 ”.) ON When shift solenoid valve A does not operate. (When driving in “D2 ” or “D3 ”.) OFF On Board Diagnosis Logic ● ● ● E BCS000QQ This is an OBD self-diagnostic item. Diagnostic trouble code “P0750 SHIFT SOLENOID/V A” with CONSULT-II or 4th judgement flicker without CONSULT-II is detected when TCM detects an improper voltage drop when it tries to operate the solenoid valve. Possible Cause ● BCS000QR Harness or connector (The solenoid circuit is open or shorted.) Shift solenoid valve A WITH CONSULT-II 5. H WITH GST Follow the procedure “WITH CONSULT-II”. WITHOUT CONSULT-II Start engine. Drive vehicle in D1 → D2 position. Perform self-diagnosis. Refer to AT-94, "Diagnostic Procedure Without CONSULT-II" . If the check result is NG, go to AT-161, "Diagnostic Procedure" . AT-159 J K L Turn ignition switch ON and select “DATA MONITOR” mode for “A/T” with CONSULT-II. Touch “START”. Start engine. Drive vehicle in “D” position and allow the transaxle to shift 1 → 2 (“GEAR”). If the check result is NG, go to AT-161, "Diagnostic Procedure" . M BCIA0031E 1. 2. 3. 4. G BCS000QS CAUTION: ● Always drive vehicle at a safe speed. ● If performing this “DTC Confirmation Procedure” again, always turn ignition switch OFF and wait at least 10 seconds before continuing. After the repair, perform the following procedure to confirm the malfunction is eliminated. 2. 3. 4. F I DTC Confirmation Procedure 1. AT BCS000QP Remarks: Specification data are reference values. Item name Condition SHIFT S/V A B DTC P0750 SHIFT SOLENOID VALVE A [EURO-OBD] Wiring Diagram — AT — SSV/A BCS000QT MCWA0248E AT-160 DTC P0750 SHIFT SOLENOID VALVE A [EURO-OBD] TCM terminal data are reference values, measured between each terminal and ground. Terminal Wire color 11 R Item Condition Shift solenoid valve A Judgement standard (Approx.) When shift solenoid valve A operates. (When driving in “D1 ” or “D4 ”.) Battery voltage When shift solenoid valve A does not operate. (When driving in “D2 ” or “D3 ”.) 0V Diagnostic Procedure BCS000QU D With CONSULT-II Start engine. Select “MAIN SIGNALS” in “DATA MONITOR” mode for “A/T” with CONSULT-II. Read out the value of “SHIFT S/V A” while driving. Check the value changes according to driving speed. Item name SHIFT S/V A B AT 1. CHECK INPUT SIGNAL 1. 2. 3. A Condition Display value When shift solenoid valve A operates. (When driving in “D1 ” or “D4 ”.) ON When shift solenoid valve A does not operate. (When driving in “D2 ” or “D3 ”.) OFF E F G H SCIA3251E I 1. 2. Without CONSULT-II Start engine. Check voltage between TCM connector terminal and ground. Item Shift solenoid valve A Connector E106 Terminal 11 Ground Condition Judgement standard (Approx.) When shift solenoid valve A operates. (When driving in “D1 ” or “D4 ”.) Battery voltage When shift solenoid valve A does not operate. (When driving in “D2 ” or “D3 ”.) 0V OK or NG OK >> GO TO 5. NG >> GO TO 2. AT-161 J K L SCIA3248E M DTC P0750 SHIFT SOLENOID VALVE A [EURO-OBD] 2. CHECK SHIFT SOLENOID VALVE A CIRCUIT 1. 2. 3. Turn ignition switch OFF. Disconnect TCM connector. Check resistance between TCM connector terminal and ground. Solenoid Valve Shift solenoid valve A Connector Terminal Resistance (Approx.) E106 11 - Ground 20 - 30 Ω OK or NG OK >> GO TO 5. NG >> GO TO 3. SCIA3249E 3. 1. 2. 3. CHECK HARNESS BETWEEN TCM AND TERMINAL CORD ASSEMBLY HARNESS CONNECTOR Turn ignition switch OFF. Disconnect terminal cord assembly harness connector and TCM connector. Check continuity between terminal cord assembly harness connector terminal and TCM connector terminal. Item Connector Terminal TCM E106 11 F13 2 Terminal cord assembly harness connector Continuity Yes 4. If OK, check harness for short to ground and short to power. 5. If OK, check continuity between ground and transaxle assembly. 6. Reinstall any part removed. OK or NG OK >> GO TO 4. NG >> Repair open circuit or short to ground or short to power in harness or connectors. SCIA3250E 4. CHECK VALVE RESISTANCE 1. 2. 3. Turn ignition switch OFF. Disconnect terminal cord assembly connector in engine room. Check resistance between terminal cord assembly harness connector terminal and ground. Solenoid valve Shift solenoid valve A Connector Terminal Resistance (Approx.) F13 2 - Ground 20 - 30 Ω OK or NG OK >> GO TO 5. NG >> Repair or replace damaged parts. SCIA3453E 5. CHECK DTC Perform AT-159, "DTC Confirmation Procedure" . OK or NG OK >> INSPECTION END NG >> GO TO 6. AT-162 DTC P0750 SHIFT SOLENOID VALVE A [EURO-OBD] 6. CHECK TCM A 1. Check TCM input/output signal. Refer to AT-80, "TCM Terminals and Reference Value" . 2. If NG, recheck TCM pin terminals for damage or loose connection with harness connector. OK or NG OK >> INSPECTION END NG >> Repair or replace damaged parts. B AT Component Inspection BCS000QV SHIFT SOLENOID VALVE A ● For removal, refer to AT-345, "Control Valve Assembly and Accumulators" . D Resistance Check ● Check resistance between terminal and ground. E Solenoid valve Shift solenoid valve A Resistance (Approx.) Terminal 2 Ground 20 - 30 Ω F G SCIA2049E H Operation Check ● Check solenoid valve by listening for its operating sound while applying battery voltage to the terminal and ground. I J K SCIA2052E L M AT-163 DTC P0755 SHIFT SOLENOID VALVE B [EURO-OBD] DTC P0755 SHIFT SOLENOID VALVE B Description PFP:31940 BCS000QW Shift solenoid valves A and B are turned ON or OFF by the TCM in response to signals sent from the PNP switch, vehicle speed and ECM (throttle opening). Gears will then be shifted to the optimum position. Gear position 1 2 3 4 Shift solenoid valve A ON (Closed) OFF (Open) OFF (Open) ON (Closed) Shift solenoid valve B ON (Closed) ON (Closed) OFF (Open) OFF (Open) CONSULT-II Reference Value BCS000QX Remarks: Specification data are reference values. Item name Condition SHIFT S/V B Display value When shift solenoid valve B operates. (When driving in “D1 ” or “D2 ”.) ON When shift solenoid valve B does not operate. (When driving in “D3 ” or “D4 ”.) OFF On Board Diagnosis Logic ● ● BCS000QY This is an OBD self-diagnostic item. Diagnostic trouble code “P0755 SHIFT SOLENOID/V B” with CONSULT-II or 5th judgement flicker without CONSULT-II is detected when TCM detects an improper voltage drop when it tries to operate the solenoid valve. Possible Cause ● ● BCS000QZ Harness or connector (The solenoid circuit is open or shorted.) Shift solenoid valve B DTC Confirmation Procedure BCS000R0 CAUTION: ● Always drive vehicle at a safe speed. ● If performing this “DTC Confirmation Procedure” again, always turn ignition switch OFF and wait at least 10 seconds before continuing. After the repair, perform the following procedure to confirm the malfunction is eliminated. WITH CONSULT-II 1. 2. 3. 4. 5. Turn ignition switch ON and select “DATA MONITOR” mode for “A/T” with CONSULT-II. Touch “START”. Start engine. Drive vehicle in D position and allow the transaxle to shift 1 → 2 → 3 (“GEAR”). If the check result is NG, go to AT-166, "Diagnostic Procedure" . BCIA0031E WITH GST Follow the procedure “WITH CONSULT-II”. WITHOUT CONSULT-II 1. 2. 3. 4. Start engine. Drive vehicle in D1 → D2 → D3 position. Perform self-diagnosis. Refer to AT-94, "Diagnostic Procedure Without CONSULT-II" . If the check result is NG, go to AT-166, "Diagnostic Procedure" . AT-164 DTC P0755 SHIFT SOLENOID VALVE B [EURO-OBD] Wiring Diagram — AT — SSV/B BCS000R1 A B AT D E F G H I J K L M MCWA0249E AT-165 DTC P0755 SHIFT SOLENOID VALVE B [EURO-OBD] TCM terminal data are reference values, measured between each terminal and ground. Terminal Wire color 12 SB Item Condition Shift solenoid valve B Judgement standard (Approx.) When shift solenoid valve B operates. (When driving in “D1 ” or “D2 ”.) Battery voltage When shift solenoid valve B does not operate. (When driving in “D3 ” or “D4 ”.) 0V Diagnostic Procedure BCS000R2 1. CHECK INPUT SIGNAL 1. 2. 3. With CONSULT-II Start engine. Select “MAIN SIGNALS” in “DATA MONITOR” mode for “A/T” with CONSULT-II. Read out the value of “SHIFT S/V B” while driving. Check the value changes according to driving speed. Item name SHIFT S/V B Condition Display value When shift solenoid valve B operates. (When driving in “D1 ” or “D2 ”.) ON When shift solenoid valve B does not operate. (When driving in “D3 ” or “D4 ”.) OFF SCIA3251E 1. 2. Without CONSULT-II Start engine. Check voltage between TCM connector terminal and ground. Item Shift solenoid valve B Connector E106 Terminal 12 Ground Condition Judgement standard (Approx.) When shift solenoid valve B operates. (When driving in “D1 ” or “D2 ”.) Battery voltage When shift solenoid valve B does not operate. (When driving in “D3 ” or “D4 ”.) 0V OK or NG OK >> GO TO 5. NG >> GO TO 2. AT-166 SCIA3253E DTC P0755 SHIFT SOLENOID VALVE B [EURO-OBD] 2. CHECK SHIFT SOLENOID VALVE B CIRCUIT 1. 2. 3. A Turn ignition switch OFF. Disconnect TCM connector. Check resistance between TCM connector terminal and ground. Solenoid Valve Shift solenoid valve B Connector Terminal Resistance (Approx.) E106 12 - Ground 5 - 20 Ω B AT OK or NG OK >> GO TO 5. NG >> GO TO 3. D SCIA3254E 3. 1. 2. 3. E CHECK HARNESS BETWEEN TCM AND TERMINAL CORD ASSEMBLY HARNESS CONNECTOR F Turn ignition switch OFF. Disconnect terminal cord assembly harness connector and TCM connector. Check continuity between terminal cord assembly harness connector terminal and TCM connector terminal. Item Connector Terminal TCM E106 12 F13 1 Terminal cord assembly harness connector G Continuity H Yes 4. If OK, check harness for short to ground and short to power. 5. If OK, check continuity between ground and transaxle assembly. 6. Reinstall any part removed. OK or NG OK >> GO TO 4. NG >> Repair open circuit or short to ground or short to power in harness or connectors. I SCIA3255E J K 4. CHECK VALVE RESISTANCE 1. 2. 3. L Turn ignition switch OFF. Disconnect terminal cord assembly connector in engine room. Check resistance between terminal cord assembly harness connector terminal and ground. Solenoid valve Shift solenoid valve B Connector Terminal Resistance (Approx.) F13 1 - Ground 5 - 20 Ω M OK or NG OK >> GO TO 5. NG >> Repair or replace damaged parts. SCIA3454E 5. CHECK DTC Perform AT-164, "DTC Confirmation Procedure" . OK or NG OK >> INSPECTION END NG >> GO TO 6. AT-167 DTC P0755 SHIFT SOLENOID VALVE B [EURO-OBD] 6. CHECK TCM 1. Check TCM input/output signal. Refer to AT-80, "TCM Terminals and Reference Value" . 2. If NG, recheck TCM pin terminals for damage or loose connection with harness connector. OK or NG OK >> INSPECTION END NG >> Repair or replace damaged parts. Component Inspection BCS000R3 SHIFT SOLENOID VALVE B ● For removal, refer to AT-345, "Control Valve Assembly and Accumulators" . Resistance Check ● Check resistance between terminal and ground. Solenoid valve Shift solenoid valve B Resistance (Approx.) Terminal 1 Ground 5 - 20Ω SCIA2055E Operation Check ● Check solenoid valve by listening for its operating sound while applying battery voltage to the terminal and ground. SCIA2058E AT-168 DTC P1705 ACCELERATOR PEDAL POSITION (APP) SENSOR [EURO-OBD] DTC P1705 ACCELERATOR PEDAL POSITION (APP) SENSOR Description PFP:22620 A BCS000R4 Electric throttle control actuator consists of throttle control motor, accelerator pedal position sensor, throttle position sensor, etc. The actuator sends signals to the ECM, and ECM sends signals to TCM via CAN communication. CONSULT-II Reference Value BCS000R5 AT Remarks: Specification data are reference values. Item name Condition THROTTLE POSI Display value (Approx.) Released accelerator pedal. 0.0/8 Fully depressed accelerator pedal. 8.0/8 On Board Diagnosis Logic ● ● B D BCS000R6 This is an OBD self-diagnostic item. Diagnostic trouble code “P1705 THROTTLE POSI SEN” with CONSULT-II or 3rd judgement flicker without CONSULT-II is detected when TCM does not receive the proper accelerator pedal position signals (input via CAN communication) from ECM. Possible Cause E F BCS000R7 Harness or connector (The sensor circuit is open or shorted.) G DTC Confirmation Procedure BCS000R8 CAUTION: If performing this “DTC Confirmation Procedure” again, always turn ignition switch OFF and wait at least 10 seconds before continuing. After the repair, perform the following procedure to confirm the malfunction is eliminated. H I WITH CONSULT-II 1. 2. 3. 4. Turn ignition switch ON. (Do not start engine.) Select “DATA MONITOR” mode for “A/T” with CONSULT-II. Depress accelerator pedal fully and release it, then wait for 5 seconds. If DTC is detected, go to AT-170, "Diagnostic Procedure" . J K L BCIA0031E WITH GST Follow the procedure “WITH CONSULT-II”. WITHOUT CONSULT-II 1. 2. 3. 4. Turn ignition switch ON. (Do not start engine.) Depress accelerator pedal fully and release it, then wait for 5 seconds. Perform self-diagnosis. Refer to AT-94, "Diagnostic Procedure Without CONSULT-II" . If the check result is NG, go to AT-170, "Diagnostic Procedure" . AT-169 M DTC P1705 ACCELERATOR PEDAL POSITION (APP) SENSOR [EURO-OBD] Diagnostic Procedure BCS000R9 1. CHECK CAN COMMUNICATION LINE Perform self-diagnosis. Refer to AT-85, "SELF-DIAGNOSTIC RESULT MODE" , AT-94, "Diagnostic Procedure Without CONSULT-II" . Is any malfunction of the “U1000 CAN COMM CIRCUIT” indicated? YES >> Check the CAN communication line. Refer to AT-102, "DTC U1000 CAN COMMUNICATION LINE" . NO >> GO TO 2. 2. CHECK INPUT SIGNAL With CONSULT-II 1. Turn ignition switch ON. (Do not start engine.) 2. Select “MAIN SIGNALS” in “DATA MONITOR” mode for “A/T” with CONSULT-II. 3. Read out the value of “THROTTLE POSI”. Item name THROTTLE POSI Condition Display value (Approx.) Released accelerator pedal. 0.0/8 Fully depressed accelerator pedal. 8.0/8 OK or NG OK >> GO TO 4. NG >> GO TO 3. SCIA3251E 3. CHECK DTC WITH ECM With CONSULT-II 1. Turn ignition switch ON. (Do not start engine.) 2. Select “SELF-DIAG RESULTS” mode for “ENGINE” with CONSULT-II. Refer to EC-104, "SELF-DIAG RESULTS MODE" . OK or NG OK >> GO TO 4. NG >> Check the DTC Detected Item. Go to EC-104, "SELFDIAG RESULTS MODE" . BCIA0030E 4. CHECK DTC Perform “DTC Confirmation Procedure”. Refer to AT-169, "DTC Confirmation Procedure" . OK or NG OK >> INSPECTION END NG >> GO TO 5. 5. CHECK TCM 1. Check TCM input/output signals. Refer to AT-80, "TCM Terminals and Reference Value" . 2. If NG, recheck TCM pin terminals for damage or loose connection with harness connector. OK or NG OK >> INSPECTION END NG >> Repair or replace damaged parts. AT-170 DTC P1760 OVERRUN CLUTCH SOLENOID VALVE [EURO-OBD] DTC P1760 OVERRUN CLUTCH SOLENOID VALVE Description PFP:31940 A BCS000RA The overrun clutch solenoid valve is activated by the TCM in response to signals sent from the PNP switch, overdrive control switch, vehicle speed and ECM (throttle opening). The overrun clutch operation will then be controlled. CONSULT-II Reference Value BCS000RB AT Remarks: Specification data are reference values. Item name Condition OVERRUN/C S/V Display value When overrun clutch solenoid valve operates. (When overrun clutch disengaged. Refer to AT-22 .) ON When overrun clutch solenoid valve does not operate. (When overrun clutch engaged. Refer to AT-22 .) OFF ● BCS000RC This is an OBD self-diagnostic item. Diagnostic trouble code “P1760 OVERRUN CLUTCH S/V” with CONSULT-II or 6th judgement flicker without CONSULT-II is detected when TCM detects an improper voltage drop when it tries to operate solenoid valve. Possible Cause ● ● D E On Board Diagnosis Logic ● BCS000RD Harness or connector (The solenoid circuit is open or shorted.) Overrun clutch solenoid valve WITH CONSULT-II 5. 6. WITH GST Follow the procedure “WITH CONSULT-II”. WITHOUT CONSULT-II 3. 4. Start engine. Drive vehicle under the following conditions: Selector lever position: “D” position (OD ON) Vehicle speed: Higher than 10 km/h (6 MPH) Perform self-diagnosis. Refer to AT-94, "Diagnostic Procedure Without CONSULT-II" . If the check result is NG, go to AT-173, "Diagnostic Procedure" . AT-171 I J K Turn ignition switch ON and select “DATA MONITOR” mode for “A/T” with CONSULT-II. Touch “START”. Start engine. Accelerate vehicle to a speed of more than 10 km/h (6 MPH) with “D” position (OD ON). Release accelerator pedal completely with “D” position (OD OFF). If the check result is NG, go to AT-173, "Diagnostic Procedure" . L M BCIA0031E 1. 2. G BCS000RE CAUTION: ● Always drive vehicle at a safe speed. ● If performing this “DTC Confirmation Procedure” again, always turn ignition switch OFF and wait at least 10 seconds before continuing. After the repair, perform the following procedure to confirm the malfunction is eliminated. 2. 3. 4. F H DTC Confirmation Procedure 1. B DTC P1760 OVERRUN CLUTCH SOLENOID VALVE [EURO-OBD] Wiring Diagram — AT — OVRCSV BCS000RF MCWA0250E AT-172 DTC P1760 OVERRUN CLUTCH SOLENOID VALVE [EURO-OBD] TCM terminal data are reference values, measured between each terminal and ground. Terminal 20 Wire color Item Condition Overrun clutch solenoid valve LG Judgement standard (Approx.) When overrun clutch solenoid valve operates. (When overrun clutch disengaged. Refer to AT-22 .) Battery voltage When overrun clutch solenoid valve dose not operate. (When overrun clutch engaged. Refer to AT-22 .) 0V Diagnostic Procedure BCS000RG D With CONSULT-II 1. Start engine. 2. Select “MAIN SIGNALS” in “DATA MONITOR” mode for “A/T” with CONSULT-II. 3. Read out the value of “OVERRUN/C S/V” while driving. Check the value changes according to driving speed. Condition OVERRUN/C S/V E F Display value G When overrun clutch solenoid valve operates. (When overrun clutch disengaged. Refer to AT-22 .) ON When overrun clutch solenoid valve does not operate. (When overrun clutch engaged. Refer to AT-22 .) OFF H SCIA3257E Without CONSULT-II 1. Start engine. 2. Check voltage between TCM connector terminal and ground. Item Overrun clutch solenoid valve Connector E106 Terminal 20 Ground B AT 1. CHECK INPUT SIGNAL Item name A J Judgement standard (Approx.) Condition When overrun clutch solenoid valve operates. (When overrun clutch disengaged. Refer to AT22 .) I K L Battery voltage When overrun clutch solenoid valve dose not operate. (When overrun clutch engaged. Refer to AT-22 .) OK or NG OK >> GO TO 5. NG >> GO TO 2. AT-173 M SCIA3258E 0V DTC P1760 OVERRUN CLUTCH SOLENOID VALVE [EURO-OBD] 2. CHECK OVERRUN CLUTCH SOLENOID VALVE CIRCUIT 1. 2. 3. Turn ignition switch OFF. Disconnect TCM connector. Check resistance between TCM connector terminal and ground. Solenoid Valve Connector Terminal Resistance (Approx.) Overrun clutch solenoid valve E106 20 - Ground 20 - 30 Ω OK or NG OK >> GO TO 5. NG >> GO TO 3. SCIA3259E 3. 1. 2. 3. CHECK HARNESS BETWEEN TCM AND TERMINAL CORD ASSEMBLY HARNESS CONNECTOR Turn ignition switch OFF. Disconnect terminal cord assembly harness connector and TCM connector. Check continuity between terminal cord assembly harness connector terminal and TCM connector terminal. Item Connector Terminal TCM E106 20 F13 3 Terminal cord assembly harness connector Continuity Yes 4. If OK, check harness for short to ground and short to power. 5. If OK, check continuity between ground and transaxle assembly. 6. Reinstall any part removed. OK or NG OK >> GO TO 4. NG >> Repair open circuit or short to ground or short to power in harness or connectors. SCIA3260E 4. CHECK VALVE RESISTANCE 1. 2. 3. Turn ignition switch OFF. Disconnect terminal cord assembly connector in engine room. Check resistance between terminal cord assembly harness connector terminal and ground. Solenoid valve Connector Terminal Resistance (Approx.) Overrun clutch solenoid valve F13 3 - Ground 20 - 30 Ω OK or NG OK >> GO TO 5. NG >> Repair or replace damaged parts. SCIA3455E 5. CHECK DTC Perform AT-171, "DTC Confirmation Procedure" . OK or NG OK >> INSPECTION END NG >> GO TO 6. AT-174 DTC P1760 OVERRUN CLUTCH SOLENOID VALVE [EURO-OBD] 6. CHECK TCM A 1. Check TCM input/output signal. Refer to AT-80, "TCM Terminals and Reference Value" . 2. If NG, recheck TCM pin terminals for damage or loose connection with harness connector. OK or NG OK >> INSPECTION END NG >> Repair or replace damaged parts. B AT Component Inspection BCS000RH OVERRUN CLUTCH SOLENOID VALVE ● For removal, refer to AT-345, "Control Valve Assembly and Accumulators" . D Resistance Check ● Check resistance between terminal and ground. E Solenoid valve Overrun clutch solenoid valve Resistance (Approx.) Terminal 3 Ground F 20 - 30Ω G SCIA2059E H Operation Check ● Check solenoid valve by listening for its operating sound while applying battery voltage to the terminal and ground. I J K SCIA2062E L M AT-175 DTC VEHICLE SPEED SENSOR MTR [EURO-OBD] DTC VEHICLE SPEED SENSOR MTR Description PFP:24814 BCS000RI The vehicle speed sensor·MTR is built into the speedometer assembly. The sensor functions as an auxiliary device to the revolution sensor when it is malfunctioning. The TCM will then use a signal sent from the vehicle speed sensor·MTR. CONSULT-II Reference Value BCS000RJ Remarks: Specification data are reference values. Item name Condition VHCL/S SE-MTR Display value During driving Approximately matches the speedometer reading. On Board Diagnosis Logic ● ● BCS000RK This is not an OBD self-diagnostic item. Diagnostic trouble code “VHCL SPEED SEN-MTR” with CONSULT-II or 2nd judgement flicker without CONSULT-II is detected when TCM does not receive the proper voltage signal from the sensor. Possible Cause ● ● BCS000RL Harness or connector (The sensor circuit is open or shorted.) Vehicle speed sensor DTC Confirmation Procedure BCS000RM CAUTION: ● Always drive vehicle at a safe speed. ● If performing this “DTC Confirmation Procedure” again, always turn ignition switch OFF and wait at least 10 seconds before continuing. After the repair, perform the following procedure to confirm the malfunction is eliminated. WITH CONSULT-II 1. 2. 3. 4. Turn ignition switch ON and select “DATA MONITOR” mode for “A/T” with CONSULT-II. Touch “START”. Start engine and accelerate vehicle from 0 to 25 km/h (0 to 16 MPH). If the check result is NG, go to AT-178, "Diagnostic Procedure" . BCIA0031E WITHOUT CONSULT-II 1. 2. 3. 4. Start engine. Drive vehicle under the following conditions: Selector lever position: “D” position Vehicle speed: Higher than 25 km/h (16 MPH) Perform self-diagnosis. Refer to AT-94, "Diagnostic Procedure Without CONSULT-II" . If the check result is NG, go to AT-178, "Diagnostic Procedure" . AT-176 DTC VEHICLE SPEED SENSOR MTR [EURO-OBD] Wiring Diagram — AT — VSSMTR BCS000RN A B AT D E F G H I J K L M MCWA0251E AT-177 DTC VEHICLE SPEED SENSOR MTR [EURO-OBD] TCM terminal data are reference values, measured between each terminal and ground. Terminal Wire color 40 R Item Condition When driving vehicle at 2 to 3 km/h (1 to 2 MPH) for 1 m (3 ft) or more. Vehicle speed sensor Diagnostic Procedure Judgement standard (Approx.) Voltage varies between less than 0V and more than 4.5V BCS000RO 1. CHECK INPUT SIGNAL With CONSULT-II 1. Start engine. 2. Select “TCM INPUT SIGNALS” in “DATA MONITOR” mode for “A/T” with CONSULT-II. 3. Read out the value of “VHCL/S SE-MTR” while driving. Check the value changes according to driving speed. Item name Condition Display value VHCL/S SE-MTR During driving Approximately matches the speedometer reading. LCIA0090E Without CONSULT-II 1. Start engine. 2. Check voltage between TCM connector terminal and ground. Item Vehicle speed sensor Connector E107 Terminal Condition Judgement standard (Approx.) 40 Ground When driving vehicle at 2 to 3 km/h (1 to 2 MPH) for 1 m (3 ft) or more. Voltage varies between less than 0V and more than 4.5V OK or NG OK >> GO TO 3. NG >> GO TO 2. SCIA3246E 2. DETECT MALFUNCTIONING ITEM Check the following items: ● Combination meter. Refer to DI-4, "COMBINATION METERS" . ● Harness for short or open between TCM and combination meter. OK or NG OK >> GO TO 3. NG >> Repair or replace damaged parts. 3. CHECK DTC Perform AT-176, "DTC Confirmation Procedure" . OK or NG OK >> INSPECTION END NG >> GO TO 4. AT-178 DTC VEHICLE SPEED SENSOR MTR [EURO-OBD] 4. CHECK TCM A 1. Check TCM input/output signal. Refer to AT-80, "TCM Terminals and Reference Value" . 2. If NG, recheck TCM pin terminals for damage or loose connection with harness connector. OK or NG OK >> INSPECTION END NG >> Repair or replace damaged parts. B AT D E F G H I J K L M AT-179 DTC BATT/FLUID TEMP SEN (A/T FLUID TEMP SENSOR CIRCUIT AND TCM POWER SOURCE) [EURO-OBD] DTC BATT/FLUID TEMP SEN (A/T FLUID TEMP SENSOR CIRCUIT AND TCM POWER SOURCE) PFP:31940 Description BCS000RP The A/T fluid temperature sensor detects the A/T fluid temperature and sends a signal to the TCM. CONSULT-II Reference Value BCS000RQ Remarks: Specification data are reference values. Item name Condition FLUID TEMP SE Display value When A/T fluid temperature is 20°C (68°F). 1.5V When A/T fluid temperature is 80°C (176°F). 0.5V On Board Diagnosis Logic ● ● BCS000RR This is not an OBD self-diagnostic item. Diagnostic trouble code “BATT/FLUID TEMP SEN” with CONSULT-II or 8th judgement flicker without CONSULT-II is detected when TCM receives an excessively low or high voltage from the sensor. Possible Cause ● ● BCS000RS Harness or connector (The sensor circuit is open or shorted.) A/T fluid temperature sensor DTC Confirmation Procedure BCS000RT CAUTION: ● Always drive vehicle at a safe speed. ● If performing this “DTC Confirmation Procedure” again, always turn ignition switch OFF and wait at least 10 seconds before continuing. After the repair, perform the following procedure to confirm the malfunction is eliminated. WITH CONSULT-II 1. 2. 3. 4. 5. Start engine. Select “DATA MONITOR” mode for “A/T” with CONSULT-II. Touch “START”. Drive vehicle under the following conditions. SLCT LVR POSI: “D” position VEHICLE SPEED: Higher than 20 km/h (12 MPH) If the check result is NG, go to AT-182, "Diagnostic Procedure" . BCIA0031E WITHOUT CONSULT-II 1. 2. 3. 4. Start engine. Drive vehicle under the following conditions. Selector lever position: D position Vehicle speed: higher than 20 km/h (12 MPH) Perform self-diagnosis. Refer to AT-94, "Diagnostic Procedure Without CONSULT-II" . If the check result is NG, go to AT-182, "Diagnostic Procedure" . AT-180 DTC BATT/FLUID TEMP SEN (A/T FLUID TEMP SENSOR CIRCUIT AND TCM POWER SOURCE) [EURO-OBD] Wiring Diagram — AT — BA/FTS BCS000RU A B AT D E F G H I J K L M MCWA0253E AT-181 DTC BATT/FLUID TEMP SEN (A/T FLUID TEMP SENSOR CIRCUIT AND TCM POWER SOURCE) [EURO-OBD] TCM terminal data are reference values, measured between each terminal and ground. Terminal Wire color 10 Item R Condition Power supply or 19 R 28 Power supply Power supply (memory back-up) LG 42 B 47 When turning ignition switch to “ON”. Battery voltage When turning ignition switch to “OFF”. 0V When turning ignition switch to “ON”. Battery voltage When turning ignition switch to “OFF”. 0V Battery voltage Always Sensor ground A/T fluid temperature sensor BR Judgement standard (Approx.) 0V and Diagnostic Procedure When A/T fluid temperature is 20°C (68°F). 1.5V When A/T fluid temperature is 80°C (176°F). 0.5V BCS000RV 1. CHECK TCM POWER SOURCE 1. 2. Turn ignition switch ON. (Do not start engine.) Check voltage between TCM connector terminals and ground. Item Connector Power supply E106 Power supply (Memory back-up) E107 Terminal Judgement standard (Approx.) 10 Battery voltage 19 Battery voltage 28 Battery voltage SCIA2656E 3. 4. Turn ignition switch OFF. Check voltage between TCM connector terminals and ground. Item Connector Power supply E106 Power supply (memory back-up) E107 Terminal Judgement standard (Approx.) 10 0V 19 0V 28 Battery voltage OK or NG OK >> GO TO 3. NG >> GO TO 2. SCIA2657E AT-182 DTC BATT/FLUID TEMP SEN (A/T FLUID TEMP SENSOR CIRCUIT AND TCM POWER SOURCE) [EURO-OBD] 2. DETECT MALFUNCTIONING ITEM A Check the following items: ● Harness for short or open between ignition switch and TCM terminals 10, 19 ● Harness for short or open between battery and TCM terminal 28 ● 10A fuse (No.7, located in the fuse block) and 10A fuse (No.58, located in the IPDM E/R) ● Ignition switch. Refer to PG-38, "GROUND" . OK or NG OK >> GO TO 9. NG >> Repair or replace damaged parts. B AT D 3. CHECK INPUT SIGNAL OF A/T FLUID TEMPERATURE SENSOR E With CONSULT-II 1. Start engine. 2. Select “TCM INPUT SIGNALS” in “DATA MONITOR” mode for “A/T” with CONSULT-II. 3. Read out the value of “FLUID TEMP SE”. Item name FLUID TEMP SE Condition Display value When A/T fluid temperature is 20°C (68°F). 1.5V When A/T fluid temperature is 80°C (176°F). 0.5V F G H I LCIA0090E Without CONSULT-II 1. Start engine. 2. Check voltage TCM connector terminals while warming up A/T. Item A/T fluid temperature sensor Connector E107 Terminal 47 - 42 J K Judgement standard (Approx.) Condition When A/T fluid temperature is 20°C (68°F). 1.5V When A/T fluid temperature is 80°C (176°F). 0.5V OK or NG OK >> GO TO 9. NG >> GO TO 4. L M SCIA2658E 4. DETECT MALFUNCTIONING ITEM Check the following items: ● Harness for short or open between TCM, ECM and terminal cord assembly ● Ground circuit for ECM Refer to EC-128, "POWER SUPPLY AND GROUND CIRCUIT" . OK or NG OK >> GO TO 5. NG >> Repair or replace damaged parts. AT-183 DTC BATT/FLUID TEMP SEN (A/T FLUID TEMP SENSOR CIRCUIT AND TCM POWER SOURCE) [EURO-OBD] 5. CHECK FLUID TEMPERATURE SENSOR CIRCUIT 1. 2. 3. Turn ignition switch OFF. Disconnect the TCM connector. Check resistance between terminals. Item A/T fluid temperature sensor Connector Terminal E107 47 - 42 Temperature °C (°F) Resistance (Approx.) 20 (68) 2.5 kΩ 80 (176) 0.3 kΩ OK or NG OK >> GO TO 9. NG >> GO TO 6. SCIA2338E 6. 1. 2. 3. CHECK HARNESS BETWEEN TCM AND TERMINAL CORD ASSEMBLY HARNESS CONNECTOR Turn ignition switch OFF. Disconnect terminal cord assembly harness connector and TCM connector. Check continuity between terminal cord assembly harness connector terminal and TCM connector terminal. Item Connector Terminal TCM E107 42 F13 7 E107 47 F13 6 Terminal cord assembly harness connector TCM Terminal cord assembly harness connector Continuity Yes Yes SCIA2660E 4. If OK, check harness for short to ground and short to power. 5. If OK, check continuity between ground and transaxle assembly. 6. Reinstall any part removed. OK or NG OK >> GO TO 7. NG >> Repair open circuit or short to ground or short to power in harness or connectors. 7. CHECK A/T FLUID TEMPERATURE SENSOR WITH TERMINAL CORD ASSEMBLY 1. 2. 3. Turn ignition switch OFF. Disconnect terminal cord assembly connector in engine room. Check resistance between terminal cord assembly terminals. Temperature °C (°F) Resistance (Approx.) 20 (68) Approx. 2.5 kΩ 80 (176) Approx. 0.3 kΩ 4. Reinstall any part removed. OK or NG OK >> GO TO 8. NG >> Repair or replace damaged parts. SCIA4948E AT-184 DTC BATT/FLUID TEMP SEN (A/T FLUID TEMP SENSOR CIRCUIT AND TCM POWER SOURCE) [EURO-OBD] 8. DETECT MALFUNCTIONING ITEM 1. 2. – • A Remove oil pan. Refer to AT-345, "Control Valve Assembly and Accumulators" . Check the following items: A/T fluid temperature sensor Check resistance between terminal cord assembly harness connector terminals while changing temperature as shown. B AT Temperature [°C (°F)] Resistance (Approx.) 20 (68) 2.5 kΩ 80 (176) 0.3 kΩ Harness of terminal cord assembly for short or open OK or NG OK >> GO TO 9. NG >> Repair or replace damaged parts. D – E SAT298F 9. CHECK DTC F Perform AT-180, "DTC Confirmation Procedure" . OK or NG OK >> INSPECTION END NG >> GO TO 10. G H 10. CHECK TCM 1. Check TCM input/output signal. Refer to AT-80, "TCM Terminals and Reference Value" . 2. If NG, recheck TCM pin terminals for damage or loose connection with harness connector. OK or NG OK >> INSPECTION END NG >> Repair or replace damaged parts. Component Inspection I J BCS000RW A/T FLUID TEMPERATURE SENSOR ● ● K Remove oil pan. Refer to AT-345, "Control Valve Assembly and Accumulators" . Check resistance between terminal cord assembly harness connector terminals while changing temperature as shown. Temperature [°C (°F)] Resistance (Approx.) 20 (68) 2.5 kΩ 80 (176) 0.3 kΩ L M SAT298F AT-185 DTC TURBINE REVOLUTION SENSOR [EURO-OBD] DTC TURBINE REVOLUTION SENSOR Description PFP:31935 BCS000RX The turbine revolution sensor (power train revolution sensor) detects forward clutch drum rpm (revolutions per minute). It is located on the input side of the automatic transaxle. The vehicle speed sensor A/T (Revolution sensor) is located on the output side of the automatic transaxle. With the two sensors, input and output rpms are accurately detected. As a result, optimal shift timing during deceleration and shift quality can be improved. CONSULT-II Reference Value BCS000RY Remarks: Specification data are reference values. Item name Condition TURBINE REV Display value During driving (lock-up ON) Approximately matches the engine speed. On Board Diagnosis Logic ● ● BCS000RZ This is not an OBD self-diagnostic item. Diagnostic trouble code “TURBINE SENSOR” with CONSULT-II or 10th judgement flicker without CONSULT-II is detected when TCM does not receive the proper voltage signal from the sensor. Possible Cause ● ● BCS000S0 Harness or connector (The sensor circuit is open or shorted.) Turbine revolution sensor (power train revolution sensor) DTC Confirmation Procedure BCS000S1 CAUTION: ● Always drive vehicle at a safe speed. ● Be careful not to rev engine into the red zone on the tachometer. ● If performing this “DTC Confirmation Procedure” again, always turn ignition switch OFF and wait at least 10 seconds before continuing. After the repair, perform the following procedure to confirm the malfunction is eliminated. WITH CONSULT-II 1. 2. 3. 4. 5. Start engine. Select “DATA MONITOR” mode for “A/T” with CONSULT-II. Touch “START”. Drive vehicle under the following conditions for more than 5 seconds. SLCT LVR POSI: “D” position VEHICLE SPEED: Higher than 40 km/h (25 MPH) ENGINE SPEED: Higher than 1,500 rpm THROTTLE POSI: Greater than 1.0/8 of the full throttle position If the check result is NG, go to AT-188, "Diagnostic Procedure" . BCIA0031E WITHOUT CONSULT-II 1. 2. 3. 4. Start engine. Drive vehicle under the following conditions for more than 5 seconds. Selector lever position: “D” position Vehicle speed: Higher than 40 km/h (25 MPH) Engine speed: Higher than 1,500 rpm Throttle position: 1.0/8 of the full throttle position Perform self-diagnosis. Refer to AT-94, "Diagnostic Procedure Without CONSULT-II" . If the check result is NG, go to AT-188, "Diagnostic Procedure" . AT-186 DTC TURBINE REVOLUTION SENSOR [EURO-OBD] Wiring Diagram — AT — PT/SEN BCS000S2 A B AT D E F G H I J K L M MCWA0254E AT-187 DTC TURBINE REVOLUTION SENSOR [EURO-OBD] TCM terminal data are reference values, measured between each terminal and ground. Terminal Wire color 38 LG 42 B Item Condition Turbine revolution sensor (power train revolution sensor) Judgement standard (Approx.) When driving at 20 km/h (12 MPH). Sensor ground Always Diagnostic Procedure 360 Hz 0V BCS000S3 1. CHECK INPUT SIGNAL With CONSULT-II 1. Start engine. 2. Select “TCM INPUT SIGNALS” in “DATA MONITOR” mode for “A/T” with CONSULT-II. 3. Read out the value of “TURBINE REV” while driving. Check the value changes according to driving speed. Item name Condition Display value TURBINE REV During driving (lock-up ON) Approximately matches the engine speed. OK or NG OK >> GO TO 8. NG >> GO TO 2. SCIA4730E 2. 1. 2. CHECK TURBINE REVOLUTION SENSOR (POWER TRAIN REVOLUTION SENSOR) With CONSULT-II Start engine. Check power supply to turbine revolution sensor (power train revolution sensor) by voltage between TCM connector terminals. Refer to AT-194, "Wiring Diagram — AT — MAIN" and AT-187, "Wiring Diagram — AT — PT/SEN" . Item Connector TCM E106, E107 Terminal 10 - 42 Judgement standard (Approx.) Battery voltage 19 - 42 3. If OK, check the pulse when vehicle cruises. Name Condition Turbine revolution sensor (power train revolution sensor) When driving at 20 km/h (12 MPH), use the CONSULT-II pulse frequency measuring function.*1 CAUTION: Connect the diagnosis data link cable to the vehicle diagnosis connector. *1: A circuit tester cannot be used to test this item. Item Connector Terminal Name Judgement standard (Approx.) TCM E107 38 Turbine revolution sensor (power train revolution sensor) 360 Hz OK or NG OK >> GO TO 8. NG >> GO TO 3. SCIA2769E AT-188 DTC TURBINE REVOLUTION SENSOR [EURO-OBD] 3. 1. 2. 3. 4. CHECK POWER AND SENSOR GROUND A Turn ignition switch OFF. Disconnect the turbine revolution sensor (power train revolution sensor) harness connector. Turn ignition switch ON. Check voltage between turbine revolution sensor (power train revolution sensor) harness connector terminals. B AT Item Connector Terminal Judgement standard (Approx.) Turbine revolution sensor (power train revolution sensor) F11 1-3 Battery voltage D E SCIA2770E 5. F Check voltage between turbine revolution sensor (power train revolution sensor) harness connector terminal and ground. Item Connector Terminal Judgement standard (Approx.) Turbine revolution sensor (power train revolution sensor) F11 1 - ground Battery voltage G H 6. If OK, check harness for short to ground and short to power. 7. Reinstall any part removed. SCIA2771E OK or NG OK >> GO TO 4. NG - 1 >> Battery voltage is not supplied between terminals 1 and 3, terminals 1 and ground: GO TO 6. NG - 2 >> Battery voltage is not supplied between terminals 1 and 3 only: GO TO 7. I J 4. CHECK HARNESS BETWEEN TCM AND TURBINE REVOLUTION SENSOR (POWER TRAIN REVOLUTION SENSOR) K 1. 2. L 3. Turn ignition switch OFF. Disconnect the turbine revolution sensor (power train revolution sensor) harness connector and TCM connector. Check continuity between TCM connector terminal and turbine revolution sensor (power train revolution sensor) harness connector terminal. Item Connector Terminal TCM E107 38 Turbine revolution sensor (power train revolution sensor) F48 2 Continuity Yes 4. If OK, check harness for short to ground and short to power. 5. Reinstall any part removed. OK or NG OK >> GO TO 5. NG >> Repair open circuit or short to ground or short to power in harness or connectors. AT-189 SCIA2772E M DTC TURBINE REVOLUTION SENSOR [EURO-OBD] 5. CHECK TCM 1. Check TCM input/output signal. Refer to AT-80, "TCM Terminals and Reference Value" . 2. If NG, re-check TCM pin terminals for damage or loose connection with harness connector. OK or NG OK >> GO TO 8. NG >> Repair or replace damaged parts. 6. CHECK HARNESS BETWEEN TCM AND TURBINE REVOLUTION SENSOR [(POWER TRAIN REVOLUTION SENSOR) POWER] 1. 2. 3. Turn ignition switch OFF. Disconnect the turbine revolution sensor (power train revolution sensor) harness connector. Check continuity between TCM connector terminals and turbine revolution sensor (power train revolution sensor) harness connector terminal. Refer to AT-52, "Circuit Diagram" and AT-194, "Wiring Diagram — AT — MAIN" . Item Connector Terminal TCM E106 10 Turbine revolution sensor (power train revolution sensor) F11 1 TCM E106 19 Turbine revolution sensor (power train revolution sensor) F11 1 Continuity Yes Yes SCIA2773E 4. If OK, check harness for short to ground and short to power. 5. Reinstall any part removed. OK or NG OK >> 10A fuse (No.58, located in the IPDM E/R) or ignition switch are malfunctioning. NG >> Repair open circuit or short to ground or short to power in harness or connectors. 7. CHECK HARNESS BETWEEN TCM AND TURBINE REVOLUTION [(POWER TRAIN REVOLUTION SENSOR) SENSOR GROUND] 1. 2. 3. Turn ignition switch OFF. Disconnect the turbine revolution sensor (power train revolution sensor) harness connector. Check continuity between TCM connector terminal and turbine revolution sensor (power train revolution sensor) harness connector terminal. Item Connector Terminal TCM E107 42 Turbine revolution sensor (power train revolution sensor) F11 3 Continuity Yes 4. If OK, check harness for short to ground and short to power. 5. Reinstall any part removed. OK or NG OK >> GO TO 5. NG >> Repair open circuit or short to ground or short to power in harness or connectors. AT-190 SCIA2774E DTC TURBINE REVOLUTION SENSOR [EURO-OBD] 8. CHECK DTC A Perform AT-186, "DTC Confirmation Procedure" . OK or NG OK >> INSPECTION END NG >> GO TO 5. B AT D E F G H I J K L M AT-191 CONTROL UNIT (RAM), CONTROL UNIT (ROM) [EURO-OBD] CONTROL UNIT (RAM), CONTROL UNIT (ROM) Description PFP:31036 BCS000S4 The TCM consists of a microcomputer and connectors for signal input and output and for power supply. The unit controls the A/T. SAT574J On Board Diagnosis Logic ● ● BCS000S5 This is not an OBD self-diagnostic item. Diagnostic trouble code “CONTROL UNIT (RAM)”, “CONTROL UNIT (ROM)” with CONSULT-II is detected when TCM memory (RAM) or (ROM) is malfunctioning. Possible Cause BCS000S6 TCM. DTC Confirmation Procedure BCS000S7 CAUTION: If performing this “DTC Confirmation Procedure” again, always turn ignition switch OFF and wait at least 10 seconds before continuing. After the repair, perform the following procedure to confirm the malfunction is eliminated. WITH CONSULT-II 1. 2. 3. 4. 5. Turn ignition switch ON and select “DATA MONITOR” mode for A/T with CONSULT-II. Touch “START”. Start engine. Run engine for at least 2 seconds at idle speed. If the check result is NG, go to AT-192, "Diagnostic Procedure" . BCIA0031E Diagnostic Procedure BCS000S8 1. CHECK DTC With CONSULT-II 1. Turn ignition switch ON and select “SELF-DIAG RESULTS” mode for A/T with CONSULT-II. 2. Touch “ERASE”. 3. Perform AT-192, "DTC Confirmation Procedure" . Is the “CONTROL UNIT (RAM)” or “CONTROL UNIT (ROM)” displayed again? YES >> Replace TCM. Refer to AT-330, "Removal and Installation (LHD)" . NO >> INSPECTION END AT-192 MAIN POWER SUPPLY AND GROUND CIRCUIT [EURO-OBD] MAIN POWER SUPPLY AND GROUND CIRCUIT Description PFP:00100 A BCS000S9 When the power supply to the TCM is cut OFF, for example because the battery is removed, and the self-diagnosis memory function stops, malfunction is detected. On Board Diagnosis Logic ● ● ● B BCS000SA This is not an OBD self-diagnostic item. AT Diagnostic trouble code “INITIAL START” with CONSULT-II is detected when TCM dose not receive the voltage signal from the battery power supply. This is not a malfunction message. (Whenever shutting OFF a power supply to the TCM, this message D appears on the screen.) Possible Cause BCS000SB E Harness or connector (Battery or ignition switch and TCM circuit is open or shorted.) DTC Confirmation Procedure BCS000SC CAUTION: If performing this “DTC Confirmation Procedure” again, always turn ignition switch OFF and wait at least 10 seconds before continuing. After the repair, perform the following procedure to confirm the malfunction is eliminated. F G WITH CONSULT-II 1. 2. 3. 4. 5. Turn ignition switch ON. (Do not start engine.) Select “DATA MONITOR” mode for “A/T” with CONSULT-II. Touch “START”. Wait for at least 2 consecutive seconds. If DTC is detected, go to AT-195, "Diagnostic Procedure" . H I J BCIA0031E K L M AT-193 MAIN POWER SUPPLY AND GROUND CIRCUIT [EURO-OBD] Wiring Diagram — AT — MAIN BCS000SD MCWA0255E AT-194 MAIN POWER SUPPLY AND GROUND CIRCUIT [EURO-OBD] TCM terminal data are reference values, measured between each terminal and ground. Condition Judgement standard (Approx.) Terminal Wire color Item 10 R Power supply 19 R Power supply 25 B Ground Always 0V 28 LG Power supply (memory back-up) Always Battery voltage 48 B Ground Always 0V or When turning ignition switch to “ON”. Battery voltage When turning ignition switch to “OFF”. 0V When turning ignition switch to “ON”. Battery voltage When turning ignition switch to “OFF”. 0V A B AT D E Diagnostic Procedure BCS000SE 1. CHECK TCM POWER SOURCE 1. 2. F Turn ignition switch ON. (Do not start engine.) Check voltage between TCM connector terminals and ground. Item Connector Power supply E106 Power supply (Memory back-up) E107 Terminal Judgement standard (Approx.) 10 Battery voltage 19 Battery voltage 28 Battery voltage G H I SCIA2656E 3. 4. J Turn ignition switch OFF. Check voltage between TCM connector terminals and ground. Item Connector Power supply E106 Power supply (Memory back-up) E107 Terminal Judgement standard (Approx.) 10 0V 19 0V 28 Battery voltage K L M OK or NG OK >> GO TO 3. NG >> GO TO 2. SCIA2657E 2. DETECT MALFUNCTIONING ITEM Check the following items: ● Harness for short or open between ignition switch and TCM terminals 10, 19 ● Harness for short or open between battery and TCM terminal 28 ● 10A fuse (No.7, located in the fuse block) and 10A fuse (No.58, located in the IPDM E/R) ● Ignition switch. Refer to PG-38, "GROUND" . OK or NG OK >> GO TO 3. NG >> Repair or replace damaged parts. AT-195 MAIN POWER SUPPLY AND GROUND CIRCUIT [EURO-OBD] 3. CHECK TCM GROUND CIRCUIT 1. 2. 3. Turn ignition switch OFF. Disconnect TCM connector. Check continuity between TCM connector terminals and ground. Item Connector Terminal Continuity Ground E107 25, 48 - Ground Yes OK or NG OK >> GO TO 4. NG >> Repair open circuit or short to ground or short to power in harness or connectors. SCIA2671E 4. CHECK DTC Perform AT-193, "DTC Confirmation Procedure" . OK or NG OK >> INSPECTION END NG >> GO TO 5. 5. CHECK TCM 1. Check TCM input/output signal. Refer to AT-80, "TCM Terminals and Reference Value" . 2. If NG, recheck TCM pin terminals for damage or loose connection with harness connector. OK or NG OK >> INSPECTION END NG >> Repair or replace damaged parts. AT-196 PNP, OD SWITCH AND CLOSED THROTTLE, WIDE OPEN THROTTLE POSITION SIGNAL CIRCUIT [EURO-OBD] PNP, OD SWITCH AND CLOSED THROTTLE, WIDE OPEN THROTTLE POSITION SIGNAL CIRCUIT PFP:31918 CONSULT-II Reference Value A BCS000SF Remarks: Specification data are reference values. Item name Condition B Display value When setting selector lever to “N” or “P” position. PN POSI SW R POSITION SW D POSITION SW 2 POSITION SW 1 POSITION SW OVERDRIVE SW CLOSED THL/SW W/O THRL/P-SW ON When setting selector lever to other positions. OFF When setting selector lever to “R” position. ON When setting selector lever to other positions. OFF When setting selector lever to “D” position. ON When setting selector lever to other positions. OFF When setting selector lever to “2” position. ON When setting selector lever to other positions. OFF When setting selector lever to “1” position. ON When setting selector lever to other positions. OFF When overdrive control switch is depressed. ON When overdrive control switch is released. OFF Released accelerator pedal. ON Depressed accelerator pedal. OFF Fully depressed accelerator pedal. ON Released accelerator pedal. OFF AT D E F G H TCM Terminals and Reference Value BCS000SG I TCM terminal data are reference values, measured between each terminal and ground. Terminal 26 27 34 35 36 Wire color Y L LG L R Item Condition PNP switch “1” position When setting selector lever to “1” position. PNP switch “2” position When setting selector lever to “2” position. PNP switch “D” position PNP switch “R” position PNP switch “N” or “P” position When setting selector lever to other positions. When setting selector lever to other positions. When setting selector lever to “D” position. and When setting selector lever to other positions. When setting selector lever to “R” position. Judgement standard (Approx.) 0V Battery voltage K 0V Battery voltage L 0V Battery voltage When setting selector lever to other positions. 0V When setting selector lever to “N” or “P” positions. Battery voltage When setting selector lever to other positions. 0V AT-197 J Battery voltage M PNP, OD SWITCH AND CLOSED THROTTLE, WIDE OPEN THROTTLE POSITION SIGNAL CIRCUIT [EURO-OBD] Diagnostic Procedure BCS000SH 1. CHECK CAN COMMUNICATION LINE Perform self-diagnosis. Refer to AT-85, "SELF-DIAGNOSTIC RESULT MODE" . Is a malfunction in the CAN communication indicated in the results? YES >> Check CAN communication line. Refer to AT-102, "DTC U1000 CAN COMMUNICATION LINE" . NO (With CONSULT-II) >>GO TO 2. NO (Without CONSULT-II) >>GO TO 3. 2. CHECK PNP SWITCH CIRCUIT With CONSULT-II 1. Turn ignition switch ON. (Do not start engine.) 2. Select “TCM INPUT SIGNALS” in “DATA MONITOR” mode for “A/T” with CONSULT-II. 3. Read out “P·N”, “R”, “D”, “2” and “1” position switches moving selector lever to each position. Item name Condition Display value PN POSI SW When setting selector lever to “N” or “P” position. ON When setting selector lever to other positions. OFF When setting selector lever to “R” position. ON When setting selector lever to other positions. OFF When setting selector lever to “D” positions. ON When setting selector lever to other positions. OFF When setting selector lever to “2” position. ON When setting selector lever to other positions. OFF When setting selector lever to “1” position. ON When setting selector lever to other positions. OFF R POSITION SW D POSITION SW 2 POSITION SW 1 POSITION SW SAT701J OK or NG OK >> GO TO 4. NG >> Check PNP switch circuit. Refer to AT-105, "DTC P0705 PARK/NEUTRAL POSITION (PNP) SWITCH" . AT-198 PNP, OD SWITCH AND CLOSED THROTTLE, WIDE OPEN THROTTLE POSITION SIGNAL CIRCUIT [EURO-OBD] 3. CHECK PNP SWITCH CIRCUIT A Without CONSULT-II 1. Turn ignition switch ON. (Do not start engine.) 2. Check voltage between TCM connector terminals and ground while moving selector lever through each position. Refer to AT106, "Wiring Diagram — AT — PNP/SW" . B AT Terminal Selector lever position 36 35 34 27 26 “P”, “N” B 0 0 0 0 “R” 0 B 0 0 0 “D” 0 0 B 0 0 “2” 0 0 0 B 0 “1” 0 0 0 0 B D E F B: Battery voltage 0: 0V OK or NG OK >> GO TO 4. NG >> Check PNP switch circuit. Refer to AT-105, "DTC P0705 PARK/NEUTRAL POSITION (PNP) SWITCH" . G H SCIA7162E I 4. CHECK PNP SWITCH 1. 2. 3. Turn ignition switch OFF. Disconnect PNP switch harness connector. Check continuity between PNP switch harness connector terminals. Refer to AT-106, "Wiring Diagram — AT — PNP/SW" . Selector lever position Terminal Continuity “P” 1 - 2, 3 - 7 “R” 3-8 Yes *Continuity should not exist in positions other than the specified positions. “N” Connector F12 1 - 2, 3 - 9 “D” 3-6 “2” 3-5 “1” 3-4 J K L M SCIA5588E OK or NG OK >> GO TO 6. NG >> GO TO 5. 5. CHECK CONTROL CABLE ADJUSTMENT Check PNP switch again with control cable disconnected from manual shaft of A/T assembly. Refer to test group 4. OK or NG OK >> Adjust control cable. Refer to AT-336, "Adjustment of A/T Position" . NG >> Repair or replace PNP switch. Refer to AT-349, "Park/Neutral Position (PNP) Switch" . AT-199 PNP, OD SWITCH AND CLOSED THROTTLE, WIDE OPEN THROTTLE POSITION SIGNAL CIRCUIT [EURO-OBD] 6. DETECT MALFUNCTIONING ITEM Check the following. ● Harness for short or open between ignition switch and PNP switch ● Harness for short or open between PNP switch and TCM ● Harness for short or open between PNP switch and combination meter ● Harness for short or open between combination meter and TCM ● 10A fuse (No.60, located in the IPDM E/R) ● Combination meter. Refer to DI-4, "COMBINATION METERS" . ● Ignition switch. Refer to PG-38, "GROUND" . OK or NG OK >> GO TO 7. NG >> Repair or replace damaged parts. 7. CHECK OVERDRIVE CONTROL SWITCH CIRCUIT With CONSULT-II 1. Turn ignition switch ON. (Do not start engine.) 2. Select “TCM INPUT SIGNALS” in “DATA MONITOR” mode for “A/T” with CONSULT-II. 3. Read out “OVERDRIVE SW”. Check the signal of overdrive control switch is indicated properly. Overdrive control switch Condition Item name OVERDRIVE SW Display value Depressed ON Released OFF SCIA4730E 1. 2. Without CONSULT-II Turn ignition switch ON. (Do not start engine.) Check voltage between A/T device harness connector terminal and ground. Refer to AT-296, "EXC.F/EURO-OBD" . Item Connector Terminal M52 1 - Ground A/T device harness connector (Overdrive control switch) Overdrive control switch Condition Judgement standard (Approx.) Released Battery voltage Depressed 0V OK or NG OK >> GO TO 10. NG >> GO TO 8. SCIA5336E AT-200 PNP, OD SWITCH AND CLOSED THROTTLE, WIDE OPEN THROTTLE POSITION SIGNAL CIRCUIT [EURO-OBD] 8. CHECK OVERDRIVE CONTROL SWITCH 1. 2. 3. A Turn ignition switch OFF. Disconnect A/T device harness connector. Check continuity between A/T device harness connector terminals. Refer to AT-296, "EXC.F/EURO-OBD" . Item Connector Terminal A/T device harness connector (Overdrive control switch) M52 1-2 Overdrive control switch condition Continuity Released No Depressed Yes B AT D OK or NG OK >> GO TO 9. NG >> Repair or replace damaged parts. SCIA5330E E 9. DETECT MALFUNCTIONING ITEM F Check the following. ● Harness for short or open between combination meter and A/T device harness connector ● Harness for short or open between A/T device harness connector and ground ● Combination meter. Refer to DI-4, "COMBINATION METERS" . OK or NG OK >> GO TO 10. NG >> Repair or replace damaged parts. G H 10. CHECK CLOSED THROTTLE POSITION AND WIDE OPEN THROTTLE POSITION SIGNAL CIR- I CUIT With CONSULT-II 1. Turn ignition switch ON. (Do not start engine.) 2. Select “TCM INPUT SIGNALS” in “DATA MONITOR” mode for A/T with CONSULT-II. 3. Read out “CLOSED THL/SW” and “W/O THRL/P-SW” depressing and releasing accelerator pedal. Check that the signals of throttle position are indicated properly. J K L M SCIA4731E Data monitor Accelerator pedal condition CLOSED THL/SW W/O THRL/P-SW Released ON OFF Fully depressed OFF ON OK or NG OK >> GO TO 11. NG >> Check the following. If any items are damaged, repair or replace damaged parts. ● Accelerator pedal position sensor. Refer to AT-169, "DTC P1705 ACCELERATOR PEDAL POSITION (APP) SENSOR" . AT-201 PNP, OD SWITCH AND CLOSED THROTTLE, WIDE OPEN THROTTLE POSITION SIGNAL CIRCUIT [EURO-OBD] 11. PERFORM SELF-DIAGNOSIS Without CONSULT-II Perform self-diagnosis. Refer to AT-94, "Diagnostic Procedure Without CONSULT-II" . OK or NG OK >> INSPECTION END NG − 1 >> Self-diagnosis does not activate: GO TO 12. NG − 2 >> DTC is displayed: Check the malfunctioning system. Refer to AT-95, "Judgement of Self-diagnosis Code" . 12. CHECK TCM 1. Check TCM input/output signal. Refer to AT-80, "TCM Terminals and Reference Value" . 2. If NG, recheck TCM pin terminals for damage or loose connection with harness connector. OK or NG OK >> INSPECTION END NG >> Repair or replace damaged parts. Component Inspection BCS000SI OVERDRIVE CONTROL SWITCH Check continuity between A/T device harness connector terminals. ● Item Connector Terminal A/T device harness connector (Overdrive control switch) M52 1-2 Overdrive control switch condition Continuity Released No Depressed Yes SCIA5330E PNP SWITCH 1. Check continuity between PNP switch harness connector terminals. Selector lever position Terminal Continuity “P” 1 - 2, 3 - 7 “R” 3-8 Yes *Continuity should not exist in positions other than the specified positions. “N” 2. 3. 4. 5. 6. Connector F12 1 - 2, 3 - 9 “D” 3-6 “2” 3-5 “1” 3-4 If NG, check again with control cable (2) disconnected from manual shaft of A/T assembly. Refer to step 1. (1): Lock nut (3): Manual shaft If OK on step 2, adjust control cable (2). Refer to AT-336, "Adjustment of A/T Position" . If NG on step 2, remove PNP switch from A/T assembly and check continuity of PNP switch terminals. Refer to step 1. If OK on step 4, adjust PNP switch. Refer to AT-350, "PARK/ NEUTRAL POSITION (PNP) SWITCH ADJUSTMENT" . If NG on step 4, replace PNP switch. Refer to AT-349, "Park/ Neutral Position (PNP) Switch" . AT-202 SCIA5588E SCIA6370J VEHICLE SPEED SENSOR·A/T (REVOLUTION SENSOR) [EXC.F/EURO-OBD] VEHICLE SPEED SENSOR·A/T (REVOLUTION SENSOR) Description [EXC.F/EURO-OBD] PFP:32702 A BCS000SJ The revolution sensor detects the revolution of the idler gear parking pawl lock gear and emits a pulse signal. The pulse signal is sent to the TCM which converts it into vehicle speed. CONSULT-II Reference Value BCS000SK Remarks: Specification data are reference values. Item name Condition VHCL/S SE-A/T B AT Display value During driving Approximately matches the speedometer reading. On Board Diagnosis Logic BCS000SL D Diagnostic trouble code “VHCL SPEED SEN-A/T” with CONSULT-II or 1st judgement flicker without CONSULT-II is detected when TCM does not receive the proper voltage signal from the sensor. E Possible Cause ● ● BCS000SM Harness or connector (Sensor circuit is open or shorted.) Revolution sensor F DTC Confirmation Procedure BCS000SN CAUTION: ● Always drive vehicle at a safe speed. ● If performing this “DTC Confirmation Procedure” again, always turn ignition switch OFF and wait at least 10 seconds before continuing. After the repair, perform the following procedure to confirm the malfunction is eliminated. WITH CONSULT-II 1. 2. 3. 4. 5. 6. 7. H I Turn ignition switch ON and select “DATA MONITOR” mode for “A/T” with CONSULT-II. Touch “START”. Drive vehicle and check for an increase of “VHCL/S SE-MTR” value. If the check result is NG, go to AT-206, "Diagnostic Procedure" . If the check result is OK, go to following step. Select “DATA MONITOR” mode for “A/T” with CONSULT-II. Touch “START”. Start engine and maintain the following conditions for at least 5 BCIA0031E consecutive seconds. VEHICLE SPEED: 30 km/h (19 MPH) or more THROTTLE POSI: More than 1.0/8 SLCT LVR POSI: “D” position Driving location: Driving the vehicle uphill (increased engine load) will help maintain the driving conditions required for this test. If the check result is NG, go to AT-206, "Diagnostic Procedure" . If the check result is OK, go to following step. Maintain the following conditions for at least 5 consecutive seconds. ENGINE SPEED: 3,500 rpm or more THROTTLE POSI: More than 1.0/8 SLCT LVR POSI: “D” position Driving location: Driving the vehicle uphill (increased engine load) will help maintain the driving conditions required for this test. WITHOUT CONSULT-II 1. 2. G Start engine. Drive vehicle under the following conditions for more than 5 seconds. Selector lever position: “D” position Vehicle speed: 30 km/h (19 MPH) or more AT-203 J K L M VEHICLE SPEED SENSOR·A/T (REVOLUTION SENSOR) [EXC.F/EURO-OBD] 3. 4. Throttle position: greater than 1.0/8 of the full throttle position Perform self-diagnosis. Refer to AT-94, "Diagnostic Procedure Without CONSULT-II" . If the check result is NG, go to AT-206, "Diagnostic Procedure" . AT-204 VEHICLE SPEED SENSOR·A/T (REVOLUTION SENSOR) [EXC.F/EURO-OBD] Wiring Diagram — AT — VSSAT BCS000SO A B AT D E F G H I J K L M MCWA0245E AT-205 VEHICLE SPEED SENSOR·A/T (REVOLUTION SENSOR) [EXC.F/EURO-OBD] TCM terminal data are reference values, measured between each terminal and ground. Terminal Wire color Item Condition 29 V Revolution sensor 42 B Sensor ground When driving at 20 km/h (12 MPH) Always Diagnostic Procedure Judgement standard (Approx.) 150 Hz 0V BCS000SP 1. CHECK INPUT SIGNAL With CONSULT-II 1. Start engine. 2. Select “TCM INPUT SIGNALS” in “DATA MONITOR” mode for “A/T” with CONSULT-II. 3. Read out the value of “VHCL/S SE·A/T” while driving. Check the value changes according to driving speed. OK or NG OK >> GO TO 8. NG >> GO TO 2. SCIA4730E 2. 1. 2. CHECK REVOLUTION SENSOR Start engine. Check power supply to revolution sensor by voltage between TCM connector terminals. Refer to AT-261, "Wiring Diagram — AT — MAIN" and AT-205, "Wiring Diagram — AT — VSSAT" . Item Connector Terminal TCM E106, E107 Judgement standard (Approx.) 10 - 42 3. Battery voltage 19 - 42 If OK, check the pulse when vehicle cruises. Item Condition When driving at 20 km/h (12 MPH), use the CONSULT-II pulse frequency measuring function.*1 Revolution sensor CAUTION: Connect the diagnosis data link cable to the data link connector. *1: A circuit tester cannot be used to test this item. Item Connector Terminal Condition Judgement standard (Approx.) TCM E107 29 When driving at 20 km/h (12 MPH) 150 Hz OK or NG OK >> GO TO 8. NG >> GO TO 3. SCIA4939E AT-206 VEHICLE SPEED SENSOR·A/T (REVOLUTION SENSOR) [EXC.F/EURO-OBD] 3. 1. 2. 3. 4. CHECK POWER AND SENSOR GROUND A Turn ignition switch OFF. Disconnect the revolution sensor harness connector. Turn ignition switch ON. (Do not start engine.) Check voltage between revolution sensor harness connector terminals. B AT Item Connector Terminal Judgement standard (Approx.) Revolution sensor F41 1-3 Battery voltage D E SCIA2614E 5. Item Connector Terminal Judgement standard (Approx.) Revolution sensor F41 1 - ground Battery voltage 6. If OK, check harness for short to ground and short to power. 7. Reinstall any part removed. OK or NG OK >> GO TO 4. NG - 1 >> Battery voltage is not supplied between terminals 1 and 3, terminals 1 and ground.:GO TO 6. NG - 2 >> Battery voltage is not supplied between terminals 1 and 3 only.: GO TO 7. 4. 1. 2. 3. F Check voltage between revolution sensor harness connector terminal and ground. G H SCIA2615E I J CHECK HARNESS BETWEEN TCM AND REVOLUTION SENSOR K Turn ignition switch OFF. Disconnect the TCM connector and revolution sensor harness connector. Check continuity between TCM connector terminal and revolution sensor harness connector terminal. Item Connector Terminal TCM E107 29 Revolution sensor F41 2 L Continuity M Yes 4. If OK, check harness for short to ground and short to power. 5. Reinstall any part removed. OK or NG OK >> GO TO 5. NG >> Repair open circuit or short to ground or short to power in harness or connectors. 5. CHECK TCM 1. Check TCM input/output signals. Refer to AT-80, "TCM Terminals and Reference Value" . 2. If NG, re-check TCM pin terminals for damage or loose connection with harness connector. OK or NG OK >> GO TO 8. NG >> Repair or replace damaged parts. AT-207 SCIA2616E VEHICLE SPEED SENSOR·A/T (REVOLUTION SENSOR) [EXC.F/EURO-OBD] 6. 1. 2. 3. CHECK HARNESS BETWEEN TCM AND REVOLUTION SENSOR (POWER) Turn ignition switch OFF. Disconnect the TCM connector and revolution sensor harness connector. Check continuity between TCM connector terminals and revolution sensor harness connector terminal. Refer to AT-52, "Circuit Diagram" and AT-261, "Wiring Diagram — AT — MAIN" . Item Connector Terminal TCM E106 10 Revolution sensor F41 1 TCM E106 19 Revolution sensor F41 1 Continuity Yes Yes 4. If OK, check harness for short to ground and short to power. 5. Reinstall any part removed. OK or NG OK >> 10A fuse (No.38, located in the IPDM E/R) or ignition switch are malfunctioning. NG >> Repair open circuit or short to ground or short to power in harness or connectors. 7. 1. 2. 3. SCIA2617E CHECK HARNESS BETWEEN TCM AND REVOLUTION SENSOR (SENSOR GROUND) Turn ignition switch OFF. Disconnect the TCM connector and revolution sensor harness connector. Check continuity between TCM connector terminal and revolution sensor harness connector terminal. Item Connector Terminal TCM E107 42 Revolution sensor F41 3 Continuity Yes 4. If OK, check harness for short to ground and short to power. 5. Reinstall any part removed. OK or NG OK >> GO TO 5. NG >> Repair open circuit or short to ground or short to power in harness or connectors. 8. CHECK DTC Perform AT-203, "DTC Confirmation Procedure" . OK or NG OK >> INSPECTION END NG >> GO TO 5. AT-208 SCIA2618E VEHICLE SPEED SENSOR MTR [EXC.F/EURO-OBD] VEHICLE SPEED SENSOR MTR Description PFP:24814 A BCS000SQ The vehicle speed sensor·MTR is built into the speedometer assembly. The sensor functions as an auxiliary device to the revolution sensor when it is malfunctioning. The TCM will then use a signal sent from the vehicle speed sensor·MTR. CONSULT-II Reference Value BCS000SR AT Remarks: Specification data are reference values. Item name Condition VHCL/S SE-MTR Display value During driving Approximately matches the speedometer reading. D On Board Diagnosis Logic BCS000SS Diagnostic trouble code “VHCL SPEED SEN-MTR” with CONSULT-II or 2nd judgement flicker without CONSULT-II is detected when TCM does not receive the proper voltage signal from the sensor. Possible Cause ● ● B E BCS000ST Harness or connector (Sensor circuit is open or shorted.) Vehicle speed sensor F DTC Confirmation Procedure BCS000SU CAUTION: ● Always drive vehicle at a safe speed. ● If performing this “DTC Confirmation Procedure” again, always turn ignition switch OFF and wait at least 10 seconds before continuing. After the repair, perform the following procedure to confirm the malfunction is eliminated. G H I WITH CONSULT-II 1. 2. 3. 4. Turn ignition switch ON and select “DATA MONITOR” mode for “A/T” with CONSULT-II. Touch “START”. Start engine and accelerate vehicle from 0 to 25 km/h (0 to 16 MPH). If the check result is NG, go to AT-211, "Diagnostic Procedure" . J K L BCIA0031E M WITHOUT CONSULT-II 1. 2. 3. 4. Start engine. Drive vehicle under the following conditions: Selector lever position: “D” position Vehicle speed: Higher than 25 km/h (16 MPH) Perform self-diagnosis. Refer to AT-94, "Diagnostic Procedure Without CONSULT-II" . If the check result is NG, go to AT-211, "Diagnostic Procedure" . AT-209 VEHICLE SPEED SENSOR MTR [EXC.F/EURO-OBD] Wiring Diagram — AT — VSSMTR BCS000SV MCWA0251E AT-210 VEHICLE SPEED SENSOR MTR [EXC.F/EURO-OBD] TCM terminal data are reference values, measured between each terminal and ground. Terminal Wire color 40 R Item Condition When driving vehicle at 2 to 3 km/h (1 to 2 MPH) for 1 m (3 ft) or more. Vehicle speed sensor Diagnostic Procedure Judgement standard (Approx.) Voltage varies between less than 0V and more than 4.5V BCS000SW 1. CHECK INPUT SIGNAL With CONSULT-II 1. Start engine. 2. Select “TCM INPUT SIGNALS” in “DATA MONITOR” mode for “A/T” with CONSULT-II. 3. Read out the value of “VHCL/S SE-MTR” while driving. Check the value changes according to driving speed. Item name Condition Display value VHCL/S SE-MTR During driving Approximately matches the speedometer reading. Vehicle speed sensor B AT D E F SCIA4730E Without CONSULT-II 1. Start engine. 2. Check voltage between TCM connector terminal and ground. Item A G H Connector Terminal Condition Judgement standard (Approx.) I E107 40 Ground When driving vehicle at 2 to 3 km/h (1 to 2 MPH) for 1 m (3 ft) or more. Voltage varies between less than 0V and more than 4.5V J OK or NG OK >> GO TO 3. NG >> GO TO 2. K SCIA4940E 2. DETECT MALFUNCTIONING ITEM L Check the following items: ● Combination meter. Refer to DI-4, "COMBINATION METERS" . ● Harness for short or open between TCM and combination meter. OK or NG OK >> GO TO 3. NG >> Repair or replace damaged parts. 3. CHECK DTC Perform AT-209, "DTC Confirmation Procedure" . OK or NG OK >> INSPECTION END NG >> GO TO 4. AT-211 M VEHICLE SPEED SENSOR MTR [EXC.F/EURO-OBD] 4. CHECK TCM 1. Check TCM input/output signals. Refer to AT-80, "TCM Terminals and Reference Value" . 2. If NG, recheck TCM pin terminals for damage or loose connection with harness connector. OK or NG OK >> INSPECTION END NG >> Repair or replace damaged parts. AT-212 ACCELERATOR PEDAL POSITION (APP) SENSOR [EXC.F/EURO-OBD] ACCELERATOR PEDAL POSITION (APP) SENSOR Description PFP:22620 A BCS000SX Electric throttle control actuator consists of throttle control motor, accelerator pedal position sensor, throttle position sensor, etc. The actuator sends signals to the ECM, and ECM sends signals to TCM via CAN communication. CONSULT-II Reference Value BCS000SY AT Remarks: Specification data are reference values. Item name Condition THROTTLE POSI B Display value (Approx.) Released accelerator pedal. 0.0/8 Fully depressed accelerator pedal. 8.0/8 On Board Diagnosis Logic D BCS000SZ Diagnostic trouble code “THROTTLE POSI SEN” with CONSULT-II or 3rd judgement flicker without CONSULT-II is detected when TCM does not receive the proper accelerator pedal position signals (input via CAN communication) from ECM. E Possible Cause F BCS000T0 Harness or connector (Sensor circuit is open or shorted.) G DTC Confirmation Procedure BCS000T1 CAUTION: If performing this “DTC Confirmation Procedure” again, always turn ignition switch OFF and wait at least 10 seconds before continuing. After the repair, perform the following procedure to confirm the malfunction is eliminated. I WITH CONSULT-II 1. 2. 3. 4. H Turn ignition switch ON. (Do not start engine.) Select “DATA MONITOR” mode for “A/T” with CONSULT-II. Depress accelerator pedal fully and release it, then wait for 5 seconds. If DTC is detected, go to AT-214, "Diagnostic Procedure" . J K L BCIA0031E WITHOUT CONSULT-II 1. 2. 3. 4. M Turn ignition switch ON. (Do not start engine.) Depress accelerator pedal fully and release it, then wait for 5 seconds. Perform self-diagnosis. Refer to AT-94, "Diagnostic Procedure Without CONSULT-II" . If the check result is NG, go to AT-214, "Diagnostic Procedure" . AT-213 ACCELERATOR PEDAL POSITION (APP) SENSOR [EXC.F/EURO-OBD] Diagnostic Procedure BCS000T2 1. CHECK CAN COMMUNICATION LINE Perform self-diagnosis. Refer to AT-85, "SELF-DIAGNOSTIC RESULT MODE" , AT-94, "Diagnostic Procedure Without CONSULT-II" . Is any malfunction of the “U1000 CAN COMM CIRCUIT” indicated? YES >> Check the CAN communication line. Refer to AT-257, "CAN COMMUNICATION LINE" . NO >> GO TO 2. 2. CHECK INPUT SIGNAL With CONSULT-II 1. Turn ignition switch ON. (Do not start engine.) 2. Select “MAIN SIGNALS” in “DATA MONITOR” mode for “A/T” with CONSULT-II. 3. Read out the value of “THROTTLE POSI”. Item name Condition Display value (Approx.) Released accelerator pedal. 0.0/8 Fully depressed accelerator pedal. 8.0/8 THROTTLE POSI OK or NG OK >> GO TO 4. NG >> GO TO 3. SCIA3251E 3. CHECK DTC WITH ECM With CONSULT-II Turn ignition switch ON. (Do not start engine.) Select “SELF-DIAG RESULTS” mode for “ENGINE” with CONSULT-II. Refer to EC-521, "SELF-DIAG RESULTS MODE" . OK or NG OK >> GO TO 4. NG >> Check the DTC Detected Item. Go to EC-521, "SELFDIAG RESULTS MODE" . 1. 2. BCIA0030E 4. CHECK DTC Perform “DTC Confirmation Procedure”. Refer to AT-213, "DTC Confirmation Procedure" . OK or NG OK >> INSPECTION END NG >> GO TO 5. 5. CHECK TCM 1. Check TCM input/output signals. Refer to AT-80, "TCM Terminals and Reference Value" . 2. If NG, recheck TCM pin terminals for damage or loose connection with harness connector. OK or NG OK >> INSPECTION END NG >> Repair or replace damaged parts. AT-214 SHIFT SOLENOID VALVE A [EXC.F/EURO-OBD] SHIFT SOLENOID VALVE A Description PFP:31940 A BCS000T3 Shift solenoid valves A and B are turned ON or OFF by the TCM in response to signals sent from the PNP switch, vehicle speed and ECM (throttle opening). Gears will then be shifted to the optimum position. Gear position 1 2 3 4 Shift solenoid valve A ON (Closed) OFF (Open) OFF (Open) ON (Closed) Shift solenoid valve B ON (Closed) ON (Closed) OFF (Open) OFF (Open) CONSULT-II Reference Value D Display value When shift solenoid valve A operates. (When driving in “D1 ” or “D4 ”.) ON When shift solenoid valve A does not operate. (When driving in “D2 ” or “D3 ”.) OFF On Board Diagnosis Logic E BCS000T5 Diagnostic trouble code “SHIFT SOLENOID/V A” with CONSULT-II or 4th judgement flicker without CONSULT-II is detected when TCM detects an improper voltage drop when it tries to operate the solenoid valve. Possible Cause ● ● AT BCS000T4 Remarks: Specification data are reference values. Item name Condition SHIFT S/V A B F G BCS000T6 Harness or connector (Solenoid circuit is open or shorted.) Shift solenoid valve A H DTC Confirmation Procedure BCS000T7 I CAUTION: ● Always drive vehicle at a safe speed. ● If performing this “DTC Confirmation Procedure” again, always turn ignition switch OFF and wait at least 10 seconds before continuing. After the repair, perform the following procedure to confirm the malfunction is eliminated. J K WITH CONSULT-II 1. 2. 3. 4. 5. Turn ignition switch ON and select “DATA MONITOR” mode for “A/T” with CONSULT-II. Touch “START”. Start engine. Drive vehicle in “D” position and allow the transaxle to shift 1 → 2 (“GEAR”). If the check result is NG, go to AT-217, "Diagnostic Procedure" . L M BCIA0031E WITHOUT CONSULT-II 1. 2. 3. 4. Start engine. Drive vehicle in D1 → D2 position. Perform self-diagnosis. Refer to AT-94, "Diagnostic Procedure Without CONSULT-II" . If the check result is NG, go to AT-217, "Diagnostic Procedure" . AT-215 SHIFT SOLENOID VALVE A [EXC.F/EURO-OBD] Wiring Diagram — AT — SSV/A BCS000T8 MCWA0248E AT-216 SHIFT SOLENOID VALVE A [EXC.F/EURO-OBD] TCM terminal data are reference values, measured between each terminal and ground. Terminal Wire color 11 R Item Condition Shift solenoid valve A Judgement standard (Approx.) When shift solenoid valve A operates. (When driving in “D1 ” or “D4 ”.) Battery voltage When shift solenoid valve A does not operate. (When driving in “D2 ” or “D3 ”.) 0V Diagnostic Procedure BCS000T9 D With CONSULT-II Start engine. Select “MAIN SIGNALS” in “DATA MONITOR” mode for “A/T” with CONSULT-II. Read out the value of “SHIFT S/V A” while driving. Check the value changes according to driving speed. Item name SHIFT S/V A B AT 1. CHECK INPUT SIGNAL 1. 2. 3. A Condition Display value When shift solenoid valve A operates. (When driving in “D1 ” or “D4 ”.) ON When shift solenoid valve A does not operate. (When driving in “D2 ” or “D3 ”.) OFF E F G H SCIA3251E I 1. 2. Without CONSULT-II Start engine. Check voltage between TCM connector terminal and ground. Item Shift solenoid valve A Connector E106 Terminal 11 Ground J Judgement standard (Approx.) Condition When shift solenoid valve A operates. (When driving in “D1 ” or “D4 ”.) Battery voltage When shift solenoid valve A does not operate. (When driving in “D2 ” or “D3 ”.) 0V OK or NG OK >> GO TO 5. NG >> GO TO 2. AT-217 K L SCIA3248E M SHIFT SOLENOID VALVE A [EXC.F/EURO-OBD] 2. CHECK SHIFT SOLENOID VALVE A CIRCUIT 1. 2. 3. Turn ignition switch OFF. Disconnect TCM connector. Check resistance between TCM connector terminal and ground. Solenoid Valve Shift solenoid valve A Connector Terminal Resistance (Approx.) E106 11 - Ground 20 - 30 Ω OK or NG OK >> GO TO 5. NG >> GO TO 3. SCIA3249E 3. 1. 2. 3. CHECK HARNESS BETWEEN TCM AND TERMINAL CORD ASSEMBLY HARNESS CONNECTOR Turn ignition switch OFF. Disconnect terminal cord assembly harness connector and TCM connector. Check continuity between terminal cord assembly harness connector terminal and TCM connector terminal. Item Connector Terminal TCM E106 11 Terminal cord assembly harness connector F13 2 Continuity Yes 4. If OK, check harness for short to ground and short to power. 5. If OK, check continuity between ground and transaxle assembly. 6. Reinstall any part removed. OK or NG OK >> GO TO 4. NG >> Repair open circuit or short to ground or short to power in harness or connectors. SCIA3250E 4. CHECK VALVE RESISTANCE 1. 2. 3. Turn ignition switch OFF. Disconnect terminal cord assembly connector in engine room. Check resistance between terminal cord assembly harness connector terminal and ground. Solenoid valve Shift solenoid valve A Connector Terminal Resistance (Approx.) F13 2 - Ground 20 - 30 Ω OK or NG OK >> GO TO 5. NG >> Repair or replace damaged parts. SCIA4942E 5. CHECK DTC Perform AT-215, "DTC Confirmation Procedure" . OK or NG OK >> INSPECTION END NG >> GO TO 6. AT-218 SHIFT SOLENOID VALVE A [EXC.F/EURO-OBD] 6. CHECK TCM A 1. Check TCM input/output signals. Refer to AT-80, "TCM Terminals and Reference Value" . 2. If NG, recheck TCM pin terminals for damage or loose connection with harness connector. OK or NG OK >> INSPECTION END NG >> Repair or replace damaged parts. B AT Component Inspection BCS000TA SHIFT SOLENOID VALVE A ● For removal, refer to AT-345, "Control Valve Assembly and Accumulators" . D Resistance Check ● Check resistance between terminal and ground. E Solenoid valve Shift solenoid valve A Resistance (Approx.) Terminal 2 Ground 20 - 30 Ω F G SCIA2049E H Operation Check ● Check solenoid valve by listening for its operating sound while applying battery voltage to the terminal and ground. I J K SCIA2052E L M AT-219 SHIFT SOLENOID VALVE B [EXC.F/EURO-OBD] SHIFT SOLENOID VALVE B Description PFP:31940 BCS000TB Shift solenoid valves A and B are turned ON or OFF by the TCM in response to signals sent from the PNP switch, vehicle speed and ECM (throttle opening). Gears will then be shifted to the optimum position. Gear position 1 2 3 4 Shift solenoid valve A ON (Closed) OFF (Open) OFF (Open) ON (Closed) Shift solenoid valve B ON (Closed) ON (Closed) OFF (Open) OFF (Open) CONSULT-II Reference Value BCS000TC Remarks: Specification data are reference values. Item name Condition SHIFT S/V B Display value When shift solenoid valve B operates. (When driving in “D1 ” or “D2 ”.) ON When shift solenoid valve B does not operate. (When driving in “D3 ” or “D4 ”.) OFF On Board Diagnosis Logic BCS000TD Diagnostic trouble code “SHIFT SOLENOID/V B” with CONSULT-II or 5th judgement flicker without CONSULT-II is detected when TCM detects an improper voltage drop when it tries to operate the solenoid valve. Possible Cause ● ● BCS000TE Harness or connector (Solenoid circuit is open or shorted.) Shift solenoid valve B DTC Confirmation Procedure BCS000TF CAUTION: ● Always drive vehicle at a safe speed. ● If performing this “DTC Confirmation Procedure” again, always turn ignition switch OFF and wait at least 10 seconds before continuing. WITH CONSULT-II 1. 2. 3. 4. 5. Turn ignition switch ON and select “DATA MONITOR” mode for “A/T” with CONSULT-II. Touch “START”. Start engine. Drive vehicle in “D” position and allow the transaxle to shift 1 → 2 → 3 (“GEAR”). If the check result is NG, go to AT-222, "Diagnostic Procedure" . BCIA0031E WITHOUT CONSULT-II 1. 2. 3. 4. Start engine. Drive vehicle in D1 → D2 → D3 position. Perform self-diagnosis. Refer to AT-94, "Diagnostic Procedure Without CONSULT-II" . If the check result is NG, go to AT-222, "Diagnostic Procedure" . AT-220 SHIFT SOLENOID VALVE B [EXC.F/EURO-OBD] Wiring Diagram — AT — SSV/B BCS000TG A B AT D E F G H I J K L M MCWA0249E AT-221 SHIFT SOLENOID VALVE B [EXC.F/EURO-OBD] TCM terminal data are reference values, measured between each terminal and ground. Terminal Wire color 12 SB Item Condition Shift solenoid valve B Judgement standard (Approx.) When shift solenoid valve B operates. (When driving in “D1 ” or “D2 ”.) Battery voltage When shift solenoid valve B does not operate. (When driving in “D3 ” or “D4 ”.) 0V Diagnostic Procedure BCS000TH 1. CHECK INPUT SIGNAL 1. 2. 3. With CONSULT-II Start engine. Select “MAIN SIGNALS” in “DATA MONITOR” mode for “A/T” with CONSULT-II. Read out the value of “SHIFT S/V B” while driving. Check the value changes according to driving speed. Item name SHIFT S/V B Condition Display value When shift solenoid valve B operates. (When driving in “D1 ” or “D2 ”.) ON When shift solenoid valve B does not operate. (When driving in “D3 ” or “D4 ”.) OFF SCIA3251E 1. 2. Without CONSULT-II Start engine. Check voltage between TCM connector terminal and ground. Item Shift solenoid valve B Connector E106 Terminal 12 Ground Condition Judgement standard (Approx.) When shift solenoid valve B operates. (When driving in “D1 ” or “D2 ”.) Battery voltage When shift solenoid valve B does not operate. (When driving in “D3 ” or “D4 ”.) 0V OK or NG OK >> GO TO 5. NG >> GO TO 2. AT-222 SCIA3253E SHIFT SOLENOID VALVE B [EXC.F/EURO-OBD] 2. CHECK SHIFT SOLENOID VALVE B CIRCUIT 1. 2. 3. A Turn ignition switch OFF. Disconnect TCM connector. Check resistance between TCM connector terminal and ground. Solenoid Valve Shift solenoid valve B Connector Terminal Resistance (Approx.) E106 12 - Ground 5 - 20 Ω B AT OK or NG OK >> GO TO 5. NG >> GO TO 3. D SCIA3254E 3. 1. 2. 3. E CHECK HARNESS BETWEEN TCM AND TERMINAL CORD ASSEMBLY HARNESS CONNECTOR F Turn ignition switch OFF. Disconnect terminal cord assembly harness connector and TCM connector. Check continuity between terminal cord assembly harness connector terminal and TCM connector terminal. Item Connector Terminal TCM E106 12 Terminal cord assembly harness connector F13 1 G Continuity H Yes 4. If OK, check harness for short to ground and short to power. 5. If OK, check continuity between ground and transaxle assembly. 6. Reinstall any part removed. OK or NG OK >> GO TO 4. NG >> Repair open circuit or short to ground or short to power in harness or connectors. I SCIA4943E J K 4. CHECK VALVE RESISTANCE 1. 2. 3. L Turn ignition switch OFF. Disconnect terminal cord assembly connector in engine room. Check resistance between terminal cord assembly harness connector terminal and ground. Solenoid valve Shift solenoid valve B Connector Terminal Resistance (Approx.) F13 1 - Ground 5 - 20 Ω M OK or NG OK >> GO TO 5. NG >> Repair or replace damaged parts. SCIA4944E 5. CHECK DTC Perform AT-220, "DTC Confirmation Procedure" . OK or NG OK >> INSPECTION END NG >> GO TO 6. AT-223 SHIFT SOLENOID VALVE B [EXC.F/EURO-OBD] 6. CHECK TCM 1. Check TCM input/output signals. Refer to AT-80, "TCM Terminals and Reference Value" . 2. If NG, recheck TCM pin terminals for damage or loose connection with harness connector. OK or NG OK >> INSPECTION END NG >> Repair or replace damaged parts. Component Inspection BCS000TI SHIFT SOLENOID VALVE B ● For removal, refer to AT-345, "Control Valve Assembly and Accumulators" . Resistance Check ● Check resistance between terminal and ground. Solenoid valve Shift solenoid valve B Resistance (Approx.) Terminal 1 Ground 5 - 20Ω SCIA2055E Operation Check ● Check solenoid valve by listening for its operating sound while applying battery voltage to the terminal and ground. SCIA2058E AT-224 OVERRUN CLUTCH SOLENOID VALVE [EXC.F/EURO-OBD] OVERRUN CLUTCH SOLENOID VALVE Description PFP:31940 A BCS000TJ The overrun clutch solenoid valve is activated by the TCM in response to signals sent from the PNP switch, overdrive control switch, vehicle speed and ECM (throttle opening). The overrun clutch operation will then be controlled. CONSULT-II Reference Value BCS000TK AT Remarks: Specification data are reference values. Item name Condition OVERRUN/C S/V Display value When overrun clutch solenoid valve operates. (When overrun clutch disengaged. Refer to AT-22 .) ON When overrun clutch solenoid valve does not operate. (When overrun clutch engaged. Refer to AT-22 .) OFF D E On Board Diagnosis Logic BCS000TL Diagnostic trouble code “OVERRUN CLUTCH S/V” with CONSULT-II or 6th judgement flicker without CONSULT-II is detected when TCM detects an improper voltage drop when it tries to operate the solenoid valve. Possible Cause ● ● Harness or connector (Solenoid circuit is open or shorted.) Overrun clutch solenoid valve G BCS000TN CAUTION: ● Always drive vehicle at a safe speed. ● If performing this “DTC Confirmation Procedure” again, always turn ignition switch OFF and wait at least 10 seconds before continuing. After the repair, perform the following procedure to confirm the malfunction is eliminated. WITH CONSULT-II 2. 3. 4. 5. 6. Turn ignition switch ON and select “DATA MONITOR” mode for “A/T” with CONSULT-II. Touch “START”. Start engine. Accelerate vehicle to a speed of more than 10 km/h (6 MPH) with “D” position (OD ON). Release accelerator pedal completely with “D” position (OD OFF). If the check result is NG, go to AT-227, "Diagnostic Procedure" . WITHOUT CONSULT-II 3. 4. Start engine. Drive vehicle under the following conditions: Selector lever position: “D” position (OD ON) Vehicle speed: Higher than 10 km/h (6 MPH) Perform self-diagnosis. Refer to AT-94, "Diagnostic Procedure Without CONSULT-II" . If the check result is NG, go to AT-227, "Diagnostic Procedure" . AT-225 H I J K L M BCIA0031E 1. 2. F BCS000TM DTC Confirmation Procedure 1. B OVERRUN CLUTCH SOLENOID VALVE [EXC.F/EURO-OBD] Wiring Diagram — AT — OVRCSV BCS000TO MCWA0250E AT-226 OVERRUN CLUTCH SOLENOID VALVE [EXC.F/EURO-OBD] TCM terminal data are reference values, measured between each terminal and ground. Terminal 20 Wire color Item Condition Overrun clutch solenoid valve LG Judgement standard (Approx.) When overrun clutch solenoid valve operates. (When overrun clutch disengaged. Refer to AT-22 .) Battery voltage When overrun clutch solenoid valve dose not operate. (When overrun clutch engaged. Refer to AT-22 .) 0V Diagnostic Procedure BCS000TP D With CONSULT-II 1. Start engine. 2. Select “MAIN SIGNALS” in “DATA MONITOR” mode for “A/T” with CONSULT-II. 3. Read out the value of “OVERRUN/C S/V” while driving. Check the value changes according to driving speed. Condition OVERRUN/C S/V E F Display value G When overrun clutch solenoid valve operates. (When overrun clutch disengaged. Refer to AT-22 .) ON When overrun clutch solenoid valve dose not operate. (When overrun clutch engaged. Refer to AT-22 .) OFF H SCIA3257E Without CONSULT-II 1. Start engine. 2. Check voltage between TCM connector terminal and ground. Item Overrun clutch solenoid valve Connector E106 Terminal 20 Ground B AT 1. CHECK INPUT SIGNAL Item name A J Judgement standard (Approx.) Condition When overrun clutch solenoid valve operates. (When overrun clutch disengaged. Refer to AT-22 .) K L Battery voltage When overrun clutch solenoid valve dose not operate. (When overrun clutch engaged. Refer to AT-22 .) OK or NG OK >> GO TO 5. NG >> GO TO 2. AT-227 I M SCIA3258E 0V OVERRUN CLUTCH SOLENOID VALVE [EXC.F/EURO-OBD] 2. CHECK OVERRUN CLUTCH SOLENOID VALVE CIRCUIT 1. 2. 3. Turn ignition switch OFF. Disconnect TCM connector. Check resistance between TCM connector terminal and ground. Solenoid Valve Connector Terminal Resistance (Approx.) Overrun clutch solenoid valve E106 20 - Ground 20 - 30 Ω OK or NG OK >> GO TO 5. NG >> GO TO 3. SCIA3259E 3. 1. 2. 3. CHECK HARNESS BETWEEN TCM AND TERMINAL CORD ASSEMBLY HARNESS CONNECTOR Turn ignition switch OFF. Disconnect terminal cord assembly harness connector and TCM connector. Check continuity between terminal cord assembly harness connector terminal and TCM connector terminal. Item Connector Terminal TCM E106 20 Terminal cord assembly harness connector F13 3 Continuity Yes 4. If OK, check harness for short to ground and short to power. 5. If OK, check continuity between ground and transaxle assembly. 6. Reinstall any part removed. OK or NG OK >> GO TO 4. NG >> Repair open circuit or short to ground or short to power in harness or connectors. SCIA3260E 4. CHECK VALVE RESISTANCE 1. 2. 3. Turn ignition switch OFF. Disconnect terminal cord assembly connector in engine room. Check resistance between terminal cord assembly harness connector terminal and ground. Solenoid valve Connector Terminal Resistance (Approx.) Overrun clutch solenoid valve F13 3 - Ground 20 - 30 Ω OK or NG OK >> GO TO 5. NG >> Repair or replace damaged parts. SCIA4945E 5. CHECK DTC Perform AT-225, "DTC Confirmation Procedure" . OK or NG OK >> INSPECTION END NG >> GO TO 6. AT-228 OVERRUN CLUTCH SOLENOID VALVE [EXC.F/EURO-OBD] 6. CHECK TCM A 1. Check TCM input/output signals. Refer to AT-80, "TCM Terminals and Reference Value" . 2. If NG, recheck TCM pin terminals for damage or loose connection with harness connector. OK or NG OK >> INSPECTION END NG >> Repair or replace damaged parts. B AT Component Inspection BCS000TQ OVERRUN CLUTCH SOLENOID VALVE ● For removal, refer to AT-345, "Control Valve Assembly and Accumulators" . D Resistance Check ● Check resistance between terminal and ground. E Solenoid valve Overrun clutch solenoid valve Resistance (Approx.) Terminal 3 Ground 20 - 30 Ω F G SCIA2059E H Operation Check ● Check solenoid valve by listening for its operating sound while applying battery voltage to the terminal and ground. I J K SCIA2062E L M AT-229 TORQUE CONVERTER CLUTCH SOLENOID VALVE [EXC.F/EURO-OBD] TORQUE CONVERTER CLUTCH SOLENOID VALVE Description PFP:31940 BCS000TR The torque converter clutch solenoid valve is activated, with the gear in D4 and D3 , by the TCM in response to signals sent from the vehicle speed sensor and the ECM (throttle opening). Lock-up piston operation will then be controlled. Lock-up operation, however, is prohibited when A/T fluid temperature is too low. When the accelerator pedal is depressed (less than 2/8) on lock-up condition, the engine speed should not change abruptly. If there is an abrupt change in engine speed, there is no lock-up. ● ● ● CONSULT-II Reference Value BCS000TS Remarks: Specification data are reference values. Item name Condition TCC S/V DUTY Display value (Approx.) Lock-up OFF ⇔ Lock-up ON 4% ⇔ 94% On Board Diagnosis Logic BCS000TT Diagnostic trouble code “T/C CLUTCH SOL/V” with CONSULT-II or 7th judgement flicker without CONSULT-II is detected when TCM detects an improper voltage drop while it tries to operate the solenoid valve. Possible Cause ● ● BCS000TU Torque converter clutch solenoid valve Harness or connector (Solenoid circuit is open or shorted.) DTC Confirmation Procedure BCS000TV CAUTION: ● Always drive vehicle at a safe speed. ● If performing this “DTC Confirmation Procedure” again, always turn ignition switch OFF and wait at least 10 seconds before continuing. After the repair, perform the following procedure to confirm the malfunction is eliminated. WITH CONSULT-II 1. 2. 3. 4. 5. Turn ignition switch ON. (Do not start engine.) Select “DATA MONITOR” mode for “A/T” with CONSULT-II and wait at least 1 second. Touch “START”. Start engine and maintain the following conditions for at least 5 consecutive seconds. VEHICLE SPEED: 80 km/h (50 MPH) or more THROTTLE POSI: 0.5/8 - 1.0/8 SLCT LVR POSI: “D” position Driving location: Driving the vehicle uphill (increased engine load) will help maintain the driving conditions required for this test. If the check result is NG, go to AT-232, "Diagnostic Procedure" . WITHOUT CONSULT-II 1. 2. 3. 4. Start engine. Drive vehicle in D1 → D2 → D3 → D4 → D4 lock-up position. Perform self-diagnosis. Refer to AT-94, "Diagnostic Procedure Without CONSULT-II" . If the check result is NG, go to AT-232, "Diagnostic Procedure" . AT-230 BCIA0031E TORQUE CONVERTER CLUTCH SOLENOID VALVE [EXC.F/EURO-OBD] Wiring Diagram — AT — TCV BCS000TW A B AT D E F G H I J K L M MCWA0246E AT-231 TORQUE CONVERTER CLUTCH SOLENOID VALVE [EXC.F/EURO-OBD] TCM terminal data are reference values, measured between each terminal and ground. Terminal Wire color Item Condition 3 O Torque converter clutch solenoid valve When A/T performs lock-up. When A/T does not perform lock-up. Diagnostic Procedure Judgement standard (Approx.) 8 - 15V 0V BCS000TX 1. CHECK INPUT SIGNAL With CONSULT-II 1. Start engine. 2. Select “MAIN SIGNALS” in “DATA MONITOR” mode for “A/T” with CONSULT-II. 3. Read out the value of “TCC S/V DUTY” while driving. Check the value changes according to driving speed. Item name Condition Display value (Approx.) TCC S/V DUTY Lock-up OFF ⇔ Lock-up ON 4% ⇔ 94% SCIA3257E Without CONSULT-II 1. Start engine. 2. Check voltage between TCM connector terminal and ground. Item Torque converter clutch solenoid valve Connector E106 Terminal 3 - Ground Condition Judgement standard (Approx.) When A/T performs lockup. 8 - 15V When A/T does not perform lock-up. 0V OK or NG OK >> GO TO 5. NG >> GO TO 2. SCIA3261E 2. CHECK TORQUE CONVERTER CLUTCH SOLENOID VALVE CIRCUIT 1. 2. 3. Turn ignition switch OFF. Disconnect TCM connector. Check resistance between TCM connector terminal and ground. Solenoid Valve Torque converter clutch solenoid valve Connector Terminal Resistance (Approx.) E106 3 - Ground 5 - 20 Ω OK or NG OK >> GO TO 5. NG >> GO TO 3. SCIA3262E AT-232 TORQUE CONVERTER CLUTCH SOLENOID VALVE [EXC.F/EURO-OBD] 3. 1. 2. 3. CHECK HARNESS BETWEEN TCM AND TERMINAL CORD ASSEMBLY HARNESS CONNECTOR Turn ignition switch OFF. Disconnect terminal cord assembly harness connector and TCM connector. Check continuity between terminal cord assembly harness connector terminal and TCM connector terminal. Item Connector Terminal TCM E106 3 Terminal cord assembly harness connector F13 5 A B Continuity AT Yes D 4. If OK, check harness for short to ground and short to power. 5. If OK, check continuity between ground and transaxle assembly. 6. Reinstall any part removed. OK or NG OK >> GO TO 4. NG >> Repair open circuit or short to ground or short to power in harness or connectors. SCIA3263E E F 4. CHECK VALVE RESISTANCE 1. 2. 3. G Turn ignition switch OFF. Disconnect terminal cord assembly connector in engine room. Check resistance between terminal cord assembly harness connector terminal and ground. Solenoid valve Connector Terminal Resistance (Approx.) Torque converter clutch solenoid valve F13 5 - Ground 5 - 20 Ω H I OK or NG OK >> GO TO 5. NG >> Repair or replace damaged parts. J SCIA4946E K 5. CHECK DTC L Perform AT-230, "DTC Confirmation Procedure" . OK or NG OK >> INSPECTION END NG >> GO TO 6. M 6. CHECK TCM 1. Check TCM input/output signals. Refer to AT-80, "TCM Terminals and Reference Value" . 2. If NG, recheck TCM pin terminals for damage or loose connection with harness connector. OK or NG OK >> INSPECTION END NG >> Repair or replace damaged parts. AT-233 TORQUE CONVERTER CLUTCH SOLENOID VALVE [EXC.F/EURO-OBD] Component Inspection BCS000TY TORQUE CONVERTER CLUTCH SOLENOID VALVE ● For removal, refer to AT-345, "Control Valve Assembly and Accumulators" . Resistance Check ● Check resistance between terminal and ground. Solenoid valve Torque converter clutch solenoid valve Resistance (Approx.) Terminal 5 Ground 5 - 20 Ω SCIA2063E Operation Check ● Check solenoid valve by listening for its operating sound while applying battery voltage to the terminal and ground. SCIA2066E AT-234 BATT/FLUID TEMP SEN (A/T FLUID TEMP SENSOR CIRCUIT AND TCM POWER SOURCE) [EXC.F/EURO-OBD] BATT/FLUID TEMP SEN (A/T FLUID TEMP SENSOR CIRCUIT AND TCM POWER SOURCE) PFP:31940 Description A BCS000TZ The A/T fluid temperature sensor detects the A/T fluid temperature and sends the signal to the TCM. CONSULT-II Reference Value BCS000U0 Remarks: Specification data are reference values. Item name Condition FLUID TEMP SE B AT Display value (Approx.) When A/T fluid temperature is 20°C (68°F). 1.5V When A/T fluid temperature is 80°C (176°F). 0.5V On Board Diagnosis Logic D BCS000U1 Diagnostic trouble code “BATT/FLUID TEMP SEN” with CONSULT-II or 8th judgement flicker without CONSULT-II is detected when TCM receives an excessively low or high voltage from the sensor. Possible Cause ● ● E BCS000U2 F Harness or connector (Sensor circuit is open or shorted.) A/T fluid temperature sensor G DTC Confirmation Procedure BCS000U3 CAUTION: ● Always drive vehicle at a safe speed. ● If performing this “DTC Confirmation Procedure” again, always turn ignition switch OFF and wait at least 10 seconds before continuing. After the repair, perform the following procedure to confirm the malfunction is eliminated. H I WITH CONSULT-II 1. 2. 3. 4. 5. Start engine. Select “DATA MONITOR” mode for “A/T” with CONSULT-II. Touch “START”. Drive vehicle under the following conditions. SLCT LVR POSI: “D” position VEHICLE SPEED: Higher than 20 km/h (12 MPH) If the check result is NG, go to AT-237, "Diagnostic Procedure" . J K L M BCIA0031E WITHOUT CONSULT-II 1. 2. 3. 4. Start engine. Drive vehicle under the following conditions. Selector lever position: “D” position Vehicle speed: Higher than 20 km/h (12 MPH) Perform self-diagnosis. Refer to AT-94, "Diagnostic Procedure Without CONSULT-II" . If the check result is NG, go to AT-237, "Diagnostic Procedure" . AT-235 BATT/FLUID TEMP SEN (A/T FLUID TEMP SENSOR CIRCUIT AND TCM POWER SOURCE) [EXC.F/EURO-OBD] Wiring Diagram — AT — BA/FTS BCS000U4 MCWA0253E AT-236 BATT/FLUID TEMP SEN (A/T FLUID TEMP SENSOR CIRCUIT AND TCM POWER SOURCE) [EXC.F/EURO-OBD] TCM terminal data are reference values, measured between each terminal and ground. Terminal Wire color 10 Item R Condition Power supply or 19 R 28 LG 42 B 47 Power supply When turning ignition switch to “ON”. Battery voltage When turning ignition switch to “OFF”. 0V When turning ignition switch to “ON”. Battery voltage When turning ignition switch to “OFF”. 0V Always Battery voltage Sensor ground Always 0V and Diagnostic Procedure When A/T fluid temperature is 20°C (68°F). 1.5V When A/T fluid temperature is 80°C (176°F). 0.5V Connector BCS000U5 Power supply E106 Power supply (memory back-up) E107 Terminal Judgement standard (Approx.) 10 Battery voltage 19 Battery voltage 28 Battery voltage AT F Turn ignition switch ON. (Do not start engine.) Check voltage between TCM connector terminal and ground. Item B E 1. CHECK TCM POWER SOURCE 1. 2. A D Power supply (memory back-up) A/T fluid temperature sensor BR Judgement standard (Approx.) G H I J K SCIA2656E 3. 4. Turn ignition switch OFF. Check voltage between TCM connector terminal and ground. Item Power supply Power supply (memory back-up) Connector E106 E107 Terminal Judgement standard (Approx.) 10 0V 19 0V 28 Battery voltage OK or NG OK >> GO TO 3. NG >> GO TO 2. L M SCIA2657E AT-237 BATT/FLUID TEMP SEN (A/T FLUID TEMP SENSOR CIRCUIT AND TCM POWER SOURCE) [EXC.F/EURO-OBD] 2. DETECT MALFUNCTIONING ITEM Check the following items: ● Harness for short or open between ignition switch and TCM terminals 10, 19 ● Harness for short or open between battery and TCM terminal 28 ● 10A fuse (No.7, located in the fuse block) and 10A fuse (No.58, located in the IPDM E/R) ● Ignition switch. Refer to PG-38, "GROUND" . OK or NG OK >> GO TO 9. NG >> Repair or replace damaged parts. 3. CHECK INPUT SIGNAL OF A/T FLUID TEMPERATURE SENSOR With CONSULT-II 1. Start engine. 2. Select “TCM INPUT SIGNALS” in “DATA MONITOR” mode for “A/T” with CONSULT-II. 3. Read out the value of “FLUID TEMP SE”. Item name FLUID TEMP SE Condition Display value (Approx.) When A/T fluid temperature is 20°C (68°F). 1.5V When A/T fluid temperature is 80°C (176°F). 0.5V SCIA4730E Without CONSULT-II 1. Start engine. 2. Check voltage TCM connector terminals while warming up A/T. Item A/T fluid temperature sensor Connector E107 Condition Judgement standard (Approx.) When A/T fluid temperature is 20°C (68°F). 1.5V When A/T fluid temperature is 80°C (176°F). 0.5V Terminal 47 - 42 OK or NG OK >> GO TO 9. NG >> GO TO 4. SCIA2658E 4. DETECT MALFUNCTIONING ITEM Check the following items: ● Harness for short or open between TCM, ECM and terminal cord assembly ● Ground circuit for ECM Refer to EC-543, "POWER SUPPLY AND GROUND CIRCUIT" . OK or NG OK >> GO TO 5. NG >> Repair or replace damaged parts. AT-238 BATT/FLUID TEMP SEN (A/T FLUID TEMP SENSOR CIRCUIT AND TCM POWER SOURCE) [EXC.F/EURO-OBD] 5. CHECK FLUID TEMPERATURE SENSOR CIRCUIT 1. 2. 3. Turn ignition switch OFF. Disconnect the TCM connector. Check resistance between TCM connector terminals. Item Connector A/T fluid temperature sensor E107 Terminal A B Temperature °C (°F) Resistance (Approx.) 20 (68) 2.5 kΩ 80 (176) 0.3 kΩ AT 47 - 42 D OK or NG OK >> GO TO 9. NG >> GO TO 6. E SCIA4947E 6. 1. 2. 3. CHECK HARNESS BETWEEN TCM AND TERMINAL CORD ASSEMBLY HARNESS CONNECTOR F Turn ignition switch OFF. Disconnect terminal cord assembly harness connector and TCM connector. Check continuity between terminal cord assembly harness connector terminals and TCM connector terminals. G Item Connector Terminal TCM E107 42 F13 7 E107 47 F13 6 Terminal cord assembly harness connector TCM Terminal cord assembly harness connector H Continuity Yes I Yes J SCIA2660E 4. If OK, check harness for short to ground and short to power. 5. If OK, check continuity between ground and transaxle assembly. 6. Reinstall any part removed. OK or NG OK >> GO TO 7. NG >> Repair open circuit or short to ground or short to power in harness or connectors. K L 7. CHECK A/T FLUID TEMPERATURE SENSOR WITH TERMINAL CORD ASSEMBLY 1. 2. 3. M Turn ignition switch OFF. Disconnect terminal cord assembly connector in engine room. Check resistance between terminal cord assembly harness connector terminals. Temperature °C (°F) Resistance (Approx.) 20 (68) 2.5 kΩ 80 (176) 0.3 kΩ 4. Reinstall any part removed. OK or NG OK >> GO TO 8. NG >> Repair or replace damaged parts. SCIA4948E AT-239 BATT/FLUID TEMP SEN (A/T FLUID TEMP SENSOR CIRCUIT AND TCM POWER SOURCE) [EXC.F/EURO-OBD] 8. DETECT MALFUNCTIONING ITEM 1. 2. – • Remove oil pan. Refer to AT-345, "Control Valve Assembly and Accumulators" . Check the following items: A/T fluid temperature sensor Check resistance between terminal cord assembly harness connector terminals while changing temperature as shown. Temperature [°C (°F)] Resistance (Approx.) 20 (68) 2.5 kΩ 80 (176) 0.3 kΩ – Harness of terminal cord assembly for short or open OK or NG OK >> GO TO 9. NG >> Repair or replace damaged parts. SAT298F 9. CHECK DTC Perform AT-235, "DTC Confirmation Procedure" . OK or NG OK >> INSPECTION END NG >> GO TO 10. 10. CHECK TCM 1. Check TCM input/output signal. Refer to AT-80, "TCM Terminals and Reference Value" . 2. If NG, recheck TCM pin terminals for damage or loose connection with harness connector. OK or NG OK >> INSPECTION END NG >> Repair or replace damaged parts. Component Inspection BCS000U6 A/T FLUID TEMPERATURE SENSOR ● ● For removal, refer to AT-345, "Control Valve Assembly and Accumulators" . Check resistance between terminal cord assembly harness connector terminals while changing temperature as shown. Temperature [°C (°F)] Resistance (Approx.) 20 (68) 2.5 kΩ 80 (176) 0.3 kΩ SAT298F AT-240 ENGINE SPEED SIGNAL [EXC.F/EURO-OBD] ENGINE SPEED SIGNAL Description PFP:24825 A BCS000U7 The engine speed signal is sent from the ECM to the TCM. B CONSULT-II Reference Value BCS000U8 Remarks: Specification data are reference values. Item name Condition ENGINE SPEED Display value Engine running Approximately matches the tachometer reading. On Board Diagnosis Logic AT BCS000U9 Diagnostic trouble code “ENGINE SPEED SIG” with CONSULT-II or 9th judgement flicker without CONSULTII is detected when TCM does not receive the proper voltage signal from ECM. Possible Cause BCS000UA D E Harness or connector (Circuit is open or shorted.) DTC Confirmation Procedure BCS000UB CAUTION: ● Always drive vehicle at a safe speed. ● If performing this “DTC Confirmation Procedure” again, always turn ignition switch OFF and wait at least 10 seconds before continuing. After the repair, perform the following procedure to confirm the malfunction is eliminated. F G H WITH CONSULT-II 1. 2. 3. 4. Turn ignition switch ON and select “DATA MONITOR” mode for “A/T” with CONSULT-II. Touch “START”. Start engine and maintain the following conditions for at least 10 consecutive seconds. VEHICLE SPEED: 10 km/h (6 MPH) or more THROTTLE POSI: More than 1.0/8 SLCT LVR POSI: “D” position If the check result is NG, go to AT-243, "Diagnostic Procedure" . I J K BCIA0031E L WITHOUT CONSULT-II 1. 2. 3. 4. Start engine. Drive vehicle under the following conditions for more than 10 seconds. Selector lever position: “D” position Vehicle speed: Higher than 10 km/h (6 MPH) Throttle position: Greater than 1.0/8 of the full throttle position Perform self-diagnosis. Refer to AT-94, "Diagnostic Procedure Without CONSULT-II" . If the check result is NG, go to AT-243, "Diagnostic Procedure" . AT-241 M ENGINE SPEED SIGNAL [EXC.F/EURO-OBD] Wiring Diagram — AT — ENGSS BCS000UC MCWA0244E AT-242 ENGINE SPEED SIGNAL [EXC.F/EURO-OBD] TCM terminal data are reference values, measured between each terminal and ground. Terminal Wire color 39 L Item Condition A Judgement standard (Approx.) Refer to EC-512 . Engine speed signal B and Diagnostic Procedure BCS000UD 1. CHECK DTC WITH ECM AT Check DTC with CONSULT-II “ENGINE”. Turn ignition switch ON and select “SELF-DIAGNOSTIC RESULTS” mode for “ENGINE” with CONSULT-II. Refer to EC-521, "SELF-DIAG RESULTS MODE" . OK or NG OK >> GO TO 2. NG >> Check ignition signal circuit for engine control. Refer to EC-784, "IGNITION SIGNAL" . 2. CHECK INPUT SIGNAL 1. 2. 3. D E F With CONSULT-II Start engine. Select “TCM INPUT SIGNALS” in “DATA MONITOR” mode for “A/T” with CONSULT-II. Read out the value of “ENGINE SPEED”. Check engine speed changes according to throttle position. Item name Condition Display value ENGINE SPEED Engine running Approximately matches the tachometer reading. G H I J SCIA4730E K Without CONSULT-II 1. Start engine. 2. Check voltage between TCM harness connector terminal and ground. Item Connector Terminal Condition Judgement standard (Approx.) Engine speed signal E107 39 Ground and Refer to EC-512 . L M SCIA3265E OK or NG OK >> GO TO 4. NG >> GO TO 3. AT-243 ENGINE SPEED SIGNAL [EXC.F/EURO-OBD] 3. CHECK HARNESS BETWEEN TCM AND ECM 1. 2. 3. Turn ignition switch OFF. Disconnect ECM connector and TCM connector. Check continuity between ECM connector and TCM connector. Item Connector Terminal TCM E107 39 ECM F50 13 Continuity Yes 4. 5. If OK, check harness for short to ground and short to power. If OK, check continuity between body ground and transaxle assembly. 6. Reinstall any part removed. OK or NG OK >> GO TO 4. NG >> Repair open circuit or short to ground or short to power in harness or connectors. 4. CHECK DTC Perform AT-241, "DTC Confirmation Procedure" . OK or NG OK >> INSPECTION END NG >> GO TO 5. 5. CHECK TCM 1. Check TCM input/output signal. Refer to AT-80, "TCM Terminals and Reference Value" . 2. If NG, recheck TCM pin terminals for damage or loose connection with harness connector. OK or NG OK >> INSPECTION END NG >> Repair or replace damaged parts. AT-244 SCIA7173E TURBINE REVOLUTION SENSOR [EXC.F/EURO-OBD] TURBINE REVOLUTION SENSOR Description PFP:31935 A BCS000UE The turbine revolution sensor (power train revolution sensor) detects forward clutch drum rpm (revolutions per minute). It is located on the input side of the automatic transaxle. The vehicle speed sensor A/T (Revolution sensor) is located on the output side of the automatic transaxle. With the two sensors, input and output rpms are accurately detected. As a result, optimal shift timing during deceleration and shift quality can be improved. CONSULT-II Reference Value BCS000UF Remarks: Specification data are reference values. Item name Condition TURBINE REV During driving (lock-up ON) Approximately matches the engine speed. D BCS000UG Diagnostic trouble code “TURBINE SENSOR” with CONSULT-II or 10st judgement flicker without CONSULT-II is detected when TCM does not receive the proper voltage signal from the sensor. Possible Cause ● AT Display value On Board Diagnosis Logic ● B E BCS000UH F Harness or connector (Sensor circuit is open or shorted.) Turbine revolution sensor (power train revolution sensor) DTC Confirmation Procedure G BCS000UI CAUTION: ● Always drive vehicle at a safe speed. ● If performing this “DTC Confirmation Procedure” again, always turn ignition switch OFF and wait at least 10 seconds before continuing. After the repair, perform the following procedure to confirm the malfunction is eliminated. H I WITH CONSULT-II 1. 2. 3. 4. 5. Start engine. Select “DATA MONITOR” mode for “A/T” with CONSULT-II. Touch “START”. Drive vehicle under the following conditions for more than 5 seconds. SLCT LVR POSI: “D” position VEHICLE SPEED: Higher than 40 km/h (25 MPH) ENGINE SPEED: Higher than 1,500 rpm THROTTLE POSI: Greater than 1.0/8 of the full throttle position If the check result is NG, go to AT-247, "Diagnostic Procedure" . J K L M BCIA0031E WITHOUT CONSULT-II 1. 2. 3. 4. Start engine. Drive vehicle under the following conditions for more than 5 seconds. Selector lever position: “D” position Vehicle speed: Higher than 40 km/h (25 MPH) Engine speed: Higher than 1,500 rpm Throttle position: 1.0/8 of the full throttle position Perform self-diagnosis. Refer to AT-94, "Diagnostic Procedure Without CONSULT-II" . If the check result is NG, go to AT-247, "Diagnostic Procedure" . AT-245 TURBINE REVOLUTION SENSOR [EXC.F/EURO-OBD] Wiring Diagram — AT — PT/SEN BCS000UJ MCWA0254E AT-246 TURBINE REVOLUTION SENSOR [EXC.F/EURO-OBD] TCM terminal data are reference values, measured between each terminal and ground. Terminal Wire color 38 LG 42 B Item Condition Turbine revolution sensor (power train revolution sensor) When driving at 20 km/h (12 MPH) Sensor ground Always Judgement standard (Approx.) A B 360 Hz 0V AT Diagnostic Procedure BCS000UK 1. CHECK INPUT SIGNAL D With CONSULT-II 1. Start engine. 2. Select “TCM INPUT SIGNALS” in “DATA MONITOR” mode for “A/T” with CONSULT-II. 3. Read out the value of “TURBINE REV” while driving. Check the value changes according to driving speed. E F Item name Condition Display value TURBINE REV During driving (lock-up ON) Approximately matches the engine speed. G OK or NG OK >> GO TO 8. NG >> GO TO 2. H SCIA4730E 2. 1. 2. CHECK TURBINE REVOLUTION SENSOR I Start engine. Check power supply to turbine revolution sensor (power train revolution sensor) by voltage between TCM connector terminals. Refer to AT-261, "Wiring Diagram — AT — MAIN" and AT-246, "Wiring Diagram — AT — PT/SEN" . J Item Connector TCM E106, E107 Terminal 10 - 42 K Judgement standard (Approx.) Battery voltage L 19 - 42 3. If OK, check the pulse when vehicle cruises. Name Turbine revolution sensor (power train revolution sensor) Condition M When driving at 20 km/h (12 MPH), use the CONSULT-II pulse frequency measuring function.*1 CAUTION: Connect the diagnosis data link cable to the vehicle diagnosis connector. *1: A circuit tester cannot be used to test this item. Item Connector Terminal Name Judgement standard (Approx.) TCM E107 38 Turbine revolution sensor (power train revolution sensor) 360 Hz OK or NG OK >> GO TO 8. NG >> GO TO 3. SCIA4949E AT-247 TURBINE REVOLUTION SENSOR [EXC.F/EURO-OBD] 3. 1. 2. 3. 4. CHECK POWER AND SENSOR GROUND Turn ignition switch OFF. Disconnect the turbine revolution sensor (power train revolution sensor) harness connector. Turn ignition switch ON. Check voltage between turbine revolution sensor (power train revolution sensor) harness connector terminals. Item Connector Terminal Judgement standard (Approx.) Turbine revolution sensor (power train revolution sensor) F11 1-3 Battery voltage SCIA2770E 5. Check voltage between turbine revolution sensor (power train revolution sensor) harness connector terminal and ground. Item Connector Terminal Judgement standard (Approx.) Turbine revolution sensor (power train revolution sensor) F11 1 - ground Battery voltage 6. If OK, check harness for short to ground and short to power. 7. Reinstall any part removed. SCIA2771E OK or NG OK >> GO TO 4. NG - 1 >> Battery voltage is not supplied between terminals 1 and 3, terminals 1 and ground.: GO TO 6. NG - 2 >> Battery voltage is not supplied between terminals 1 and 3 only.: GO TO 7. 4. CHECK HARNESS BETWEEN TCM AND TURBINE REVOLUTION SENSOR (POWER TRAIN REVOLUTION SENSOR) 1. 2. 3. Turn ignition switch OFF. Disconnect the turbine revolution sensor (power train revolution sensor) harness connector. Check continuity between TCM connector terminal and turbine revolution sensor (power train revolution sensor) harness connector terminal. Item Connector Terminal TCM E107 38 Turbine revolution sensor (power train revolution sensor) F11 2 Continuity Yes 4. If OK, check harness for short to ground and short to power. 5. Reinstall any part removed. OK or NG OK >> GO TO 5. NG >> Repair open circuit or short to ground or short to power in harness or connectors. AT-248 SCIA2772E TURBINE REVOLUTION SENSOR [EXC.F/EURO-OBD] 5. CHECK TCM A 1. Check TCM input/output signals. Refer to AT-80, "TCM Terminals and Reference Value" . 2. If NG, re-check TCM pin terminals for damage or loose connection with harness connector. OK or NG OK >> GO TO 8. NG >> Repair or replace damaged parts. B AT 6. CHECK HARNESS BETWEEN TCM AND TURBINE REVOLUTION SENSOR [(POWER TRAIN REVOLUTION SENSOR) POWER] 1. 2. 3. D Turn ignition switch OFF. Disconnect the turbine revolution sensor (power train revolution sensor) harness connector. Check continuity between TCM connector terminals and turbine revolution sensor (power train revolution sensor) harness connector terminal. Refer to AT-52, "Circuit Diagram" and AT-261, "Wiring Diagram — AT — MAIN" . E F Item Connector Terminal TCM E106 10 Turbine revolution sensor (power train revolution sensor) F11 1 TCM E106 19 Turbine revolution sensor (power train revolution sensor) F11 1 Continuity Yes Yes G SCIA2773E 4. If OK, check harness for short to ground and short to power. 5. Reinstall any part removed. OK or NG OK >> 10A fuse (No.58, located in the IPDM E/R) or ignition switch are malfunctioning. NG >> Repair open circuit or short to ground or short to power in harness or connectors. H I J 7. CHECK HARNESS BETWEEN TCM AND TURBINE REVOLUTION SENSOR [(POWER TRAIN REVOLUTION SENSOR) SENSOR GROUND] 1. 2. 3. Turn ignition switch OFF. Disconnect the turbine revolution sensor (power train revolution sensor) harness connector. Check continuity between TCM connector terminal and turbine revolution sensor (power train revolution sensor) harness connector terminal. Item Connector Terminal TCM E107 42 Turbine revolution sensor (power train revolution sensor) F11 3 L M Continuity Yes 4. If OK, check harness for short to ground and short to power. 5. Reinstall any part removed. OK or NG OK >> GO TO 5. NG >> Repair open circuit or short to ground or short to power in harness or connectors. AT-249 K SCIA2774E TURBINE REVOLUTION SENSOR [EXC.F/EURO-OBD] 8. CHECK DTC Perform AT-245, "DTC Confirmation Procedure" . OK or NG OK >> INSPECTION END NG >> GO TO 5. AT-250 LINE PRESSURE SOLENOID VALVE [EXC.F/EURO-OBD] LINE PRESSURE SOLENOID VALVE Description PFP:31940 A BCS000UL The line pressure solenoid valve regulates the oil pump discharge pressure to suit the driving condition in response to signals sent from the TCM. The line pressure duty cycle value is not constant when the closed throttle position switch is ON. To confirm the line pressure duty cycle at low-pressure, the accelerator (throttle) should be open until the closed throttle position switch is OFF. CONSULT-II Reference Value Display value (Approx.) Small throttle opening (Low line pressure) ⇔ Large throttle opening (High line pressure) D 0% ⇔ 94% On Board Diagnosis Logic BCS000UN Diagnostic trouble code “LINE PRESSURE S/V” with CONSULT-II or 11th judgement flicker without CONSULT-II is detected when TCM detects an improper voltage drop while it tries to operate the solenoid valve. Possible Cause ● ● Harness or connector (Solenoid circuit is open or shorted.) Line pressure solenoid valve BCS000UP H I J WITH CONSULT-II 4. F G CAUTION: ● Always drive vehicle at a safe speed. ● If performing this “DTC Confirmation Procedure” again, always turn ignition switch OFF and wait at least 10 seconds before continuing. After the repair, perform the following procedure to confirm the malfunction is eliminated. 2. 3. E BCS000UO DTC Confirmation Procedure 1. AT BCS000UM Remarks: Specification data are reference values. Item name Condition LINE PRES DTY B Turn ignition switch ON and select “DATA MONITOR” mode for “A/T” with CONSULT-II. Touch “START”. Depress accelerator pedal completely and wait at least 1 second. If the check result is NG, go to AT-253, "Diagnostic Procedure" . K L M BCIA0031E WITHOUT CONSULT-II 1. 2. 3. 4. Start engine. With brake pedal depressed, shift the lever from “P” → “N” → “D” → “N” → “P” positions. Perform self-diagnosis. Refer to AT-94, "Diagnostic Procedure Without CONSULT-II" . If the check result is NG, go to AT-253, "Diagnostic Procedure" . AT-251 LINE PRESSURE SOLENOID VALVE [EXC.F/EURO-OBD] Wiring Diagram — AT — LPSV BCS000UQ MCWA0247E AT-252 LINE PRESSURE SOLENOID VALVE [EXC.F/EURO-OBD] TCM terminal data are reference values, measured between each terminal and ground. Terminal 1 2 Wire color Item Condition When releasing accelerator pedal after warming up engine. Line pressure solenoid valve P When depressing accelerator pedal fully after warming up engine. When releasing accelerator pedal after warming up engine. Line pressure solenoid valve (with dropping resistor) V When depressing accelerator pedal fully after warming up engine. Diagnostic Procedure Judgement standard (Approx.) 1.5 - 3.0V A B 0V AT 4 - 14V 0V D BCS000UR 1. CHECK INPUT SIGNAL E With CONSULT-II 1. Turn ignition switch ON. (Do not start engine.) 2. Select “MAIN SIGNALS” in “DATA MONITOR” mode for “A/T” with CONSULT-II. 3. Read out the value of “LINE PRES DTY” while driving. Check the value changes according to driving speed. F G Display value (Approx.) Item name Condition LINE PRES DTY Small throttle opening (Low line pressure) ⇔ Large throttle opening (High line pressure) H 0% ⇔ 94% I SCIA3251E J Without CONSULT-II 1. Turn ignition switch ON. (Do not start engine.) 2. Check voltage between TCM connector terminals and ground. Item Line pressure solenoid valve Line pressure solenoid valve (with dropping resistor) Connector E106 E106 Terminal 1 - Ground 2 - Ground K Condition Judgement standard (Approx.) L When releasing accelerator pedal after warming up engine. 1.5 - 3.0V M When depressing accelerator pedal fully after warming up engine. 0V When releasing accelerator pedal after warming up engine. 4 - 14V When depressing accelerator pedal fully after warming up engine. 0V SCIA3267E OK or NG OK >> GO TO 5. NG >> GO TO 2. AT-253 LINE PRESSURE SOLENOID VALVE [EXC.F/EURO-OBD] 2. CHECK DROPPING RESISTOR 1. 2. 3. Turn ignition switch OFF. Disconnect dropping resistor harness connector in engine room. Check resistance between terminals. Item Dropping resistor Connector Terminal Resistance (Approx.) E58 1-2 12 Ω OK or NG OK >> GO TO 3. NG >> Repair or replace damaged parts. SCIA4950E 3. CHECK VALVE RESISTANCE 1. 2. 3. Turn ignition switch OFF. Disconnect terminal cord assembly connector in engine room. Check resistance between terminal cord assembly harness connector terminal and ground. Solenoid valve Connector Terminal Resistance (Approx.) Line pressure solenoid valve F13 4 - Ground 2.5 - 5.0 Ω OK or NG OK >> GO TO 4. NG >> Repair or replace damaged parts. SCIA4951E AT-254 LINE PRESSURE SOLENOID VALVE [EXC.F/EURO-OBD] 4. 1. 2. 3. CHECK HARNESS BETWEEN TCM AND TERMINAL CORD ASSEMBLY HARNESS CONNECTOR Turn ignition switch OFF. Disconnect terminal cord assembly harness connector and TCM connector. Check continuity between terminal cord assembly harness connector terminal and TCM connector terminal. Item Connector Terminal TCM E106 1 F13 4 Terminal cord assembly harness connector B Continuity AT Yes D SCIA3272E 4. Check continuity between terminal cord assembly harness connector terminal and dropping resistor harness connector terminal. Item Dropping resistor harness connector Terminal cord assembly harness connector A Connector Terminal E106 2 F13 4 E F Continuity G Yes H SCIA7194E I 5. Check continuity between dropping resistor harness connector terminal and TCM connector terminal. Item Connector Terminal TCM E106 2 E58 1 Dropping resistor harness connector J Continuity Yes 6. If OK, check harness for short to ground and short to power. 7. If OK, check continuity between ground and transaxle assembly. 8. Reinstall any part removed. OK or NG OK >> GO TO 5. NG >> Repair open circuit or short to ground or short to power in harness or connectors. 5. CHECK DTC Perform AT-251, "DTC Confirmation Procedure" . OK or NG OK >> INSPECTION END NG >> GO TO 6. 6. CHECK TCM 1. Check TCM input/output signals. Refer to AT-80, "TCM Terminals and Reference Value" . 2. If NG, recheck TCM pin terminals for damage or loose connection with harness connector. OK or NG OK >> INSPECTION END NG >> Repair or replace damaged parts. AT-255 K L SCIA7195E M LINE PRESSURE SOLENOID VALVE [EXC.F/EURO-OBD] Component Inspection BCS000US LINE PRESSURE SOLENOID VALVE ● For removal, refer to AT-345, "Control Valve Assembly and Accumulators" . Resistance Check ● Check resistance between terminal and ground. Solenoid valve Resistance (Approx.) Terminal Line pressure solenoid valve 4 Ground 2.5 - 5 Ω SCIA4951E Operation Check ● Check solenoid valve by listening for its operating sound while applying battery voltage to the terminal and ground. SCIA3275E DROPPING RESISTOR ● Check resistance between terminals. Item Dropping resistor Connector Terminal Resistance (Approx.) E58 1-2 12 Ω SCIA4950E AT-256 CAN COMMUNICATION LINE [EXC.F/EURO-OBD] CAN COMMUNICATION LINE Description PFP:31940 A BCS000UT CAN (Controller Area Network) is a serial communication line for real time application. It is an on-vehicle multiplex communication line with high data communication speed and excellent malfunction detection ability. B Many electronic control units are equipped onto a vehicle, and each control unit shares information and links with other control units during operation (not independent). In CAN communication, control units are connected with 2 communication lines (CAN H line, CAN L line) allowing a high rate of information transmission AT with less wiring. Each control unit transmits/receives data but selectively reads required data only. On Board Diagnosis Logic BCS000UU Diagnostic trouble code “U1000 CAN COMM CIRCUIT” with CONSULT-II or 12th judgement flicker without CONSULT-II is detected when TCM cannot communicate to other control units. Possible Cause BCS000UV D E Harness or connector (CAN communication line is open or shorted.) DTC Confirmation Procedure BCS000UW CAUTION: ● Always drive vehicle at a safe speed. ● If performing this “DTC Confirmation Procedure” again, always turn ignition switch OFF and wait at least 10 seconds before continuing. After the repair, perform the following procedure to confirm the malfunction is eliminated. WITH CONSULT-II 1. 2. 3. 4. 5. Turn ignition switch ON. Select “DATA MONITOR” mode for “A/T” with CONSULT-II. Touch “START”. Wait at least 6 seconds or start engine and wait for at least 6 seconds. If DTC is detected, go to AT-259, "Diagnostic Procedure" . F G H I J K BCIA0031E L WITHOUT CONSULT-II 1. 2. 3. 4. Turn ignition switch ON. Wait at least 6 seconds or start engine and wait at least 6 seconds. Perform self-diagnosis. Refer to AT-94, "Diagnostic Procedure Without CONSULT-II" . If DTC is detected, go to AT-259, "Diagnostic Procedure" . AT-257 M CAN COMMUNICATION LINE [EXC.F/EURO-OBD] Wiring Diagram — AT — CAN BCS000UX MCWA0241E AT-258 CAN COMMUNICATION LINE [EXC.F/EURO-OBD] TCM terminal data are reference values, measured between each terminal and ground. Terminal Wire color Item Condition Judgement standard (Approx.) 5 L CAN H — — 6 Y CAN L — — Diagnostic Procedure A B BCS000UY 1. CHECK CAN COMMUNICATION CIRCUIT AT With CONSULT-II 1. Turn ignition switch ON and start engine. 2. Select “SELF-DIAG RESULTS” mode for “A/T” with CONSULTII. Is any malfunction of the “CAN COMM CIRCUIT” indicated? YES >> Print out CONSULT-II screen, GO TO LAN section. Refer to LAN-3, "Precautions When Using CONSULT-II" . NO >> INSPECTION END D E F G SCIA7135E H I J K L M AT-259 MAIN POWER SUPPLY AND GROUND CIRCUIT [EXC.F/EURO-OBD] MAIN POWER SUPPLY AND GROUND CIRCUIT Description PFP:00100 BCS000UZ When the power supply to the TCM is cut “OFF”, for example because the battery is removed, and the selfdiagnostics memory function stops, malfunction is detected. On Board Diagnosis Logic ● ● BCS000V0 Diagnostic trouble code “INITIAL START” with CONSULT-II is detected when TCM does not receive the voltage signal from the battery power supply. This is not a malfunction message. (Whenever shutting “OFF” a power supply to the TCM, this message appears on the screen.) Possible Cause BCS000V1 Harness or connector (Battery or ignition switch and TCM circuit is open or shorted.) DTC Confirmation Procedure BCS000V2 CAUTION: If performing this “DTC Confirmation Procedure” again, always turn ignition switch OFF and wait at least 10 seconds before continuing. After the repair, perform the following procedure to confirm the malfunction is eliminated. WITH CONSULT-II 1. 2. 3. 4. 5. Turn ignition switch ON. (Do not start engine.) Select “DATA MONITOR” mode for “A/T” with CONSULT-II. Touch “START”. Wait for at least 2 consecutive seconds. If DTC is detected, go to AT-262, "Diagnostic Procedure" . BCIA0031E AT-260 MAIN POWER SUPPLY AND GROUND CIRCUIT [EXC.F/EURO-OBD] Wiring Diagram — AT — MAIN BCS000V3 A B AT D E F G H I J K L M MCWA0255E AT-261 MAIN POWER SUPPLY AND GROUND CIRCUIT [EXC.F/EURO-OBD] TCM terminal data are reference values, measured between each terminal and ground. Condition Judgement standard (Approx.) Terminal Wire color Item 10 R Power supply 19 R Power supply 25 B Ground Always 0V 28 LG Power supply (memory back-up) Always Battery voltage 48 B Ground Always 0V or When turning ignition switch to “ON”. Battery voltage When turning ignition switch to “OFF”. 0V When turning ignition switch to “ON”. Battery voltage When turning ignition switch to “OFF”. 0V Diagnostic Procedure BCS000V4 1. CHECK TCM POWER SOURCE 1. 2. Turn ignition switch ON. (Do not start engine.) Check voltage between TCM connector terminals and ground. Name Connector Power supply E106 Power supply (memory back-up) E107 Terminal Judgement standard (Approx.) 10 Battery voltage 19 Battery voltage 28 Battery voltage SCIA2656E 3. 4. Turn ignition switch OFF. Check voltage between TCM connector terminals and ground. Name Connector Power supply E106 Power supply (memory back-up) E107 Terminal Judgement standard (Approx.) 10 0V 19 0V 28 Battery voltage OK or NG OK >> GO TO 3. NG >> GO TO 2. SCIA2657E 2. DETECT MALFUNCTIONING ITEM Check the following items: Harness for short or open between ignition switch and TCM terminals 10, 19 ● Harness for short or open between battery and TCM terminal 28 ● 10A fuse (No.7, located in the fuse block) and 10A fuse (No.58, located in the IPDM E/R) ● Ignition switch. Refer to PG-38, "GROUND" . OK or NG OK >> GO TO 3. NG >> Repair or replace damaged parts. ● AT-262 MAIN POWER SUPPLY AND GROUND CIRCUIT [EXC.F/EURO-OBD] 3. CHECK TCM GROUND CIRCUIT 1. 2. A Turn ignition switch OFF. Check continuity between TCM connector terminals and ground. B Item Connector Terminal Continuity Ground E107 25, 48 - Ground Yes AT OK or NG OK >> GO TO 4. NG >> Repair open circuit or short to ground or short to power in harness or connectors. D SCIA2671E E 4. CHECK DTC Perform AT-260, "DTC Confirmation Procedure" . OK or NG OK >> INSPECTION END NG >> GO TO 5. F G 5. CHECK TCM 1. Check TCM input/output signals. Refer to AT-80, "TCM Terminals and Reference Value" . 2. If NG, recheck TCM pin terminals for damage or loose connection with harness connector. OK or NG OK >> INSPECTION END NG >> Repair or replace damaged parts. H I J K L M AT-263 A/T 1ST GEAR FUNCTION [EXC.F/EURO-OBD] A/T 1ST GEAR FUNCTION Description ● ● PFP:31940 BCS000V5 This malfunction will not be detected while the OD OFF indicator lamp is indicating another self-diagnosis malfunction. This malfunction is detected when the A/T does not shift into first gear position as instructed by the TCM. This is not caused by electrical malfunction (circuits open or shorted) but by mechanical malfunction such as control valve sticking, improper solenoid valve operation, etc. Gear position 1 2 3 4 Shift solenoid valve A ON (Closed) OFF (Open) OFF (Open) ON (Closed) Shift solenoid valve B ON (Closed) ON (Closed) OFF (Open) OFF (Open) On Board Diagnosis Logic ● ● ● BCS000V6 Diagnostic trouble code “A/T 1ST GR FNCTN” with CONSULT-II is detected when A/T cannot be shifted to the 1st gear position even if electrical circuit is good. This diagnosis monitors actual gear position by checking the torque converter slip ratio calculated by TCM as follows: Torque converter slip ratio = A x C/B A: Output shaft revolution signal from revolution sensor B: Engine speed signal from ECM C: Gear ratio determined as gear position which TCM supposes If the actual gear position is higher than the position (1st) supposed by TCM, the slip ratio will be more than normal. In case the ratio exceeds the specified value, TCM judges this diagnosis malfunction. This malfunction will be caused when either shift solenoid valve A is stuck open or shift solenoid valve B is stuck open. Gear positions supposed by TCM are as follows: In case of gear position with no malfunctions: 1 , 2, 3 and 4 positions In case of gear position with shift solenoid valve A stuck open: 2* , 2, 3 and 3 positions In case of gear position with shift solenoid valve B stuck open: 4* , 3, 3 and 4 positions to each gear position above *: “A/T 1ST GR FNCTN” is detected. Possible Cause ● ● ● ● BCS000V7 Shift solenoid valve A Shift solenoid valve B Each clutch Hydraulic control circuit AT-264 A/T 1ST GEAR FUNCTION [EXC.F/EURO-OBD] DTC Confirmation Procedure BCS000V8 CAUTION: ● Always drive vehicle at a safe speed. ● If performing this “DTC Confirmation Procedure” again, always turn ignition switch OFF and wait at least 10 seconds before continuing. After the repair, perform the following procedure to confirm the malfunction is eliminated. WITH CONSULT-II 1. 2. 3. 4. 5. – 6. – – 7. 8. Gear on actual transmission shift pattern when screen is changed to 1 → 2 → 3 → 4 D E F G H I J K L 1→2→3→4 No malfunction exists. 2→2→3→3 Malfunction for “A/T 1ST GR FNCTN ” exists. 9. B AT Start engine and select “DATA MONITOR” mode for “A/T” with CONSULT-II. Touch “START”. Make sure that output voltage of A/T fluid temperature sensor is within the range below. FLUID TEMP SE: 0.4 - 1.5V If out of range, drive the vehicle to decrease the voltage (warm up the fluid) or stop engine to increase the voltage (cool down the fluid). Select “1ST GR FNCTN P0731” of “DTC WORK SUPPORT” BCIA0031E mode for “A/T” with CONSULT-II and touch “START”. Accelerate vehicle to 20 to 25 km/h (12 to 16 MPH) under the following conditions and release the accelerator pedal completely. THROTTLE POSI: Less than 1.0/8 (at all times during step 4) SLCT LVR POSI: “D” position Make sure that “GEAR” shows “2” after releasing pedal. Depress accelerator pedal to WOT (more than 7.0/8 of “THROTTLE POSI”) quickly from a speed of 20 to 25 km/h (12 to 16 MPH) until “TESTING” changes to “STOP VEHICLE” or “COMPLETED”. (It will take approximately 3 seconds.) If the check result NG appears on CONSULT-II screen, go to AT-266, "Diagnostic Procedure" . If “STOP VEHICLE” appears on CONSULT-II screen, go to the following step. Make sure that “GEAR” shows “1” when depressing accelerator pedal to WOT. If “TESTING” does not appear on CONSULT-II for a long time, select “SELF-DIAG RESULTS” for “A/T”. In case a DTC other than “A/T 1ST GR FNCTN” is shown, refer to AT-86, "Display Items List (Except for EURO-OBD models)" . Stop vehicle. Follow the instruction displayed. (Check for normal shifting referring to the table below.) Vehicle condition A 4→3→3→4 Make sure that “OK” is displayed. (If “NG” is displayed, refer to “Diagnostic Procedure”.) Refer to AT-266, "Diagnostic Procedure" . Refer to AT-67, "Vehicle Speed at Which Gear Shifting Occurs" . AT-265 M A/T 1ST GEAR FUNCTION [EXC.F/EURO-OBD] Diagnostic Procedure BCS000V9 1. CHECK VALVE RESISTANCE 1. – – 2. Remove control valve assembly. Refer to AT-345, "Control Valve Assembly and Accumulators" . Shift solenoid valve A Shift solenoid valve B Check resistance between terminal cord assembly harness connector terminals and ground. Refer to AT-216, "Wiring Diagram — AT — SSV/A" and AT-221, "Wiring Diagram — AT — SSV/B" . Solenoid valve Shift solenoid valve A Shift solenoid valve B Terminal 2 1 Ground Resistance (Approx.) 20 - 30 Ω 5 - 20 Ω OK or NG OK >> GO TO 2. NG >> Repair or replace damaged parts. SCIA3594E 2. CHECK VALVE OPERATION Remove control valve assembly. Refer to AT-345, "Control Valve Assembly and Accumulators" . – Shift solenoid valve A – Shift solenoid valve B 2. Check solenoid valve by listening for its operating sound while applying battery voltage to the terminals and ground. Refer to AT-216, "Wiring Diagram — AT — SSV/A" and AT-221, "Wiring Diagram — AT — SSV/B" . OK or NG OK >> GO TO 3. NG >> Repair or replace shift solenoid valve assembly. 1. SCIA3595E AT-266 A/T 1ST GEAR FUNCTION [EXC.F/EURO-OBD] 3. CHECK CONTROL VALVE A Disassemble control valve assembly. Refer to AT-392, "Control Valve Assembly" . Check to ensure that: – Valve, sleeve and plug slide along valve bore under their own weight. – Valve, sleeve and plug are free from burrs, dents and scratches. – Control valve springs are free from damage, deformation and fatigue. – Hydraulic line is free from obstacles. OK or NG OK >> GO TO 4. NG >> Repair control valve assembly. 1. 2. 4. CHECK DTC B AT D E Perform AT-265, "DTC Confirmation Procedure" . OK or NG OK >> INSPECTION END NG >> Check control valve again. Repair or replace control valve assembly. F G H I J K L M AT-267 A/T 2ND GEAR FUNCTION [EXC.F/EURO-OBD] A/T 2ND GEAR FUNCTION Description ● ● PFP:31940 BCS000VA This malfunction will not be detected while the OD OFF indicator lamp is indicating another self-diagnosis malfunction. This malfunction is detected when the A/T does not shift into second gear position as instructed by the TCM. This is not caused by electrical malfunction (circuits open or shorted) but by mechanical malfunction such as control valve sticking, improper solenoid valve operation, etc. Gear position 1 2 3 4 Shift solenoid valve A ON (Closed) OFF (Open) OFF (Open) ON (Closed) Shift solenoid valve B ON (Closed) ON (Closed) OFF (Open) OFF (Open) On Board Diagnosis Logic ● ● ● BCS000VB Diagnostic trouble code “A/T 2ND GR FNCTN” with CONSULT-II is detected when A/T cannot be shifted to the 2nd gear position even if electrical circuit is good. This diagnosis monitors actual gear position by checking the torque converter slip ratio calculated by TCM as follows: Torque converter slip ratio = A x C/B A: Output shaft revolution signal from revolution sensor B: Engine speed signal from ECM C: Gear ratio determined as gear position which TCM supposes If the actual gear position is higher than the position (2nd) supposed by TCM, the slip ratio will be more than normal. In case the ratio exceeds the specified value, TCM judges this diagnosis malfunction. This malfunction will be caused when shift solenoid valve B is stuck open. Gear positions supposed by TCM are as follows: In case of gear position with no malfunctions: 1, 2 , 3 and 4 positions In case of gear position with shift solenoid valve B stuck open: 4, 3* , 3 and 4 positions to each gear position above *: “A/T 2ND GR FNCTN” is detected. Possible Cause ● ● ● BCS000VC Shift solenoid valve B Each clutch Hydraulic control circuit AT-268 A/T 2ND GEAR FUNCTION [EXC.F/EURO-OBD] DTC Confirmation Procedure BCS000VD CAUTION: ● Always drive vehicle at a safe speed. ● If performing this “DTC Confirmation Procedure” again, always turn ignition switch OFF and wait at least 10 seconds before continuing. After the repair, perform the following procedure to confirm the malfunction is eliminated. WITH CONSULT-II 1. 2. 3. 4. 5. – 6. – – 7. 8. Gear on actual transmission shift pattern when screen is changed to 1 → 2 → 3 → 4 No malfunction exists 1→2→3→4 Malfunction for “A/T 2ND GR FNCTN” exists. 4→3→3→4 9. B AT Start engine and select “DATA MONITOR” mode for “A/T” with CONSULT-II. Touch “START”. Make sure that output voltage of A/T fluid temperature sensor is within the range below. FLUID TEMP SE: 0.4 - 1.5V If out of range, drive the vehicle to decrease the voltage (warm up the fluid) or stop engine to increase the voltage (cool down the fluid). Select “2ND GR FNCTN P0732” of “DTC WORK SUPPORT” BCIA0031E mode for “A/T” with CONSULT-II and touch “START”. Accelerate vehicle to 45 to 50 km/h (28 to 31 MPH) under the following conditions and release the accelerator pedal completely. THROTTLE POSI: Less than 1.0/8 SLCT LVR POSI: “D” position Make sure that “GEAR” shows “3” or “4” after releasing pedal. Depress accelerator pedal to WOT (more than 7.0/8 of “THROTTLE POSI”) quickly from a speed of 45 to 50 km/h (28 to 31 MPH) until “TESTING” changes to “STOP VEHICLE” or “COMPLETE”. (It will take approximately 3 seconds.) If the check result NG appears on CONSULT-II screen, go to AT-270, "Diagnostic Procedure" . If “STOP VEHICLE” appears on CONSULT-II screen, go to following step. Make sure that “GEAR” shows “2” when depressing accelerator pedal to WOT. If “TESTING” does not appear on CONSULT-II for a long time, select “SELF-DIAG RESULTS” for “A/T”. In case a DTC other than “A/T 2ND GR FNCTN” is shown, refer to AT-86, "Display Items List (Except for EURO-OBD models)" . Stop vehicle. Follow the instruction displayed. (Check for normal shifting referring to the table below.) Vehicle condition A Make sure that “OK” is displayed. (If “NG” is displayed, refer to “Diagnostic Procedure”.) Refer to AT-270, "Diagnostic Procedure" . Refer to AT-67, "Vehicle Speed at Which Gear Shifting Occurs" . AT-269 D E F G H I J K L M A/T 2ND GEAR FUNCTION [EXC.F/EURO-OBD] Diagnostic Procedure BCS000VE 1. CHECK VALVE RESISTANCE 1. – 2. Remove control valve assembly. Refer to AT-345, "Control Valve Assembly and Accumulators" . Shift solenoid valve B Check resistance between terminal cord assembly harness connector terminal and ground. Refer to AT-221, "Wiring Diagram — AT — SSV/B" . Solenoid valve Shift solenoid valve B Terminal 1 Ground Resistance (Approx.) 5 - 20 Ω OK or NG OK >> GO TO 2. NG >> Repair or replace shift solenoid valve assembly. SCIA2055E 2. CHECK VALVE OPERATION Remove control valve assembly. Refer to AT-345, "Control Valve Assembly and Accumulators" . – Shift solenoid valve B 2. Check solenoid valve by listening for its operating sound while applying battery voltage to the terminal and ground. Refer to AT221, "Wiring Diagram — AT — SSV/B" . OK or NG OK >> GO TO 3. NG >> Repair or replace shift solenoid valve assembly. 1. SCIA2058E 3. CHECK CONTROL VALVE Disassemble control valve assembly. Refer to AT-392, "Control Valve Assembly" . Check to ensure that: – Valve, sleeve and plug slide along valve bore under their own weight. – Valve, sleeve and plug are free from burrs, dents and scratches. – Control valve springs are free from damage, deformation and fatigue. – Hydraulic line is free from obstacles. OK or NG OK >> GO TO 4. NG >> Repair control valve assembly. 1. 2. 4. CHECK DTC Perform AT-269, "DTC Confirmation Procedure" . OK or NG OK >> INSPECTION END NG >> Check control valve again. Repair or replace control valve assembly. AT-270 A/T 3RD GEAR FUNCTION [EXC.F/EURO-OBD] A/T 3RD GEAR FUNCTION Description ● ● PFP:31940 A BCS000VF This malfunction will not be detected while the OD OFF indicator lamp is indicating another self-diagnosis malfunction. B This malfunction is detected when the A/T does not shift into third gear position as instructed by the TCM. This is not caused by electrical malfunction (circuits open or shorted) but by mechanical malfunction such as control valve sticking, improper solenoid valve operation, malfunctioning servo piston or brake band, AT etc. Gear position 1 2 3 4 Shift solenoid valve A ON (Closed) OFF (Open) OFF (Open) ON (Closed) Shift solenoid valve B ON (Closed) ON (Closed) OFF (Open) OFF (Open) On Board Diagnosis Logic ● ● ● BCS000VG Diagnostic trouble code “A/T 3RD GR FNCTN” with CONSULT-II is detected when A/T cannot be shifted to the 3rd gear position even if electrical circuit is good. This diagnosis monitors actual gear position by checking the torque converter slip ratio calculated by TCM as follows: Torque converter slip ratio = A x C/B A: Output shaft revolution signal from revolution sensor B: Engine speed signal from ECM C: Gear ratio determined as gear position which TCM supposes If the actual gear position is higher than the position (3rd) supposed by TCM, the slip ratio will be more than normal. In case the ratio exceeds the specified value, TCM judges this diagnosis malfunction. This malfunction will be caused when shift solenoid valve A is stuck closed. Gear positions supposed by TCM are as follows. In case of gear position with no malfunctions: 1, 2, 3 and 4 positions In case of gear position with shift solenoid valve A stuck closed: 1, 1, 4* and 4 positions to each gear position above *: “A/T 3RD GR FNCTN” is detected. Possible Cause ● ● ● D E F G H I J BCS000VH Shift solenoid valve A Each clutch Hydraulic control circuit K L M AT-271 A/T 3RD GEAR FUNCTION [EXC.F/EURO-OBD] DTC Confirmation Procedure BCS000VI CAUTION: ● Always drive vehicle at a safe speed. ● If performing this “DTC Confirmation Procedure” again, always turn ignition switch OFF and wait at least 10 seconds before continuing. After the repair, perform the following procedure to confirm the malfunction is eliminated. WITH CONSULT-II 1. 2. 3. 4. 5. – 6. – – 7. 8. Start engine and select “DATA MONITOR” mode for “A/T” with CONSULT-II. Touch “START”. Make sure that output voltage of A/T fluid temperature sensor is within the range below. FLUID TEMP SE: 0.4 - 1.5V If out of range, drive the vehicle to decrease the voltage (warm up the fluid) or stop engine to increase the voltage (cool down the fluid). Select “3RD GR FNCTN P0733” of “DTC WORK SUPPORT” BCIA0031E mode for “A/T” with CONSULT-II and touch “START”. Accelerate vehicle to 60 to 75 km/h (37 to 47 MPH) under the following conditions and release the accelerator pedal completely. THROTTLE POSI: Less than 1.0/8 (at all times during step 4) SLCT LVR POSI: “D” position Make sure that “GEAR” shows “4” after releasing pedal. Depress accelerator pedal steadily with 3.5/8 - 4.5/8 of “THROTTLE POSI” from a speed of 60 to 75 km/h (37 to 47 MPH) until “TESTING” changes to “STOP VEHICLE” or “COMPLETED”. (It will take approximately 3 seconds.) If the check result NG appears on CONSULT-II screen, go to AT-273, "Diagnostic Procedure" . If “STOP VEHICLE” appears on CONSULT-II screen, go to following step. Make sure that “GEAR” shows “3” when depressing accelerator pedal with 3.5/8 - 4.5/8 of “THROTTLE POSI”. If “TESTING” does not appear on CONSULT-II for a long time, select “SELF-DIAG RESULTS” for “A/T”. In case a DTC other than “A/T 3RD GR FNCTN” is shown, refer to AT-86, "Display Items List (Except for EURO-OBD models)" . Stop vehicle. Follow the instruction displayed. (Check for normal shifting referring to the table below.) Vehicle condition Gear on actual transmission shift pattern when screen is changed to 1 → 2 → 3 → 4 No malfunction exists. 1→2→3→4 Malfunction for “A/T 3RD GR FNCTN” exists. 1→1→4→4 9. Make sure that “OK” is displayed. (If “NG” is displayed, refer to “Diagnostic Procedure”.) Refer to AT-273, "Diagnostic Procedure" . Refer to AT-67, "Vehicle Speed at Which Gear Shifting Occurs" . AT-272 A/T 3RD GEAR FUNCTION [EXC.F/EURO-OBD] Diagnostic Procedure BCS000VJ 1. CHECK VALVE RESISTANCE 1. – – 2. A Remove control valve assembly. Refer to AT-345, "Control Valve Assembly and Accumulators" . Shift solenoid valve A Shift solenoid valve B Check resistance between terminal cord assembly harness connector terminals and ground. Refer to AT-216, "Wiring Diagram — AT — SSV/A" and AT-221, "Wiring Diagram — AT — SSV/B" . Solenoid valve Shift solenoid valve A Shift solenoid valve B Terminal 2 1 Ground B AT D Resistance (Approx.) 20 - 30 Ω E 5 - 20 Ω OK or NG OK >> GO TO 2. NG >> Repair or replace shift solenoid valve assembly. F G H I SCIA3594E 2. CHECK VALVE OPERATION J Remove control valve assembly. Refer to AT-345, "Control Valve Assembly and Accumulators" . – Shift solenoid valve A – Shift solenoid valve B 2. Check solenoid valve by listening for its operating sound while applying battery voltage to the terminals and ground. Refer to AT-216, "Wiring Diagram — AT — SSV/A" and AT-221, "Wiring Diagram — AT — SSV/B" . OK or NG OK >> GO TO 3. NG >> Repair or replace shift solenoid valve assembly. 1. K L M SCIA3595E AT-273 A/T 3RD GEAR FUNCTION [EXC.F/EURO-OBD] 3. CHECK CONTROL VALVE Disassemble control valve assembly. Refer to AT-392, "Control Valve Assembly" . Check to ensure that: – Valve, sleeve and plug slide along valve bore under their own weight. – Valve, sleeve and plug are free from burrs, dents and scratches. – Control valve springs are free from damage, deformation and fatigue. – Hydraulic line is free from obstacles. OK or NG OK >> GO TO 4. NG >> Repair control valve assembly. 1. 2. 4. CHECK DTC Perform AT-272, "DTC Confirmation Procedure" . OK or NG OK >> INSPECTION END NG >> Check control valve again. Repair or replace control valve assembly. AT-274 A/T 4TH GEAR FUNCTION [EXC.F/EURO-OBD] A/T 4TH GEAR FUNCTION Description ● ● PFP:31940 A BCS000VK This malfunction will not be detected while the OD OFF indicator lamp is indicating another self-diagnosis malfunction. B This malfunction is detected when the A/T does not shift into fourth gear position or the torque converter clutch does not lock up as instructed by the TCM. This is not caused by electrical malfunction (circuits open or shorted) but by mechanical malfunction such as control valve sticking, improper solenoid valve AT operation, malfunctioning oil pump or torque converter clutch, etc. Gear position 1 2 3 4 Shift solenoid valve A ON (Closed) OFF (Open) OFF (Open) ON (Closed) Shift solenoid valve B ON (Closed) ON (Closed) OFF (Open) OFF (Open) CONSULT-II REFERENCE VALUE IN DATA MONITOR MODE Remarks: Specification data are reference values. Item name Condition LINE PRES DTY ● ● ● ● ● ● 0% ⇔ 94% F BCS000VL Diagnostic trouble code “A/T 4TH GR FNCTN” with CONSULT-II is detected when A/T cannot be shifted to the 4th gear position even if electrical circuit is good. This diagnosis monitors actual gear position by checking the torque converter slip ratio calculated by TCM as follows: Torque converter slip ratio = A x C/B A: Output shaft revolution signal from revolution sensor B: Engine speed signal from ECM C: Gear ratio determined as gear position which TCM supposes If the actual gear position is much lower than the position (4th) supposed by TCM, the slip ratio will be much less than normal. In case the ratio does not reach the specified value, TCM judges this diagnosis malfunction. This malfunction will be caused when shift solenoid valve B is stuck closed. Gear positions supposed by TCM are as follows. In case of gear position with no malfunctions: 1, 2, 3 and 4 positions In case of gear position with shift solenoid valve A stuck open: 2, 2, 3 and 3* positions In case of gear position with shift solenoid valve B stuck closed: 1, 2, 2 and 1* positions to each gear position above *: “A/T 4TH GR FNCTN” is detected. Possible Cause ● E Display value (Approx.) Small throttle opening (Low line pressure) ⇔ Large throttle opening (High line pressure) On Board Diagnosis Logic ● D G H I J K L BCS000VM M Shift solenoid valve A Shift solenoid valve B Line pressure solenoid valve Each clutch Hydraulic control circuit AT-275 A/T 4TH GEAR FUNCTION [EXC.F/EURO-OBD] DTC Confirmation Procedure BCS000VN CAUTION: ● Always drive vehicle at a safe speed. ● If performing this “DTC Confirmation Procedure” again, always turn ignition switch OFF and wait at least 10 seconds before continuing. After the repair, perform the following procedure to confirm the malfunction is eliminated. WITH CONSULT-II 1. 2. 3. 4. 5. – 6. – – 7. 8. Start engine and select “DATA MONITOR” mode for “A/T” with CONSULT-II. Touch “START”. Make sure that output voltage of A/T fluid temperature sensor is within the range below. FLUID TEMP SE: 0.4 - 1.5V If out of range, drive the vehicle to decrease the voltage (warm up the fluid) or stop engine to increase the voltage (cool down the fluid). Select “4TH GR FNCTN P0734” of “DTC WORK SUPPORT” BCIA0031E mode for “A/T” with CONSULT-II and touch “START”. Accelerate vehicle to 55 to 65 km/h (34 to 40 MPH) under the following conditions and release the accelerator pedal completely. THROTTLE POSI: Less than 5.5/8 (at all times during step 4) SLCT LVR POSI: “D” position Make sure that “GEAR” shows “3” after releasing pedal. Depress accelerator pedal steadily with 1.0/8 - 2.0/8 of “THROTTLE POSI” from a speed of 55 to 65 km/h (34 to 40 MPH) until “TESTING” has turned to “STOP VEHICLE” or “COMPLETED”. (It will take approximately 3 seconds.) If the check result NG appears on CONSULT-II screen, go to AT-277, "Diagnostic Procedure" . If “STOP VEHICLE” appears on CONSULT-II screen, go to following step. Make sure that “GEAR” shows “4” when depressing accelerator pedal with 1.0/8 - 2.0/8 of “THROTTLE POSI”. If “TESTING” does not appear on CONSULT-II for a long time, select “SELF-DIAG RESULTS” for “A/T”. In case a DTC other than “A/T 4TH GR FNCTN” is shown, refer to AT-86, "Display Items List (Except for EURO-OBD models)" . Stop vehicle. Follow the instruction displayed. (Check for normal shifting referring to the table below.) Vehicle condition Gear on actual transmission shift pattern when screen is changed to 1 → 2 → 3 → 4 1→2→3→4 No malfunction exists 2→2→3→3 Malfunction for “A/T 4TH GR FNCTN” exists. 9. 1→2→2→1 Make sure that “OK” is displayed. (If “NG” is displayed, refer to “Diagnostic Procedure”.) Refer to AT-277, "Diagnostic Procedure" . Refer to AT-67, "Vehicle Speed at Which Gear Shifting Occurs" . AT-276 A/T 4TH GEAR FUNCTION [EXC.F/EURO-OBD] Diagnostic Procedure 1. CHECK SHIFT-UP (D3 BCS000VO A TO D4 ) During AT-61, "Cruise Test — Part 1" . Does A/T shift from D3 to D4 at the specified speed? YES >> GO TO 11. NO >> GO TO 2. B AT D SCIA7190E E 2. CHECK LINE PRESSURE Perform line pressure test. Refer to AT-56, "LINE PRESSURE TEST" . OK or NG OK >> GO TO 3. NG >> GO TO 7. F G 3. CHECK VALVE RESISTANCE 1. – – 2. Remove control valve assembly. Refer to AT-345, "Control Valve Assembly and Accumulators" . Shift solenoid valve A Shift solenoid valve B Check resistance between terminal cord assembly harness connector terminals and ground. Refer to AT-216, "Wiring Diagram — AT — SSV/A" and AT-221, "Wiring Diagram — AT — SSV/B" . Solenoid valve Shift solenoid valve A Shift solenoid valve B Terminal 2 1 Ground H I J Resistance (Approx.) K 20 - 30 Ω 5 - 20 Ω OK or NG OK >> GO TO 4. NG >> Replace solenoid valve assembly. L M SCIA3594E AT-277 A/T 4TH GEAR FUNCTION [EXC.F/EURO-OBD] 4. CHECK VALVE OPERATION Remove control valve assembly. Refer to AT-345, "Control Valve Assembly and Accumulators" . – Shift solenoid valve A – Shift solenoid valve B 2. Check solenoid valve by listening for its operating sound while applying battery voltage to the terminals and ground. Refer to AT-216, "Wiring Diagram — AT — SSV/A" and AT-221, "Wiring Diagram — AT — SSV/B" . OK or NG OK >> GO TO 5. NG >> Replace solenoid valve assembly. 1. SCIA3595E 5. CHECK CONTROL VALVE Disassemble control valve assembly. Refer to AT-392, "Control Valve Assembly" . Check to ensure that: – Valve, sleeve and plug slide along valve bore under their own weight. – Valve, sleeve and plug are free from burrs, dents and scratches. – Control valve springs are free from damage, deformation and fatigue. – Hydraulic line is free from obstacles. OK or NG OK >> GO TO 6. NG >> Repair control valve. 1. 2. 6. CHECK SHIFT-UP (D3 TO D4 ) During AT-61, "Cruise Test — Part 1" . Does A/T shift from D3 to D4 at the specified speed? YES >> GO TO 11. NO >> Check control valve again. Repair or replace control valve assembly. SCIA7190E AT-278 A/T 4TH GEAR FUNCTION [EXC.F/EURO-OBD] 7. CHECK VALVE RESISTANCE 1. – 2. A Remove control valve assembly. Refer to AT-345, "Control Valve Assembly and Accumulators" . Line pressure solenoid valves Check resistance between terminal cord assembly harness connector terminal and ground. Refer to AT-252, "Wiring Diagram — AT — LPSV" . Solenoid valve Line pressure solenoid valve Terminal 4 Ground B AT Resistance (Approx.) 2.5 - 5 Ω D OK or NG OK >> GO TO 8. NG >> Replace solenoid valve assembly. SCIA4951E E 8. CHECK VALVE OPERATION F Remove control valve assembly. Refer to AT-345, "Control Valve Assembly and Accumulators" . – Line pressure solenoid valves 2. Check solenoid valve by listening for its operating sound while applying battery voltage to the terminal and ground. Refer to AT252, "Wiring Diagram — AT — LPSV" . OK or NG OK >> GO TO 9. NG >> Replace solenoid valve assembly. 1. G H I SCIA3275E J 9. CHECK CONTROL VALVE K Disassemble control valve assembly. Refer to AT-392, "Control Valve Assembly" . Check line pressure circuit valves for sticking. – Pilot valve – Shift solenoid valve A – Shift solenoid valve B OK or NG OK >> GO TO 10. NG >> Repair or replace control valve. 1. 2. 10. CHECK SHIFT-UP (D3 L M TO D4 ) During AT-61, "Cruise Test — Part 1" . Does A/T shift from D3 to D4 at the specified speed? YES >> GO TO 11. NO >> Check control valve again. Repair or replace control valve assembly. SCIA7190E AT-279 A/T 4TH GEAR FUNCTION [EXC.F/EURO-OBD] 11. CHECK DTC Perform AT-276, "DTC Confirmation Procedure" . OK or NG OK >> INSPECTION END NG >> Perform AT-61, "Cruise Test — Part 1" again and return to the start point of this test group. AT-280 A/T TCC S/V FUNCTION (LOCK-UP) [EXC.F/EURO-OBD] A/T TCC S/V FUNCTION (LOCK-UP) Description ● ● PFP:31940 A BCS000VP This malfunction will not be detected while the OD OFF indicator lamp is indicating another self-diagnosis malfunction. B This malfunction is detected when the A/T does not shift into fourth gear position or the torque converter clutch does not lock-up as instructed by the TCM. This is not caused by electrical malfunction (circuits open or shorted) but by mechanical malfunction such as control valve sticking, improper solenoid valve AT operation, malfunctioning oil pump or torque converter clutch, etc. CONSULT-II Reference Value BCS000VQ D Remarks: Specification data are reference values. Item name Condition TCC S/V DUTY Display value (Approx.) Lock-up OFF ⇔ Lock-up ON 4% ⇔ 94% E On Board Diagnosis Logic ● ● ● BCS000VR Diagnostic trouble code “A/T TCC S/V FNCTN” with CONSULT-II is detected when A/T cannot perform lock-up even if electrical circuit is good. This diagnosis monitors actual gear position by checking the torque converter slip ratio calculated by TCM as follows: Torque converter slip ratio = A x C/B A: Output shaft revolution signal from revolution sensor B: Engine speed signal from ECM C: Gear ratio determined as gear position which TCM supposes If the actual gear position is much lower than the position (4th) supposed by TCM, the slip ratio will be much less than normal. In case the ratio does not reach the specified value, TCM judges this diagnosis malfunction. This malfunction will be caused when shift solenoid valve B is stuck closed. Gear positions supposed by TCM are as follows. In case of gear position with no malfunctions: 1, 2, 3 and 4 positions In case of gear position with shift solenoid valve B stuck closed: 1, 2, 2 and 1* positions to each gear position above *: “A/T TCC S/V FNCTN” is detected. Possible Cause ● ● ● ● BCS000VS Line pressure solenoid valve Torque converter clutch solenoid valve Each clutch Hydraulic control circuit F G H I J K L M AT-281 A/T TCC S/V FUNCTION (LOCK-UP) [EXC.F/EURO-OBD] DTC Confirmation Procedure BCS000VT CAUTION: ● Always drive vehicle at a safe speed. ● If performing this “DTC Confirmation Procedure” again, always turn ignition switch OFF and wait at least 10 seconds before continuing. After the repair, perform the following procedure to confirm the malfunction is eliminated. WITH CONSULT-II 1. 2. 3. 4. 5. – – – 6. Start engine and select “DATA MONITOR” mode for “A/T” with CONSULT-II. Touch “START”. Make sure that output voltage of A/T fluid temperature sensor is within the range below. FLUID TEMP SE: 0.4 - 1.5V If out of range, drive vehicle to decrease voltage (warm up the fluid) or stop engine to increase voltage (cool down the fluid). Select “TCC S/V FNCTN P0744” of “DTC WORK SUPPORT” mode for “A/T” with CONSULT-II and touch “START”. BCIA0031E Accelerate vehicle to more than 80 km/h (50 MPH) and maintain the following conditions continuously until “TESTING” has turned to “COMPLETE”. (It will take approximately 30 seconds after “TESTING” shows.) THROTTLE POSI: 1.0/8 - 2.0/8 (at all times during step 4) SLCT LVR POSI: “D” position TCC S/V DUTY: More than 94% VEHICLE SPEED: Constant speed of more than 80 km/h (50 MPH) Make sure that “GEAR” shows “4”. For shift schedule, refer to AT-67, "Vehicle Speed at Which Gear Shifting Occurs" . If “TESTING” does not appear on CONSULT-II for a long time, select “SELF-DIAG RESULTS”. In case a DTC other than “A/T TCC S/V FNCTN” is shown, refer to AT-86, "Display Items List (Except for EURO-OBD models)" . Make sure that “OK” is displayed. (If “NG” is displayed, refer to “DIAGNOSTIC PROCEDURE”.) Refer to AT-283, "Diagnostic Procedure" . Refer to AT-67, "Vehicle Speed at Which Lock-up Occurs/Releases" . AT-282 A/T TCC S/V FUNCTION (LOCK-UP) [EXC.F/EURO-OBD] Diagnostic Procedure 1. CHECK SHIFT-UP (D3 BCS000VU A TO D4 ) During AT-61, "Cruise Test — Part 1" . Does A/T shift from D3 to D4 at the specified speed? YES >> GO TO 11. NO >> GO TO 2. B AT D SCIA7190E E 2. CHECK LINE PRESSURE Perform line pressure test. Refer to AT-56, "LINE PRESSURE TEST" . OK or NG OK >> GO TO 3. NG >> GO TO 6. F G 3. CHECK CONTROL VALVE Disassemble control valve assembly. Refer to AT-392, "Control Valve Assembly" . Check to ensure that: – Valve, sleeve and plug slide along valve bore under their own weight. – Valve, sleeve and plug are free from burrs, dents and scratches. – Control valve springs are free from damage, deformation and fatigue. – Hydraulic line is free from obstacles. OK or NG OK >> GO TO 4. NG >> Repair or replace control valve. 1. 2. 4. CHECK SHIFT-UP (D3 H I J K TO D4 ) During AT-61, "Cruise Test — Part 1" . Does A/T shift from D3 to D4 at the specified speed? YES >> GO TO 5. NO >> Check control valve again. Repair or replace control valve assembly. L M SCIA7190E 5. CHECK DTC Perform AT-282, "DTC Confirmation Procedure" . OK or NG OK >> INSPECTION END NG >> GO TO 11. Check for proper lock-up. AT-283 A/T TCC S/V FUNCTION (LOCK-UP) [EXC.F/EURO-OBD] 6. CHECK VALVE RESISTANCE 1. – 2. Remove control valve assembly. Refer to AT-345, "Control Valve Assembly and Accumulators" . Line pressure solenoid valve Check resistance between terminal cord assembly harness connector terminal and ground. Refer to AT-252, "Wiring Diagram — AT — LPSV" . Solenoid valve Line pressure solenoid valve Terminal 4 Ground Resistance (Approx.) 2.5 - 5 Ω OK or NG OK >> GO TO 7. NG >> Replace solenoid valve assembly. SCIA4951E 7. CHECK VALVE OPERATION Remove control valve assembly. Refer to AT-345, "Control Valve Assembly and Accumulators" . Line pressure solenoid valve 2. Check solenoid valve by listening for its operating sound while applying battery voltage to the terminal and ground. Refer to AT252, "Wiring Diagram — AT — LPSV" . OK or NG OK >> GO TO 8. NG >> Replace solenoid valve assembly. 1. – SCIA3275E 8. CHECK CONTROL VALVE Disassemble control valve assembly. Refer to AT-392, "Control Valve Assembly" . Check line pressure circuit valves for sticking. – Pressure regulator valve – Pilot valve – Pressure modifier valve OK or NG OK >> GO TO 9. NG >> Repair or replace control valve. 1. 2. 9. CHECK SHIFT-UP (D3 TO D4 ) During AT-61, "Cruise Test — Part 1" . Does A/T shift from D3 to D4 at the specified speed? YES >> GO TO 10. NO >> Check control valve again. Repair or replace control valve assembly. SCIA7190E AT-284 A/T TCC S/V FUNCTION (LOCK-UP) [EXC.F/EURO-OBD] 10. CHECK DTC A Perform AT-282, "DTC Confirmation Procedure" . OK or NG OK >> INSPECTION END NG >> GO TO 11. B 11. CHECK LOCK-UP AT During AT-61, "Cruise Test — Part 1" . A/T perform lock-up at the specified speed? YES >> Perform AT-61, "Cruise Test — Part 1" again and return to the start point of this test group. NO >> GO TO 12. D E F SCIA7191E 12. CHECK VALVE RESISTANCE 1. – 2. G Remove control valve assembly. Refer to AT-345, "Control Valve Assembly and Accumulators" . Torque converter clutch solenoid valve Check resistance between terminal cord assembly harness connector terminal and ground. Refer to AT-231, "Wiring Diagram — AT — TCV" . Solenoid valve Torque converter clutch solenoid valve I Resistance (Approx.) Terminal 5 H Ground J 5 - 20 Ω OK or NG OK >> GO TO 13. NG >> Replace solenoid valve assembly. K SCIA2063E 13. CHECK VALVE OPERATION L Remove control valve assembly. Refer to AT-345, "Control Valve Assembly and Accumulators" . – Torque converter clutch solenoid valve 2. Check solenoid valve by listening for its operating sound while applying battery voltage to the terminal and ground. Refer to AT231, "Wiring Diagram — AT — TCV" . OK or NG OK >> GO TO 14. NG >> Replace solenoid valve assembly. 1. M SCIA2066E AT-285 A/T TCC S/V FUNCTION (LOCK-UP) [EXC.F/EURO-OBD] 14. CHECK CONTROL VALVE Disassemble control valve assembly. Refer to AT-392, "Control Valve Assembly" . Check control valves for sticking. – Torque converter clutch control valve – Torque converter clutch relief valve OK or NG OK >> GO TO 15. NG >> Repair or replace control valve. 1. 2. 15. CHECK LOCK-UP During AT-61, "Cruise Test — Part 1" . A/T perform lock-up at the specified speed? YES >> GO TO 16. NO >> Check control valve again. Repair or replace control valve assembly. SCIA7191E 16. CHECK DTC Perform AT-282, "DTC Confirmation Procedure" . OK or NG OK >> INSPECTION END NG >> Perform AT-61, "Cruise Test — Part 1" again and return to the start point of this test group. AT-286 CONTROL UNIT (RAM), CONTROL UNIT (ROM) [EXC.F/EURO-OBD] CONTROL UNIT (RAM), CONTROL UNIT (ROM) Description PFP:31036 A BCS000VV The TCM consists of a microcomputer and connectors for signal input and output and for power supply. The unit controls the A/T. B AT D SAT574J E On Board Diagnosis Logic BCS000VW Diagnostic trouble code “CONTROL UNIT (RAM)”, “CONTROL UNIT (ROM)” with CONSULT-II is detected when TCM memory (RAM) or (ROM) is malfunctioning. Possible Cause TCM. G DTC Confirmation Procedure BCS000VY CAUTION: If performing this “DTC Confirmation Procedure” again, always turn ignition switch OFF and wait at least 10 seconds before continuing. After the repair, perform the following procedure to confirm the malfunction is eliminated. 2. 3. 4. 5. H I WITH CONSULT-II 1. F BCS000VX Turn ignition switch ON and select “DATA MONITOR” mode for A/T with CONSULT-II. Touch “START”. Start engine. Run engine for at least 2 seconds at idle speed. If the check result is NG, go to AT-287, "Diagnostic Procedure" . J K L BCIA0031E Diagnostic Procedure BCS000VZ 1. CHECK DTC With CONSULT-II 1. Turn ignition switch ON and select “SELF-DIAG RESULTS” mode for A/T with CONSULT-II. 2. Touch “ERASE”. 3. Perform AT-287, "DTC Confirmation Procedure" . Is the “CONTROL UNIT (RAM)” or “CONTROL UNIT (ROM)” displayed again? YES >> Replace TCM. NO >> INSPECTION END AT-287 M PNP, OD SWITCH AND CLOSED THROTTLE, WIDE OPEN THROTTLE POSITION SIGNAL CIRCUIT [EXC.F/EURO-OBD] PNP, OD SWITCH AND CLOSED THROTTLE, WIDE OPEN THROTTLE POSITION SIGNAL CIRCUIT PFP:31918 CONSULT-II Reference Value BCS000W0 Remarks: Specification data are reference values. Item name Condition PN POSI SW R POSITION SW D POSITION SW 2 POSITION SW 1 POSITION SW OVERDRIVE SW CLOSED THL/SW W/O THRL/P-SW Display value When setting selector lever to “N” or “P” position. ON When setting selector lever to other positions. OFF When setting selector lever to “R” position. ON When setting selector lever to other positions. OFF When setting selector lever to “D” position. ON When setting selector lever to other positions. OFF When setting selector lever to “2” position. ON When setting selector lever to other positions. OFF When setting selector lever to “1” position. ON When setting selector lever to other positions. OFF When overdrive control switch is depressed. ON When overdrive control switch is released. OFF Released accelerator pedal. ON Depressed accelerator pedal. OFF Fully depressed accelerator pedal. ON Released accelerator pedal. OFF TCM Terminals and Reference Value BCS000W1 TCM terminal data are reference values, measured between each terminal and ground. Terminal Wire color 26 Y 27 34 35 36 L LG L R Item Condition PNP switch “1” position When setting selector lever to “1” position. PNP switch “2” position When setting selector lever to “2” position. PNP switch “D” position PNP switch “R” position PNP switch “N” or “P” position When setting selector lever to other positions. When setting selector lever to other positions. When setting selector lever to “D” position. and When setting selector lever to other positions. When setting selector lever to “R” position. Judgement standard (Approx.) Battery voltage 0V Battery voltage 0V Battery voltage 0V Battery voltage When setting selector lever to other positions. 0V When setting selector lever to “N” or “P” positions. Battery voltage When setting selector lever to other positions. 0V AT-288 PNP, OD SWITCH AND CLOSED THROTTLE, WIDE OPEN THROTTLE POSITION SIGNAL CIRCUIT [EXC.F/EURO-OBD] Diagnostic Procedure BCS000W2 1. CHECK CAN COMMUNICATION LINE A Perform the self-diagnosis. Refer to AT-85, "SELF-DIAGNOSTIC RESULT MODE" . Is a malfunction in the CAN communication indicated in the results? YES >> Check CAN communication line. Refer to AT-257, "CAN COMMUNICATION LINE" . NO (With CONSULT-II) >>GO TO 2. NO (Without CONSULT-II) >>GO TO 3. B AT 2. CHECK PNP SWITCH CIRCUIT D With CONSULT-II 1. Turn ignition switch ON. (Do not start engine.) 2. Select “TCM INPUT SIGNALS” in “DATA MONITOR” mode for “A/T” with CONSULT-II. 3. Read out “P·N”, “R”, “D”, “2” and “1” position switches moving selector lever to each position. Item name Condition Display value PN POSI SW When setting selector lever to “N” or “P” position. ON When setting selector lever to other positions. OFF When setting selector lever to “R” position. ON When setting selector lever to other positions. OFF When setting selector lever to “D” positions. ON When setting selector lever to other positions. OFF R POSITION SW D POSITION SW 2 POSITION SW 1 POSITION SW E F G SAT701J When setting selector lever to “2” position. ON When setting selector lever to other positions. OFF When setting selector lever to “1” position. ON When setting selector lever to other positions. OFF H I J K OK or NG OK >> GO TO 7. NG >> GO TO 4. L M AT-289 PNP, OD SWITCH AND CLOSED THROTTLE, WIDE OPEN THROTTLE POSITION SIGNAL CIRCUIT [EXC.F/EURO-OBD] 3. CHECK PNP SWITCH CIRCUIT Without CONSULT-II 1. Turn ignition switch ON. (Do not start engine.) 2. Check voltage between TCM connector terminals and ground while moving selector lever through each position. Refer to AT296, "EXC.F/EURO-OBD" . Terminal Selector lever position 36 35 34 27 26 “P”, “N” B 0 0 0 0 “R” 0 B 0 0 0 “D” 0 0 B 0 0 “2” 0 0 0 B 0 “1” 0 0 0 0 B B: Battery voltage 0: 0V OK or NG OK >> GO TO 7. NG >> GO TO 4. SCIA7162E 4. CHECK PNP SWITCH 1. 2. 3. Turn ignition switch OFF. Disconnect PNP switch harness connector. Check continuity between PNP switch harness connector terminals. Selector lever position Terminal Continuity “P” 1 - 2, 3 - 7 “R” 3-8 Yes *Continuity should not exist in positions other than the specified positions. “N” Connector F12 1 - 2, 3 - 9 “D” 3-6 “2” 3-5 “1” 3-4 SCIA5588E OK or NG OK >> GO TO 6. NG >> GO TO 5. 5. CHECK CONTROL CABLE ADJUSTMENT Check PNP switch again with control cable disconnected from manual shaft of A/T assembly. Refer to test group 4. OK or NG OK >> Adjust control cable. Refer to AT-336, "Adjustment of A/T Position" . NG >> Repair or replace PNP switch. Refer to AT-349, "Park/Neutral Position (PNP) Switch" . AT-290 PNP, OD SWITCH AND CLOSED THROTTLE, WIDE OPEN THROTTLE POSITION SIGNAL CIRCUIT [EXC.F/EURO-OBD] 6. DETECT MALFUNCTIONING ITEM A Check the following. ● Harness for short or open between ignition switch and PNP switch ● Harness for short or open between PNP switch and TCM ● Harness for short or open between PNP switch and combination meter ● Harness for short or open between combination meter and TCM ● 10A fuse (No.60, located in the IPDM E/R) ● Combination meter. Refer to DI-4, "COMBINATION METERS" . ● Ignition switch. Refer to PG-38, "GROUND" . OK or NG OK >> GO TO 7. NG >> Repair or replace damaged parts. B AT D E 7. CHECK OVERDRIVE CONTROL SWITCH CIRCUIT F With CONSULT-II 1. Turn ignition switch ON. (Do not start engine.) 2. Select “TCM INPUT SIGNALS” in “DATA MONITOR” mode for “A/T” with CONSULT-II. 3. Read out “OVERDRIVE SW”. Check the signal of overdrive control switch is indicated properly. Overdrive control switch Condition Item name OVERDRIVE SW G H Display value Depressed ON Released OFF I SCIA4730E 1. 2. Without CONSULT-II Turn ignition switch ON. (Do not start engine.) Check voltage between A/T device harness connector terminal and ground. Refer to AT-296, "EXC.F/EURO-OBD" . Item Connector A/T device harness connector (Overdrive control switch) M52 Terminal 1 - Ground Overdrive control switch Condition Judgement standard (Approx.) Released Battery voltage Depressed 0V OK or NG OK >> GO TO 10. NG >> GO TO 8. K L M SCIA5336E AT-291 J PNP, OD SWITCH AND CLOSED THROTTLE, WIDE OPEN THROTTLE POSITION SIGNAL CIRCUIT [EXC.F/EURO-OBD] 8. CHECK OVERDRIVE CONTROL SWITCH 1. 2. 3. Turn ignition switch OFF. Disconnect A/T device harness connector. Check continuity between A/T device harness connector terminals. Refer to AT-296, "EXC.F/EURO-OBD" . Item Connector Terminal A/T device harness connector (Overdrive control switch) M52 1-2 Overdrive control switch condition Continuity Released No Depressed Yes OK or NG OK >> GO TO 9. NG >> Repair or replace damaged parts. SCIA5330E 9. DETECT MALFUNCTIONING ITEM Check the following. ● Harness for short or open between combination meter and A/T device harness connector ● Harness for short or open between A/T device harness connector and ground ● Combination meter. Refer to DI-4, "COMBINATION METERS" . OK or NG OK >> GO TO 10. NG >> Repair or replace damaged parts. 10. CHECK CLOSED THROTTLE POSITION AND WIDE OPEN THROTTLE POSITION SIGNAL CIRCUIT With CONSULT-II 1. Turn ignition switch ON. (Do not start engine.) 2. Select “TCM INPUT SIGNALS” in “DATA MONITOR” mode for A/T with CONSULT-II. 3. Read out “CLOSED THL/SW” and “W/O THRL/P-SW” depressing and releasing accelerator pedal. Check that the signals of throttle position are indicated properly. SCIA4731E Data monitor Accelerator pedal condition CLOSED THL/SW W/O THRL/P-SW Released ON OFF Fully depressed OFF ON OK or NG OK >> GO TO 11. NG >> Check the following. If any items are damaged, repair or replace damaged parts. ● Accelerator pedal position sensor. Refer to AT-213, "ACCELERATOR PEDAL POSITION (APP) SENSOR" . AT-292 PNP, OD SWITCH AND CLOSED THROTTLE, WIDE OPEN THROTTLE POSITION SIGNAL CIRCUIT [EXC.F/EURO-OBD] 11. PERFORM SELF-DIAGNOSIS A Without CONSULT-II Perform self-diagnosis. Refer to AT-94, "Diagnostic Procedure Without CONSULT-II" . B OK or NG OK >> INSPECTION END NG − 1 >> Self-diagnosis does not activate: GO TO 12. NG − 2 >> DTC is displayed: Check the malfunctioning system. Refer to AT-95, "Judgement of Self-diagno- AT sis Code" . 12. CHECK TCM D 1. Check TCM input/output signal. Refer to AT-80, "TCM Terminals and Reference Value" . 2. If NG, recheck TCM pin terminals for damage or loose connection with harness connector. OK or NG OK >> INSPECTION END NG >> Repair or replace damaged parts. Component Inspection E F BCS000W3 OVERDRIVE CONTROL SWITCH Check continuity between A/T device harness connector terminals. ● Item Connector Terminal A/T device harness connector (Overdrive control switch) M52 1-2 Overdrive control switch condition Continuity Released No Depressed Yes G H I SCIA5330E J PNP SWITCH 1. Check continuity between PNP switch harness connector terminals. Selector lever position Terminal Continuity “P” 1 - 2, 3 - 7 “R” 3-8 Yes *Continuity should not exist in positions other than the specified positions. “N” 2. 3. 4. 5. 6. Connector F12 1 - 2, 3 - 9 “D” 3-6 “2” 3-5 “1” 3-4 If NG, check again with control cable (2) disconnected from manual shaft of A/T assembly. Refer to step 1. (1): Lock nut (3): Manual shaft If OK on step 2, adjust control cable (2). Refer to AT-336, "Adjustment of A/T Position" . If NG on step 2, remove PNP switch from A/T assembly and check continuity of PNP switch terminals. Refer to step 1. If OK on step 4, adjust PNP switch. Refer to AT-350, "PARK/ NEUTRAL POSITION (PNP) SWITCH ADJUSTMENT" . If NG on step 4, replace PNP switch. Refer to AT-349, "Park/ Neutral Position (PNP) Switch" . AT-293 K L M SCIA5588E SCIA6370J TROUBLE DIAGNOSIS FOR SYMPTOMS [ALL] TROUBLE DIAGNOSIS FOR SYMPTOMS Wiring Diagram — AT — NONDTC [ALL] PFP:00007 BCS000YJ EURO-OBD MCWA0258E AT-294 TROUBLE DIAGNOSIS FOR SYMPTOMS [ALL] TCM terminal data are reference values. measured between each terminal and ground. Terminal Wire color Item Condition Judgement standard (Approx.) 5 L CAN H — — 6 Y CAN L — — 30 L CONSULT-II (RX) — — 31 BR CONSULT-II (TX) — — A B AT D E F G H I J K L M AT-295 TROUBLE DIAGNOSIS FOR SYMPTOMS [ALL] EXC.F/EURO-OBD BCS000W4 MCWA0256E AT-296 TROUBLE DIAGNOSIS FOR SYMPTOMS [ALL] A B AT D E F G H I J K L M MCWA0259E AT-297 TROUBLE DIAGNOSIS FOR SYMPTOMS [ALL] TCM terminal data are reference values, measured between each terminal and ground. Terminal 26 Wire color Y Item Condition PNP switch “1” position and 27 L PNP switch “2” position Judgement standard (Approx.) When setting selector lever to “1” position. Battery voltage When setting selector lever to other positions. 0V When setting selector lever to “2” position. Battery voltage When setting selector lever to other positions. 0V 30 L CONSULT- II (RX) — — 31 BR CONSULT- II (TX) — — 34 35 LG L PNP switch “D” position PNP switch “R” position and 36 R PNP switch “N” or “P” position AT-298 When setting selector lever to “D” position. Battery voltage When setting selector lever to other positions. 0V When setting selector lever to “R” position. Battery voltage When setting selector lever to other positions. 0V When setting selector lever to “N” or “P” position. Battery voltage When setting selector lever to other positions. 0V TROUBLE DIAGNOSIS FOR SYMPTOMS [ALL] OD OFF Indicator Lamp Does Not Come On BCS000W5 SYMPTOM: OD OFF indicator lamp does not come on for about 2 seconds when turning ignition switch to ON. 1. CHECK CAN COMMUNICATION LINE A B Perform self-diagnosis. Refer to AT-85, "SELF-DIAGNOSTIC RESULT MODE" . Is a malfunction in CAN communication indicated in the results? AT YES >> Check CAN communication line. Refer to AT-102, "DTC U1000 CAN COMMUNICATION LINE" (EURO-OBD) or AT-257, "CAN COMMUNICATION LINE" (Except for EURO-OBD). NO >> GO TO 2. D CHECK TCM POWER SOURCE 2. 1. 2. Turn ignition switch ON. (Do not start engine.) Check voltage between TCM connector terminals and ground. Refer to AT-194, "Wiring Diagram — AT — MAIN" (EURO-OBD) or AT-261, "Wiring Diagram — AT — MAIN" (Except for EUROOBD). Item Connector E106 TCM connector Terminal F Judgement standard (Approx.) G 10 19 E107 E Battery voltage 28 H SCIA2656E 3. 4. Turn ignition switch OFF. Check voltage between TCM connector terminals and ground. Item TCM connector Connector E106 E107 Terminal Judgement standard (Approx.) 10 0V 19 0V 28 Battery voltage I J K OK or NG OK >> GO TO 4. NG >> GO TO 3. L SCIA2657E 3. DETECT MALFUNCTIONING ITEM M Check the following. ● Harness for short or open between ignition switch and TCM connector terminals 10, 19 ● Harness for short or open between battery and TCM connector terminal 28 ● 10A fuse (No.7, located in the fuse block) and 10A fuse (No.58, located in the IPDM E/R) ● Ignition switch. Refer to PG-4, "POWER SUPPLY ROUTING CIRCUIT" . OK or NG OK >> GO TO 4. NG >> Repair or replace damaged parts. AT-299 TROUBLE DIAGNOSIS FOR SYMPTOMS [ALL] 4. CHECK TCM GROUND CIRCUIT 1. 2. 3. Turn ignition switch OFF. Disconnect TCM connector. Check continuity between TCM connector terminals and ground. Refer to AT-194, "Wiring Diagram — AT — MAIN" (EURO-OBD) or AT-261, "Wiring Diagram — AT — MAIN" (Except for EUROOBD). Item Connector Terminal Continuity TCM connector E107 25, 48 - Ground Yes OK or NG OK >> GO TO 5. NG >> Repair open circuit or short to ground or short to power in harness or connectors. 5. DETECT MALFUNCTIONING ITEM Check the following. Harness for short or open between ignition switch and combination meter ● Combination meter. Refer to DI-4, "COMBINATION METERS" . OK or NG OK >> GO TO 6. NG >> Repair or replace damaged parts. ● 6. CHECK SYMPTOM Check again. Refer to AT-58, "Check Before Engine is Started" . OK or NG OK >> INSPECTION END NG >> GO TO 7. 7. CHECK TCM 1. Check TCM input/output. Refer to AT-80, "TCM Terminals and Reference Value" . 2. If NG, recheck TCM pin terminals for damage or loose connection with harness connector. OK or NG OK >> INSPECTION END NG >> Repair or replace damaged parts. AT-300 SCIA2671E TROUBLE DIAGNOSIS FOR SYMPTOMS [ALL] Engine Cannot Be Started in “P” and “N” Position BCS000W6 A SYMPTOM: ● Engine cannot be started with selector lever in “P” or “N” position. ● Engine can be started with selector lever in “D”, “2”, “1” or “R” position. B 1. CHECK SELF-DIAGNOSIS RESULTS Perform self-diagnosis. Refer to AT-85, "SELF-DIAGNOSTIC RESULT MODE" or AT-94, "Diagnostic Proce- AT dure Without CONSULT-II" . Is any malfunction detected by self-diagnostic results? YES >> Check the malfunctioning system. Refer to AT-85, "SELF-DIAGNOSTIC RESULT MODE" or AT- D 95, "Judgement of Self-diagnosis Code" . NO >> GO TO 2. 2. CHECK PNP SWITCH E Check continuity between PNP switch harness connector terminals. Refer to AT-106, "Wiring Diagram — AT — PNP/SW" (EURO-OBD) or AT-296, "EXC.F/EURO-OBD" (Except for EURO-OBD). F Selector lever position “P”, “N” Connector F12 terminal 1-2 Other positions Continuity G Yes No OK or NG OK >> GO TO 4. NG >> GO TO 3. H SCIA5606E I 3. CHECK CONTROL CABLE ADJUSTMENT Check PNP switch again with control cable disconnected from manual shaft of A/T assembly. Refer to test group 2. OK or NG OK >> Adjust control cable. Refer to AT-336, "Adjustment of A/T Position" . NG >> 1. Check PNP switch (Refer to test group 2.) again after adjusting PNP switch (Refer to AT-350 ). – If OK, INSPECTION END – If NG, repair or replace PNP switch. Refer to AT-349, "Park/Neutral Position (PNP) Switch" . J K L 4. CHECK STARTING SYSTEM Check starting system. Refer to SC-45, "STARTING SYSTEM" . OK or NG OK >> INSPECTION END NG >> Repair or replace damaged parts. AT-301 M TROUBLE DIAGNOSIS FOR SYMPTOMS [ALL] In “P” Position, Vehicle Moves Forward or Backward When Pushed BCS000W7 SYMPTOM: Vehicle moves when it is pushed forward or backward with selector lever in “P” position. 1. CHECK CONTROL CABLE Check control cable. Refer to AT-337, "Checking of A/T Position" . OK or NG OK >> GO TO 2. NG >> Adjust control cable. Refer to AT-336, "Adjustment of A/T Position" . 2. CHECK PARKING COMPONENTS Check parking components. Refer to AT-360, "Components" and AT-369, "DISASSEMBLY" . OK or NG OK >> INSPECTION END NG >> Repair or replace damaged parts. SAT282F In “N” Position, Vehicle Moves BCS000W8 SYMPTOM: Vehicle moves forward or backward when selecting “N” position. 1. CHECK CONTROL CABLE Check control cable. Refer to AT-337, "Checking of A/T Position" . OK or NG OK >> GO TO 2. NG >> Adjust control cable. Refer to AT-336, "Adjustment of A/T Position" . 2. CHECK A/T FLUID LEVEL Check A/T fluid level. Refer to AT-18, "Checking A/T Fluid" . OK or NG OK >> GO TO 3. NG >> Refill ATF. 3. CHECK A/T FLUID CONDITION 1. Remove oil pan. Refer to AT-360, "Components" . 2. Check A/T fluid condition. Refer to AT-53, "Fluid Condition Check" . OK or NG OK >> GO TO 5. NG >> GO TO 4. AT-302 TROUBLE DIAGNOSIS FOR SYMPTOMS [ALL] 4. DETECT MALFUNCTIONING ITEM A Disassemble A/T. Refer to AT-369, "Disassembly" . Check the following items: – Forward clutch assembly. Refer to AT-419, "Forward and Overrun Clutches" . – Overrun clutch assembly. Refer to AT-419, "Forward and Overrun Clutches" . – Reverse clutch assembly. Refer to AT-408, "Reverse Clutch" . OK or NG OK >> GO TO 5. NG >> Repair or replace damaged parts. 1. 2. B AT D 5. CHECK SYMPTOM Check again. Refer to AT-59, "Check at Idle" . OK or NG OK >> INSPECTION END NG >> GO TO 6. E F 6. CHECK TCM G 1. Check TCM input/output signals. Refer to AT-80, "TCM Terminals and Reference Value" . 2. If NG, recheck TCM pin terminals for damage or loose connection with harness connector. OK or NG OK >> INSPECTION END NG >> Repair or replace damaged parts. Large Shock “N” → “R” Position H BCS000W9 I SYMPTOM: There is a large shock when changing from “N” to “R” position. 1. CHECK SELF-DIAGNOSTIC RESULTS J Perform self-diagnosis. Refer to AT-85, "SELF-DIAGNOSTIC RESULT MODE" or AT-94, "Diagnostic Procedure Without CONSULT-II" . Is any malfunction detected by self-diagnostic results? YES >> Check the malfunctioning system. Refer to AT-85, "SELF-DIAGNOSTIC RESULT MODE" or AT95, "Judgement of Self-diagnosis Code" . NO >> GO TO 2. 2. CHECK LINE PRESSURE K L M Check line pressure at idle with selector lever in “D” position. Refer to AT-56, "LINE PRESSURE TEST" . OK or NG OK >> GO TO 4. NG >> GO TO 3. AT-303 TROUBLE DIAGNOSIS FOR SYMPTOMS [ALL] 3. DETECT MALFUNCTIONING ITEM Remove control valve assembly. Refer to AT-345, "Control Valve Assembly and Accumulators" . Check the following items: – Valves to control line pressure (Pressure regulator valve, pressure modifier valve, pilot valve and pilot filter) – Line pressure solenoid valve – Oil pump assembly. Refer to AT-388, "Oil Pump" . OK or NG OK >> GO TO 4. NG >> Repair or replace damaged parts. 1. 2. 4. CHECK SYMPTOM Check again. Refer to AT-59, "Check at Idle" . OK or NG OK >> INSPECTION END NG >> GO TO 5. 5. CHECK TCM 1. Check TCM input/output signals. Refer to AT-80, "TCM Terminals and Reference Value" . 2. If NG, recheck TCM pin terminals for damage or loose connection with harness connector. OK or NG OK >> INSPECTION END NG >> Repair or replace damaged parts. Vehicle Does Not Creep Backward in “R” Position BCS000WA SYMPTOM: Vehicle does not creep backward when selecting “R” position. 1. CHECK A/T FLUID LEVEL Check A/T fluid level. Refer to AT-18, "Checking A/T Fluid" . OK or NG OK >> GO TO 2. NG >> Refill ATF. 2. CHECK LINE PRESSURE Check line pressure at idle with selector lever in “R” position. Refer to AT-56, "LINE PRESSURE TEST" . OK or NG OK >> GO TO 4. NG >> GO TO 3. AT-304 TROUBLE DIAGNOSIS FOR SYMPTOMS [ALL] 3. DETECT MALFUNCTIONING ITEM A Remove control valve assembly. Refer to AT-345, "Control Valve Assembly and Accumulators" . Check the following items: – Valves to control line pressure (Pressure regulator valve, pressure modifier valve, pilot valve and pilot fil- B ter) – Line pressure solenoid valve AT 3. Disassemble A/T. Refer to AT-369, "Disassembly" . 4. Check the following item: – Oil pump assembly. Refer to AT-388, "Oil Pump" . D OK or NG OK >> GO TO 4. NG >> Repair or replace damaged parts. E 1. 2. 4. CHECK STALL REVOLUTION Check stall revolution with selector lever in “1” and “R” positions. Refer to AT-53, "STALL TEST" . OK or NG OK >> GO TO 6. OK in “1” position, NG in “R” position>> GO TO 5. NG in both “1” and “R” positions>> GO TO 7. 5. DETECT MALFUNCTIONING ITEM F G H Disassemble A/T. Refer to AT-369, "Disassembly" . Check the following items: – Low & reverse brake assembly. Refer to AT-426, "Low & Reverse Brake" . – Reverse clutch assembly. Refer to AT-408, "Reverse Clutch" . OK or NG OK >> GO TO 6. NG >> Repair or replace damaged parts. 1. 2. 6. CHECK A/T FLUID CONDITION I J K 1. Remove oil pan. Refer to AT-360, "Components" . 2. Check A/T fluid condition. Refer to AT-53, "Fluid Condition Check" . OK or NG OK >> GO TO 8. NG >> GO TO 7. 7. DETECT MALFUNCTIONING ITEM 1. 2. Disassemble A/T. Refer to AT-369, "Disassembly" . Check the following items: – Reverse clutch assembly. Refer to AT-408, "Reverse Clutch" . – High clutch assembly. Refer to AT-413, "High Clutch" . – Low & reverse brake assembly. Refer to AT-426, "Low & Reverse Brake" . – Forward clutch assembly. Refer to AT-419, "Forward and Overrun Clutches" . – Overrun clutch assembly. Refer to AT-419, "Forward and Overrun Clutches" . OK or NG OK >> GO TO 8. NG >> Repair or replace damaged parts. AT-305 L M TROUBLE DIAGNOSIS FOR SYMPTOMS [ALL] 8. CHECK SYMPTOM Check again. Refer to AT-59, "Check at Idle" . OK or NG OK >> INSPECTION END NG >> GO TO 9. 9. CHECK TCM 1. Check TCM input/output signals. Refer to AT-80, "TCM Terminals and Reference Value" . 2. If NG, recheck TCM pin terminals for damage or loose connection with harness connector. OK or NG OK >> INSPECTION END NG >> Repair or replace damaged parts. Vehicle Does Not Creep Forward in “D”, “2” or “1” Position BCS000WB SYMPTOM: Vehicle does not creep forward when selecting “D”, “2” or “1” position. 1. CHECK A/T FLUID LEVEL Check A/T fluid level. Refer to AT-18, "Checking A/T Fluid" . OK or NG OK >> GO TO 2. NG >> Refill ATF. 2. CHECK LINE PRESSURE Check line pressure at idle with selector lever in “D” position. Refer to AT-56, "LINE PRESSURE TEST" . OK or NG OK >> GO TO 4. NG >> GO TO 3. 3. DETECT MALFUNCTIONING ITEM Remove control valve assembly. Refer to AT-345, "Control Valve Assembly and Accumulators" . Check the following items: – Valves to control line pressure (Pressure regulator valve, pressure modifier valve, pilot valve and pilot filter) – Line pressure solenoid valve 3. Disassemble A/T. Refer to AT-369, "Disassembly" . 4. Check the following item: – Oil pump assembly. Refer to AT-388, "Oil Pump" . OK or NG OK >> GO TO 4. NG >> Repair or replace damaged parts. 1. 2. 4. CHECK STALL REVOLUTION Check stall revolution with selector lever in “D” position. Refer to AT-53, "STALL TEST" . OK or NG OK >> GO TO 6. NG >> GO TO 5. AT-306 TROUBLE DIAGNOSIS FOR SYMPTOMS [ALL] 5. DETECT MALFUNCTIONING ITEM A Disassemble A/T. Refer to AT-369, "Disassembly" . Check the following items: – Oil pump assembly. Refer to AT-388, "Oil Pump" . – Forward clutch assembly. Refer to AT-419, "Forward and Overrun Clutches" . – Forward one-way clutch. Refer to AT-431, "Rear Internal Gear and Forward Clutch Hub" . – Low one-way clutch. Refer to AT-369, "Disassembly" . – Torque converter. Refer to AT-369, "Disassembly" . OK or NG OK >> GO TO 7. NG >> Repair or replace damaged parts. 1. 2. B AT D E 6. CHECK A/T FLUID CONDITION 1. Remove oil pan. Refer to AT-360, "Components" . 2. Check A/T fluid condition. Refer to AT-53, "Fluid Condition Check" . OK or NG OK >> GO TO 7. NG >> GO TO 5. F G 7. CHECK SYMPTOM H Check again. Refer to AT-59, "Check at Idle" . OK or NG OK >> INSPECTION END NG >> GO TO 8. I 8. CHECK TCM J 1. Check TCM input/output signals. Refer to AT-80, "TCM Terminals and Reference Value" . 2. If NG, recheck TCM pin terminals for damage or loose connection with harness connector. OK or NG OK >> INSPECTION END NG >> Repair or replace damaged parts. K L Vehicle Cannot Be Started from D1 BCS000WC SYMPTOM: Vehicle cannot be started from D1 on “Cruise Test — Part 1”. 1. CHECK SYMPTOM Check symptom. Refer to AT-59, "Check at Idle" . Is “Vehicle Dose Not Creep Backward in “R” Position” OK? OK >> GO TO 2. NG >> GO TO AT-304, "Vehicle Does Not Creep Backward in “R” Position" . 2. CHECK SELF-DIAGNOSTIC RESULTS Perform self-diagnosis. Refer to AT-85, "SELF-DIAGNOSTIC RESULT MODE" or AT-94, "Diagnostic Procedure Without CONSULT-II" . Is any malfunction detected by self-diagnostic results? YES >> Check the malfunctioning system. Refer to AT-85, "SELF-DIAGNOSTIC RESULT MODE" or AT95, "Judgement of Self-diagnosis Code" . NO >> GO TO 3. AT-307 M TROUBLE DIAGNOSIS FOR SYMPTOMS [ALL] 3. CHECK ACCELERATOR PEDAL POSITION SENSOR Check accelerator pedal position sensor. Refer to AT-169, "DTC P1705 ACCELERATOR PEDAL POSITION (APP) SENSOR" (EURO-OBD) or AT-213, "ACCELERATOR PEDAL POSITION (APP) SENSOR" (Except for EURO-OBD). OK or NG OK >> GO TO 4. NG >> Repair or replace accelerator pedal position sensor. 4. CHECK LINE PRESSURE Check line pressure at stall point with selector lever in “D” position. Refer to AT-56, "LINE PRESSURE TEST" . OK or NG OK >> GO TO 6. NG >> GO TO 5. 5. DETECT MALFUNCTIONING ITEM Remove control valve assembly. Refer to AT-345, "Control Valve Assembly and Accumulators" . Check the following items: – Shift valve A – Shift valve B – Shift solenoid valve A – Shift solenoid valve B – Pilot valve – Pilot filter 3. Disassemble A/T. Refer to AT-369, "Disassembly" . 4. Check the following items: – Forward clutch assembly. Refer to AT-419, "Forward and Overrun Clutches" . – Low one-way clutch. Refer to AT-369, "Disassembly" . – Forward one-way clutch. Refer to AT-431, "Rear Internal Gear and Forward Clutch Hub" . – High clutch assembly. Refer to AT-413, "High Clutch" . – Torque converter. Refer to AT-369, "Disassembly" . – Oil pump assembly. Refer to AT-388, "Oil Pump" . OK or NG OK >> GO TO 8. NG >> Repair or replace damaged parts. 1. 2. 6. CHECK A/T FLUID CONDITION 1. Remove oil pan. Refer to AT-360, "Components" . 2. Check A/T fluid condition. Refer to AT-53, "Fluid Condition Check" . OK or NG OK >> GO TO 7. NG >> GO TO 5. AT-308 TROUBLE DIAGNOSIS FOR SYMPTOMS [ALL] 7. DETECT MALFUNCTIONING ITEM A Remove control valve assembly. Refer to AT-345, "Control Valve Assembly and Accumulators" . Check the following items: – Shift valve A – Shift valve B – Shift solenoid valve A – Shift solenoid valve B – Pilot valve – Pilot filter OK or NG OK >> GO TO 8. NG >> Repair or replace damage parts. 1. 2. B AT D E 8. CHECK SYMPTOM F Check again. Refer to AT-61, "Cruise Test — Part 1" . OK or NG OK >> INSPECTION END NG >> GO TO 9. G 9. CHECK TCM H 1. Check TCM input/output signals. Refer to AT-80, "TCM Terminals and Reference Value" . 2. If NG, recheck TCM pin terminals for damage or loose connection with harness connector. OK or NG OK >> INSPECTION END NG >> Repair or replace damaged parts. A/T Does Not Shift: D1 → D2 or Does Not Kickdown: D4 → D2 I BCS000WD SYMPTOM: A/T does not shift from D1 to D2 at the specified speed on “Cruise Test — Part 1”. A/T does not shift from D4 to D2 when depressing accelerator pedal fully at the specified speed on “Cruise Test — Part 2”. 1. CHECK SYMPTOM J K L Check symptom . Refer to AT-59, "Check at Idle" and AT-61, "Cruise Test — Part 1" . Are “Vehicle Dose Not Creep Forward in “D”, “2” or “1” Position” and “Vehicle Cannot Be Started from D1 ” OK? YES >> GO TO 2. NG >> GO TO AT-306, "Vehicle Does Not Creep Forward in “D”, “2” or “1” Position" and AT-307, "Vehicle Cannot Be Started from D1" . 2. CHECK CONTROL CABLE Check control cable. Refer to AT-337, "Checking of A/T Position" . OK or NG OK >> GO TO 3. NG >> Adjust control cable. Refer to AT-336, "Adjustment of A/T Position" . 3. CHECK VEHICLE SPEED SENSOR·A/T AND VEHICLE SPEED SENSOR·MTR CIRCUIT Check vehicle speed sensor·A/T (revolution sensor) and vehicle speed sensor·MTR circuit. Refer to AT-115, "DTC P0720 VEHICLE SPEED SENSOR·A/T (REVOLUTION SENSOR)" (EURO-OBD) or AT-203, "VEHICLE SPEED SENSOR·A/T (REVOLUTION SENSOR)" (Except for EURO-OBD) and AT-176, "DTC VEHICLE AT-309 M TROUBLE DIAGNOSIS FOR SYMPTOMS [ALL] SPEED SENSOR MTR" (EURO-OBD) or AT-209, "VEHICLE SPEED SENSOR MTR" (Except for EUROOBD). OK or NG OK >> GO TO 4. NG >> Repair or replace vehicle speed sensor·A/T (revolution sensor) and vehicle speed sensor·MTR circuits. 4. CHECK ACCELERATOR PEDAL POSITION SENSOR Check accelerator pedal position sensor. Refer to AT-169, "DTC P1705 ACCELERATOR PEDAL POSITION (APP) SENSOR" (EURO-OBD) or AT-213, "ACCELERATOR PEDAL POSITION (APP) SENSOR" (Except for EURO-OBD). OK or NG OK >> GO TO 5. NG >> Repair or replace accelerator pedal position sensor. 5. CHECK A/T FLUID CONDITION 1. Remove oil pan. Refer to AT-360, "Components" . 2. Check A/T fluid condition. Refer to AT-53, "Fluid Condition Check" . OK or NG OK >> GO TO 7. NG >> GO TO 6. 6. DETECT MALFUNCTIONING ITEM Remove control valve. Refer to AT-345, "Control Valve Assembly and Accumulators" . Check the following items: – Shift valve A – Shift valve B – Shift solenoid valve A – Shift solenoid valve B – Pilot valve – Pilot filter 3. Disassemble A/T. Refer to AT-369, "Disassembly" . 4. Check the following items: – Servo piston assembly – Brake band OK or NG OK >> GO TO 8. NG >> Repair or replace damaged parts. 1. 2. AT-310 TROUBLE DIAGNOSIS FOR SYMPTOMS [ALL] 7. DETECT MALFUNCTIONING ITEM A Remove control valve. Refer to AT-345, "Control Valve Assembly and Accumulators" . Check the following items: – Shift valve A – Shift valve B – Shift solenoid valve A – Shift solenoid valve B – Pilot valve – Pilot filter OK or NG OK >> GO TO 8. NG >> Repair or replace damaged parts. 1. 2. B AT D E 8. CHECK SYMPTOM F Check again. Refer to AT-61, "Cruise Test — Part 1" and AT-64, "Cruise Test — Part 2" . OK or NG OK >> INSPECTION END NG >> GO TO 9. G 9. CHECK TCM H 1. Check TCM input/output signals. Refer to AT-80, "TCM Terminals and Reference Value" . 2. If NG, recheck TCM pin terminals for damage or loose connection with harness connector. OK or NG OK >> INSPECTION END NG >> Repair or replace damaged parts. A/T Does Not Shift: D2 → D3 I BCS000WE SYMPTOM: A/T does not shift from D2 to D3 at the specified speed on “Cruise Test — Part 1” and “Cruise Test — Part 2”. J K 1. CHECK SYMPTOM Check symptom. Refer to AT-59, "Check at Idle" and AT-61, "Cruise Test — Part 1" . Are “Vehicle Does Not Creep Forward in “D”, “2” or “1” Position” and “Vehicle Cannot Be Started from D1 ” OK? YES >> GO TO 2. NO >> Go to AT-306, "Vehicle Does Not Creep Forward in “D”, “2” or “1” Position" and AT-307, "Vehicle Cannot Be Started from D1" . 2. CHECK CONTROL CABLE Check control cable. Refer to AT-337, "Checking of A/T Position" . OK or NG OK >> GO TO 3. NG >> Adjust control cable. Refer to AT-336, "Adjustment of A/T Position" . 3. CHECK VEHICLE SPEED SENSOR·A/T AND VEHICLE SPEED SENSOR·MTR CIRCUIT Check vehicle speed sensor·A/T (revolution sensor) and vehicle speed sensor·MTR circuit. Refer to AT-115, "DTC P0720 VEHICLE SPEED SENSOR·A/T (REVOLUTION SENSOR)" (EURO-OBD) or AT-203, "VEHICLE SPEED SENSOR·A/T (REVOLUTION SENSOR)" (Except for EURO-OBD) and AT-176, "DTC VEHICLE AT-311 L M TROUBLE DIAGNOSIS FOR SYMPTOMS [ALL] SPEED SENSOR MTR" (EURO-OBD) or AT-209, "VEHICLE SPEED SENSOR MTR" (Except for EUROOBD). OK or NG OK >> GO TO 4. NG >> Repair or replace vehicle speed sensor·A/T (revolution sensor) and vehicle speed sensor·MTR circuits. 4. CHECK ACCELERATOR PEDAL POSITION SENSOR Check accelerator pedal position sensor. Refer to AT-169, "DTC P1705 ACCELERATOR PEDAL POSITION (APP) SENSOR" (EURO-OBD) or AT-213, "ACCELERATOR PEDAL POSITION (APP) SENSOR" (Except for EURO-OBD). OK or NG OK >> GO TO 5. NG >> Repair or replace accelerator pedal position sensor. 5. CHECK A/T FLUID CONDITION 1. Remove oil pan. Refer to AT-360, "Components" . 2. Check A/T fluid condition. Refer to AT-53, "Fluid Condition Check" . OK or NG OK >> GO TO 7. NG >> GO TO 6. 6. DETECT MALFUNCTIONING ITEM Remove control valve assembly. Refer to AT-345, "Control Valve Assembly and Accumulators" . Check the following items: – Shift valve B – Shift solenoid valve B – Pilot valve – Pilot filter 3. Disassemble A/T. Refer to AT-369, "Disassembly" . 4. Check the following items: – Servo piston assembly – High clutch assembly. Refer to AT-413, "High Clutch" . – Oil pump assembly. Refer to AT-388, "Oil Pump" . OK or NG OK >> GO TO 8. NG >> Repair or replace damaged parts. 1. 2. 7. DETECT MALFUNCTIONING ITEM Remove control valve assembly. Refer to AT-345, "Control Valve Assembly and Accumulators" . Check the following items: – Shift valve B – Shift solenoid valve B – Pilot valve – Pilot filter OK or NG OK >> GO TO 8. NG >> Repair or replace damaged parts. 1. 2. AT-312 TROUBLE DIAGNOSIS FOR SYMPTOMS [ALL] 8. CHECK SYMPTOM A Check again. Refer to AT-61, "Cruise Test — Part 1" and AT-64, "Cruise Test — Part 2" . OK or NG OK >> INSPECTION END NG >> GO TO 9. 9. CHECK TCM B AT 1. Check TCM input/output signal. Refer to AT-80, "TCM Terminals and Reference Value" . 2. If NG, recheck TCM pin terminals for damage or loose connection with harness connector. OK or NG OK >> INSPECTION END NG >> Repair or replace damaged parts. D E F G H I J K L M AT-313 TROUBLE DIAGNOSIS FOR SYMPTOMS [ALL] A/T Does Not Shift: D3 → D4 BCS000WF SYMPTOM: ● A/T does not shift from D3 to D4 at the specified speed on “Cruise Test — Part 1” and “Cruise Test — Part 2”. ● A/T must be warm before D3 to D4 shift will occur. 1. CHECK SYMPTOM Check symptom. Refer to AT-59, "Check at Idle" and AT-61, "Cruise Test — Part 1" . Are “Vehicle Does Not Creep Forward in “D”, “2” or “1” Position” and “Vehicle Cannot Be Started from D1 ” OK? YES >> GO TO 2. NO >> Go to AT-306, "Vehicle Does Not Creep Forward in “D”, “2” or “1” Position" and AT-307, "Vehicle Cannot Be Started from D1" . 2. CHECK SELF-DIAGNOSTIC RESULTS Perform self-diagnosis. Refer to AT-85, "SELF-DIAGNOSTIC RESULT MODE" or AT-94, "Diagnostic Procedure Without CONSULT-II" . Is any malfunction detected by self-diagnostic results? YES >> Check the malfunctioning system. Refer to AT-85, "SELF-DIAGNOSTIC RESULT MODE" or AT95, "Judgement of Self-diagnosis Code" . NO >> GO TO 3. 3. CHECK ACCELERATOR PEDAL POSITION SENSOR Check accelerator pedal position sensor. Refer to AT-169, "DTC P1705 ACCELERATOR PEDAL POSITION (APP) SENSOR" (EURO-OBD) or AT-213, "ACCELERATOR PEDAL POSITION (APP) SENSOR" (Except for EURO-OBD). OK or NG OK >> GO TO 4. NG >> Repair or replace accelerator pedal position sensor. 4. CHECK A/T FLUID CONDITION 1. Remove oil pan. Refer to AT-360, "Components" . 2. Check A/T fluid condition. Refer to AT-53, "Fluid Condition Check" . OK or NG OK >> GO TO 6. NG >> GO TO 5. AT-314 TROUBLE DIAGNOSIS FOR SYMPTOMS [ALL] 5. DETECT MALFUNCTIONING ITEM A Remove control valve assembly. Refer to AT-345, "Control Valve Assembly and Accumulators" . Check the following items: – Shift valve A – Overrun clutch control valve – Shift solenoid valve A – Overrun clutch solenoid valve – Pilot valve – Pilot filter 3. Disassemble A/T. Refer to AT-369, "Disassembly" . 4. Check the following items: – Servo piston assembly – Brake band – Torque converter. Refer to AT-369, "Disassembly" . – Oil pump assembly. Refer to AT-388, "Oil Pump" . OK or NG OK >> GO TO 7. NG >> Repair or replace damaged parts. 1. 2. B AT D E F G 6. DETECT MALFUNCTIONING ITEM H Remove control valve assembly. Refer to AT-345, "Control Valve Assembly and Accumulators" . Check the following items: – Shift valve A – Overrun clutch control valve – Shift solenoid valve A – Pilot valve – Pilot filter OK or NG OK >> GO TO 7. NG >> Repair or replace damaged parts. 1. 2. I J K 7. CHECK SYMPTOM L Check again. Refer to AT-61, "Cruise Test — Part 1" and AT-64, "Cruise Test — Part 2" . OK or NG OK >> INSPECTION END NG >> GO TO 8. M 8. CHECK TCM 1. Check TCM input/output signals. Refer to AT-80, "TCM Terminals and Reference Value" . 2. If NG, recheck TCM pin terminals for damage or loose connection with harness connector. OK or NG OK >> INSPECTION END NG >> Repair or replace damaged parts. AT-315 TROUBLE DIAGNOSIS FOR SYMPTOMS [ALL] A/T Does Not Perform Lock-up BCS000WG SYMPTOM: A/T does not perform lock-up at the specified speed on “Cruise Test — Part 1”. 1. CHECK SELF-DIAGNOSTIC RESULTS Perform self-diagnosis. Refer to AT-85, "SELF-DIAGNOSTIC RESULT MODE" or AT-94, "Diagnostic Procedure Without CONSULT-II" . Is any malfunction detected by self-diagnostic results? YES >> Check the malfunctioning system. Refer to AT-85, "SELF-DIAGNOSTIC RESULT MODE" or AT95, "Judgement of Self-diagnosis Code" . NO >> GO TO 2. 2. CHECK ACCELERATOR PEDAL POSITION SENSOR Check accelerator pedal position sensor. Refer to AT-169, "DTC P1705 ACCELERATOR PEDAL POSITION (APP) SENSOR" (EURO-OBD) or AT-213, "ACCELERATOR PEDAL POSITION (APP) SENSOR" (Except for EURO-OBD). OK or NG OK >> GO TO 3. NG >> Repair or replace accelerator pedal position sensor. 3. DETECT MALFUNCTIONING ITEM Remove control valve. Refer to AT-345, "Control Valve Assembly and Accumulators" . Check following items: – Torque converter clutch control valve – Torque converter clutch solenoid valve – Torque converter relief valve – Pilot valve – Pilot filter 3. Disassemble A/T. Refer to AT-369, "Disassembly" . 4. Check the following items: – Torque converter. Refer to AT-369, "Disassembly" . OK or NG OK >> GO TO 4. NG >> Repair or replace damaged parts. 1. 2. 4. CHECK SYMPTOM Check again. Refer to AT-61, "Cruise Test — Part 1" . OK or NG OK >> INSPECTION END NG >> GO TO 5. 5. CHECK TCM 1. Check TCM input/output signals. Refer to AT-80, "TCM Terminals and Reference Value" . 2. If NG, recheck TCM pin terminals for damage or loose connection with harness connector. OK or NG OK >> INSPECTION END NG >> Repair or replace damaged parts. AT-316 TROUBLE DIAGNOSIS FOR SYMPTOMS [ALL] A/T Does Not Hold Lock-up Condition SYMPTOM: A/T does not hold lock-up condition for more than 30 seconds on “Cruise Test — Part 1”. 1. CHECK SELF-DIAGNOSTIC RESULTS BCS000WH A B Perform self-diagnosis. Refer to AT-85, "SELF-DIAGNOSTIC RESULT MODE" or AT-94, "Diagnostic Procedure Without CONSULT-II" . AT Is any malfunction detected by self-diagnostic results? YES >> Check the malfunctioning system. Refer to AT-85, "SELF-DIAGNOSTIC RESULT MODE" or AT95, "Judgement of Self-diagnosis Code" . D NO >> GO TO 2. 2. CHECK A/T FLUID CONDITION 1. Remove oil pan. Refer to AT-360, "Components" . 2. Check A/T fluid condition. Refer to AT-53, "Fluid Condition Check" . OK or NG OK >> GO TO 4. NG >> GO TO 3. 3. DETECT MALFUNCTIONING ITEM E F G Remove control valve assembly. Refer to AT-345, "Control Valve Assembly and Accumulators" . Check the following items: – Torque converter clutch control valve – Torque converter clutch solenoid valve – Pilot valve – Pilot filter 3. Disassemble A/T. Refer to AT-369, "Disassembly" . 4. Check the following items: – Torque converter. Refer to AT-369, "Disassembly" . – Oil pump assembly. Refer to AT-388, "Oil Pump" . OK or NG OK >> GO TO 5. NG >> Repair or replace damaged parts. 1. 2. H I J K L 4. DETECT MALFUNCTIONING ITEM Remove control valve assembly. Refer to AT-345, "Control Valve Assembly and Accumulators" . Check the following items: – Torque converter clutch control valve – Torque converter clutch solenoid valve – Pilot valve – Pilot filter OK or NG OK >> GO TO 5. NG >> Repair or replace damaged parts. 1. 2. 5. CHECK SYMPTOM Check again. Refer to AT-61, "Cruise Test — Part 1" . OK or NG OK >> INSPECTION END NG >> GO TO 6. AT-317 M TROUBLE DIAGNOSIS FOR SYMPTOMS [ALL] 6. CHECK TCM 1. Check TCM input/output signals. Refer to AT-80, "TCM Terminals and Reference Value" . 2. If NG, recheck TCM pin terminals for damage or loose connection with harness connector. OK or NG OK >> INSPECTION END NG >> Repair or replace damaged parts. Lock-up Is Not Released BCS000WI SYMPTOM: Lock-up is not released when accelerator pedal is released on “Cruise Test — Part 1”. 1. CHECK SELF-DIAGNOSTIC RESULTS Perform self-diagnosis. Refer to AT-85, "SELF-DIAGNOSTIC RESULT MODE" or AT-94, "Diagnostic Procedure Without CONSULT-II" . Is any malfunction detected by self-diagnostic results? YES >> Check the malfunctioning system. Refer to AT-85, "SELF-DIAGNOSTIC RESULT MODE" or AT95, "Judgement of Self-diagnosis Code" . NO >> GO TO 2. 2. CHECK SYMPTOM Check again. Refer to AT-61, "Cruise Test — Part 1" . OK or NG OK >> INSPECTION END NG >> GO TO 3. 3. CHECK TCM 1. Check TCM input/output signals. Refer to AT-80, "TCM Terminals and Reference Value" . 2. If NG, recheck TCM pin terminals for damage or loose connection with harness connector. OK or NG OK >> INSPECTION END NG >> Repair or replace damaged parts. Engine Speed Does Not Return to Idle (Light Braking D4 → D3 ) BCS000WJ SYMPTOM: Engine speed does not smoothly return to idle when A/T shifts from D4 to D3 on “Cruise Test — Part 1”. 1. CHECK SELF-DIAGNOSTIC RESULTS Perform self-diagnosis. Refer to AT-85, "SELF-DIAGNOSTIC RESULT MODE" or AT-94, "Diagnostic Procedure Without CONSULT-II" . Is any malfunction detected by self-diagnostic results? YES >> Check the malfunctioning system. Refer to AT-85, "SELF-DIAGNOSTIC RESULT MODE" or AT95, "Judgement of Self-diagnosis Code" . NO >> GO TO 2. 2. CHECK ACCELERATOR PEDAL POSITION SENSOR Check accelerator pedal position sensor. Refer to AT-169, "DTC P1705 ACCELERATOR PEDAL POSITION (APP) SENSOR" (EURO-OBD) or AT-213, "ACCELERATOR PEDAL POSITION (APP) SENSOR" (Except for EURO-OBD). OK or NG OK >> GO TO 3. NG >> Repair or replace accelerator pedal position sensor. AT-318 TROUBLE DIAGNOSIS FOR SYMPTOMS [ALL] 3. CHECK A/T FLUID CONDITION A 1. Remove oil pan. Refer to AT-360, "Components" . 2. Check A/T fluid condition. Refer to AT-53, "Fluid Condition Check" . OK or NG OK >> GO TO 5. NG >> GO TO 4. B AT 4. DETECT MALFUNCTIONING ITEM Remove control valve assembly. Refer to AT-345, "Control Valve Assembly and Accumulators" . Check the following items: – Overrun clutch control valve – Overrun clutch reducing valve – Overrun clutch solenoid valve 3. Disassemble A/T. Refer to AT-369, "Disassembly" . 4. Check the following items: – Overrun clutch assembly. Refer to AT-419, "Forward and Overrun Clutches" . OK or NG OK >> GO TO 6. NG >> Repair or replace damaged parts. 1. 2. 5. DETECT MALFUNCTIONING ITEM D E F G H Remove control valve assembly. Refer to AT-345, "Control Valve Assembly and Accumulators" . Check the following items: – Overrun clutch control valve – Overrun clutch reducing valve – Overrun clutch solenoid valve OK or NG OK >> GO TO 6. NG >> Repair or replace damaged parts. 1. 2. I J K 6. CHECK SYMPTOM Check again. Refer to AT-61, "Cruise Test — Part 1" . OK or NG OK >> INSPECTION END NG >> GO TO 7. 7. CHECK TCM 1. Check TCM input/output signals. Refer to AT-80, "TCM Terminals and Reference Value" . 2. If NG, recheck TCM pin terminals for damage or loose connection with harness connector. OK or NG OK >> INSPECTION END NG >> Repair or replace damaged parts. AT-319 L M TROUBLE DIAGNOSIS FOR SYMPTOMS [ALL] A/T Does Not Shift: D4 → D3 , When OD OFF BCS000WK SYMPTOM: A/T does not shift from D4 to D3 when OD OFF (OD OFF indicator lamp is on) on “Cruise Test — Part 3”. 1. CHECK CAN COMMUNICATION LINE Perform self-diagnosis. Refer to AT-85, "SELF-DIAGNOSTIC RESULT MODE" or AT-94, "Diagnostic Procedure Without CONSULT-II" . Is a malfunction in CAN communication indicated in the results? YES >> Check CAN communication line. Refer to AT-102, "DTC U1000 CAN COMMUNICATION LINE" (EURO-OBD) or AT-257, "CAN COMMUNICATION LINE" (Except for EURO-OBD). NO >> GO TO 2. 2. CHECK OVERDRIVE CONTROL SWITCH CIRCUIT With CONSULT-II 1. Turn ignition switch ON. (Do not start engine) 2. Select “TCM INPUT SIGNALS” in “DATA MONITOR” mode for “A/T” with CONSULT-II. 3. Read out “OVERDRIVE SW”. Check the signal of the overdrive control switch is indicated properly. Item name OVERDRIVE SW Overdrive control switch Condition Display value Depressed ON Released OFF SCIA4730E 1. 2. Without CONSULT-II Turn ignition switch ON. (Do not start engine) Check voltage between A/T device harness connector terminal and ground. Refer to AT-296, "EXC.F/EURO-OBD" . Item A/T device harness connector (Overdrive control switch) Connector M52 Terminal 1 - Ground Overdrive control switch Condition Judgement standard (Approx.) Released Battery voltage Depressed 0V OK or NG SCIA5336E OK >> GO TO AT-311, "A/T Does Not Shift: D2 → D3" . NG >> Check overdrive control switch circuit. Refer to AT-197, "PNP, OD SWITCH AND CLOSED THROTTLE, WIDE OPEN THROTTLE POSITION SIGNAL CIRCUIT" (EURO-OBD) or AT-288, "PNP, OD SWITCH AND CLOSED THROTTLE, WIDE OPEN THROTTLE POSITION SIGNAL CIRCUIT" (Except for EURO-OBD). AT-320 TROUBLE DIAGNOSIS FOR SYMPTOMS [ALL] A/T Does Not Shift: D3 → 22 , When Selector Lever “D” → “2” Position BCS000WL SYMPTOM: A/T does not shift from D3 to 22 when changing selector lever from “D” to “2” position on “Cruise Test — Part 3”. A B 1. CHECK SYMPTOM Check symptom. Refer to AT-61, "Cruise Test — Part 1" or AT-64, "Cruise Test — Part 2" . Is “A/T Does Not Shift: D1 → D2 or Does Not Kickdown: D4 → D2 ” OK? YES (With CONSULT-II) >>GO TO 2. YES (Without CONSULT-II) >>GO TO 3. NO >> GO TO AT-309, "A/T Does Not Shift: D1 → D2 or Does Not Kickdown: D4 → D2" . AT D 2. CHECK PNP SWITCH CIRCUIT E With CONSULT-II 1. Turn ignition switch ON. (Do not start engine.) 2. Select “TCM INPUT SIGNALS” in “DATA MONITOR” mode for “A/T” with CONSULT-II. 3. Read out “P·N”, “R”, “D”, “2” and “1” position switches moving selector lever to each position. Monitor item Condition Display value When setting selector lever to “N” or “P” position. ON PN POSI SW When setting selector lever to other positions. OFF When setting selector lever to “R” position. ON When setting selector lever to other positions. OFF When setting selector lever to “D” positions. ON When setting selector lever to other positions. OFF When setting selector lever to “2” position. ON When setting selector lever to other positions. OFF When setting selector lever to “1” position. ON When setting selector lever to other positions. OFF R POSITION SW D POSITION SW 2 POSITION SW 1 POSITION SW F G H SAT701J OK or NG OK >> INSPECTION END NG >> Check PNP switch circuit. Refer to AT-105, "DTC P0705 PARK/NEUTRAL POSITION (PNP) SWITCH" (EURO-OBD) or AT-288, "PNP, OD SWITCH AND CLOSED THROTTLE, WIDE OPEN THROTTLE POSITION SIGNAL CIRCUIT" (Except for EURO-OBD). AT-321 I J K L M TROUBLE DIAGNOSIS FOR SYMPTOMS [ALL] 3. CHECK PNP SWITCH CIRCUIT Without CONSULT-II 1. Turn ignition switch ON. (Do not start engine.) 2. Check voltage between TCM connector terminals and ground while moving selector lever through each position. Refer to AT106, "Wiring Diagram — AT — PNP/SW" (EURO-OBD) or AT296, "EXC.F/EURO-OBD" (Except for EURO-OBD). Terminal Selector lever position 36 35 34 27 26 “P”, “N” B 0 0 0 0 “R” 0 B 0 0 0 “D” 0 0 B 0 0 “2” 0 0 0 B 0 “1” 0 0 0 0 B B: Battery voltage 0: 0V OK or NG OK >> INSPECTION END NG >> Check PNP switch circuit. Refer to AT-105, "DTC P0705 PARK/NEUTRAL POSITION (PNP) SWITCH" (EUROOBD) or AT-288, "PNP, OD SWITCH AND CLOSED THROTTLE, WIDE OPEN THROTTLE POSITION SIGNAL CIRCUIT" (Except for EURO-OBD). AT-322 SCIA7162E TROUBLE DIAGNOSIS FOR SYMPTOMS [ALL] A/T Does Not Shift: 22 → 11 , When Selector Lever “2” → “1” Position BCS000WM SYMPTOM: A/T does not shift from 22 to 11 when changing selector lever from “2” to “1” position on “Cruise Test — Part 3”. B 1. CHECK PNP SWITCH CIRCUIT With CONSULT-II 1. Turn ignition switch ON. (Do not start engine.) 2. Select “TCM INPUT SIGNALS” in “DATA MONITOR” mode for “A/T” with CONSULT-II. 3. Read out “P·N”, “R”, “D”, “2” and “1” position switches moving selector lever to each position. Monitor item Condition Display value When setting selector lever to “N” or “P” position. ON PN POSI SW When setting selector lever to other positions. OFF When setting selector lever to “R” position. ON When setting selector lever to other positions. OFF When setting selector lever to “D” positions. ON When setting selector lever to other positions. OFF R POSITION SW D POSITION SW 2 POSITION SW 1 POSITION SW A AT D E F SAT701J When setting selector lever to “2” position. ON When setting selector lever to other positions. OFF When setting selector lever to “1” position. ON When setting selector lever to other positions. OFF OK or NG OK >> GO TO 3 NG >> Check PNP switch circuit. Refer to AT-105, "DTC P0705 PARK/NEUTRAL POSITION (PNP) SWITCH" (EURO-OBD) or AT-288, "PNP, OD SWITCH AND CLOSED THROTTLE, WIDE OPEN THROTTLE POSITION SIGNAL CIRCUIT" (Except for EURO-OBD). G H I J K L M AT-323 TROUBLE DIAGNOSIS FOR SYMPTOMS [ALL] 2. CHECK PNP SWITCH CIRCUIT Without CONSULT-II 1. Turn ignition switch ON. (Do not start engine.) 2. Check voltage between TCM connector terminals and ground while moving selector lever through each position. Refer to AT106, "Wiring Diagram — AT — PNP/SW" (EURO-OBD) or AT296, "EXC.F/EURO-OBD" (Except for EURO-OBD). Terminal Selector lever position 36 35 34 27 26 “P”, “N” B 0 0 0 0 “R” 0 B 0 0 0 “D” 0 0 B 0 0 “2” 0 0 0 B 0 “1” 0 0 0 0 B B: Battery voltage 0: 0V OK or NG OK >> GO TO 3 NG >> Check PNP switch circuit. Refer to AT-105, "DTC P0705 PARK/NEUTRAL POSITION (PNP) SWITCH" (EUROOBD) or AT-288, "PNP, OD SWITCH AND CLOSED THROTTLE, WIDE OPEN THROTTLE POSITION SIGNAL CIRCUIT" (Except for EURO-OBD). SCIA7162E 3. CHECK CONTROL CABLE Check control cable. Refer to AT-337, "Checking of A/T Position" . OK or NG OK >> GO TO 4. NG >> Adjust control cable. Refer to AT-336, "Adjustment of A/T Position" . 4. CHECK VEHICLE SPEED SENSOR·A/T AND VEHICLE SPEED SENSOR·MTR CIRCUIT Check vehicle speed sensor·A/T (revolution sensor) and vehicle speed sensor·MTR circuit. Refer to AT-115, "DTC P0720 VEHICLE SPEED SENSOR·A/T (REVOLUTION SENSOR)" (EURO-OBD) or AT-203, "VEHICLE SPEED SENSOR·A/T (REVOLUTION SENSOR)" (Except for EURO-OBD) and AT-176, "DTC VEHICLE SPEED SENSOR MTR" (EURO-OBD) or AT-209, "VEHICLE SPEED SENSOR MTR" (Except for EUROOBD). OK or NG OK >> GO TO 5. NG >> Repair or replace vehicle speed sensor·A/T (revolution sensor) and vehicle speed sensor·MTR circuits. 5. CHECK A/T FLUID CONDITION 1. Remove oil pan. Refer to AT-360, "Components" . 2. Check A/T fluid condition. Refer to AT-53, "Fluid Condition Check" . OK or NG OK >> GO TO 7. NG >> GO TO 6. AT-324 TROUBLE DIAGNOSIS FOR SYMPTOMS [ALL] 6. DETECT MALFUNCTIONING ITEM A Remove control valve assembly. Refer to AT-345, "Control Valve Assembly and Accumulators" . Check the following items: – Shift valve A – Shift solenoid valve A – Overrun clutch control valve – Overrun clutch solenoid valve 3. Disassemble A/T. Refer to AT-369, "Disassembly" . 4. Check the following items: – Servo piston assembly – Brake band OK or NG OK >> GO TO 7. NG >> Repair or replace damaged parts. 1. 2. B AT D E F 7. CHECK SYMPTOM Check again. Refer to AT-65, "Cruise Test — Part 3" . OK or NG OK >> INSPECTION END NG >> GO TO 8. G H I SAT778B J 8. CHECK TCM 1. Check TCM input/output signals. Refer to AT-80, "TCM Terminals and Reference Value" . 2. If NG, recheck TCM pin terminals for damage or loose connection with harness connector. OK or NG OK >> INSPECTION END NG >> Repair or replace damaged parts. Vehicle Does Not Decelerate by Engine Brake K L BCS000WN SYMPTOM: ● Vehicle does not decelerate by engine brake when shifting from 22 (12 ) to 11 “Cruise Test — Part 3”. ● Vehicle does not decelerate by engine brake when OD OFF (OD OFF indicator lamp is on) on “Cruise Test — Part 3”. ● Vehicle does not decelerate by engine brake when shifting A/T from “D” to “2” position on “Cruise Test — Part 3”. 1. CHECK CAN COMMUNICATION LINE Perform self-diagnosis. Refer to AT-85, "SELF-DIAGNOSTIC RESULT MODE" or AT-94, "Diagnostic Procedure Without CONSULT-II" . Is a malfunction in CAN communication indicated in the results? YES >> Check CAN communication line. Refer to AT-102, "DTC U1000 CAN COMMUNICATION LINE" (EURO-OBD) or AT-257, "CAN COMMUNICATION LINE" (Except for EURO-OBD). NO >> GO TO 2. AT-325 M TROUBLE DIAGNOSIS FOR SYMPTOMS [ALL] 2. CHECK OVERDRIVE CONTROL SWITCH CIRCUIT With CONSULT-II Turn ignition switch ON. (Do not start engine) Select “TCM INPUT SIGNALS” in “DATA MONITOR” mode for “A/T” with CONSULT-II. 3. Read out “OVERDRIVE SW”. Check the signal of the overdrive control switch is indicated properly. 1. 2. Item name OVERDRIVE SW Overdrive control switch Condition Display value Depressed ON Released OFF SCIA4730E Without CONSULT-II 1. Turn ignition switch ON. (Do not start engine) 2. Check voltage between A/T device harness connector terminal and ground. Refer to AT-296, "EXC.F/EURO-OBD" . Item A/T device harness connector (Overdrive control switch) Connector Terminal M52 1 - Ground Overdrive control switch Condition Judgement standard (Approx.) Released Battery voltage Depressed 0V OK or NG SCIA5336E OK (With CONSULT-II)>>GO TO 3. OK (Without CONSULT-II)>>GO TO 4. NG >> Check overdrive control switch circuit. Refer to AT-197, "PNP, OD SWITCH AND CLOSED THROTTLE, WIDE OPEN THROTTLE POSITION SIGNAL CIRCUIT" (EURO-OBD) or AT-288, "PNP, OD SWITCH AND CLOSED THROTTLE, WIDE OPEN THROTTLE POSITION SIGNAL CIRCUIT" (Except for EURO-OBD). AT-326 TROUBLE DIAGNOSIS FOR SYMPTOMS [ALL] 3. CHECK PNP SWITCH CIRCUIT A With CONSULT-II Turn ignition switch ON. (Do not start engine.) Select “TCM INPUT SIGNALS” in “DATA MONITOR” mode for “A/T” with CONSULT-II. 3. Read out “P·N”, “R”, “D”, “2” and “1” position switches moving selector lever to each position. 1. 2. Monitor item Condition Display value PN POSI SW When setting selector lever to “N” or “P” position. ON When setting selector lever to other positions. OFF When setting selector lever to “R” position. ON R POSITION SW D POSITION SW 2 POSITION SW 1 POSITION SW B AT D E SAT701J When setting selector lever to other positions. OFF When setting selector lever to “D” positions. ON When setting selector lever to other positions. OFF When setting selector lever to “2” position. ON When setting selector lever to other positions. OFF When setting selector lever to “1” position. ON When setting selector lever to other positions. OFF F G OK or NG OK >> GO TO 5 NG >> Check PNP switch circuit. Refer to AT-105, "DTC P0705 PARK/NEUTRAL POSITION (PNP) SWITCH" (EURO-OBD) or AT-288, "PNP, OD SWITCH AND CLOSED THROTTLE, WIDE OPEN THROTTLE POSITION SIGNAL CIRCUIT" (Except for EURO-OBD). 4. CHECK PNP SWITCH CIRCUIT H I J Without CONSULT-II 1. Turn ignition switch ON. (Do not start engine.) 2. Check voltage between TCM connector terminals and ground while moving selector lever through each position. Refer to AT106, "Wiring Diagram — AT — PNP/SW" (EURO-OBD) or AT296, "EXC.F/EURO-OBD" (Except for EURO-OBD). K L Terminal Selector lever position 36 35 34 27 26 “P”, “N” B 0 0 0 0 “R” 0 B 0 0 0 “D” 0 0 B 0 0 “2” 0 0 0 B 0 “1” 0 0 0 0 B M B: Battery voltage 0: 0V OK or NG OK >> GO TO 5 NG >> Check PNP switch circuit. Refer to AT-105, "DTC P0705 PARK/NEUTRAL POSITION (PNP) SWITCH" (EUROOBD) or AT-288, "PNP, OD SWITCH AND CLOSED THROTTLE, WIDE OPEN THROTTLE POSITION SIGNAL CIRCUIT" (Except for EURO-OBD). AT-327 SCIA7162E TROUBLE DIAGNOSIS FOR SYMPTOMS [ALL] 5. CHECK CONTROL CABLE Check control cable. Refer to AT-337, "Checking of A/T Position" . OK or NG OK >> GO TO 6. NG >> Adjust control cable. Refer to AT-336, "Adjustment of A/T Position" . 6. CHECK VEHICLE SPEED SENSOR·A/T AND VEHICLE SPEED SENSOR·MTR CIRCUIT Check vehicle speed sensor·A/T (revolution sensor) and vehicle speed sensor·MTR circuit. Refer to AT-115, "DTC P0720 VEHICLE SPEED SENSOR·A/T (REVOLUTION SENSOR)" (EURO-OBD) or AT-203, "VEHICLE SPEED SENSOR·A/T (REVOLUTION SENSOR)" (Except for EURO-OBD) and AT-176, "DTC VEHICLE SPEED SENSOR MTR" (EURO-OBD) or AT-209, "VEHICLE SPEED SENSOR MTR" (Except for EUROOBD). OK or NG OK >> GO TO 7. NG >> Repair or replace vehicle speed sensor·A/T (revolution sensor) and vehicle speed sensor·MTR circuits. 7. CHECK ACCELERATOR PEDAL POSITION SENSOR Check accelerator pedal position sensor. Refer to AT-169, "DTC P1705 ACCELERATOR PEDAL POSITION (APP) SENSOR" (EURO-OBD) or AT-213, "ACCELERATOR PEDAL POSITION (APP) SENSOR" (Except for EURO-OBD). OK or NG OK >> GO TO 8. NG >> Repair or replace accelerator pedal position sensor. 8. CHECK A/T FLUID CONDITION 1. Remove oil pan. Refer to AT-360, "Components" . 2. Check A/T fluid condition. Refer to AT-53, "Fluid Condition Check" . OK or NG OK >> GO TO 10. NG >> GO TO 9. 9. DETECT MALFUNCTIONING ITEM Remove control valve assembly. Refer to AT-345, "Control Valve Assembly and Accumulators" . Check the following. – Shift valve A – Overrun clutch solenoid valve 3. Disassemble A/T. Refer to AT-369, "Disassembly" . 4. Check the following. – Overrun clutch assembly. Refer to AT-419, "Forward and Overrun Clutches" . – Low & reverse brake assembly. Refer to AT-426, "Low & Reverse Brake" . OK or NG OK >> GO TO 10. NG >> Repair or replace damaged parts. 1. 2. 10. CHECK SYMPTOM Check again. Refer to AT-65, "Cruise Test — Part 3" . OK or NG OK >> INSPECTION END NG >> GO TO 11. AT-328 TROUBLE DIAGNOSIS FOR SYMPTOMS [ALL] 11. CHECK TCM A 1. Check TCM input/output signals. Refer to AT-80, "TCM Terminals and Reference Value" . 2. If NG, recheck TCM pin terminals for damage or loose connection with harness connector. OK or NG OK >> INSPECTION END NG >> Repair or replace damaged parts. TCM Self-diagnosis Does Not Activate B AT BCS000WO SYMPTOM: OD OFF indicator lamp does not come on in TCM self-diagnostic procedure even if the lamp circuit is good. D DESCRIPTION ● E PNP switch PNP switch assembly includes a transaxle position switch. The transaxle position switch detects the selector lever position and sends a signal to the TCM. F G SCIA7141E ● Overdrive control switch Overdrive control switch detects the switch position (ON or OFF) and sends a signal to the TCM. H I J K SCIA7142E L ● Closed throttle position signal and wide open throttle position signal ECM judges throttle opening based on a signal from accelerator pedal position sensor, and sends the signal via CAN communication to the TCM. M SCIA7143E DIAGNOSTIC PROCEDURE NOTE: The diagnostic procedure includes inspection for the PNP stitch, overdrive control switch, closed throttle position signal and wide open throttle position signal circuit. Refer to AT-197, "PNP, OD SWITCH AND CLOSED THROTTLE, WIDE OPEN THROTTLE POSITION SIGNAL CIRCUIT" (EURO-OBD) or AT-288, "PNP, OD SWITCH AND CLOSED THROTTLE, WIDE OPEN THROTTLE POSITION SIGNAL CIRCUIT" (Except for EURO-OBD). AT-329 TRANSMISSION CONTROL MODULE [ALL] TRANSMISSION CONTROL MODULE Removal and Installation (LHD) PFP:31036 BCS000WP COMPONENTS SCIA6963E 1. TCM Refer to GI section to make sure icons (symbol marks) in the figure. Refer to GI-11, "Components" . REMOVAL 1. 2. 3. Disconnect the battery cable from the negative terminal. Disconnect TCM harness connectors (1) from TCM (2). (3): Instrument lower finisher Remove TCM (2). MCIB0178E INSTALLATION Install in the reverse order of removal. AT-330 TRANSMISSION CONTROL MODULE [ALL] Removal and Installation (RHD) BCS000YK A COMPONENTS B AT D E F MCIB0169E 1. G TCM Refer to GI section to make sure icons (symbol marks) in the figure. Refer to GI-11, "Components" . H REMOVAL 1. 2. 3. 4. Disconnect the battery cable from the negative terminal. Remove glove box assembly. Refer to IP-12, "GLOVE BOX ASSEMBLY" . Disconnect TCM harness connectors (1) from TCM (2). Remove TCM (2). I J K L MCIB0170E INSTALLATION M Install in the reverse order of removal. AT-331 SHIFT CONTROL SYSTEM [ALL] SHIFT CONTROL SYSTEM Control Device Removal and Installation PFP:34901 BCS000WQ CONTROL DEVICE COMPONENTS SCIA6961E 1. Selector lever knob 2. Knob cover 3. Lock pin 4. Overdrive control switch 5. Knob finisher 6. Selector button 7. Selector button return spring 8. Position indicator plate 9. Position lamp 10. Dust cover 11. Bracket 12. Shift lock solenoid and park position switch assembly 13. A/T device harness connector 14. Plate 15. Control device assembly Refer to GI section to make sure icons (symbol marks) in the figure. Refer to GI-11, "Components" . AT-332 SHIFT CONTROL SYSTEM [ALL] CONTROL CABLE COMPONENTS Refer to the figure below for control cable removal and installation procedure. NOTE: Remove battery, air duct (inlet), air duct and air cleaner case before working on the transaxle side. Refer to SC-51, "Removal and Installation (CR Engine Models)" and EM-18, "AIR CLEANER AND AIR DUCT" . A B AT D E F G SCIA6222J 1. Selector lever knob 2. Control device assembly 3. Lock plate 4. Floor panel 5. Control cable 6. Bracket 7. Lock plate 8. Lock nut 9. A/T assembly 10. Bracket H I 11. Bracket Refer to GI section to make sure icons (symbol marks) in the figure. Refer to GI-11, "Components" . J REMOVAL CAUTION: Make sure that parking brake is applied before removal/installation. 1. Set selector lever in “N” position. 2. Remove center console assembly. Refer to IP-4, "INSTRUMENT PANEL ASSEMBLY" . 3. Disconnect A/T device harness connector (1). 4. Remove key interlock cable from control device assembly. Refer to AT-342, "KEY INTERLOCK CABLE" . K L M SCIA6965E AT-333 SHIFT CONTROL SYSTEM [ALL] 5. 6. Remove control device assembly fitting bolts (1). Remove exhaust front tube, center muffler and heat plates. Refer to EM-24, "EXHAUST MANIFOLD AND THREE WAY CATALYST" . SCIA6966E 7. Remove plate (1) from control device assembly. : Vehicle front SCIA6967E 8. 9. Remove lock plate (1) from control cable (2). : Vehicle front Remove control cable (2) from control device assembly. SCIA6968E 10. Insert flat-bladed screwdrivers at (A) and (B) as shown in the figure, and press both tabs (E) and (F) at the front (C) and rear (D) slightly toward the center of control device assembly to remove control device assembly downward of the vehicle. : Vehicle front SCIA6970E AT-334 SHIFT CONTROL SYSTEM [ALL] INSTALLATION A Note the following, and install in the reverse order of removal. ● When installing control cable (1) to control device assembly (2), make sure that control cable (1) is fully pressed in with the ribbed (A) surface facing downward of the vehicle. : Vehicle front ● After installation is completed, adjust and check A/T position. Refer to AT-336, "Adjustment of A/T Position" and AT-337, "Checking of A/T Position" . B AT D SCIA6253E Control Device Disassembly and Assembly BCS000WR DISASSEMBLY NOTE: Refer to AT-332, "CONTROL DEVICE COMPONENTS" to disassemble. 1. Remove selector lever knob from control device assembly. Refer to AT-336, "Selector Lever Knob Removal and Installation" . 2. Remove position lamp from position indicator plate (1). 3. Insert a flat-bladed screwdriver to (A) (at 4 locations) as shown in the figure, and bend each hook slightly to raise position indicator plate (1) and remove from control device assembly (2). 4. Remove bracket from control device assembly (2). 5. Remove A/T device harness connector from control device assembly (2). SCIA6969E 6. Release tabs (A) on shift lock solenoid and park position switch assembly from hooks (B) on control device assembly to shift lock solenoid and park position switch assembly. E F G H I J K L M SCIA6977E ASSEMBLY Assemble in the reverse order of disassembly. AT-335 SHIFT CONTROL SYSTEM [ALL] Selector Lever Knob Removal and Installation BCS000WS REMOVAL CAUTION: Make sure that parking brake is applied before removal/installation. 1. Set selector lever knob (1) in “N” position. 2. Slide knob cover (2) downward. 3. Pull out lock pin (3) from selector lever knob (1). 4. Remove selector lever knob (1) and knob cover (2) as a set from selector lever. CAUTION: Do not push selector button. SCIA6971E INSTALLATION 1. 2. 3. 4. Insert lock pin (1) to selector lever knob (2). Install knob cover (3) to selector lever knob (2). Set selector lever in “N” position. Install selector lever knob over selector lever until a click is felt. CAUTION: ● Do not tilt selector lever knob when installing. Install it straight, and do not tap or apply any shock to install it. ● Do not push selector button. SCIA6972E Adjustment of A/T Position BCS000WT Move selector lever from “P” position to “1” position. You should be able to feel the detents in each position. If the detents cannot be felt or if the pointer indicating the position is improperly aligned, the control cable needs adjustment. 1. Place selector lever in “P” position. CAUTION: Turn wheels more than 1/4 rotations and apply the park lock. 2. Remove air duct (inlet) and air duct. Refer to EM-18, "AIR CLEANER AND AIR DUCT" . 3. Remove lock nut (1) and control cable (2) from manual shaft (3). 4. Place manual shaft (3) in “P” position. 5. Hold the control cable (2) at the end. Push and pull it twice or three times, and then pull it with a specified force. Temporarily tighten lock nut (1) with the control cable loose. Specified force 6. 7. 8. 9. : 9.8 N (1.0 kg, 2.2 lb) Tighten lock nut (1) to the specified torque. Refer to AT-333, "CONTROL CABLE COMPONENTS" . CAUTION: Do not apply any force to manual shaft (3) after lock nut (1) is tightened. Move selector lever from “P” to “1” position again. Make sure that selector lever moves smoothly. Check A/T position. AT-337, "Checking of A/T Position" . Install any part removed. AT-336 SCIA6370J SHIFT CONTROL SYSTEM [ALL] Checking of A/T Position 1. 2. 3. 4. 5. 6. 7. 8. BCS000WU A Place selector lever in “P” position, and turn ignition switch ON (Do not start engine.). Make sure selector lever can be shifted to other than “P” position when brake pedal is depressed. Also make sure selector lever can be shifted from “P” position only when brake pedal is depressed. B Move selector lever and check for excessive effort, sticking, noise or rattle. Confirm selector lever stops at each position with the feel of engagement when it is moved through all the positions. Check whether or not the actual position selector lever is in matches the position shown by the AT shift position indicator and transaxle body. The method of operating selector lever to individual positions correctly should be as shown in the figure. D Confirm back-up lamps illuminate only when selector lever is placed in “R” position. Confirm back-up lamps do not illuminate when selector lever is in “P” or “N” position even if it is pushed toward “R” position without pressing selector button. E Confirm engine can only be started with selector lever in “P” and “N” positions. Make sure A/T is locked completely in “P” position. F SCIA6984E G H I J K L M AT-337 A/T SHIFT LOCK SYSTEM [ALL] A/T SHIFT LOCK SYSTEM Description ● ● PFP:34950 BCS000WV The mechanical key interlock mechanism also operates as a shift lock: With the ignition switch turned to ON, selector lever cannot be shifted from “P” position to any other position unless brake pedal is depressed. With the key removed, selector lever cannot be shifted from “P” position to any other position. The key cannot be removed unless selector lever is placed in “P” position. The shift lock and key interlock mechanisms are controlled by the ON-OFF operation of the shift lock solenoid and by the operation of the rotator and slider located inside key cylinder, respectively. Shift Lock System Parts Location BCS000WW MCIB0180E 1. Park position switch 2. Shift lock solenoid A. Brake pedal AT-338 3. Stop lamp switch A/T SHIFT LOCK SYSTEM [ALL] Wiring Diagram — AT — SHIFT BCS000WX A B AT D E F G H I J K L M MCWA0252E AT-339 A/T SHIFT LOCK SYSTEM [ALL] Diagnostic Procedure BCS000WY SYMPTOM 1: ● Selector lever cannot be moved from “P” position with ignition switch in ON position and brake pedal depressed. ● Selector lever can be moved from “P” position with ignition key in ON position and brake pedal released. ● Selector lever can be moved from “P” position when ignition switch is removed from key cylinder. SYMPTOM 2: ● Ignition key cannot be removed when selector lever is set to “P” position. ● Ignition key can be removed when selector lever is set to any position except “P” position. 1. CHECK KEY INTERLOCK CABLE Check key interlock cable for damage. OK or NG OK >> GO TO 2. NG >> Repair key interlock cable. Refer to AT-342, "KEY INTERLOCK CABLE" . 2. CHECK A/T POSITION Check A/T position. Refer to AT-337, "Checking of A/T Position" . OK or NG OK >> GO TO 3. NG >> Adjust control cable. Refer to AT-336, "Adjustment of A/T Position" . 3. CHECK SHIFT LOCK SOLENOID AND PARK POSITION SWITCH 1. 2. 3. Turn ignition switch ON. (Do not start engine.) Selector lever is set in “P” position. Check operation sound. Condition Brake pedal Operation sound When ignition switch is turned to ON position and selector lever is set in “P” position. Depressed Yes Released No OK or NG OK >> INSPECTION END NG >> GO TO 4. 4. CHECK POWER SOURCE 1. 2. Turn ignition switch ON. (Do not start engine.) Check voltage between A/T device harness connector terminal 5 and ground. Voltage : Battery voltage OK or NG OK >> GO TO 7. NG >> GO TO 5. SCIA7171E AT-340 A/T SHIFT LOCK SYSTEM [ALL] 5. CHECK STOP LAMP SWITCH 1. 2. 3. A Turn ignition switch OFF. Disconnect stop lamp switch harness connector. Check continuity between stop lamp switch harness connector terminals 3 and 4. Condition B Continuity When brake pedal is depressed Yes When brake pedal is released No Check stop lamp switch after adjusting brake pedal. Refer to BR-6, "BRAKE PEDAL" . OK or NG OK >> GO TO 6. NG >> Repair or replace damaged parts. AT D SCIA2126E 6. DETECT MALFUNCTIONING ITEM F Check the following. If any items are damaged, repair or replace damaged parts. ● Harness for short or open between ignition switch and stop lamp switch harness connector ● Harness for short or open between stop lamp switch harness connector and A/T device harness connector ● 10A fuse [No.4, located in the fuse block (J/B)] ● Ignition switch, Refer to PG-4, "POWER SUPPLY ROUTING CIRCUIT" . OK or NG OK >> INSPECTION END NG >> Repair or replace damaged parts. 7. CHECK GROUND CIRCUIT 1. 2. E G H I J Turn ignition switch OFF. Check continuity between stop lamp switch harness connector terminal 3 and ground. K Continuity should exist. L OK or NG OK >> Replace shift lock solenoid and park position switch assembly. NG >> Repair open circuit or short to ground or short to power in harness or connectors. M MCIB0176E AT-341 KEY INTERLOCK CABLE [ALL] KEY INTERLOCK CABLE Removal and Installation PFP:34908 BCS001EF COMPONENTS MCIB0181E 1. Key interlock cable 2. Key cylinder 3. Control device assembly A. Lock plate B. Holder C. Clip D. Slider E. Key interlock rod F. Adjust holder G. Casing cap REMOVAL CAUTION: Make sure that parking brake is applied before removal/installation. 1. Set selector lever in “N” position. 2. Remove selector lever knob. Refer to AT-336, "Selector Lever Knob Removal and Installation" . 3. Remove center console assembly. Refer to IP-4, "INSTRUMENT PANEL ASSEMBLY" . 4. Slide slider (A) toward casing cap (B) while pressing tabs (C) on slider to separate slider (A) from adjust holder (D). 5. Remove casing cap (B) from cable bracket on control device assembly. 6. Remove key interlock cable from key interlock rod (E). SCIA6975E AT-342 KEY INTERLOCK CABLE [ALL] 7. 8. 9. Remove steering column cover upper/lower and instrument lower finisher. Refer to IP-4, "INSTRUMENT PANEL ASSEMBLY" . Pull out lock plate (A) from holder (B). Remove key interlock cable (1) from key cylinder (2). A B AT SCIA6976E D 10. Remove clip (1), and then remove key interlock cable (2). E F G MCIB0177E INSTALLATION CAUTION: ● Install key interlock cable in such a way that it will not be damaged by sharp bends, twists or interference with adjacent parts. ● After installing key interlock cable to control device assembly, make sure that casing cap and bracket are firmly secured in their positions. 1. Place selector lever in “P” position. 2. Turn ignition switch to “ACC” or “ON” position. 3. Set key interlock cable (1) to key cylinder (2). 4. Install lock plate (A) to holder (B). 5. Turn ignition switch to “LOCK” position. H I J K L M SCIA6976E 6. 7. Temporarily install adjust holder (A) to key interlock rod (B). Install casing cap (C) to cable bracket (D) on control device assembly. CAUTION: ● Do not bend or twist key interlock cable excessively when installing. ● After installing key interlock cable to cable bracket (D) on control device assembly, make sure casing caps (C) is firmly secured in cable bracket (D) on control device assembly. ● If casing cap (C) is loose [less than 39.2 N (4.0 kg, 8.8 lb) removing force], replace key interlock cable. AT-343 SCIA6188E KEY INTERLOCK CABLE [ALL] 8. Slide slider (A) toward key interlock rod (D) while pressing pull lock (B) down to securely connect adjust holder (C) with key interlock rod (D). CAUTION: ● Do not press tabs when holding slider (A) ● Do not apply any force at the right angle to key interlock rod (D) when slider (A). SCIA6978E 9. 10. 11. 12. 13. Place clip (1). (2): Key interlock cable Install steering column cover upper/lower and instrument lower finisher. Refer to IP-4, "INSTRUMENT PANEL ASSEMBLY" . Install center console assembly. Refer to IP-4, "INSTRUMENT PANEL ASSEMBLY" . Install selector lever knob. Refer to AT-336, "Selector Lever Knob Removal and Installation" . Check shift lock system. Refer to AT-338, "Description" . MCIB0177E AT-344 ON-VEHICLE SERVICE [ALL] ON-VEHICLE SERVICE Control Valve Assembly and Accumulators PFP:00000 A BCS000X2 COMPONENTS B AT D E F G H I SCIA6216J 1. A/T 2. O-ring 3. 4. Control valve assembly 5. Oil pan gasket 6. Oil pan 7. Drain plug gasket 8. Drain plug 9. Magnet 10. Oil pan fitting bolt J Return spring 11. Snap ring 12. O-ring 13. Servo release accumulator piston 14. N-D accumulator piston 15. O-ring 16. Return spring 17. Lip seal K L Refer to GI section to make sure icons (symbol marks) in the figure. Refer to GI-11, "Components" . REMOVAL AND INSTALLATION Removal 1. 2. 3. 4. 5. 6. M Disconnect the battery cable from the negative terminal. Remove engine under cover and fender protector (LH). Refer to EI-14, "FENDER PROTECTOR" . Drain ATF from drain hole. Remove oil pan and oil pan gasket. Check foreign materials in oil pan to help determine cause of malfunction. If the ATF is very dark, smell burned or contains foreign particles, friction material (clutches, band) may need replacement. A tacky film that will not wipe clean indicates varnish build up. Varnish can cause valves, servo, and clutches to stick and can inhibit pump pressure. ● If ATF contains frictional material (clutch, bands, etc.), replace radiator and flush cooler line using cleaning solvent and compressed air after repair of A/T. Refer to CO12, "RADIATOR" . SCIA3476E Remove magnets from oil pan. AT-345 ON-VEHICLE SERVICE [ALL] 7. 8. 9. Disconnect terminal cord assembly harness connector. Remove snap ring from terminal body. Remove terminal cord assembly by pushing terminal body into transaxle case. SCIA4853E 10. Remove control valve assembly fitting bolts A , B and C . Bolt length, number and location: Bolt symbol Bolt length “ ” mm (in) Number of bolts A B C 40.0 mm (1.575 in) 33.0 mm (1.299 in) 43.5 mm (1.713 in) 5 6 2 SCIA5911J 11. Remove control valve assembly from transaxle case. CAUTION: Be careful not to drop manual valve and servo release accumulator return spring. 12. Remove manual valve from control valve assembly. CAUTION: Be careful not to drop manual valve. 13. Remove O-ring from terminal body. 14. Disassemble and inspect control valve assembly if necessary. Refer to AT-392, "Control Valve Assembly" , AT-401, "Control Valve Upper Body" and AT-405, "Control Valve Lower Body" . SCIA3150E 15. Remove servo release accumulator piston and N-D accumulator piston by applying compressed air if necessary. CAUTION: Hold each piston with lint-free cloth. SCIA4854E AT-346 ON-VEHICLE SERVICE [ALL] a. Apply compressed air to the oil hole as shown in the figure, and remove servo release accumulator piston from transaxle case. CAUTION: Strong flow of air will push the accumulator piston out along with a splash of ATF. Cover the area with lint-free cloth and blow air little by little to avoid this. A B AT SAT019DA D b. Apply compressed air to the oil hole as shown in the figure, and remove N-D accumulator piston and return spring from transaxle case. CAUTION: Strong flow of air will push the accumulator piston out along with a splash of ATF. Cover the area with lint-free cloth and blow air little by little to avoid this. E F G SAT020D c. Remove O-rings (1) from servo release accumulator piston (2) and N-D accumulator piston (3). CAUTION: Wrap the removed servo release accumulator piston (2) and N-D accumulator piston (3) in a lint-free cloth. H I J SCIA6033J K 16. Remove lip seals (1) from transaxle case. L M SCIA5895J AT-347 ON-VEHICLE SERVICE [ALL] Inspection ● ● Inspect the sliding surfaces of each accumulator piston and transaxle case, and replace if damaged or dented. (1): Servo release accumulator piston (2): N-D accumulator piston Inspect the sliding surfaces of manual valve and valve body, and replace if damaged or dented. SCIA6035J ● Inspect each return spring, and replace if damaged, deformed or worn. Refer to AT-476, "Accumulator" for free length (L1 ) and length (L2 ). (1): Return spring (Servo release accumulator) (2): Return spring (N-D accumulator) CAUTION: Do not remove spring retainer (3). SCIA6955E Installation Note the following, and install in the reverse order of removal. ● Set manual shaft in “N” position, then align manual plate (1) with groove in manual valve (2). ● After installing control valve assembly to transaxle case, make sure that selector lever can be moved to all positions. ● After completing installation, check for A/T fluid leakage and A/T fluid level. Refer to AT-18, "Checking A/T Fluid" . CAUTION: ● Completely remove all moisture, oil and old gasket, etc. from the oil pan gasket mounting surface of transaxle case and oil pan. ● Do not reuse O-rings, lip seals, oil pan gasket and oil pan fitting bolts. ● Apply ATF to manual valve, O-rings, lip seals and sliding surfaces transaxle case. AT-348 SCIA7090E ON-VEHICLE SERVICE [ALL] Park/Neutral Position (PNP) Switch BCS000X3 A COMPONENTS B AT D E F SCIA6932J 1. A/T 2. G PNP switch Refer to GI section to make sure icons (symbol marks) in the figure. Refer to GI-11, "Components" . H REMOVAL AND INSTALLATION Removal 1. 2. 3. 4. 5. 6. 7. Disconnect the battery cable from the negative terminal. Remove air duct (inlet). Refer to EM-18, "AIR CLEANER AND AIR DUCT" . Remove control cable (1) from manual shaft. Refer to AT-333, "CONTROL CABLE COMPONENTS" . Disconnect PNP switch harness connector (2). Remove PNP switch fitting bolts. Set manual shaft in “P” position. Remove PNP switch from A/T. I J K L SCIA6028J M Installation Note the following, and install in the reverse order of removal. ● Align PNP switch position when installing. ● After installation is completed, adjust and check A/T position. Refer to AT-336, "Adjustment of A/T Position" , AT-337, "Checking of A/T Position" . ● After installation is completed, check continuity of PNP switch. Refer to AT-202, "PNP SWITCH" . AT-349 ON-VEHICLE SERVICE [ALL] PARK/NEUTRAL POSITION (PNP) SWITCH ADJUSTMENT 1. 2. Set selector lever and manual shaft (1) in “N” position. Remove air duct (inlet). Refer to EM-18, "AIR CLEANER AND AIR DUCT" . 3. Remove control cable from manual shaft (1). Refer to AT-333, "CONTROL CABLE COMPONENTS" 4. Loosen PNP switch fitting bolts. 5. Insert the pin (3) [4 mm (0.16 in) dia.] straight into manual shaft (1) adjustment hole. 6. Rotate PNP switch (2) until the pin (3) can also be inserted straight into hole in PNP switch (2). SCIA6218J 7. Tighten PNP switch fitting bolts to the specified torque. Refer to AT-349, "COMPONENTS" . 8. Remove the pin (3) from adjustment hole after adjusting PNP switch (2). 9. Check continuity of PNP switch (2). Refer to AT-202, "PNP SWITCH" . 10. Adjust and check A/T position. Refer to AT-336, "Adjustment of A/T Position" , AT-337, "Checking of A/T Position" . 11. Reinstall any parts removed. Revolution Sensor BCS000X4 COMPONENTS SCIA6933J 1. A/T 2. Revolution sensor Refer to GI section to make sure icons (symbol marks) in the figure. Refer to GI-11, "Components" . REMOVAL AND INSTALLATION Removal 1. 2. Disconnect the battery cable from the negative terminal. Remove air duct (inlet), air duct and air cleaner case. Refer to EM-18, "AIR CLEANER AND AIR DUCT" . AT-350 ON-VEHICLE SERVICE [ALL] 3. 4. 5. Disconnect revolution sensor harness connector. Remove clip (1). Remove revolution sensor (2) from A/T. : Bolt (2) A B AT SCIA6206J D Installation Note the following, and install in the reverse order of removal. CAUTION: Ensure revolution sensor harness is firmly secured with bolt. (1): Revolution sensor : Bolt (1) E F G H SCIA6518J Turbine Revolution Sensor (Power Train Revolution Sensor) BCS000X5 COMPONENTS I J K L M SCIA6934J 1. A/T 2. O-ring 3. Turbine revolution sensor (power train revolution sensor) Refer to GI section to make sure icons (symbol marks) in the figure. Refer to GI-11, "Components" . REMOVAL AND INSTALLATION Removal 1. 2. Disconnect the battery cable from the negative terminal. Remove air duct (inlet). Refer to EM-18, "AIR CLEANER AND AIR DUCT" . AT-351 ON-VEHICLE SERVICE [ALL] 3. 4. 5. Remove control cable (1). Refer to AT-333, "CONTROL CABLE COMPONENTS" . Disconnect PNP switch harness connector (2). Remove bracket (3) of control cable. Refer to AT-333, "CONTROL CABLE COMPONENTS" . SCIA6262J 6. 7. 8. 9. Disconnect turbine revolution sensor (power train revolution sensor) harness connector (1). Remove turbine revolution sensor (power train revolution sensor) fitting bolt. : Bolt (1) Remove turbine revolution sensor (power train revolution sensor) (2) from A/T. Remove O-ring from turbine revolution sensor (power train revolution sensor) (2). SCIA6513J Installation Note the following, and install in the reverse order of removal. CAUTION: ● Do not reuse O-ring. ● Apply ATF to O-ring. After installing control cable, adjust and check A/T position. Refer to AT-336, "Adjustment of A/T Position" , AT337, "Checking of A/T Position" . AT-352 ON-VEHICLE SERVICE [ALL] Differential Side Oil Seal BCS000X6 A COMPONENTS B AT D E F SCIA6935J 1. A/T 2. LH differential side oil seal 3. G RH differential side oil seal Refer to GI section to make sure icons (symbol marks) in the figure. Refer to GI-11, "Components" . H REMOVAL AND INSTALLATION Removal 1. 2. Remove front drive shaft. Refer to FAX-13, "Removal and Installation" . Remove differential side oil seal using a flat-bladed screwdriver. CAUTION: Be careful not to scratch transaxle case and converter housing. I J K L SCIA4857E M AT-353 ON-VEHICLE SERVICE [ALL] Installation Note the following, and install in the reverse order of removal. ● Drive each differential side oil seal evenly using a drift (SST and commercial service tool) so that differential side oil seal protrudes by the dimension “C” or “D” respectively. (1): LH differential side oil seal (2): RH differential side oil seal (A): Transaxle case side (B): Converter housing side Unit: mm (in) Dimension “C” 0 ± 0.5 (0 ± 0.020) Dimension “D” 1.1 ± 0.5 (0.043 ± 0.020) SCIA7226E NOTE: Differential side oil seal pulling direction is used as the reference. Drift to be used: Location Tool number Transaxle case side (A) ST35325000 KV31103000 Converter housing side (B) Commercial service tool [Inner diameter: 47 mm (1.85 in), outer diameter: 54 mm (2.13 in)] After installing differential side oil seal, check A/T fluid leakage and A/T fluid level. Refer to AT-18, "Checking A/T Fluid" . AT-354 AIR BREATHER HOSE [ALL] AIR BREATHER HOSE Removal and Installation PFP:31098 A BCS000YL COMPONENTS B AT D E F G SCIA6208J 1. Air cleaner case 2. Air duct 3. Air breather hose 4. Clip 5. Air breather tube 6. A/T H REMOVAL 1. 2. 3. Remove battery. Refer to SC-14, "Removal and Installation" . Remove air duct (inlet), air duct and air cleaner case. Refer to EM-118, "AIR CLEANER AND AIR DUCT" . Remove air breather hose. I J INSTALLATION Note the following, and install in the reverse order of removal. ● Install air breather hose (1) to air breather tube (2) so that the paint mark (3) faces upward. Also make sure air breather hose end laps with air breather tube 17 mm (0.67 in) or more. ● When installing air breather hose to air duct and air cleaner case, make sure to fully insert the hose with clip. CAUTION: Make sure air breather hose is not collapsed or blocked due to folding or bending when installed. K L M SCIA6350J AT-355 TRANSAXLE ASSEMBLY [ALL] TRANSAXLE ASSEMBLY Removal and Installation PFP:32020 BCS000X7 COMPONENTS SCIA6766J 1. Rear torque rod 2. Rear engine mounting bracket 4. A/T fluid level gauge 5. O-ring 6. Fluid cooler tube 7. Copper washer 8. Bracket 9. Fluid cooler tube 10. A/T assembly 11. Engine mounting bracket (LH) 3. A/T fluid charging pipe 12. Bracket 13. Washer Refer to GI section to make sure icons (symbol marks) in the figure. Refer to GI-11, "Components" . : For tightening torque, refer to AT-358, "INSTALLATION" . REMOVAL 1. 2. 3. Disconnect the battery cable from the negative terminal. Remove air duct (inlet), air duct and air cleaner case. Refer to EM-18, "AIR CLEANER AND AIR DUCT" . Remove air breather hose. AT-356 TRANSAXLE ASSEMBLY [ALL] 4. 5. 6. 7. Remove control cable (1). Refer to AT-333, "CONTROL CABLE COMPONENTS" . Disconnect PNP switch harness connector (2). Remove bracket (3) of control cable. Remove engine under cover and fender protector. Refer to EI14, "FENDER PROTECTOR" . A B AT SCIA6262J D 8. 9. Disconnect following harness connector and wire harness. ● Turbine revolution sensor (power train revolution sensor) harness connector (1) ● Body ground harness (2) ● Terminal cord assembly harness connector (3) ● Revolution sensor harness connector (4) Remove starter motor. Refer to SC-51, "Removal and Installation (CR Engine Models)" . E F G H I J SCIA6812J 10. Turn crankshaft to remove four tightening bolts for drive plate and torque converter. CAUTION: Crankshaft should be rotated clockwise, viewed from front of engine. 11. Disconnect A/T fluid cooler hoses. 12. Remove front drive shafts. Refer to FAX-13, "Removal and Installation" . 13. Remove heat insulator. Refer to EM-24, "EXHAUST MANIFOLD AND THREE WAY CATALYST" . SCIA6225J 14. Support A/T assembly using a transmission jack. CAUTION: When setting the transmission jack, be careful not to allow it to collide against the drain plug. 15. Remove rear torque rod and rear engine mounting bracket. Refer to EM-70, "ENGINE ASSEMBLY" . 16. Support engine assembly using a transmission jack. CAUTION: When setting the transmission jack, be careful not to allow it to collide against the drain plug. 17. Remove A/T assembly fixing bolts. 18. Remove engine mounting insulator (LH). Refer to EM-70, "ENGINE ASSEMBLY" . AT-357 K L M TRANSAXLE ASSEMBLY [ALL] 19. Remove A/T assembly from engine assembly. CAUTION: ● Secure torque converter to prevent it from dropping. ● Secure A/T assembly to a transmission jack. 20. Remove engine mounting bracket (LH). Refer to AT-356, "COMPONENTS" . ATM0479D 21. 22. 23. 24. 25. Remove fluid cooler tubes (1) and copper washers. Remove A/T fluid level gauge (2). Remove A/T fluid charging pipe (3). Remove O-ring from A/T fluid charging pipe (3). Remove bracket from A/T assembly. SCIA6813J INSPECTION Installation and Inspection of Torque Converter ● After inserting a torque converter to a A/T, be sure to check dimension “A” to ensure it is within the reference value limit. Dimension “A”: 16.2 mm (0.638 in) or more SAT430D INSTALLATION Note the following, and install in the reverse order of removal, while paying attention to the following work. CAUTION: Do not reuse O-ring and copper washers. Refer to AT-356, "COMPONENTS" . ● When installing A/T assembly to engine assembly, attach fixing bolts in accordance with the following standard. Bolt No. 1 2 3 4 Number of bolts 2 2 1 3 40 (1.57) 44 (1.73) 69 (2.72) 49 (1.93) Bolt length “L” [mm (in)] Tightening torque [N·m (kg-m, ft-lb)] 48 (4.9, 35) (A): A/T to engine (B): Engine to A/T SCIA7096E AT-358 TRANSAXLE ASSEMBLY [ALL] ● Align the positions of tightening bolts for drive plate with those of torque converter, and temporarily tighten bolts. Then, tighten bolts to the specified torque. : A 51 N·m (5.2 kg-m, 38 ft-lb) B CAUTION: ● When turning crankshaft, turn it clockwise as viewed from front of engine. AT ● When tightening the tighten bolts for the torque converter after fixing crankshaft pulley bolts, be sure to confirm the SCIA6225J tightening torque of crankshaft pulley mounting bolts. D Refer to EM-50, "TIMING CHAIN" . ● After converter is installed to drive plate, rotate crankshaft several turns and check to be sure that A/T rotates freely without binding. E ● After completing installation, check for A/T fluid leakage, A/T fluid level and A/T positions. Refer to AT-18, "Checking A/T Fluid" and AT-337, "Checking of A/T Position" . F G H I J K L M AT-359 OVERHAUL [ALL] OVERHAUL Components PFP:00000 BCS000X8 SCIA7177E AT-360 OVERHAUL [ALL] 1. Pinion mate gear thrust washer 2. Pinion mate gear 3. Pinion mate shaft 4. Lock pin 5. Side gear 6. Side gear thrust washer 7. Differential side bearing 8. Differential case 9. Final gear 10. Differential side bearing adjusting shim 11. Plug 12. O-ring 13. Bracket 14. RH differential side oil seal 15. Torque converter 16. Converter housing 17. Differential lubricant tube 18. Clip 19. O-ring 20. O-ring 21. Oil pump housing oil seal 22. Oil pump housing 23. Outer gear 24. Inner gear 25. Oil pump cover 26. Seal ring 27. Oil pump assembly Refer to GI section to make sure icons (symbol marks) in the figure. Refer to GI-11, "Components" . A B AT D E F G H I J K L M AT-361 OVERHAUL [ALL] SCIA5893J 1. Retaining plate 2. Driven plate 3. Dish plate 4. Snap ring 5. Spring retainer assembly 6. Reverse clutch piston 7. Seal ring 8. D-ring 9. Reverse clutch drum AT-362 OVERHAUL [ALL] 10. Thrust washer 11. Reverse clutch assembly 12. Drive plate 13. Snap ring 14. Needle bearing 15. Front sun gear 16. Needle bearing 17. High clutch hub 18. Snap ring 19. Retaining plate 20. Drive plate 21. Snap ring 22. Cancel cover 23. Spring retainer assembly 24. High clutch piston 25. Input shaft assembly (high clutch drum) 26. Needle bearing 27. High clutch assembly 28. Bearing race 29. Seal ring 30. Driven plate 31. Needle bearing 32. Needle bearing 33. Overrun clutch hub 34. End bearing 35. Forward clutch hub 36. Needle bearing 37. Rear planetary carrier 38. Rear sun gear 39. Front planetary carrier 40. Low one-way clutch 41. Snap ring 42. Needle bearing 43. Needle bearing 44. Rear internal gear 45. Thrust washer 46. Forward one-way clutch 47. Thrust washer 48. Thrust washer 49. Forward clutch drum 50. Seal ring 51. Seal ring 52. Overrun clutch piston 53. Spring retainer assembly 54. Snap ring 55. Dish plate 56. Driven plate 57. Retaining plate 58. Snap ring 59. Dish plate 60. Driven plate 61. Retaining plate 62. Snap ring 63. Forward clutch assembly and overrun clutch assembly 64. Drive plate 65. Drive plate 66. D-ring 67. Forward clutch piston 68. D-ring 69. Seal ring 70. Driven plate 71. Snap ring 72. Low & reverse brake assembly 73. Retaining plate 74. Drive plate 75. Retaining plate 76. Dish plate 77. Driven plate 78. Snap ring 79. Spring retainer assembly 80. Low & reverse brake piston 81. D-ring A B AT D E F G H I Refer to GI section to make sure icons (symbol marks) in the figure. Refer to GI-11, "Components" . J K L M AT-363 OVERHAUL [ALL] SCIA7178E 1. Snap ring 2. Governor cap 3. O-ring 4. Lock nut 5. Anchor end pin 6. Transaxle case 7. Reduction pinion gear bearing 8. Reduction pinion gear 9. Brake band AT-364 OVERHAUL [ALL] 10. Output shaft 11. Seal ring 12. Output shaft bearing 13. Seal ring 14. Bearing retainer 15. O-ring 16. Servo release accumulator piston 17. Return spring 18. Control valve assembly 19. Oil pan gasket 20. Oil pan 21. Drain plug gasket 22. Drain plug 23. Magnet 24. Oil pan fitting bolt 25. Snap ring 26. O-ring 27. O-ring 28. N-D accumulator piston 29. Return spring 30. O-ring 31. Lip seal 32. Turbine revolution sensor (power train revolution sensor) 33. O-ring 34. Retaining pin 35. Detent spring 36. Retaining pin 37. Manual shaft 38. Manual shaft oil seal 39. Manual plate 40. Parking rod plate 41. Parking rod 42. OD servo piston retainer 43. Snap ring 44. O-ring 45. OD servo piston 46. D-ring 47. Servo piston retainer 48. O-ring 49. E-ring 50. Spring retainer 51. OD servo return spring 52. D-ring 53. Band servo piston 54. Band servo thrust washer 55. Band servo piston stem 56. 2nd servo return spring 57. PNP switch 58. Parking shaft 59. Return spring 60. Output gear adjusting spacer 61. Output gear bearing 62. Output gear 63. Side cover gasket 64. Side cover 65. Side cover fitting bolt 66. Lock nut 67. Idler gear 68. Idler gear bearing 69. Reduction pinion gear adjusting shim 70. Parking actuator support 71. Parking pawl 72. LH differential side oil seal A B AT D E F G H 73. Revolution sensor Refer to GI section to make sure icons (symbol marks) in the figure. Refer to GI-11, "Components" . I However, refer to the following symbol for others. : Apply locking sealant (Loctite #518). J K L M AT-365 OVERHAUL [ALL] Oil Channel BCS000X9 SCIA5925E AT-366 OVERHAUL [ALL] Locations of Adjusting Shims, Needle Bearings and Thrust Washers BCS000XA A B AT D E F G H I J K L M SCIA6051J ● Refer to AT-474, "SERVICE DATA AND SPECIFICATIONS (SDS)" . AT-367 OVERHAUL [ALL] Locations of Snap Rings BCS000XB SCIA6170J ● Refer to AT-474, "SERVICE DATA AND SPECIFICATIONS (SDS)" . AT-368 DISASSEMBLY [ALL] DISASSEMBLY Disassembly 1. 2. PFP:31020 A BCS000XC Drain ATF through drain hole. Remove drain plug gasket from drain plug. B AT D SCIA0003E 3. E Remove torque converter. F G H SAT008D 4. a. b. c. Check torque converter one-way clutch using check tool as shown in the figure. Insert check tool into groove of bearing support built into oneway clutch outer race. When fixing bearing support with check tool, rotate one-way clutch spline using screwdriver. Check that inner race rotates clockwise only. If not, replace torque converter assembly. I J K L M SAT009D AT-369 DISASSEMBLY [ALL] 5. 6. Remove turbine revolution sensor (power train revolution sensor) (1) from transaxle case (2). : Bolt (1) Remove O-ring (3) from turbine revolution sensor (power train revolution sensor) (1). SCIA7004J 7. Remove revolution sensor (1) from transaxle case (2). : Bolt (2) SCIA7170J 8. 9. Set manual shaft (1) in “P” position. Remove PNP switch (2) from transaxle case. : Bolt (3) SCIA5904J 10. Remove oil pan fitting bolts. 11. Remove oil pan and oil pan gasket. 12. Check foreign materials in oil pan to help determine causes of malfunction. If the ATF is very dark, smells burned, or contains foreign particles, frictional material (clutches, band) may need replacement. A tacky film that will not wipe clean indicates varnish build up. Varnish can cause valves, servo, and clutches to stick and can inhibit pump pressure. ● If frictional material is detected, replace radiator after repair of A/T. Refer to CO-12, "RADIATOR" . 13. Remove magnets from oil pan. SCIA3476E AT-370 DISASSEMBLY [ALL] 14. Remove control valve assembly according to the following procedures. a. Remove snap ring (1) from terminal body (2). CAUTION: Do not expand snap ring (1) excessively. b. Push terminal body (2) into transaxle case. A B AT SCIA6030J D c. Remove control valve assembly fitting bolts A , B and C . Bolt length, number and location: Bolt symbol Bolt length “ ” [mm (in)] Number of bolts A B C 40.0 mm (1.575 in) 33.0 mm (1.299 in) 43.5 mm (1.713 in) 5 6 2 E F G SCIA5911J H d. Remove control valve assembly from transaxle case. CAUTION: Be careful not to drop manual valve. 15. Remove manual valve from control valve assembly. ● Inspect the sliding surfaces of manual valve and valve body, and replace if damaged or dented. CAUTION: Be careful not to drop manual valve. 16. Remove O-ring from terminal body. I J K L SCIA3150E 17. Remove return spring from servo release accumulator piston. M SCIA3477E AT-371 DISASSEMBLY [ALL] 18. Apply compressed air into the oil hole as shown in the figure, and remove servo release accumulator piston from transaxle case. CAUTION: Strong flow of air will push the accumulator piston out along with a splash of ATF. Cover the area with lint-free cloth and blow air little by little to avoid this. SAT019DA 19. Apply compressed air into the oil hole as shown in the figure, and remove N-D accumulator piston and return spring from transaxle case. CAUTION: Strong flow of air will push the accumulator piston out along with a splash of ATF. Cover the area with lint freecloth and blow air little by little to avoid this. SAT020D 20. Remove O-rings (1) from servo release accumulator piston (2) and N-D accumulator piston (3). CAUTION: Wrap the removed servo release accumulator piston (2) and N-D accumulator piston (3) in a lint-free cloth. SCIA6033J ● Inspect the sliding surfaces of each accumulator piston and transaxle case, and replace if damaged or dented. (1): Servo release accumulator piston (2): N-D accumulator piston SCIA6035J AT-372 DISASSEMBLY [ALL] ● Inspect each return spring, and replace if deformed or worn. Refer to AT-476, "Accumulator" for free length (L1 ) and length (L2 ). (1): Return spring (Servo release accumulator) (2): Return spring (N-D accumulator) CAUTION: Do not remove spring retainer (3). A B AT D E F G SCIA6955E 21. Remove lip seals (1) from transaxle case. H I J SCIA5895J 22. Remove converter housing according to the following procedures. a. Remove converter housing fitting bolts (1), (2) and (3) using a power tool. b. Remove bracket from converter housing c. Remove converter housing by tapping it lightly. K L M SCIA6956E AT-373 DISASSEMBLY [ALL] d. Remove O-ring (1) from differential lubricant hole. SCIA5918J 23. Remove plug from converter housing. 24. Remove O-ring from plug. 25. Remove final drive assembly (1) from transaxle case. SCIA6034J 26. Remove differential side bearing adjusting shim from transaxle case. SCIA4938E 27. Remove RH differential side oil seal from converter housing using a flat-bladed screwdriver. CAUTION: Be careful not to scratch converter housing. SCIA3283E AT-374 DISASSEMBLY [ALL] 28. Remove differential lubricant tube and clips from converter housing. A B AT SCIA3284E D 29. Remove oil pump assembly according to the following procedures. a. Remove O-ring from input shaft assembly (high clutch drum). E F G SCIA5634E b. c. H Remove oil pump assembly fitting bolts, and then remove oil pump assembly (1) from transaxle case. Remove O-ring from oil pump assembly (1). I J K SCIA6036J d. Remove bearing race (1) and thrust washer (2) from oil pump assembly (3). L M SCIA6957E AT-375 DISASSEMBLY [ALL] 30. Remove brake band according to the following procedures. a. Loosen lock nut (1), and then remove anchor end pin (2) and lock nut (1) as a set from transaxle case. SCIA6037J b. Remove brake band from transaxle case. SAT038D ● To prevent brake linings from cracking or peeling, do not stretch the flexible band unnecessarily. When removing brake band, always secure it with a clip as shown in the figure. Leave the clip in position after removing brake band. SAT039D c. Check brake band facing for damage, cracks, wear or burns. SAT040D 31. Remove input shaft assembly (high clutch assembly) and reverse clutch assembly according to the following procedures. a. Remove input shaft assembly (high clutch assembly) (1) with reverse clutch assembly (2). SCIA6038J AT-376 DISASSEMBLY [ALL] b. Remove input shaft assembly (high clutch assembly) (1) from reverse clutch assembly (2). A B AT SCIA6958E c. Remove needle bearing (1) from input shaft assembly (high clutch drum) (2). ● Inspect needle bearing (1) and input shaft assembly (high clutch drum) (2), and replace if damaged or worn. D E F G SCIA6959E 32. Remove needle bearing from high clutch hub. ● Inspect needle bearing, and replace if damaged or worn. H I J SAT371D 33. Remove high clutch hub from front sun gear. ● Inspect high clutch hub, and replace if damaged or worn. K L M SAT370D 34. Remove needle bearing from front sun gear. ● Inspect needle bearing, and replace if damaged or worn. SAT369D AT-377 DISASSEMBLY [ALL] 35. Remove front sun gear from front planetary carrier. SAT368D 36. Remove needle bearing (1) from front sun gear (2). ● Inspect needle bearing (1) and front sun gear (2), and replace if damaged or worn. SCIA6960E 37. Remove front planetary carrier and low one-way clutch according to the following procedures. a. Remove snap ring using a flat-bladed screwdriver. SCIA3633E b. Remove low one-way clutch (1) and front planetary carrier (2) as a set from transaxle case. SCIA5896J AT-378 DISASSEMBLY [ALL] c. d. Check that low one-way clutch rotates counter-clockwise around front planetary carrier. Then try to turn it clockwise and check that it is locked. ● Replace low one-way clutch if necessary. Remove low one-way clutch from front planetary carrier by turning it in the direction of unlock. ● Inspect low one-way clutch, and replace if damaged or worn. A B AT SAT048D D e. Remove needle bearing (1) from front planetary carrier (2). ● Inspect needle bearing (1) and front planetary carrier (2), and replace if damaged or worn. E F G SCIA6047J f. Check clearance between pinion washer and front planetary carrier using feeler gauge. H Standard clearance and allowable limit: Refer to AT-478, "Planetary Carrier" . ● I Replace front planetary carrier if the clearance exceeds allowable limit. J SAT050D 38. Remove rear planetary carrier and rear sun gear according to the following procedures. a. Remove rear planetary carrier (with rear sun gear) from transaxle case. K L M SAT051D AT-379 DISASSEMBLY [ALL] b. Remove rear sun gear from rear planetary carrier. ● Inspect rear sun gear, and replace if damaged or worn. SAT052D c. Remove needle bearing (1) from rear planetary carrier (2). ● Inspect needle bearing (1) and rear planetary carrier (2), and replace if damaged or worn. SCIA5927J d. Check clearance between pinion washer and rear planetary carrier using feeler gauge. Standard clearance and allowable limit: Refer to AT-478, "Planetary Carrier" . ● Replace rear planetary carrier if the clearance exceeds allowable limit. SAT054D 39. Remove rear internal gear (1) and forward clutch hub (2) as a set from forward clutch drum. SCIA5897J 40. Remove needle bearing (1) from rear internal gear (2). ● Inspect needle bearing (1), and replace if damaged or worn. SCIA6041J AT-380 DISASSEMBLY [ALL] 41. Remove overrun clutch hub (1) from forward clutch drum. A B AT SCIA5898J 42. Remove thrust washer (1) from overrun clutch hub (2). ● Inspect thrust washer (1) and overrun clutch hub (2), and replace if damaged or worn. D E F G SCIA5899J 43. Remove forward clutch assembly and overrun clutch assembly (1) from transaxle case. H I J SCIA5900J 44. Remove needle bearing (1) and thrust washer (2) from bearing retainer. ● Inspect needle bearing (1) and thrust washer (2), and replace damaged or worn. K L M SCIA5901J 45. Remove side cover fitting bolts (1), and then remove side cover by lightly tapping it using a soft hammer. CAUTION: Be careful not to damage side cover. 46. Remove side cover gasket from side cover. SCIA6039J AT-381 DISASSEMBLY [ALL] 47. a. b. c. Remove output shaft, output gear and reduction gear according to the following procedures. Set manual shaft in “P” position to fix idler gear and output gear. Unlock both idler gear and output gear lock nuts using a pin punch. Remove idler gear and output gear lock nuts. SAT704D d. Remove idler gear (2) and output gear (1) using Tool A. Tool number: e. ST27180001 Remove reduction pinion gear and output shaft from transaxle case. SCIA6991E f. g. Remove reduction pinion gear adjusting shim (1) from reduction pinion gear (2). Remove output gear adjusting spacer (3) from output shaft (4). SCIA5902J 48. Remove bearing retainer fitting bolts, and then remove bearing retainer (1) from transaxle case. SCIA5909J AT-382 DISASSEMBLY [ALL] 49. Remove return spring (2) from parking shaft (3) using a flatbladed screwdriver. (1): Parking pawl ● Inspect return spring (2), and replace if damaged or worn. A B AT SCIA6996E D 50. Draw out parking shaft (1), and then remove parking pawl (2) from transaxle case. ● Inspect parking shaft (1) and parking pawl (2), and replace if damaged or worn. E F G SCIA6997E 51. Remove parking actuator support (1) from transaxle case. ● Inspect parking actuator support (1), and replace if damaged or worn. 52. Remove snap ring from transaxle case using a flat-bladed screwdriver. 53. Remove governor cap from transaxle case. 54. Remove O-ring from governor cap. H I J SCIA6998E 55. Remove LH differential side oil seal from transaxle case using a flat-bladed screwdriver. CAUTION: Be careful not to scratch transaxle case. K L M ATM0076D AT-383 REPAIR FOR COMPONENT PARTS [ALL] REPAIR FOR COMPONENT PARTS Manual Shaft PFP:00000 BCS000XD COMPONENTS SCIA5907J 1. Manual shaft oil seal 2. Parking rod 3. Retaining pin 4. Parking rod plate 5. Retaining pin 6. Manual plate 7. Manual shaft 8. Detent spring 9. Retaining pin Refer to GI section to make sure icons (symbol marks) in the figure. Refer to GI-11, "Components" . REMOVAL 1. Remove detent spring from transaxle case. SAT313G 2. Drive out retaining pin of manual plate using the pin punch. SAT076D AT-384 REPAIR FOR COMPONENT PARTS [ALL] 3. Pull out retaining pin (2) of parking rod plate (1) using nippers. A B AT SCIA5806J D 4. Pull out retaining pin (1) of manual shaft using nippers. E F G SCIA6514J 5. 6. 7. 8. Remove parking rod plate (with parking rod) (3) from manual shaft (1). Remove parking rod from parking rod plate (3). Remove manual plate (2) from manual shaft (1). Draw out manual shaft (1) from transaxle case. H I J SCIA7005E 9. Remove manual shaft oil seal from transaxle case using a flatbladed screwdriver. CAUTION: Be careful not to scratch transaxle case. K L M SAT080D INSPECTION Check component parts, and replace if damaged or worn. AT-385 REPAIR FOR COMPONENT PARTS [ALL] INSTALLATION 1. 2. Drive manual shaft oil seal into transaxle case using a drift [commercial service tool: 22 mm (0.87 in) dia.]. CAUTION: ● Do not reuse manual shaft oil seal. ● Apply ATF to outer surface of manual shaft oil seal. Install parking rod to parking rod plate. SAT081D 3. 4. Insert manual shaft (1) to transaxle case, and install manual plate (2) to manual shaft (1). Install parking rod plate (with parking rod) (3) to manual shaft (1). SCIA7005E 5. 6. Align groove of manual shaft and hole of transaxle case using a pin punch A [commercial service tool: 2 mm (0.08 in) dia.]. Drive retaining pin of manual shaft into transaxle case using Tool (B). Tool number B: ST23540000 CAUTION: Do not reuse retaining pin. SCIA7006E 7. Set parking rod plate (1) onto manual shaft, and drive retaining pin (2) of parking rod plate (1). Tool number A: ST23540000 CAUTION: The retaining pin end should protrude approx. 3mm (0.12 in) (B) from the outer surface of parking rod plate (1). SCIA7107E AT-386 REPAIR FOR COMPONENT PARTS [ALL] 8. Set manual plate (1) onto manual shaft, and drive retaining pin (2) of manual plate (1). Tool number A: A ST23540000 CAUTION: The retaining pin end should protrude approx. 3mm (0.12 in) (B) from the outer surface of manual plate (1). B AT SCIA7108E D 9. Install detent spring on transaxle case. 10. Tighten detent spring fitting bolt to the specified torque. Refer to AT-384, "COMPONENTS" . E F G SAT042F H I J K L M AT-387 REPAIR FOR COMPONENT PARTS [ALL] Oil Pump BCS000XE COMPONENTS SCIA5908J 1. Oil pump housing oil seal 2. Oil pump housing 3. Outer gear 4. Inner gear 5. Oil pump cover 6. Seal ring Refer to GI section to make sure icons (symbol marks) in the figure. Refer to GI-11, "Components" . DISASSEMBLY 1. Remove seal rings (1) from oil pump assembly (2). SCIA7016E 2. Remove bolts in the order as shown in the figure, and remove oil pump cover. SAT091D AT-388 REPAIR FOR COMPONENT PARTS [ALL] 3. Remove inner gear and outer gear from oil pump housing. A B AT SAT092D D 4. Remove oil pump housing oil seal using a flat-bladed screwdriver. CAUTION: Be careful not to scratch oil pump housing. E F G SCIA2840E H I J K L M AT-389 REPAIR FOR COMPONENT PARTS [ALL] INSPECTION Oil Pump Housing, Oil Pump Cover, Inner Gear and Outer Gear Check for wear or damage. Replace if necessary. Side Clearances ● Measure side clearance of inner gear and outer gear in at least four places around each outside edge. Maximum measured values should be within the specified clearance. Standard clearance: ● ● Refer to AT-478, "Oil Pump" . If clearance is less than standard, select inner gear and outer gear as a set so that clearance is within specifications. Refer to “Parts Information” for the inner gear and outer gear selection. If clearance is more than standard, replace whole oil pump assembly except oil pump cover. SCIA4957E ● Measure clearance between outer gear and oil pump housing. Standard clearance and allowable limit: Refer to AT-478, "Oil Pump" . ● If not within allowable limit, replace whole oil pump assembly except oil pump cover. SAT096D Seal Ring Clearance ● Measure clearance between seal ring and ring groove. Standard clearance and allowable limit: Refer to AT-478, "Oil Pump" . ● If not within allowable limit, replace oil pump cover assembly. SAT097D AT-390 REPAIR FOR COMPONENT PARTS [ALL] ASSEMBLY 1. A Install oil pump housing oil seal on oil pump housing. CAUTION: ● Do not reuse oil pump housing oil seal. ● Apply ATF to outer surface of oil pump housing oil seal. B AT SAT900DA 2. Install inner gear and outer gear on oil pump housing. CAUTION: Be careful with the direction of inner gear. D E F G SAT092D 3. a. b. H Install oil pump cover on oil pump housing. Wrap masking tape around splines of oil pump cover assembly to protect seal. Position oil pump cover assembly on oil pump housing assembly, then remove masking tape. Tighten oil pump cover fitting bolts in the order as shown in the figure, and then tighten them to the specified torque in the same order. Refer to AT-388, "COMPONENTS" . I J K SAT101D 4. L Install seal rings (1) to oil pump assembly (2) carefully after packing ring groove with petroleum jelly. CAUTION: Do not spread gap of seal rings (1) excessively while installing. The seal rings (1) may be deformed. M SCIA7016E AT-391 REPAIR FOR COMPONENT PARTS [ALL] Control Valve Assembly BCS000XF COMPONENTS SCIA5967J 1. Pilot filter 2. Control valve upper body 3. 4. Separating plate 5. Control valve inter body 6. Steel ball Steel ball 7. Support plate 8. Separating plate 9. Control valve lower body 10. Line pressure relief valve spring 11. Check ball 12. Torque converter pressure holding spring 13. Solenoid valve assembly 14. Terminal body 15. O-ring 16. O-ring 17. O-ring 18. Oil strainer Refer to GI section to make sure icons (symbol marks) in the figure. Refer to GI-11, "Components" . AT-392 REPAIR FOR COMPONENT PARTS [ALL] DISASSEMBLY A Place control valve assembly with control valve upper body (1) side down. Remove bolts (A) to (G), reamer bolts (F), nuts and support plates (4) according to the following procedures. Separate control valve upper body (1), control valve inter body (2) and control valve lower body (3). B AT D E F G SCIA7058E H Bolt length, number and location: Bolt symbol Bolt length “ ” [mm (in)] Number of bolts *: A B C D E F* G 13.5 (0.531) 58.0 (2.283) 40.0 (1.575) 66.0 (2.598) 33.0 (1.299) 78.0 (3.071) 18.0 (0.709) 6 3 6 11 2 2 1 J Reamer bolt and nut. 1. I Remove bolts (A), (D), reamer bolt (F) and nut , and remove oil strainer (1) from control valve assembly. K L M SCIA7007E 2. Remove bolts (A), (C) and (G), and then remove solenoid valve assembly (1) from control valve assembly. SCIA7008E AT-393 REPAIR FOR COMPONENT PARTS [ALL] 3. Remove O-rings from solenoid valves and terminal body. SCIA7180E 4. Place control valve upper body face down, and remove bolts (B), reamer bolt (F) and nut. CAUTION: Remove bolts with control valve upper body facing down, because control valve upper body and control valve inter body may come off and steel ball may fall and be lost. ATL0020D 5. Remove control valve lower body (1) from control valve inter body (2). (3): Control valve upper body SCIA7181E 6. 7. Turn over control valve lower body (1). Remove bolts (E), support plates (2) and separating plate (3) from control valve lower body (1). SCIA7009E 8. Remove check balls (1), line pressure relief valve springs (2) and torque converter pressure holding spring (3) from control valve lower body. CAUTION: Be careful not to lose check balls (1), line pressure relief valve springs (2) and torque converter pressure holding spring (3). SCIA6491J AT-394 REPAIR FOR COMPONENT PARTS [ALL] 9. Remove control valve inter body from control valve upper body. A B AT SCIA4977E D 10. Remove pilot filter (1) from control valve upper body (2). 11. Remove separating plate from control valve upper body (2). E F G SCIA7011E 12. Check to see that steel balls are properly positioned in control valve inter body and then remove them. CAUTION: Be careful not to lose steel balls. H I J SAT870J 13. Check to see that steel balls are properly positioned in control valve upper body and then remove them. CAUTION: Be careful not to lose steel balls. K L M SAT871J AT-395 REPAIR FOR COMPONENT PARTS [ALL] INSPECTION Control Valve Lower and Upper Bodies CAUTION: Be careful not to lose these parts. ● Check to see that retainer plates are properly positioned in control valve lower body. SCIA4978E ● Check to see that retainer plates are properly positioned in control valve upper body. SCIA4979E Oil Strainer Check wire netting of oil strainer for damage. Replace if necessary. SCIA3291E Shift Solenoid Valves “A” and “B”, Line Pressure Solenoid Valve, Torque Converter Clutch Solenoid Valve and Overrun Clutch Solenoid Valve Measure resistance. ● For shift solenoid valve A, refer to AT-163, "Component Inspection" (EURO-OBD) or AT-219, "Component Inspection" (Except for EURO-OBD). ● For shift solenoid valve B, refer to AT-168, "Component Inspection" (EURO-OBD) or AT-224, "Component Inspection" (Except for EURO-OBD). ● For line pressure solenoid valve, refer to AT-158, "Component Inspection" (EURO-OBD) or AT-256, "Component Inspection" (Except for EURO-OBD). SCIA3485E ● For torque converter clutch solenoid valve, refer to AT-146, "Component Inspection" (EURO-OBD) or AT-234, "Component Inspection" (Except for EURO-OBD). ● For overrun clutch solenoid valve, refer to AT-175, "Component Inspection" (EURO-OBD) or AT-229, "Component Inspection" (Except for EURO-OBD). AT-396 REPAIR FOR COMPONENT PARTS [ALL] A/T Fluid Temperature Sensor Measure resistance. ● For A/T fluid temperature sensor, refer to AT-185, "Component Inspection" (EURO-OBD) or AT-240, "Component Inspection" (Except for EURO-OBD). B Line Pressure Relief Valve Springs and Torque Converter Pressure Holding Spring ● ● A Check each spring for damage or deformation. Also measure free length and outer diameter. Refer to AT-476, "Control Valves" . Replace springs if deformed or fatigued. AT D E SAT138D ASSEMBLY 1. a. F Install control valve upper, inter and lower body. Place oil circuit of control valve upper body face up. Install steel balls in their proper positions. G H I SAT871J b. Install reamer bolts (F) from bottom of control valve upper body (1). Using reamer bolts (F) as guides, install separating plate (2) as a set. J K L SCIA7010E c. Install pilot filter (1) on control valve upper body (2). SCIA7011E AT-397 M REPAIR FOR COMPONENT PARTS [ALL] d. Place control valve inter body as shown in figure (side of control valve lower body face up). Install steel balls in their proper positions. SAT870J e. Install control valve inter body (1) on control valve upper body (2) using reamer bolts (F) as guides. CAUTION: Be careful not to dislocate or drop steel balls. SCIA7012E f. Install check balls (1), line pressure relief valve springs (2) and torque converter pressure holding spring (3) in their proper positions in control valve lower body (4). SCIA6491J g. h. Install bolts (E) from bottom of control valve lower body (1). Using bolts (E) as guides, install separating plate (2) as a set. Install support plates (3) on control valve lower body (1). SCIA7013E i. Install control valve lower body (1) on control valve inter body (2) using reamer bolts (F) as guides, and tighten reamer bolts (F) slightly. SCIA7014E AT-398 REPAIR FOR COMPONENT PARTS [ALL] 2. Install O-rings on solenoid valves and terminal body. A B AT SCIA7180E 3. Install and tighten bolts. (1): Control valve upper body (2): Control valve inter body (3): Control valve lower body (4): Support plate D E F G H I J SCIA7058E K Bolt length, number and location: Bolt symbol Bolt length “ ” [mm (in)] Number of bolts Tightening torque [N·m (kg-m, in-lb)] *: a. A B C D E F* G 13.5 (0.531) 58.0 (2.283) 40.0 (1.575) 66.0 (2.598) 33.0 (1.299) 78.0 (3.071) 18.0 (0.709) 6 3 6 11 2 2 1 L 7.84 (0.80, 69) 3.92 (0.40, 35) 7.84 (0.80, 69) Reamer bolt and nut. Install and tighten bolts (B) to the specified torque. : 7.84 N·m (0.80 kg-m, 69 in-lb) ATL0032D AT-399 M REPAIR FOR COMPONENT PARTS [ALL] b. c. Install solenoid valve assembly (1) on control valve assembly. Tighten bolts (A), (C) and (G) to the specified torque. : 7.84 N·m (0.80 kg-m, 69 in-lb) SCIA7008E d. e. Remove reamer bolts (F), and then set oil strainer (1) on control valve assembly Install and tighten bolts (A), (D), reamer bolts (F) and nuts to the specified torque. : 7.84 N·m (0.80 kg-m, 69 in-lb) SCIA7131E f. Tighten bolts (E) to the specified torque. : 3.92 N·m (0.40 kg-m, 35 in-lb) ATL0035D AT-400 REPAIR FOR COMPONENT PARTS [ALL] Control Valve Upper Body BCS000XG A COMPONENTS B AT D E F G H I J K L M SCIA2960J AT-401 REPAIR FOR COMPONENT PARTS [ALL] 1. Retainer plate 2. Plug 3. 4. Cooler check valve 5. Control valve upper body 6. Cooler check valve spring Pilot valve 7. Pilot valve spring 8. Retainer plate 9. 1-2 accumulator retainer plate 10. 1-2 accumulator piston spring 11. 1-2 accumulator piston 12. Plug 13. Retainer plate 14. Retainer plate 15. Plug 16. 1st reducing valve 17. 1st reducing valve spring 18. Retainer plate 19. 3-2 timing valve spring 20. 3-2 timing valve 21. Retainer plate 22. Plug 23. Overrun clutch reducing valve 24. Overrun clutch reducing valve spring 25. Retainer plate 26. Torque converter relief valve spring 27. Torque converter relief valve 28. Retainer plate 29. Sleeve 30. Plug 31. Torque converter clutch control valve 32. spring Torque converter clutch control valve 33. Retainer plate 34. Plug 1-2 accumulator valve spring 36. 1-2 accumulator valve 35. DISASSEMBLY 1. Remove valves at retainer plates. CAUTION: Do not use a magnetic pick-up tool. SCIA4979E a. Use a flat-bladed screwdriver A to remove retainer plates (1). SCIA7136E b. Remove retainer plates (1) while holding spring, plugs (2) or sleeves using a flat-bladed screwdriver A. CAUTION: Remove plugs (2) slowly to prevent internal parts from jumping out. SCIA7137E AT-402 REPAIR FOR COMPONENT PARTS [ALL] c. Place mating surface of valve body face down, and remove internal parts. CAUTION: ● If a valve is hard to remove, place valve body face down and lightly tap it with a soft hammer. ● Be careful not to drop or damage valves and sleeves. A B AT SAT137D D INSPECTION Valve Springs ● ● E Check each valve spring for damage or deformation. Also measure free length and outer diameter. Refer to AT-476, "Control Valves" . Replace valve springs if deformed or fatigued. F G H SAT138D Control Valves Check sliding surfaces of valves, sleeves and plugs. Replace if necessary. I ASSEMBLY CAUTION: ● Apply ATF to all components before installation. ● Lay control valve body down when installing valves. Do not stand control valve body upright. J K L SAT139D Lubricate control valve body and all valves with ATF. Install control valves by sliding them carefully into their bores. CAUTION: ● Install each control valve one by one. ● Install control valves after checking, because some of them are similar. ● Be careful not to scratch or damage valve body. SAT140DA AT-403 M REPAIR FOR COMPONENT PARTS [ALL] ● Wrap a small flat-bladed screwdriver A with vinyl tape and use it to insert valves into their proper positions. SCIA7138E ● – Install retainer plates (1). While pushing plug or return spring, install retainer plate (1) using a flat-bladed screwdriver A. SCIA7139E 1-2 Accumulator Valve ● ● Install 1-2 accumulator valve (1), 1-2 accumulator valve spring and plug. Align 1-2 accumulator retainer plate (2) from opposite side of control valve body. Install 1-2 accumulator valve piston spring (3), 1-2 accumulator piston (4), plug (5) and retainer plate (6). SCIA7182E Retainer Plate (Control Valve Upper Body) Install proper retainer plates. Refer to AT-401, "COMPONENTS" . Unit: mm (in) Loca tion L14 L15 Retainer plate designation Width “A” Pilot valve Length “B” 21.5 (0.846) 1-2 accumulator valve 40.5 (1.594) 1-2 accumulator piston L16 1st reducing valve L17 3-2 timing valve L18 Overrun clutch reducing valve 24.0 (0.945) L19 Torque converter relief valve 21.5 (0.846) L20 Torque converter clutch control valve 28.0 (1.102) L21 Cooler check valve 24.0 (0.945) 21.5 (0.846) 6.0 (0.236) AT-404 SAT086F REPAIR FOR COMPONENT PARTS [ALL] Control Valve Lower Body BCS000XH A COMPONENTS B AT D E F G H I J K L M SCIA2959J AT-405 REPAIR FOR COMPONENT PARTS [ALL] 1. Retainer plate 2. Pressure modifier piston spring 3. Pressure modifier piston 4. Parallel pin 5. Sleeve 6. Pressure modifier valve spring 7. Pressure modifier valve 8. Control valve lower body 9. Manual valve 10. Pressure regulator valve 11. Pressure regulator valve spring 12. Spring seat 13. Plug 14. Retainer plate 15. Sleeve 16. Overrun clutch control valve spring 17. Overrun clutch control valve 18. Plug 19. Retainer plate 20. Accumulator control valve spring 21. Accumulator control valve 22. Plug 23. Retainer plate 24. Retainer plate 25. Shift valve A spring 26. Shift valve A 27. Retainer plate 28. Plug 29. Shuttle plug 30. Shuttle valve spring 31. Shuttle valve 32. Shift valve B spring 33. Shift valve B 34. Plug 35. Retainer plate DISASSEMBLY Remove valves at retainer plate. For removal procedures, refer to AT-402, "DISASSEMBLY" . SCIA4978E INSPECTION Valve Springs ● ● Check each valve spring for damage or deformation. Also measure free length and outer diameter. Refer to AT-476, "Control Valves" . Replace valve springs if deformed or fatigued. SAT138D Control Valves Check sliding surfaces of control valves, sleeves and plugs for damage. Replace if necessary. ASSEMBLY CAUTION: ● Apply ATF to all components before installation. ● Lay control valve body down when installing valves. Do not stand control valve body upright. SAT139D AT-406 REPAIR FOR COMPONENT PARTS [ALL] Install control valves. For installation procedures, refer to AT-403, "ASSEMBLY" . A B AT SCIA4978E D Retainer Plate (Control Valve Lower Body) Install proper retainer plates. Refer to AT-405, "COMPONENTS" . Unit: mm (in) Loca tion Retainer plate designation Width “A” Length “B” E Type L3 Pressure regulator valve L4 Overrun clutch control valve L5 Accumulator control valve L6 Shift valve A L7 Shuttle valve L12 Shift valve B 17.0 (0.669) 24.0 (0.945) II L13 Pressure modifier valve 6.0 (0.236) 28.0 (1.102) I F 6.0 (0.236) 28.0 (1.102) I G SAT089F H I J K L M AT-407 REPAIR FOR COMPONENT PARTS [ALL] Reverse Clutch BCS000XI COMPONENTS SCIA6939J 1. Reverse clutch drum 2. D-ring 3. Seal ring 4. Reverse clutch piston 5. Spring retainer assembly 6. Snap ring 7. Dish plate 8. Driven plate 9. Retaining plate 10. Snap ring 11. Drive plate Refer to GI section to make sure icons (symbol marks) in the figure. Refer to GI-11, "Components" . DISASSEMBLY 1. a. b. c. d. 2. 3. Check operation of reverse clutch Install seal rings to drum support of oil pump assembly, and set reverse clutch assembly. Apply compressed air into the oil hole at the location as shown in the figure. Check to see that retaining plate moves to snap ring. If retaining plate does not contact snap ring: ● D-ring might be damaged. ● Seal ring might be damaged. ● Fluid might be leaking past piston check ball. SAT155D Remove snap ring (1) using a flat-bladed screwdriver A. Remove retaining plate, drive plates, driven plates and dish plates. SCIA7024J AT-408 REPAIR FOR COMPONENT PARTS [ALL] 4. 5. Set SST on spring retainer assembly, and remove snap ring from reverse clutch drum while compressing spring retainer assembly. CAUTION: Set SST directly over return springs. Remove spring retainer assembly from reverse clutch drum. CAUTION: Do not remove return springs from spring retainer. A B AT SAT157D D 6. Install seal rings to drum support of oil pump assembly (1), and set reverse clutch drum (2). Then apply compressed air into the oil hole at the location as shown in the figure to remove reverse clutch piston (3) from reverse clutch drum (2). CAUTION: Do not flow air in too quickly or reverse clutch piston (3) and ATF could jump out. Carefully flow air in little by little while protecting with lint-free cloth. E F G SCIA5999J 7. Remove D-ring (1) and seal ring (2) from reverse clutch piston (3). H I J SCIA5998J K L M AT-409 REPAIR FOR COMPONENT PARTS [ALL] INSPECTION Reverse Clutch Snap Ring Check for deformation, fatigue or damage. Replace if necessary. Reverse Clutch Drive Plates ● ● Check facing for burns, cracks or damage. Replace if necessary. Measure thickness of facing. Thickness of drive plate Standard and allowable limit: Refer to AT-476, "REVERSE CLUTCH" . CAUTION: ● Measure the thickness at 3 locations and find the average. ● Inspect ALL drive plates. ● Replace if the thickness is below the allowable limit. SAT162D Reverse Clutch Dish Plates ● ● Check for deformation or damage. Measure thickness (t) of dish plate. Replace if damaged, deformed or worn. Thickness of dish plate (t): 2.87 mm (0.1130 in) SAT163D Reverse Clutch Spring Retainer Assembly Measure length (L) of spring retainer assembly. Replace if damaged, deformed or worn. Length (L): 20.1 mm (0.791 in) CAUTION: Do not remove return springs (A) from spring retainer (B) SCIA7025J Reverse Clutch Piston ● ● ● Make sure that check balls are not fixed. Apply compressed air to check ball oil hole opposite from return spring. Make sure there is no air leakage. Apply compressed air to oil hole on return spring side to make sure that air leaks past ball. SAT164D Reverse Clutch Drum Check for deformation or damage. Replace if necessary. AT-410 REPAIR FOR COMPONENT PARTS [ALL] ASSEMBLY 1. A Install D-ring (1) and seal ring (2) on reverse clutch piston (3). CAUTION: Be careful with the direction of seal ring (2). B AT SCIA5998J 2. Install reverse clutch piston by turning it slowly. CAUTION: Apply ATF to inner surface of reverse clutch drum. D E F G SAT159D 3. H Install spring retainer assembly (1) to reverse clutch piston (2). I J K SCIA6000J 4. Set SST on spring retainer assembly, and install snap ring while compressing spring retainer assembly. CAUTION: Set SST directly over return springs. L M SAT157D AT-411 REPAIR FOR COMPONENT PARTS [ALL] 5. Install dish plates (5), driven plates (4), drive plates (3) and retaining plate (2). (1): Snap ring (2): Retaining plate (3): Drive plate (4): Driven plate (5): Dish plate Drive plate/Driven plate: 2/2 CAUTION: Be careful with the order of plates. SCIA7003J NOTE: Install two dish plates fitting each installation direction with reverse clutch drum groove displaced slightly. SAT170D 6. Install snap ring (1) using a flat-bladed screwdriver A. SCIA7024J 7. Measure clearance between retaining plate and snap ring using feeler gauge. If not within allowable limit, select proper retaining plate. Refer to “Parts Information” for retaining plate selection. Specified clearance Standard and allowable limit: Refer to AT-476, "REVERSE CLUTCH" . 8. Check operation of reverse clutch. Refer to AT-408, "DISASSEMBLY" . SAT174D AT-412 REPAIR FOR COMPONENT PARTS [ALL] High Clutch BCS000XJ A COMPONENTS B AT D E F SCIA6741E 1. Seal ring 2. Driven plate 3. G Retaining plate 4. Snap ring 5. Drive plate 6. Snap ring 7. Cancel cover 8. Spring retainer assembly 9. High clutch Piston H 10. Input shaft assembly (high clutch drum) I DISASSEMBLY 1. a. b. c. Check operation of high clutch. Apply compressed air into the oil hole (A) of input shaft assembly (high clutch drum) at the location as shown in the figure. CAUTION: Block the oil hole (A) on the opposite side with lint-free cloth (B). Check to see that retaining plate moves to snap ring. If retaining plate does not contact snap ring: ● High clutch piston seal might be damaged. J K L SCIA7032E 2. Remove seal rings from input shaft assembly (high clutch drum). SCIA4890E AT-413 M REPAIR FOR COMPONENT PARTS [ALL] 3. 4. Remove snap ring using a flat-bladed screwdriver. Remove retaining plate, drive plates and driven plates. SCIA4891E 5. Set Tool A on cancel cover, and remove snap ring (1) from input shaft assembly (high clutch drum) while compressing spring retainer assembly. Tool number: KV31103200 CAUTION: Do not expand snap ring (1) excessively. SCIA6001J 6. Remove cancel cover (1) and spring retainer assembly (2) from input shaft assembly (high clutch drum) (3). CAUTION: Do not remove return springs from spring retainers. SCIA7036E 7. Apply compressed air into the oil hole (A) at the location as shown in the figure to remove high clutch piston from input shaft assembly (high clutch drum). CAUTION: ● Do not blow air in too quickly, or high clutch piston and ATF could jump out. Carefully blow air little by little while protecting with lint-free cloth (B). ● Block the oil hole on the opposite side with lint-free cloth (B). SCIA7033E AT-414 REPAIR FOR COMPONENT PARTS [ALL] INSPECTION High Clutch Snap Ring A Check for deformation, fatigue or damage. Replace if necessary. High Clutch Drive Plates ● ● B Check facing for burns, cracks or damage. Replace if necessary. Measure thickness of facing. AT Thickness of drive plate Standard and allowable limit: Refer to AT-477, "HIGH CLUTCH" . CAUTION: ● Measure the thickness at 3 locations and find the average. ● Inspect ALL drive plates. ● Replace if the thickness is below the allowable limit. D E SAT162D High Clutch Spring Retainer Assembly F Check length (L) of springs retainer assembly. Replace if damaged, deformed or worn. Length (L): G 20.6 mm (0.811 in) CAUTION: Do not remove return springs (A) from spring retainers (B). H I SCIA7038E High Clutch Piston and Cancel Cover J Check for deformation or damage. Replace if necessary. Input Shaft Assembly (High Clutch Drum) K Check for deformation or damage. Replace if necessary. Seal Ring Clearance ● ● Install new seal rings onto input shaft assembly (high clutch drum). Measure clearance between seal ring and ring groove. L M Standard clearance and allowable limit: Refer to AT-478, "Input Shaft" . ● If not within allowable limit, replace input shaft assembly (high clutch drum). SCIA4901E AT-415 REPAIR FOR COMPONENT PARTS [ALL] ASSEMBLY 1. Install high clutch piston by turning it slowly. CAUTION: Apply ATF to inner surface of input shaft assembly (high clutch drum) and high clutch piston. SAT111F 2. Install spring retainer assembly (2) and cancel cover (1) on input shaft assembly (high clutch drum) (3). SCIA7036E 3. Set Tool A on cancel cover, and install snap ring (1) to input shaft assembly (high clutch drum) while slowly compressing spring retainer assembly. Tool number: KV31103200 CAUTION: Do not expand snap ring (1) excessively. ● Install spring retainer assembly without tilting. ● SCIA6001J ● Do not align snap ring gap with cancel cover stopper. SAT113F AT-416 REPAIR FOR COMPONENT PARTS [ALL] 4. Install driven plates (4), (5), drive plates (3) and retaining plate (2). (1): Snap ring (2): Retaining plate (3): Drive plate (4): Driven plate (5): Driven plate Drive plate/Driven plate: 3/6 (1+5) CAUTION: Be careful with the order and direction of plates. A B AT SCIA5996E D 5. Install snap ring using a flat-bladed screwdriver. E F G SCIA4891E 6. Set dial indicator A on retaining plate (1), and measure clearance between retaining plate (1) and snap ring (2). If not within allowable limit, select proper retaining plate (1). Refer to “Parts Information” for retaining plate selection. H I Specified clearance Standard and allowable limit: Refer to AT-477, "HIGH CLUTCH" . 7. J Check operation of high clutch. Refer to AT-413, "DISASSEMBLY" . SCIA5858E 8. K Install seal rings to input shaft assembly (high clutch drum). L M SCIA4890E AT-417 REPAIR FOR COMPONENT PARTS [ALL] CAUTION: Roll paper around seal rings to prevent seal rings from spreading. SAT198D AT-418 REPAIR FOR COMPONENT PARTS [ALL] Forward and Overrun Clutches BCS000XK A COMPONENTS B AT D E F G H I SCIA7183E 1. Dish plate 2. Driven plate 3. Retaining plate 4. Snap ring 5. Dish plate 6. Driven plate 7. Retaining plate 8. Snap ring 9. Forward clutch 10. Drive plate 11. Drive plate 12. Overrun clutch 13. Snap ring 14. Spring retainer assembly 15. Overrun clutch piston 16. D-ring 17. Seal ring 18. Forward clutch piston 19. D-ring 20. Seal ring 21. Forward clutch drum J K L Refer to GI section to make sure icons (symbol marks) in the figure. Refer to GI-11, "Components" . DISASSEMBLY 1. a. b. c. d. Check operation of forward clutch. Install seal rings to bearing retainer, and set forward clutch drum. Apply compressed air into oil hole of bearing retainer at the location as shown in the figure. Check to see that retaining plate moves to snap ring. If retaining plate does not contact snap ring: ● D-ring might be damaged. ● Seal ring might be damaged. ● Fluid might be leaking past piston check ball. AT-419 M SAT201D REPAIR FOR COMPONENT PARTS [ALL] 2. a. b. c. d. 3. 4. Check operation of overrun clutch. Install seal rings to bearing retainer, and set forward clutch drum. Apply compressed air into oil hole of bearing retainer at the location as shown in the figure. Check to see that retaining plate moves to snap ring. If retaining plate does not contact snap ring: ● D-ring might be damaged. ● Seal ring might be damaged. ● Fluid might be leaking past piston check ball. SAT202D Remove snap ring for forward clutch from forward clutch drum using a flat-bladed screwdriver. Remove retaining plate, drive plates, driven plates and dish plate for forward clutch. SCIA4894E 5. 6. Remove snap ring for overrun clutch from forward clutch drum using a flat-bladed screwdriver. Remove retaining plate, drive plates, driven plates and dish plate for overrun clutch. SCIA4895E 7. 8. Set SST on spring retainer assembly, and remove snap ring from forward clutch drum while compressing spring retainer assembly. CAUTION: ● Set SST directly over return springs. ● Do not expand snap ring excessively. Remove spring retainer assembly from forward clutch drum. CAUTION: Do not remove return springs from spring retainer. SAT205D 9. Install seal rings to bearing retainer (1), and set forward clutch drum. Then apply compressed air into the oil hole at the location as shown in the figure to remove overrun clutch piston from forward clutch piston. CAUTION: Do not blow air in too quickly, or overrun clutch piston and ATF could jump out. Carefully blow air little by little while protecting with lint-free cloth. SCIA6004J AT-420 REPAIR FOR COMPONENT PARTS [ALL] 10. Install seal rings to bearing retainer (1), and set forward clutch drum. Then apply compressed air into the oil hole at the location as shown in the figure to remove forward clutch piston from forward clutch drum. CAUTION: Do not blow air in too quickly, or forward clutch piston and ATF could jump out. Carefully blow air little by little while protecting with lint-free cloth. A B AT SCIA6003J D 11. Remove seal rings (1) and D-rings (2) from forward clutch piston (3) and overrun clutch piston (4). E F G SCIA6005J INSPECTION Forward Clutch and Overrun Clutch Snap Rings H Check for deformation, fatigue or damage. Replace if necessary. Forward Clutch and Overrun Clutch Drive Plates ● ● I Check facing for burns, cracks or damage. Replace if necessary. Measure thickness of facing. Thickness of drive plate Forward clutch Standard and allowable limit: Refer to AT-477, "FORWARD CLUTCH" . Overrun clutch Standard and allowable limit: Refer to AT-477, "OVERRUN CLUTCH" . J K L SAT162D CAUTION: ● Measure the thickness at 3 locations and find the average. ● Inspect ALL drive plates. ● Replace if the thickness is below the allowable limit. M Forward Clutch and Overrun Clutch Dish Plates ● ● Check for deformation or damage. Measure thickness (t) of dish plate. Replace if damaged, deformed or worn. Thickness of dish plate (t) Forward clutch: 2.5 mm (0.098 in) Overrun clutch: 2.15 mm (0.0846 in) SAT163D AT-421 REPAIR FOR COMPONENT PARTS [ALL] Forward Clutch and Overrun Clutch Spring Retainer Assembly Check length (L) of spring retainer assembly. Replace if damaged, deformed or worn. Length (L): 27.7 mm (0.1091 in) CAUTION: Do not remove return springs (A) from spring retainer (B) SCIA7025J Forward Clutch Drum ● ● ● Make sure that check balls are not fixed. Apply compressed air to check ball oil hole from outside of forward clutch drum. Make sure air leaks past ball. Apply compressed air to oil hole from inside of forward clutch drum. Make sure there is no air leakage. SAT213D Overrun Clutch Piston ● ● ● Make sure that check balls are not fixed. Apply compressed air to check ball oil hole opposite return spring. Make sure there is no air leakage. Apply compressed air to oil hole on return spring side. Make sure that air leaks through ball hole. SAT212D ASSEMBLY 1. Install seal rings (1) and D-rings (2) on forward clutch piston (3) and overrun clutch piston (4). CAUTION: Be careful with the direction of seal rings (1). SCIA6005J AT-422 REPAIR FOR COMPONENT PARTS [ALL] 2. Install overrun clutch piston on forward clutch piston by turning it slowly. CAUTION: Apply ATF to inner surface of forward clutch piston. A B AT SAT215D D 3. Install forward clutch piston with overrun clutch piston on forward clutch drum by turning it slowly. CAUTION: Apply ATF to inner surface of forward clutch drum. E F G SAT216D 4. Align notch in forward clutch piston with groove in forward clutch drum. H I J SAT217D 5. K Install spring retainer assembly (1) on overrun clutch piston (2). L M SCIA6019J 6. Set SST on spring retainer assembly, and install snap ring while compressing spring retainer assembly. CAUTION: ● Set SST directly over return springs. ● Do not expand snap ring excessively. SAT205D AT-423 REPAIR FOR COMPONENT PARTS [ALL] ● Do not align snap ring gap with spring retainer assembly stopper. SAT134F 7. Install dish plate (5), driven plates (4), drive plates (3) and retaining plate (2) for overrun clutch. (1): Snap ring (2): Retaining plate (3): Drive plate (4): Driven plate (5): Dish plate Drive plate/Driven plate: 3/4 CAUTION: Be careful with the order of plates. SCIA5993E 8. Install snap ring for overrun clutch using a flat-bladed screwdriver. SCIA4895E 9. Measure clearance between overrun clutch retaining plate and snap ring using feeler gauge. If not within allowable limit, select proper retaining plate. Refer to “Parts Information” for retaining plate selection. Specified clearance Standard and allowable limit: Refer to AT-477, "OVERRUN CLUTCH" . SAT227D 10. Install dish plate (5), driven plates (4), drive plates (3) and retaining plate (2) for forward clutch. (1): Snap ring (2): Retaining plate (3): Drive plate (4): Driven plate (5): Dish plate Drive plate/Driven plate: 5/5 CAUTION: Be careful with the order of plates. SCIA5992E AT-424 REPAIR FOR COMPONENT PARTS [ALL] 11. Install snap ring for forward clutch using a flat-bladed screwdriver. A B AT SCIA4894E 12. Measure clearance between forward clutch retaining plate and snap ring using feeler gauge. If not within allowable limit, select proper retaining plate. Refer to “Parts Information” for retaining plate selection. D E Specified clearance Standard and allowable limit: Refer to AT-477, "FORWARD CLUTCH" . F 13. Check operation of forward clutch and overrun clutch. Refer to AT-419, "DISASSEMBLY" . G SAT228D H I J K L M AT-425 REPAIR FOR COMPONENT PARTS [ALL] Low & Reverse Brake BCS000XL COMPONENTS SCIA6007J 1. Seal ring 2. D-ring 3. Low & reverse brake piston 4. Spring retainer assembly 5. Snap ring 6. Driven plate 7. Retaining plate 8. Driven plate 9. Retaining plate 10. Snap ring 11. Drive plate 12. Dish plate Refer to GI section to make sure icons (symbol marks) in the figure. Refer to GI-11, "Components" . DISASSEMBLY 1. a. b. c. Check operation of low & reverse brake. Apply compressed air into oil hole of transaxle case at the location as shown in the figure. Check to see that retaining plate moves to snap ring. If retaining plate does not contact snap ring: ● D-ring might be damaged. ● Seal ring might be damaged. SAT230D 2. 3. Remove snap ring (1) using a flat-bladed screwdriver A. Remove retaining plates, drive plates, driven plates, dish plates. SCIA7039E AT-426 REPAIR FOR COMPONENT PARTS [ALL] 4. 5. Set SST on spring retainer assembly, and remove snap ring from transaxle case while compressing spring retainer assembly. CAUTION: Set SST directly over return springs. Remove spring retainer assembly from transaxle case. CAUTION: Do not remove return springs from spring retainer. A B AT SAT242D D 6. 7. 8. Apply compressed air into the oil hole on transaxle case as shown in the figure to raise piston while strongly pressing the whole low & reverse brake piston by hand. When applying compressed air, strongly press the whole piston and adjust the pressure so that it is raised evenly. Portion (A) (low & reverse brake pressure) especially tends to tilt. CAUTION: Apply air gradually and allow low & reverse brake piston to come out evenly. Remove low & reverse brake piston from transaxle case by turning it. Inspect transaxle case. Replace if damaged or worn. E F G H I J SCIA6346J 9. K Remove seal ring (1) and D-ring (2) from low & reverse brake piston (3). L M SCIA6516J AT-427 REPAIR FOR COMPONENT PARTS [ALL] INSPECTION Low & Reverse Brake Snap Rings Check for deformation, fatigue or damage. Replace if necessary. Low & Reverse Brake Drive Plates ● ● Check facing for burns, cracks or damage. Replace if necessary. Measure thickness of facing. Thickness of drive plate Standard and allowable limit: Refer to AT-477, "LOW & REVERSE BRAKE" . CAUTION: ● Measure the thickness at 3 locations and find the average. ● Inspect ALL drive plates. ● Replace if the thickness is below the allowable limit. SAT162D Low & Reverse Brake Dish Plates ● ● Check for deformation or damage. Measure thickness (t) of dish plate. Replace if damaged, deformed or worn. Thickness of dish plate (t): 2.93 mm (0.1154 in) SAT163D Low & Reverse Brake Spring Retainer Assembly Check length (L) of spring retainer assembly. Replace if damaged, deformed or worn. Length (L): 26.3 mm (1.035 in) CAUTION: Do not remove return springs (A) from spring retainer (B) SCIA7025J ASSEMBLY 1. Install seal ring (1) and D-ring (2) on low & reverse brake piston (3). SCIA6516J AT-428 REPAIR FOR COMPONENT PARTS [ALL] 2. Install low & reverse brake piston in transaxle case while turning it. CAUTION: Apply ATF to inner surface of transaxle case. A B AT SAT239D D 3. Install spring retainer assembly (1) on low & reverse brake piston (2). E F G SCIA6020J 4. Set SST on spring retainer assembly, and install snap ring while compressing spring retainer assembly. CAUTION: Set SST directly over return springs. H I J SAT242D 5. Install driven plates (4), dish plates (6), retaining plates (2), (5) and drive plates (3). (1): Snap ring (2): Retaining plate (3): Drive plate (4): Driven plate (5): Retaining plate (6): Dish plate Drive plate/Driven plate: 4/4 CAUTION: Be careful with the order of plates AT-429 K L M SCIA5994E REPAIR FOR COMPONENT PARTS [ALL] NOTE: Install two dish plates fitting each installation direction with groove displaced slightly. SAT254E 6. Install snap ring (1) using a flat-bladed screwdriver A. SCIA7039E 7. Measure clearance between retaining plate and snap ring. If not within allowable limit, select proper retaining plate (front side). Refer to “Parts Information” for retaining plate selection. Specified clearance Standard and allowable limit: Refer to AT-477, "LOW & REVERSE BRAKE" . 8. Check operation of low & reverse brake. Refer to AT-426, "DISASSEMBLY" . SAT246D AT-430 REPAIR FOR COMPONENT PARTS [ALL] Rear Internal Gear and Forward Clutch Hub BCS000XM A COMPONENTS B AT D E F SCIA5880J 1. End bearing 2. Forward clutch hub 4. Rear internal gear 5. Forward one-way clutch 3. G Thrust washer H Refer to GI section to make sure icons (symbol marks) in the figure. Refer to GI-11, "Components" . DISASSEMBLY 1. Remove forward clutch hub from rear internal gear. I J K SAT251D 2. L Remove end bearing (1) from rear internal gear (2). M SCIA7028E AT-431 REPAIR FOR COMPONENT PARTS [ALL] 3. Remove thrust washer from rear internal gear. SCIA3691E 4. Remove end bearing (2) from forward one-way clutch (3). (1): Forward clutch hub SCIA7026E 5. Remove forward one-way clutch from forward clutch hub. SAT255D AT-432 REPAIR FOR COMPONENT PARTS [ALL] INSPECTION Rear Internal Gear and Forward Clutch Hub A Check rubbing surfaces for wear or damage. Replace if necessary. (1): Rear internal gear (2): Forward clutch hub B AT D SCIA5881J End Bearings and Forward One-way Clutch ● ● E Check end bearings (1) for deformation and damage. Replace if necessary. Check forward one-way clutch (2) for wear and damage. Replace if necessary. F G H SCIA7027E ASSEMBLY 1. I Install forward one-way clutch on forward clutch hub. CAUTION: Be careful with the direction of forward one-way clutch. J K L SAT976H 2. Install end bearing (2) on forward one-way clutch (3). (1): Forward clutch hub M SCIA7026E AT-433 REPAIR FOR COMPONENT PARTS [ALL] 3. Install thrust washer on rear internal gear. CAUTION: Align pawls of thrust washer with holes of rear internal gear. SCIA3690E 4. Install end bearing (1) on rear internal gear (2). SCIA7028E 5. Install forward clutch hub on rear internal gear. CAUTION: ● Check operation of forward one-way clutch. Hold rear internal gear and turn forward clutch hub. Check forward clutch hub for correct locking and unlocking directions. ● If not as shown in figure, check the installation direction of forward one-way clutch. AAT426 AT-434 REPAIR FOR COMPONENT PARTS [ALL] Output Shaft, Output Gear, Idler Gear, Reduction Pinion Gear and Bearing Retainer BCS000XN A COMPONENTS B AT D E F G H I J SCIA5883J 1. Idler gear 2. Idler gear bearing 4. Reduction pinion gear bearing 5. Reduction pinion gear 6. Output shaft bearing 7. Seal ring 8. Bearing retainer 9. Output shaft 10. Seal ring 11. Output gear adjusting spacer 13. Output gear 14. Lock nut 3. L 12. Output gear bearing M Refer to GI section to make sure icons (symbol marks) in the figure. Refer to GI-11, "Components" . DISASSEMBLY 1. K Reduction pinion gear adjusting shim Remove seal rings from output shaft and bearing retainer. SAT666D AT-435 REPAIR FOR COMPONENT PARTS [ALL] 2. a. Remove output shaft bearing according to the following procedures. Set output shaft bearing inner race (1) on a drift A [commercial service tool: inner diameter of 31 mm (1.22 in)], and set a suitable drift B on output shaft (2), and press output shaft (2) to remove output shaft bearing inner race (1). CAUTION: Set a drift A on output shaft bearing inner race (1). SCIA7041E b. Set SST on output shaft bearing outer race, and remove output shaft bearing outer race from bearing retainer. SAT168K 3. a. b. Remove output gear bearing according to the following procedures. Insert a flat-bladed screwdriver A between the mating surfaces of output gear (1) and output gear bearing inner race (2), and enlarge the gap. CAUTION: Be careful not to damage output gear (1). Set a drift B [commercial service tool: 33 mm (1.30 in) dia.] on output gear (1), and remove output gear bearing inner race (2) using a puller C (commercial service tool). SCIA7042E c. Set Tool A on output gear bearing outer race (1), and remove output gear bearing outer race (1) from bearing retainer (2). Tool number: KV381054S0 SCIA7043E 4. a. b. Remove idler gear bearing according to the following procedures. Insert a flat-bladed screwdriver A between the mating surfaces of idler gear (1) and idler gear bearing inner race (2), and enlarge the gap. CAUTION: Be careful not to damage idler gear (1). Set a drift B [commercial service tool: 34 mm (1.34 in) dia.] on idler gear (1), and remove idler gear bearing inner race (2) using a puller C (commercial service tool). SCIA7044E AT-436 REPAIR FOR COMPONENT PARTS [ALL] c. Set SST on idler gear bearing outer race, and remove idler gear bearing outer race from transaxle case. A B AT SAT859DD D 5. a. Remove reduction pinion gear bearing according to the following procedures. Set SST on reduction pinion gear bearing inner race, and press reduction pinion gear to remove reduction pinion gear bearing inner race. CAUTION: Set SST on reduction pinion gear bearing inner race. E F G NAT048 b. Remove reduction pinion gear bearing outer race from transaxle case. H I J SAT651D K L M AT-437 REPAIR FOR COMPONENT PARTS [ALL] INSPECTION Output Shaft, Output Gear, Idler Gear and Reduction Pinion Gear Check for wear, damage or crack. Replace if necessary. Bearings Make sure bearings roll freely and are free from noise, cracks, pitting or wear. ● When replacing taper roller bearing, replace outer and inner race as a set. Check for damage or deformation. Replace if necessary. ● Seal Ring Clearance ● ● Install new seal rings (1) on output shaft (2). Measure clearance “A” between each seal ring and groove. Standard clearance and allowable limit: Refer to AT-478, "Output Shaft" . ● ● ● Replace output shaft (2) if the measurements exceed the allowable limit. Install new seal rings (1) on bearing retainer (3). Measure clearance “A” between each seal ring and groove. Standard clearance and allowable limit: Refer to AT-479, "Bearing Retainer" . ● SCIA7045E Replace bearing retainer (3) if the measurements exceed the allowable limit. ASSEMBLY 1. a. Install reduction pinion gear bearing according to the following procedures. Set SST on reduction pinion gear bearing inner race, and press reduction pinion gear to reduction pinion gear bearing inner race. CAUTION: Set SST on reduction pinion gear bearing inner race. NAT049 b. c. Install reduction pinion gear bearing outer race to transaxle case. Tighten reduction pinion gear bearing outer race fitting bolts to the specified torque. Refer to AT-435, "COMPONENTS" . SAT651D 2. Checking reduction pinion gear bearing preload. Refer to AT-453, "REDUCTION PINION GEAR BEARING PRELOAD" . AT-438 REPAIR FOR COMPONENT PARTS [ALL] 3. a. Install idler gear bearing according to the following procedures. CAUTION: Do not reuse idler gear bearing. Set Tool A and a suitable drift B on idler gear bearing inner race (1), and press idler gear bearing inner race (1) to idler gear (2). Tool number: A B KV35272000 CAUTION: Set Tool A on idler gear bearing inner race (1). AT SCIA7046E D b. Set SST on idler gear bearing outer race, and drive idler gear bearing outer race into transaxle case. E F G NAT051 4. a. Install output shaft bearing according to the following procedures. Set a drift A [commercial service tool: inner diameter of 31 mm (1.22 in)] and a suitable drift B on output shaft bearing inner race (1), and press output shaft (2) to output shaft bearing inner race (1). CAUTION: Set a drift on output shaft bearing inner race (1). H I J SCIA7048E b. K Set SST on output shaft bearing outer race, and drive output shaft bearing outer race to bearing retainer. L M SCIA0270E 5. Checking output shaft bearing preload. Refer to AT-455, "OUTPUT SHAFT BEARING PRELOAD" . AT-439 REPAIR FOR COMPONENT PARTS [ALL] 6. a. Install seal rings according to the following procedures. Install seal rings (1) evenly to the grooves on output shaft (2) and bearing retainer (3), and fully close the opening. SCIA7049E CAUTION: Roll paper around seal rings to prevent seal rings from spreading. SCIA2190E 7. a. Install output gear bearing according to the following procedures. CAUTION: Do not reuse output gear bearing. Set Tool A and a suitable drift B on output gear bearing inner race (1), and press output gear bearing inner race (1) to output gear (2). Tool number: KV35272000 CAUTION: Set Tool A on output gear bearing inner race (1). b. SCIA7047E Set SST on output gear bearing outer race, and drive output gear bearing outer race to bearing retainer. SCIA0268E AT-440 REPAIR FOR COMPONENT PARTS [ALL] Band Servo Piston Assembly BCS000XO A COMPONENTS B AT D E F SCIA5891J 1. Lock nut 2. Anchor end pin 3. 4. Servo piston retainer 5. D-ring 6. OD servo piston 7. O-ring 8. Snap ring 9. OD servo piston retainer G O-ring 10. E-ring 11. Spring retainer 12. OD servo return spring 13. D-ring 14. Band servo piston 15. Band servo thrust washer 16. Band servo piston stem 17. 2nd servo return spring H I Refer to GI section to make sure icons (symbol marks) in the figure. Refer to GI-11, "Components" . DISASSEMBLY 1. J Push in OD servo piston assembly using a puller A (commercial service tool) and a suitable drift B, and then remove snap ring (1) from transaxle case using a flat-bladed screwdriver C. K L M SCIA7050E 2. 3. Apply compressed air into the oil hole as shown in the figure to remove OD servo piston assembly and band servo piston assembly. CAUTION: Do not blow air in too quickly, or OD servo piston assembly, band servo piston assembly and ATF could jump out. Carefully blow air little by little while protecting with lint-free cloth A. Remove 2nd servo return spring from transaxle case. SCIA7051E AT-441 REPAIR FOR COMPONENT PARTS [ALL] 4. Wrap OD servo piston retainer (1) using lint-free cloth A, and then apply compressed air into the band servo piston stem hole on OD servo piston (2) to remove OD servo piston (2) from OD servo piston retainer (1). CAUTION: Do not blow air in too quickly, or OD servo piston (2) and ATF could jump out. Carefully blow air little by little while protecting with lint-free cloth A. SCIA7052E 5. Remove D-ring (1) from OD servo piston (2). SCIA7053E 6. Remove O-rings (1), (2) and (3) from OD servo piston retainer (4). (1): O-ring (small diameter) (2): O-ring (medium diameter) (3): O-ring (large diameter) SCIA6492J 7. Press in band servo piston assembly to remove from servo piston retainer. SAT293D 8. Place band servo piston stem on a wooden block, and remove E-ring from band servo piston stem using a flat-bladed screwdriver while pressing spring retainer downward. SCIA4336E AT-442 REPAIR FOR COMPONENT PARTS [ALL] 9. Remove spring retainer (1), OD servo return spring (2), band servo piston (3) and band servo thrust washer (4) from band servo piston stem (5). A B AT SCIA7054E D 10. Remove O-rings from servo piston retainer. E F G SCIA3671E 11. Remove D-rings from band servo piston. H I J SCIA3688E INSPECTION Pistons, Retainers and Piston Stem K L Check the sliding surfaces for damage or excessive wear. Replace if necessary. Return Springs ● ● Check each return spring for damage or deformation. Also measure free length. Refer to AT-478, "Band Servo" . Replace springs if deformed or fatigued. M SAT138D AT-443 REPAIR FOR COMPONENT PARTS [ALL] ASSEMBLY 1. Install D-rings to band servo piston. SCIA3688E 2. Install band servo thrust washer (4), band servo piston (3), OD servo return spring (2) and spring retainer (1) to band servo piston stem (5). SCIA7054E 3. Place band servo piston stem (1) on a wooden block, and install E-ring (2) to band servo piston stem (1) while pressing spring retainer (3) downward. SCIA7056E 4. Install O-rings to servo piston retainer SCIA3671E AT-444 REPAIR FOR COMPONENT PARTS [ALL] 5. Install band servo piston assembly to servo piston retainer by pushing it inward. A B AT SAT303D D 6. Install D-ring (1) to OD servo piston (2). E F G SCIA7053E 7. Install O-rings (1), (2) and (3) to OD servo piston retainer (4). (1): O-ring (small diameter) (2): O-ring (medium diameter) (3): O-ring (large diameter) H I J SCIA6492J 8. K Install OD servo piston (1) to OD servo piston retainer (2) fitting the figure direction on it. L M SCIA7057E 9. Install 2nd servo return spring (2) and band servo piston assembly (3) to transaxle case (1). SCIA6310J AT-445 REPAIR FOR COMPONENT PARTS [ALL] 10. Install OD servo piston assembly (2) to transaxle case (1). SCIA6010J 11. Push in OD servo piston assembly using a puller A (commercial service tool) and a suitable drift B, and install snap ring (1) to transaxle case using a flat-bladed screwdriver C. SCIA7050E AT-446 REPAIR FOR COMPONENT PARTS [ALL] Final Drive BCS000XP A COMPONENTS B AT D E F SCIA7184E 1. Pinion mate gear thrust washer 2. Pinion mate gear 3. Pinion mate shaft 4. Side gear 5. Side gear thrust washer 6. Lock pin 7. Differential side bearing 8. Differential case 9. Final gear G H 10. Differential side bearing adjusting shim Refer to GI section to make sure icons (symbol marks) in the figure. Refer to GI-11, "Components" . I DISASSEMBLY 1. Remove final gear from differential case. J K L SCIA0286J 2. a. Remove differential side bearings according to the following procedures. Set a drift A [commercial service tool: 38 mm (1.50 in) dia.] on differential case (1), and remove differential side bearing (RH side) (2) from differential case (1) using a puller B (commercial service tool) and another puller C (commercial service tool). SCIA7059E AT-447 M REPAIR FOR COMPONENT PARTS [ALL] b. Set a drift A [commercial service tool: 38 mm (1.50 in) dia.] on differential case (1), and remove differential side bearing (LH side) (2) from differential case (1) using a puller B (commercial service tool). SCIA7060E 3. a. Remove pinion mate gear and side gear according to the following procedures. Drive out lock pin from differential case (1) using Tool A. Tool number: KV32101000 SCIA7034E b. c. d. Remove pinion mate shaft from differential case. Rotate pinion mate gears and pinion mate gear thrust washers to remove. Remove side gears and side gear thrust washers from differential case. SAT316D INSPECTION Gears, Washers, Pinion Mate Shaft and Differential Case Check the sliding surfaces for wear, seizure, crack or damage. Replace if necessary. MTK0135D AT-448 REPAIR FOR COMPONENT PARTS [ALL] Bearings A Make sure bearings roll freely and are free from noise, cracks, pitting or wear. Replace if necessary. B AT SPD715 D ASSEMBLY 1. a. b. 2. a. b. Install pinion mate gears and side gears according to the following procedures. Attach side gear thrust washers to side gears, then install pinion mate gear thrust washers and pinion mate gears in place. CAUTION: Apply plenty of ATF to each sliding / rotating surface before assembly. Set 2 pinion mate gears and thrust washers on the same axis, and while rotating them simultaneously, align them with the insert hole of pinion mate shaft on differential case to insert pinion mate shaft. CAUTION: After aligning 2 pinion mate gears with side gear teeth and centering with pinion mate shaft, take pinion mate shaft out and move pinion mate gears in place while rotating the them simultaneously. E F G H SAT318D I Select side gear thrust washers according to the following procedures. Place differential case in the upright position so that the side gear to be measured is at the top. (A): Location for inserting feeler gauge (B): Side gear tooth (C): The center line of differential case In order to maximize the back clearance, rotate side gears so that a tooth on side gears at the top and bottom will align at the same position as shown in the figure. J K L SCIA7064E AT-449 M REPAIR FOR COMPONENT PARTS [ALL] c. i. ii. Adjust the back clearance of side gear according to the following procedures. Insert feeler gauges A of the same thickness to the back of side gear from both sides, preventing side gear from falling, to measure the clearance. ● Measure clearance 3 times by rotating side gears and take the average. CAUTION: In all 3 measurements, maximize the clearance by aligning teeth on side gears at the top and bottom at the same position. Select side gear thrust washer so that the clearance will fall within the standard. Differential side gear clearance: Refer to AT-478, "Final Drive" . iii. Turn differential case upside down, and measure the back clearance of the other side gear in the same manner. NOTE: Adjust the clearance to approx. 0.1 mm (0.004 in) for used differential [driven approx. 3,000 km (1864 mile) or more]. ● Refer to “Parts Information” for side gear thrust washers selection. 3. SCIA7061E Install lock pin (1) to pinion mate shaft using the pin punch A. Tool number: KV32101000 CAUTION: Make sure that lock pin (1) flush with differential case. SCIA7228E 4. Set Tool A on differential side bearing (RH side) (1), and press differential side bearing (RH side) (1) to differential case (2). Tool number: ST33200000 CAUTION: Set Tool A on differential side bearing inner race. SCIA7062E AT-450 REPAIR FOR COMPONENT PARTS [ALL] 5. Set Tool A on differential side bearing (LH side) (1), and press differential side bearing (LH side) (1) to differential case (2). Tool number: A ST33200000 CAUTION: Set Tool A on differential side bearing inner race. B AT SCIA7063E D 6. Install final gear on differential case, and tighten fitting bolts to the specified torque in the numerical order as shown in the figure. Refer to AT-447, "COMPONENTS" . E F G SCIA0294J H I J K L M AT-451 ASSEMBLY [ALL] ASSEMBLY Assembly (1) 1. PFP:00000 BCS000XQ Drive each differential side oil seal evenly using a drift (SST and commercial service tool) so that differential side oil seal protrudes by the dimension “C” or “D” respectively. (1): LH differential side oil seal (2): RH differential side oil seal (A): Transaxle case side (B): Converter housing side Unit: mm (in) Dimension “C” 0 ± 0.5 (0 ± 0.020) Dimension “D” 1.1 ± 0.5 (0.043 ± 0.020) SCIA7226E NOTE: Differential side oil seal pulling direction is used as the reference. Drift to be used: 2. 3. 4. 5. 6. Location Tool number Transaxle case side (A) ST35325000 KV31103000 Converter housing side (B) Commercial service tool [Inner diameter: 47 mm (1.85 in), outer diameter: 54 mm (2.13 in)] Install O-ring on governor cap. CAUTION: ● Do not reuse O-ring. ● Apply ATF to O-ring. Install governor cap in transaxle case. Install snap ring in transaxle case. Install parking actuator support (1) on transaxle case. (A): Inside (B): Outside CAUTION: Be careful with the direction of parking actuator support (1). Tighten parking actuator support fitting bolts to the specified torque. Refer to AT-360, "Components" . SCIA5910J 7. Install parking pawl (2) on transaxle case, and fix it with parking shaft (1). SCIA6997E AT-452 ASSEMBLY [ALL] 8. Install return spring (2) on parking shaft (3) and parking pawl (1) using a flat-bladed screwdriver. A B AT SCIA6996E D Adjustment (1) BCS000XR REDUCTION PINION GEAR BEARING PRELOAD 1. a. b. Select proper thickness of reduction pinion gear adjusting shim using the following procedures. Place reduction pinion gear on transaxle case as shown in the figure. Install idler gear bearing outer race on transaxle case. Refer to AT-435, "COMPONENTS" . E F G H SCIA3623E c. d. Place idler gear bearing inner race on outer race. Measure dimensions “B”, “C” and “D”, and calculate dimension “A”. I “A”: Distance between the surface of idler gear bearing inner race and the adjusting shim mating surface of reduction pinion gear. A = D − (B + C) J K SCIA3624E ● ● Measure dimension “B” between the end of reduction pinion gear and the surface of transaxle case. Measure dimension “B” in at least two places, and take the average. M SCIA3625E AT-453 L ASSEMBLY [ALL] ● ● Measure dimension “C” between the surface of idler gear bearing inner race and the surface of transaxle case. Measure dimension “C” in at least two places, and take the average. SCIA3626E ● ● ● ● Remove reduction pinion gear from transaxle case. Measure dimension “D” between the end of reduction pinion gear and the adjusting shim mating surface of reduction pinion gear. Measure dimension “D” in at least two places, and take the average. Calculate dimension “A”. A = D − (B + C) SAT336DA e. f. Measure dimension “E” between the end of idler gear and idler gear bearing inner race mating surface of idler gear. ● Measure dimension “E” in at least two places, and take the average. Select proper thickness of reduction pinion gear adjusting shim. Refer to “Parts Information” for reduction pinion gear adjusting shim selection. Proper shim thickness = A − E − 0.05 mm (0.0020 in)* (*: Bearing preload) SAT337D 2. 3. 4. Install reduction pinion gear (1) and reduction pinion gear adjusting shim (2) selected in step 2-e on transaxle case. CAUTION: Apply ATF to reduction pinion gear bearing. Press idler gear bearing inner race on idler gear (3). Refer to AT435, "COMPONENTS" . Set Tool A on idler gear (3), and press idler gear (3) on reduction pinion gear (1). CAUTION: ● Apply ATF to idler gear bearing. ● Press idler gear (3) until idler gear (3) fully contacts reduction pinion gear bearing adjusting shim (2). Tool number: 5. 6. ST35271000 Set manual shaft in “P” position to fix idler gear (3). Tighten lock nut of idler gear to the specified torque. Refer to AT-360, "Components" . CAUTION: Lock idler gear with parking pawl when tightening lock nut. AT-454 SCIA7110E ASSEMBLY [ALL] 7. Measure turning torque of reduction pinion gear. A Turning torque of reduction pinion gear: Refer to AT-478, "Reduction Pinion Gear" . ● ● When measuring turning torque, turn reduction pinion gear in both directions several times to seat bearing rollers correctly. If turning torque is out of specification, decrease or increase thickness of reduction pinion gear adjusting shim. B AT SAT190FB D OUTPUT SHAFT BEARING PRELOAD 1. a. b. c. Select proper thickness of output gear adjusting spacer using the following procedures. Remove paper rolled around output shaft. Install output gear bearing outer race on bearing retainer. Refer to AT-435, "COMPONENTS" . Place bearing retainer on output shaft. E F G SAT682D d. e. Place output gear bearing inner race on bearing retainer. Measure dimensions “G” and “H”, and calculate dimension “F”. H I “F”: Distance between the surface of output gear bearing inner race and adjusting spacer mating surface of output shaft. F=H−G J K SAT683D ● ● L Measure dimension “G” between end of output shaft and surface of output gear bearing inner race. Measure dimension “G” in at least two places, and take the average. M SAT684D AT-455 ASSEMBLY [ALL] ● ● ● Measure dimension “H” between end of output shaft and adjusting spacer mating surface of output shaft. Measure dimension “H” in at least two places, and take the average. Calculate dimension “F”. F=H−G SAT685D f. g. Measure dimension “I” between end of output gear (adjusting spacer mating surface) and output gear bearing inner race fitting surface. ● Measure dimension “I” in at least two places, and take the average. Select proper thickness of output gear adjusting spacer. Refer to “Parts Information” for output gear adjusting spacer selection. Proper spacer thickness = F − I − [0.03 − 0.08 mm (0.0012 − 0.0031 in)]* (*: Bearing preload) 2. 3. SAT686D Install bearing retainer (1) in transaxle case. Tighten bearing retainer fitting bolts to the specified torque. Refer to AT-360, "Components" . SCIA5909J 4. 5. 6. Install output shaft (1) and output gear adjusting spacer (2) selected in step 1-f on transaxle case. CAUTION: ● Apply ATF to output shaft bearing. ● Do not force output shaft to install or seal ring may be damaged. Press output gear bearing inner race on output gear (3). Refer to AT-435, "COMPONENTS" . Set Tool A on output gear (3), and press output gear (3) on output shaft (1). CAUTION: ● Apply ATF to output gear bearing. ● Do not pinch seal ring when output shaft is pressed in. ● Press output gear (3) until output gear (3) fully contacts output gear adjusting space (2). Tool number: 7. 8. ST35271000 Set manual shaft in “P” position to fix idler gear. Tighten lock nut of output gear to the specified torque. Refer to AT-360, "Components" . CAUTION: ● Do not reuse lock nut. ● Lock idler gear with parking pawl when tightening lock nut. AT-456 SCIA7080E ASSEMBLY [ALL] 9. Remove idler gear (1) using Tool A to measure output shaft bearing preload. Tool number: A ST27180001 B AT SCIA5921J D 10. Measure turning torque of output shaft. Turning torque of output shaft: Refer to AT-478, "Output Shaft" . E When measuring turning torque, turn output shaft in both directions several times to seat bearing rollers correctly. ● If turning torque is out of specification, decrease or increase thickness of output gear adjusting spacer. 11. Press idler gear on reduction pinion gear. Refer to AT-453, "REDUCTION PINION GEAR BEARING PRELOAD" . ● F G SAT190FB 12. Tighten lock nut (1) of idler gear to the specified torque. Refer to AT-360, "Components" . 13. After properly adjusting turning torque, clinch lock nuts (1) of idler gear and output gear as shown in the figure. H I L1 : 3 mm (0.12 in) or more L2 : 1 mm (0.04 in) or more J SCIA5922J 14. Install side cover gasket and side cover on transaxle case. CAUTION: ● Do not reuse side cover gasket. ● Completely remove all moisture, oil and old gasket, etc. from the transaxle case and side cover mating surfaces. 15. Tighten side cover fitting bolts (1) to the specified torque. Refer to AT-360, "Components" . L M SCIA6039J Assembly (2) 1. 2. BCS000XS Remove paper rolled around bearing retainer. Install thrust washer on bearing retainer. CAUTION: Align pawls of thrust washer with holes of bearing retainer. SAT354D AT-457 K ASSEMBLY [ALL] 3. Install forward clutch assembly and overrun clutch assembly (1) into transaxle case. CAUTION: ● Align teeth of low & reverse brake drive plates before installing. ● Make sure that bearing retainer seal rings are not spread. SCIA5900J 4. Install needle bearing (1) on bearing retainer. CAUTION: Be careful with the direction of needle bearing. SCIA5926J 5. Install thrust washer (1) on overrun clutch hub (2). CAUTION: Align pawls of thrust washer (1) with holes of overrun clutch hub (2). SCIA5899J 6. Install overrun clutch hub (1) into forward clutch drum. CAUTION: Align teeth of overrun clutch drive plates before installing. SCIA5898J 7. Hold forward clutch hub, and check that rear internal gear locks when tried to rotate counterclockwise. CAUTION: If rear internal gear rotates counterclockwise, check installation direction of forward one-way clutch. SCIA7078E AT-458 ASSEMBLY [ALL] 8. Install needle bearing (1) on rear internal gear (2). CAUTION: Be careful with the direction of needle bearing (1). A B AT SCIA6041J 9. Install rear internal gear (1) and forward clutch hub (2) as a set into forward clutch drum. CAUTION: Align teeth of forward clutch drive plates before installing. D E F G SCIA5897J 10. Install needle bearing (1) on rear planetary carrier (2). CAUTION: Be careful with the direction of needle bearing (1). H I J SCIA5927J 11. Install rear sun gear on rear planetary carrier. CAUTION: Be careful with the direction of rear sun gear. K L M SAT052D 12. Install rear planetary carrier in transaxle case. SAT051D AT-459 ASSEMBLY [ALL] 13. Install needle bearing (1) on front planetary carrier (2). CAUTION: Be careful with the direction of needle bearing (1). SCIA6047J 14. Install low one-way clutch to front planetary carrier by turning it in the direction of unlock. 15. Check that low one-way clutch rotates counterclockwise around front planetary carrier. Then try to turn it clockwise and check that it is locked. SAT048D 16. Install front planetary carrier (2) and low one-way clutch (1) as a set into transaxle case. SCIA5896J 17. Install snap ring into transaxle case using a flat-bladed screwdriver. SCIA3633E 18. Install needle bearing (1) on front sun gear (2). CAUTION: Be careful with the direction of needle bearing (1). SCIA6960E AT-460 ASSEMBLY [ALL] 19. Install front sun gear on front planetary carrier. A B AT SAT368D 20. Install needle bearing on front sun gear. CAUTION: Be careful with the direction of needle bearing. D E F G SAT369D 21. Install high clutch hub on front sun gear. H I J SAT370D 22. Install needle bearing on high clutch hub. CAUTION: Be careful with the direction of needle bearing. 23. Remove paper rolled around input shaft assembly (high clutch drum). L M SAT371D 24. Install input shaft assembly (high clutch assembly) (1). CAUTION: Align teeth of high clutch drive plates before installing. SCIA7079E AT-461 K ASSEMBLY [ALL] 25. Install reverse clutch assembly. CAUTION: Align teeth of reverse clutch drive plates before installing. SAT373D Adjustment (2) BCS000XT When any parts listed below are replaced, adjust total end play and reverse clutch end play. Part name Total end play Reverse clutch end play Transaxle case ● ● Overrun clutch hub ● ● Rear internal gear ● ● Rear planetary carrier ● ● Rear sun gear ● ● Front planetary carrier ● ● Front sun gear ● ● High clutch hub ● ● Input shaft assembly (high clutch drum) ● ● Oil pump cover ● ● Reverse clutch drum — ● TOTAL END PLAY ● ● Measure clearance between reverse clutch drum and needle bearing for oil pump cover. Select proper thickness of bearing race so that end play is within specifications. SCIA3661E 1. Measure dimensions “K” and “L”, and then calculate dimension “J”. SCIA3662E AT-462 ASSEMBLY [ALL] a. Measure dimension “K”. A B AT SCIA3663E D b. c. Measure dimension “L”. Calculate dimension “J”. E “J”: Distance between oil pump fitting surface of transaxle case and needle bearing mating surface of input shaft assembly (high clutch drum). J=K–L F G SCIA3664E 2. a. Measure dimension “M”. Place bearing race and needle bearing on oil pump assembly. H I J SAT378D b. Measure dimension “M”. “M”: “M1 ”: Distance between transaxle case fitting surface of oil pump cover and needle bearing on oil pump cover. Indication of gauge L M SAT379D c. Measure thickness of straightedge “t”. M = M1 – t 3. K Adjust total end play “T1 ”. T1 = J – M Total end play “T1 ”: Refer to AT-479, "Total End Play" . ● Select proper thickness of bearing race so that total end play is within specifications. Refer to “Parts Information” for bearing race selection. AT-463 SAT443D ASSEMBLY [ALL] REVERSE CLUTCH END PLAY ● ● Measure clearance between oil pump cover and thrust washer for reverse clutch drum. Select proper thickness of thrust washer so that end play is within specification. SCIA3665E 1. Measure dimensions “O” and “P”, and then calculate dimension “N”. SCIA3666E a. b. Place thrust washer on reverse clutch drum. Measure dimension “O”. SCIA3667E c. d. Measure dimension “P”. Calculate dimension “N”. “N”: Distance between oil pump fitting surface of transaxle case and thrust washer on reverse clutch drum. N=O–P SCIA3668E AT-464 ASSEMBLY [ALL] 2. Measure dimensions “R” and “S”, and then calculate dimension “Q”. A B AT SAT384D D a. Measure dimension “R”. E F G SAT385D b. c. Measure dimension “S”. Calculate dimension “Q”. H “Q”: Distance between transaxle case fitting surface and thrust washer mating surface. Q=R–S I J SAT386D 3. Adjust reverse clutch end play “T2 ”. T2 = N – Q Reverse clutch end play: Refer to AT-479, "Reverse Clutch End Play" . ● 3. L Select proper thickness of thrust washer so that reverse clutch end play is within specifications. Refer to “Parts Information” for thrust washer selection. Assembly (3) 1. 2. K BCS000XU Remove reverse clutch assembly. Install needle bearing on input shaft assembly (high clutch drum). CAUTION: Be careful with the direction of needle bearing. Install reverse clutch assembly. CAUTION: Align teeth of reverse clutch drive plates before installing. SAT387D AT-465 M ASSEMBLY [ALL] 4. Install anchor end pin (2) and lock nut (1) on transaxle case. SCIA6037J 5. 6. Place brake band on outside of reverse clutch drum. Tighten anchor end pin just enough so that brake band is evenly fitted on reverse clutch drum. SAT038D 7. 8. 9. Install bearing race selected in total end play adjustment step on oil pump cover. Install thrust washer selected in reverse clutch end play adjustment step on oil pump cover. Install O-ring to oil pump assembly. CAUTION: ● Do not reuse O-ring. ● Apply ATF to O-ring. SCIA3629E 10. Install oil pump assembly (1) on transaxle case. 11. Tighten oil pump fitting bolts to the specified torque. Refer to AT360, "Components" . SCIA6036J 12. Install O-ring to input shaft assembly (high clutch drum). SCIA4928E AT-466 ASSEMBLY [ALL] 13. Adjust brake band. a. Tighten anchor end pin to the specified torque. : A 4.9 N·m (0.50 kg-m, 43 in-lb) B AT SAT394D b. D Back off anchor end pin two and a half turns. E F G SAT395D c. Tighten lock nut while holding anchor end pin. Refer to AT-360, "Components" . H I J SAT396D K 14. Apply compressed air into oil holes of transaxle case and check operation of brake band. L M SAT397D 15. Select proper thickness of differential side bearing adjusting shim using the following procedures. ● Measure differential side bearing end play, and calculate the adjusting shim thickness so that the end play is within the specifications. Differential side bearing end play: Refer to AT-478, "Final Drive" . AT-467 ASSEMBLY [ALL] a. Place a straightedge A onto transaxle case (1), and measure the depth “T” of transaxle case (1) to the mating surface for differential side bearing using depth gauge B. T = (Measurement) - (Straightedge thickness) ● Measure the depth “T” in at least two places, and take the average. SCIA7114E b. c. Install final drive assembly onto converter housing (1). Place a straightedge A onto differential case (2), and measure the height “U” to the end of converter housing (1) using depth gauge B. ● Measure the height “U” in at least two places, and take the average. SCIA7115E d. e. Place a straightedge A onto differential case (1), and measure the height “V” to the end of differential side bearing outer race using depth gauge B. ● Measure the height “V” in at least two places, and take the average. Select proper thickness of differential side bearing adjusting shim. Refer to “Parts Information” for differential side bearing adjusting shim selection. Proper shim thickness = T - U + V + [0 - 0.15 mm (0 - 0.0059 in)]* (* : differential side bearing end play) SCIA7116E 16. Install differential side bearing adjusting shim selected in differential side bearing end play adjustment step on transaxle case. SCIA4938E AT-468 ASSEMBLY [ALL] 17. Install final drive assembly (1) on transaxle case. A B AT SCIA6034J D 18. Install differential lubricant tube and clips on converter housing. 19. Tighten differential lubricant tube fitting bolts to the specified torque. Refer to AT-360, "Components" . E F G SCIA3284E 20. Install O-ring (1) on differential oil port of transaxle case as shown in the figure. H I J SCIA5918J 21. Apply locking sealant (loctite #518) to transaxle case as shown in the figure. : Inside of transaxle case “A” “B” “C” “D” K L : 3 - 5 mm (0.12 - 0.20 in) : 8 mm (0.31 in) R : 1.5 mm (0.059 in) dia. : 4 mm (0.16 in) M CAUTION: Completely remove all moisture, oil and old sealant, etc. from the transaxle case and converter housing mating surfaces. AT-469 SCIA7089E ASSEMBLY [ALL] 22. Install converter housing on transaxle case. 23. Install bracket on converter housing. 24. Tighten converter housing fitting bolts (1), (2) and (3) to the specified torque. Refer to AT-360, "Components" . Bolt 1 Bolt length [mm (in)] 30 (1.18) Number of bolts *: 2 10 3* 40 (1.57) 9 1 Tighten with bracket. SCIA6956E 25. Install O-ring to plug. CAUTION: ● Do not reuse O-ring. ● Apply ATF to O-ring. 26. Install plug to converter housing. 27. Tighten plug fitting bolt to the specified torque. Refer to AT-360, "Components" . 28. Install accumulator pistons. a. Install O-rings (1) on servo release accumulator piston (2) and N-D accumulator piston (3). Refer to AT-476, "Accumulator" . SCIA6033J b. Install return springs (1), servo release accumulator piston (2) and N-D accumulator piston (3) into transaxle case (4). Refer to AT-476, "Accumulator" . SCIA6042J 29. Install lip seals (1) for band servo oil holes on transaxle case. SCIA5895J AT-470 ASSEMBLY [ALL] 30. Install control valve assembly on transaxle case. a. Install O-ring on terminal body. CAUTION: ● Do not reuse O-ring. ● Apply ATF to O-ring. b. Insert manual valve into control valve assembly. CAUTION: Be careful not to drop manual valve. A B AT SCIA3999E D c. d. Set manual shaft in “N” position. Install control valve assembly on transaxle case while aligning manual valve (2) with manual plate (1). E F G SCIA7090E e. f. Install terminal body (2) into transaxle case by pushing it. Install snap ring (1) to terminal body (2). H I J SCIA6030J g. K Tighten bolts A , B and C to the specified torque. Refer to AT-360, "Components" . Bolt length, number and location: Bolt symbol Bolt length “ ” [mm (in)] L A B C 40.0 mm (1.575 in) 33.0 mm (1.299 in) 43.5 mm (1.713 in) 5 6 2 Number of bolts M SCIA5911J 31. Install oil pan. a. Attach magnets on oil pan. AT-471 ASSEMBLY [ALL] b. c. d. e. f. 32. a. b. c. d. i. ii. e. f. 33. 34. 35. Install oil pan gasket on transaxle case. CAUTION: ● Completely remove all moisture, oil and old gasket, etc. from the oil pan gasket mounting surface of transaxle case. ● Do not reuse oil pan gasket. Install oil pan on transaxle case. CAUTION: Completely remove all moisture, oil and old gasket, etc. from the oil pan gasket mounting surface of oil pan. Tighten oil pan fitting bolts (1) to the specified torque. Refer to AT-360, "Components" . CAUTION: ● Always replace oil pan fitting bolts (1) as they are self-sealing bolts. ● Tighten four bolts in a criss-cross pattern to prevent dislocation of gasket. Install drain plug gasket and drain plug (2) to oil pan. CAUTION: Do not reuse drain plug gasket. Tighten drain plug to the specified torque. Refer to AT-360, "Components" . Install PNP switch (2) on transaxle case. : Bolt (3) Set manual shaft (1) in “P” position. Temporarily install PNP switch (2) on manual shaft (1). Set manual shaft (1) in “N” position. Use a 4 mm (0.16 in) dia. pin for this adjustment. Insert the pin straight into the manual shaft (1) adjustment hole. Rotate PNP switch (2) until the pin can also be inserted straight into hole in PNP switch (2). Tighten PNP switch fitting bolts to the specified torque. Refer to AT-360, "Components" . Remove pin from adjustment hole after adjusting PNP switch (2). Install O-ring (3) to turbine revolution sensor (power train revolution sensor) (1). Install turbine revolution sensor (power train revolution sensor) (1) to transaxle case (2). : Bolt (1) Tighten turbine revolution sensor (power train revolution sensor) fitting bolt to the specified torque. Refer to AT-360, "Components" . SCIA6050J SCIA5904J SCIA7004J 36. Install revolution sensor (1) to transaxle case (2). 37. Tighten revolution sensor fitting bolts to the specified torque. Refer to AT-360, "Components" . : Bolt (2) SCIA7170J AT-472 ASSEMBLY [ALL] CAUTION: Ensure revolution sensor harness is firmly secured with bolt. (1): Revolution sensor : Bolt (1) A B AT SCIA6518J 38. Install torque converter. a. Pour ATF into torque converter. ● Approximately 1 liter (7/8 Imp pt) of fluid is required for a new torque converter. ● When reusing old torque converter, add the same amount of ATF as was drained. D E F G SAT428DA b. H Install torque converter while aligning notches of torque converter with notches of oil pump. I J K SAT429D c. Measure distance “A” to make sure that torque converter is in proper position. Distance “A”: L 16.2 mm (0.638 in) or more M SAT430D AT-473 SERVICE DATA AND SPECIFICATIONS (SDS) [ALL] SERVICE DATA AND SPECIFICATIONS (SDS) General Specifications PFP:00030 BCS000YM Engine HR16DE Automatic transaxle model RE4F03B Automatic transaxle assembly Transaxle gear ratio Model code number 3CX02 1st 2.861 2nd 1.562 3rd 1.000 4th 0.697 Reverse 2.310 Final drive 4.072 Recommended fluid Fluid capacity [ Nissan Genuine ATF Matic D or equivalent* 7.7 (6-3/4) (Imp qt)] *: Refer to MA-24, "RECOMMENDED FLUIDS AND LUBRICANTS" . Vehicle Speed at Which Gear Shifting Occurs Throttle position ● BCS000YN Vehicle speed [km/h (MPH)] D1 → D2 D2 → D3 D3 → D4 D4 → D3 D3 → D2 D2 → D1 Full throttle 51 - 59 (32 - 37) 97 - 105 (60 - 65) 154 - 162 (96 - 101) 150 - 158 (93 - 98) 87 - 95 (54 - 59) 41 - 49 (25 - 30) Half throttle 31 - 39 (19 - 24) 60 - 68 (37 - 42) 122 - 130 (76 - 81) 63 - 71 (39 - 44) 36 - 44 (22 - 27) 5 - 13 (3 - 8) At half throttle, the accelerator opening is 4/8 of the full opening. Vehicle Speed at When Lock-up Occurs/Releases BCS000YO Vehicle speed [km/h (MPH)] Throttle position 2.0/8 Selector lever position Lock-up “ON” Lock-up “OFF” D position 76 - 84 (47 - 52) 56 - 64 (35 - 40) D position (OD OFF) 96 - 104 (60 - 65) 93 - 101 (58 - 63) Stall Speed BCS000YP Stall revolution (rpm) 2,250 - 2,700 Line Pressure Engine speed BCS000YQ Line pressure [kPa (bar, kg/cm2 , psi)] D, 2nd and 1st positions R position Idle speed 500 (5.0, 5.1, 73) 778 (7.8, 7.9, 113) Stall speed 1,159 (11.6, 11.8, 168) 1,803 (18.0, 18.4, 262) AT-474 SERVICE DATA AND SPECIFICATIONS (SDS) [ALL] Adjusting shims, Needle Bearings, Thrust Washers and Snap Rings BCS000YR NOTE: Refer to AT-367, "Locations of Adjusting Shims, Needle Bearings and Thrust Washers" or AT-368, "Locations of Snap Rings" . A B OUTER DIAMETER AND INNER DIAMETER OF NEEDLE BEARINGS Unit: mm (in) Location Outer diameter Inner diameter A 47.0 (1.850) 32.0 (1.260) B 35.0 (1.378) 20.1 (0.791) C 60.0 (2.362) 42.0 (1.654) D 60.0 (2.362) 45.0 (1.772) E 47.0 (1.850) 30.0 (1.181) F 42.6 (1.677) 26.1 (1.028) G 48.0 (1.890) 33.5 (1.319) H 58.99 (2.3224) 42.1 (1.657) AT D E F OUTER DIAMETER AND INNER DIAMETER OF THRUST WASHERS Unit: mm (in) Location Outer diameter Inner diameter I 72.0 (2.835) 55.5 (2.185) J, K 82.0 (3.228) 59.0 (2.323) L 78.5 (3.091) 62.4 (2.457) G H OUTER DIAMETER AND INNER DIAMETER OF BEARING RACES AND ADJUSTING SHIMS Unit: mm (in) Location Outer diameter Inner diameter M 48.0 (1.890) 33.0 (1.299) N 29.0 (1.142) 25.0 (0.984) O 34.3 (1.350) 26.1 (1.028) P 79.5 (3.130) 72.0 (2.835) I J K OUTER DIAMETER OF SNAP RINGS Unit: mm (in) Location L Outer diameter 1 142.0 (5.59) 2 M 3 4 162.3 (6.39) 5 7 113.0 (4.45) 8 135.4 (5.33) 9 126.0 (4.96) INNER DIAMETER OF SNAP RINGS Unit: mm (in) Location Inner diameter 6 32.0 (1.260) 10 63.5 (2.500) AT-475 SERVICE DATA AND SPECIFICATIONS (SDS) [ALL] Control Valves BCS000YS CONTROL VALVE SPRINGS Unit: mm (in) Location spring designation L14 Pilot valve spring L15 Upper body Lower body Free length (l) Outer diameter (D) 38.98 (1.5346) 8.9 (0.350) 1–2 accumulator valve spring 20.5 (0.807) 6.95 (0.2737) 1–2 accumulator piston spring 55.66 (2.1913) 19.5 (0.768) L16 1st reducing valve spring 27.0 (1.063) 7.0 (0.276) L17 3–2 timing valve spring 23.0 (0.906) 6.65 (0.2618) L18 Overrun clutch reducing valve spring 37.5 (1.476) 7.0 (0.276) L19 Torque converter relief valve spring 33.3 (1.311) 9.0 (0.354) L20 Torque converter clutch control valve spring 53.01 (2.0870) 6.5 (0.256) L21 Cooler check valve spring 28.04 (1.1039) 7.15 (0.2815) L3 Pressure regulator valve spring 45.0 (1.772) 15.0 (0.591) L4 Overrun clutch control valve spring 21.7 (0.854) 7.0 (0.276) L5 Accumulator control valve spring 22.0 (0.866) 6.5 (0.256) L6 Shift valve A spring 21.7 (0.854) 7.0 (0.276) L7 Shuttle valve spring 51.0 (2.008) 5.65 (0.2224) L12 Shift valve B spring 21.7 (0.854) 7.0 (0.276) Pressure modifier valve spring 32.0 (1.260) 6.9 (0.272) L13 Pressure modifier piston spring 30.5 (1.201) 9.8 (0.386) — Line pressure relief valve spring 17.02 (0.6701) 8.0 (0.315) — Torque converter pressure holding spring 9.0 (0.354) 7.3 (0.287) Accumulator BCS000YT RETURN SPRINGS Unit: mm (in) Location Free length (L1 ) Servo release accumulator 62.8 (2.472) Unit: mm (in) Location Length (L2 ) N-D accumulator 46.5 (1.831) O-RINGS Unit: mm (in) Location Inner diameter (Small) Inner diameter (Large) Servo release accumulator 26.9 (1.059) 44.2 (1.740) N-D accumulator 34.6 (1.362) 39.4 (1.551) Clutches and Brakes BCS000YU REVERSE CLUTCH Number of drive plates 2 Number of driven plates 2 Drive plate thickness [mm (in)] Driven plate thickness [mm (in)] Clearance [mm (in)] Standard 2.0 (0.079) Allowable limit 1.8 (0.070) Standard 2.0 (0.079) Standard 0.5 - 0.8 (0.020 - 0.031) Allowable limit 1.2 (0.047) AT-476 SERVICE DATA AND SPECIFICATIONS (SDS) [ALL] HIGH CLUTCH Number of drive plates 3 Number of driven plates 6 (1*1 + 5*2 ) Drive plate thickness [mm (in)] Driven plate thickness [mm (in)] Standard 1.6 (0.063) Allowable limit 1.4 (0.055) Standard Standard Clearance [mm (in)] A B *1 *2 1.5 (0.059) 2.0 (0.079) AT 1.4 - 1.8 (0.055 - 0.070) Allowable limit 2.4 (0.094) D FORWARD CLUTCH Number of drive plates 5 Number of driven plates 5 Drive plate thickness [mm (in)] Driven plate thickness [mm (in)] Clearance [mm (in)] Standard 1.8 (0.070) Allowable limit 1.6 (0.063) Standard 2.0 (0.079) Standard 0.45 - 0.85 (0.0177 - 0.0335) E F 1.85 (0.0728) G Number of drive plates 3 H Number of driven plates 4 Allowable limit OVERRUN CLUTCH Drive plate thickness [mm (in)] Driven plate thickness [mm (in)] Clearance [mm (in)] Standard 1.6 (0.063) Allowable limit 1.4 (0.055) Standard 2.0 (0.079) Standard 1.0 - 1.4 (0.039 - 0.055) Allowable limit K Number of drive plates 4 Number of driven plates 4 Driven plate thickness [mm (in)] Clearance [mm (in)] J 2.0 (0.079) LOW & REVERSE BRAKE Drive plate thickness [mm (in)] I Standard 2.0 (0.079) Allowable limit 1.8 (0.070) Standard 2.0 (0.079) Standard 1.4 - 1.8 (0.055 - 0.070) Allowable limit 2.6 (0.102) BRAKE BAND Anchor end pin tightening torque [N·m (kg-m, in-lb)] 4.9 (0.50, 43) Number of returning revolutions for anchor end pin 2.5 Lock nut tightening torque [N·m (kg-m, ft-lb)] 33.9 (3.5, 25) AT-477 L M SERVICE DATA AND SPECIFICATIONS (SDS) [ALL] Final Drive BCS000YV DIFFERENTIAL SIDE GEAR CLEARANCE Clearance between side gear and differential case with washer [mm (in)] 0.1 - 0.2 (0.004 - 0.008) DIFFERENTIAL SIDE BEARING END PLAY Differential side bearing end play [mm (in)] 0 - 0.15 (0 - 0.0059) Planetary Carrier BCS000YW Clearance between planetary carrier and pinion washer [mm (in)] Standard Allowable limit 0.15 - 0.70 (0.0059 - 0.0276) 0.80 (0.0315) Oil Pump BCS000YX Oil pump side clearance 0.02 - 0.04 (0.0008 - 0.0016) Clearance between oil pump housing and outer gear [mm (in] Standard Allowable limit Oil pump cover seal ring clearance [mm (in)] Standard Allowable limit 0.08 - 0.15 (0.0031 - 0.0059) 0.15 (0.0059) 0.10 - 0.25 (0.0039 - 0.0098) 0.25 (0.0098) Input Shaft BCS000YY SEAL RING CLEARANCE Standard Input shaft seal ring clearance [mm (in)] Allowable limit 0.10 - 0.25 (0.0039 - 0.0098) 0.25 (0.098) SEAL RING Unit: mm (in) Outer diameter Inner diameter Width 24 (0.94) 20.4 (0.803) 1.97 (0.0776) Reduction Pinion Gear BCS000YZ TURNING TORQUE Turning torque of reduction pinion gear [N·m (kg-m, in-lb)] 0.11 - 0.69 (0.02 - 0.07, 1 - 6) Band Servo BCS000Z0 RETURN SPRINGS Unit: mm (in) Return spring Free length 2nd servo return spring 32.5 (1.280) OD servo return spring 38.52 (1.5165) Output Shaft BCS000Z1 SEAL RING CLEARANCE Standard Output shaft seal ring clearance [mm (in)] Allowable limit 0.10 - 0.25 (0.0039 - 0.0098) 0.25 (0.0098) SEAL RING Unit: mm (in) Outer diameter Inner diameter Width 29.5 (1.161) 26.2 (1.031) 1.95 (0.0768) TURNING TORQUE Turning torque of output shaft [N·m (kg-m, in-lb)] 0.25 - 0.88 (0.03 - 0.08, 3 - 7) AT-478 SERVICE DATA AND SPECIFICATIONS (SDS) [ALL] Bearing Retainer BCS000Z2 A SEAL RING CLEARANCE Bearing retainer seal ring clearance [mm (in)] Standard 0.10 - 0.25 (0.0039 - 0.0098) Allowable limit 0.25 (0.0098) B Total End Play BCS000Z3 Total end play [mm (in)] 0.25 - 0.55 (0.0098 - 0.0217) AT Reverse Clutch End Play BCS000Z4 Reverse clutch end play [mm (in)] 0.65 - 1.0 (0.0256 - 0.039) D Removal and Installation BCS000Z5 Distance between end of converter housing and torque converter [mm (in)] 16.2 (0.638) E Shift Solenoid Valves BCS000Z6 Gear position 1 2 3 4 Shift solenoid valve A ON (Closed) OFF (Open) OFF (Open) ON (Closed) Shift solenoid valve B ON (Closed) ON (Closed) OFF (Open) OFF (Open) F G Solenoid Valves BCS000Z7 Solenoid valve designation Resistance (Approx.) Terminal 20 - 30 Ω 2 Shift solenoid valve B 5 - 20 Ω 1 Overrun clutch solenoid valve 20 - 30 Ω 3 Line pressure solenoid valve 2.5 - 5.0 Ω 4 5 - 20 Ω 5 Shift solenoid valve A Torque converter clutch solenoid valve A/T Fluid Temperature Sensor I BCS000Z8 Remarks: Specification data are reference values. Condition Cold [20°C (68°F)] ↓ Hot [80°C (176°F)] H J Specification (Approx.) 1.5V ↓ 0.5V K 2.5 kΩ ↓ 0.3 kΩ L Revolution Sensor BCS000Z9 Condition Judgement standard When driving at 20 km/h (12 MPH) M 150 Hz (Approx.) Dropping Resistor BCS000ZA Resistance 12Ω (Approx.) Turbine Revolution Sensor (Power Train Revolution Sensor) Condition Judgement standard When driving at 20 km/h (12 MPH) 360 Hz (Approx.) AT-479 BCS000ZB SERVICE DATA AND SPECIFICATIONS (SDS) [ALL] AT-480 AUTOMATIC AIR CONDITIONER J AIR CONDITIONER SECTION ATC AUTOMATIC AIR CONDITIONER A B C D CONTENTS PRECAUTIONS .......................................................... 4 Precautions for Supplemental Restraint System (SRS) “AIR BAG” and “SEAT BELT PRE-TENSIONER” .................................................................. 4 PrecautionsforProcedureswithoutCowlTopCover..... 4 Precautions for Working with HFC-134a (R-134a)..... 4 General Refrigerant Precautions .............................. 4 Lubricant Precautions .............................................. 5 Precautions for Refrigerant Connection ................... 5 FEATURES OF NEW TYPE REFRIGERANT CONNECTION ...................................................... 5 O-RING AND REFRIGERANT CONNECTION..... 6 Precautions for Servicing Compressor ..................... 8 Precautions for Service Equipment .......................... 8 RECOVERY/RECYCLING EQUIPMENT .............. 8 ELECTRONIC LEAK DETECTOR ........................ 8 VACUUM PUMP ................................................... 9 MANIFOLD GAUGE SET ...................................... 9 SERVICE HOSES ................................................. 9 SERVICE COUPLERS ........................................ 10 REFRIGERANT WEIGHT SCALE ...................... 10 CALIBRATING ACR4 WEIGHT SCALE .............. 10 CHARGING CYLINDER ...................................... 10 Precautions for Leak Detection Dye ........................11 IDENTIFICATION .................................................11 IDENTIFICATION LABEL FOR VEHICLE ............11 PREPARATION ......................................................... 12 HFC-134a (R-134a) Service Tools and Equipment... 12 Commercial Service Tools ...................................... 14 REFRIGERATION SYSTEM ..................................... 15 Refrigerant Cycle ................................................... 15 REFRIGERANT FLOW ....................................... 15 FREEZE PROTECTION ..................................... 15 Refrigerant System Protection ............................... 15 REFRIGERANT PRESSURE SENSOR ............. 15 PRESSURE RELIEF VALVE ............................... 15 Component Layout ................................................. 16 LUBRICANT .............................................................. 17 Maintenance of Lubricant Quantity in Compressor... 17 LUBRICANT ........................................................ 17 LUBRICANT RETURN OPERATION .................. 17 LUBRICANT ADJUSTING PROCEDURE FOR COMPONENTS REPLACEMENT EXCEPT COMPRESSOR .................................................. 18 LUBRICANT ADJUSTING PROCEDURE FOR COMPRESSOR REPLACEMENT ....................... 18 AIR CONDITIONER CONTROL ............................... 20 System Construction .............................................. 20 AIR MIX DOOR CONTROL (AUTOMATIC TEMPERATURE CONTROL) ..................................... 20 FAN SPEED CONTROL ...................................... 20 INTAKE DOOR CONTROL ................................. 20 OUTLET DOOR CONTROL ................................ 20 MAGNET CLUTCH CONTROL ........................... 21 SELF-DIAGNOSTIC SYSTEM ............................ 21 Description of Control System ................................ 22 Control Operation ................................................... 22 DISPLAY SCREEN .............................................. 23 AUTO SWITCH ................................................... 23 TEMPERATURE CONTROL SWITCH (POTENTIO TEMPERATURE CONTROL) ....................... 23 RECIRCULATION (REC) SWITCH ..................... 23 FRESH (FRE) SWITCH ...................................... 23 DEFROSTER (DEF) SWITCH ............................. 23 REAR WINDOW DEFOGGER SWITCH ............. 23 OFF SWITCH ...................................................... 23 A/C SWITCH ....................................................... 23 MODE SWITCH .................................................. 23 FAN SWITCH ...................................................... 23 Discharge Air Flow ................................................. 24 System Description ................................................. 25 SWITCHES AND THEIR CONTROL FUNCTION... 25 CAN Communication System Description .............. 25 TROUBLE DIAGNOSIS ............................................ 26 CONSULT-II Function (BCM) ................................. 26 CONSULT-II BASIC OPERATION ....................... 26 DATA MONITOR ................................................. 26 ATC-1 E F G H I ATC K L M How to Perform Trouble Diagnosis for Quick and Accurate Repair ...................................................... 27 WORK FLOW ...................................................... 27 SYMPTOM TABLE .............................................. 27 ComponentParts and Harness Connector Location... 28 ENGINE COMPARTMENT .................................. 28 PASSENGER COMPARTMENT .......................... 29 Circuit Diagram ....................................................... 30 Wiring Diagram —A/C— CR Engine Models .......... 31 Wiring Diagram —A/C—HR Engine Models ........... 35 Wiring Diagram —A/C— K9K Engine Models ........ 39 Wiring Diagram —PTC/H— K9K Engine LHD Models ........................................................................... 43 Auto Amp. Terminals and Reference Value ............ 44 PIN CONNECTOR TERMINAL LAYOUT ............ 44 TERMINALS AND REFERENCE VALUE FOR AUTO AMP. ......................................................... 44 Self-diagnosis Function .......................................... 46 DESCRIPTION .................................................... 46 FUNCTION CONFIRMATION PROCEDURE ...... 48 AUXILIARY MECHANISM: TEMPERATURE SETTING TRIMMER ........................................... 54 Operational Check .................................................. 55 CHECKING MEMORY FUNCTION ..................... 55 CHECKING BLOWER ......................................... 55 CHECKING DISCHARGE AIR ............................ 55 CHECKING RECIRCULATION ............................ 56 CHECKING TEMPERATURE INCREASE .......... 56 CHECKING TEMPERATURE DECREASE ......... 56 CHECK A/C SWITCH .......................................... 56 CHECKING AUTO MODE ................................... 57 Power Supply and Ground Circuit for Auto Amp. ... 57 INSPECTION FLOW ........................................... 57 COMPONENT DESCRIPTION ............................ 58 DIAGNOSTIC PROCEDURE FORA/C SYSTEM... 58 Mode Door Motor Circuit ........................................ 60 INSPECTION FLOW ........................................... 60 SYSTEM DESCRIPTION .................................... 61 COMPONENT DESCRIPTION ............................ 62 DIAGNOSTIC PROCEDURE FOR MODE DOOR MOTOR ................................................... 63 Air Mix Door Motor Circuit ...................................... 64 INSPECTION FLOW ........................................... 64 SYSTEM DESCRIPTION .................................... 65 COMPONENT DESCRIPTION ............................ 66 DIAGNOSTIC PROCEDURE FOR AIR MIX DOOR MOTOR ................................................... 67 Intake Door Motor Circuit ........................................ 68 INSPECTION FLOW ........................................... 68 SYSTEM DESCRIPTION .................................... 69 COMPONENT DESCRIPTION ............................ 70 DIAGNOSTIC PROCEDURE FOR INTAKE DOOR MOTOR ................................................... 70 Blower Motor Circuit ............................................... 71 INSPECTION FLOW ........................................... 71 SYSTEM DESCRIPTION .................................... 72 DIAGNOSTIC PROCEDURE FOR BLOWER MOTOR ............................................................... 73 COMPONENT INSPECTION .............................. 77 Magnet Clutch Circuit ..............................................78 INSPECTION FLOW ............................................78 SYSTEM DESCRIPTION .....................................79 DIAGNOSTIC PROCEDURE FOR MAGNET CLUTCH ..............................................................79 COMPONENT INSPECTION ...............................85 Insufficient Cooling ..................................................86 INSPECTION FLOW ............................................86 PERFORMANCE TEST DIAGNOSIS ..................88 PERFORMANCE CHART ....................................90 TROUBLE DIAGNOSIS FOR UNUSUAL PRESSURE ...................................................................91 Insufficient Heating .................................................94 INSPECTION FLOW ............................................94 Noise .......................................................................96 INSPECTION FLOW ............................................96 Self-diagnosis .........................................................97 INSPECTION FLOW ............................................97 Memory Function ....................................................98 INSPECTION FLOW ............................................98 Ambient Sensor Circuit ...........................................99 COMPONENT DESCRIPTION ............................99 AMBIENT TEMPERATURE INPUT PROCESS...99 DIAGNOSTIC PROCEDURE FOR AMBIENT SENSOR ..............................................................99 COMPONENT INSPECTION ............................. 101 In-vehicle Sensor Circuit ....................................... 102 COMPONENT DESCRIPTION .......................... 102 DIAGNOSTIC PROCEDURE FOR IN-VEHICLE SENSOR ............................................................ 102 COMPONENT INSPECTION ............................. 104 Sunload Sensor Circuit ......................................... 105 COMPONENT DESCRIPTION .......................... 105 SUNLOAD INPUT PROCESS ........................... 105 DIAGNOSTIC PROCEDURE FOR SUNLOAD SENSOR ............................................................ 105 COMPONENT INSPECTION ............................. 107 Intake Sensor Circuit ............................................. 108 COMPONENT DESCRIPTION .......................... 108 DIAGNOSTICPROCEDUREFORINTAKESENSOR ................................................................... 108 COMPONENT INSPECTION ............................. 110 Engine Coolant Temperature Circuit ..................... 111 CONTROLLER ........................................................ 112 Removal and Installation of Controller .................. 112 REMOVAL .......................................................... 112 INSTALLATION .................................................. 112 Disassembly and Assembly of Controller ............. 112 DISASSEMBLY .................................................. 112 ASSEMBLY ........................................................ 113 AMBIENT SENSOR ................................................ 114 Removal and Installation ....................................... 114 REMOVAL .......................................................... 114 INSTALLATION .................................................. 114 IN-VEHICLE SENSOR ............................................ 115 Removal and Installation ....................................... 115 REMOVAL .......................................................... 115 INSTALLATION .................................................. 115 ATC-2 SUNLOAD SENSOR ...............................................116 Removal and Installation .......................................116 REMOVAL ..........................................................116 INSTALLATION ..................................................116 INTAKE SENSOR ....................................................117 Removal and Installation .......................................117 REMOVAL ..........................................................117 INSTALLATION ..................................................117 A/C UNIT ASSEMBLY .............................................118 Removal and Installation .......................................118 REMOVAL ..........................................................118 INSTALLATION ................................................. 120 Disassembly and Assembly ................................. 121 BLOWER MOTOR .................................................. 123 Removal and Installation ...................................... 123 REMOVAL ......................................................... 123 INSTALLATION ................................................. 123 INTAKE DOOR MOTOR ......................................... 124 Removal and Installation ...................................... 124 REMOVAL ......................................................... 124 INSTALLATION ................................................. 124 AIR MIX DOOR MOTOR ......................................... 125 Removal and Installation ...................................... 125 REMOVAL ......................................................... 125 INSTALLATION ................................................. 125 MODE DOOR MOTOR ........................................... 126 Removal and Installation ...................................... 126 REMOVAL ......................................................... 126 INSTALLATION ................................................. 126 POWER TRANSISTOR .......................................... 127 Removal and Installation ...................................... 127 REMOVAL ......................................................... 127 INSTALLATION ................................................. 127 HEATER CORE ...................................................... 128 Removal and Installation ...................................... 128 REMOVAL ......................................................... 128 INSTALLATION ................................................. 128 AIR CONDITIONER FILTER ................................... 129 Removal and Installation ...................................... 129 FUNCTION ........................................................ 129 REPLACEMENT TIMING .................................. 129 REPLACEMENT PROCEDURES ..................... 129 DUCTS AND GRILLES .......................................... 130 Removal and Installation ...................................... 130 REMOVAL ......................................................... 130 INSTALLATION ................................................. 134 REFRIGERANT LINES ........................................... 135 HFC-134a (R-134a) Service Procedure ............... 135 SETTING OF SERVICE TOOLS AND EQUIPMENT ................................................................ 135 Components ......................................................... 137 CR ENGINE MODELS ...................................... 137 HR ENGINE MODELS ...................................... 138 K9K ENGINE MODELS ..................................... 139 Removal and Installation of Compressor .............. 140 REMOVAL ......................................................... 140 INSTALLATION ................................................. 140 CHECK DISC TO PULLEY CLEARANCE ......... 141 Removal and Installation for Pipe and Hose ........ 141 REMOVAL ......................................................... 141 INSTALLATION ................................................. 141 Removal and Installation for Refrigerant Pressure Sensor .................................................................. 142 REMOVAL AND INSTALLATION ...................... 142 Removal and Installation for Condenser (Models without Integrated Condenser) ............................. 142 REMOVAL ......................................................... 142 INSTALLATION ................................................. 143 Removal and Installation for Condenser (Models with Integrated Condenser) .................................. 143 REMOVAL ......................................................... 143 INSTALLATION ................................................. 143 RemovalandInstallationforLiquidTank(HREngine with A/T Models) ................................................... 144 REMOVAL ......................................................... 144 INSTALLATION ................................................. 144 RemovalandInstallationfor LiquidTank (ExceptHR Engine with A/T Models) ....................................... 144 REMOVAL ......................................................... 144 INSTALLATION ................................................. 145 Removal and Installation for Evaporator .............. 145 REMOVAL ......................................................... 145 INSTALLATION ................................................. 145 Removal and Installation for Expansion Valve ...... 145 REMOVAL ......................................................... 145 INSTALLATION ................................................. 146 Checking for Refrigerant Leaks ............................ 147 Checking System for Leaks Using the Fluorescent Leak Detector ....................................................... 147 Dye Injection ......................................................... 147 Electronic Refrigerant Leak Detector .................... 148 PRECAUTIONS FOR HANDLING LEAK DETECTOR ....................................................... 148 CHECKING PROCEDURE ............................... 149 SERVICE DATA AND SPECIFICATIONS (SDS) .... 151 COMPRESSOR .................................................... 151 LUBRICANT ......................................................... 151 REFRIGERANT .................................................... 151 ENGINE IDLING SPEED ...................................... 151 BELT TENSION .................................................... 151 ATC-3 A B C D E F G H I ATC K L M PRECAUTIONS PFP:00001 PRECAUTIONS Precautions for Supplemental Restraint System (SRS) “AIR BAG” and “SEAT BELT PRE-TENSIONER” BJS000AI The Supplemental Restraint System such as “AIR BAG” and “SEAT BELT PRE-TENSIONER”, used along with a front seat belt, helps to reduce the risk or severity of injury to the driver and front passenger for certain types of collision. Information necessary to service the system safely is included in the SRS and SB section of this Service Manual. WARNING: ● To avoid rendering the SRS inoperative, which could increase the risk of personal injury or death in the event of a collision which would result in air bag inflation, all maintenance must be performed by an authorized NISSAN/INFINITI dealer. ● Improper maintenance, including incorrect removal and installation of the SRS, can lead to personal injury caused by unintentional activation of the system. For removal of Spiral Cable and Air Bag Module, see the SRS section. ● Do not use electrical test equipment on any circuit related to the SRS unless instructed to in this Service Manual. SRS wiring harnesses can be identified by yellow and/or orange harnesses or harness connectors. Precautions for Procedures without Cowl Top Cover BJS000AJ When performing the procedure after removing cowl top cover, cover the lower end of windshield with urethane, etc. PIIB3706J Precautions for Working with HFC-134a (R-134a) BJS000AK WARNING: ● Use only specified lubricant for the HFC-134a (R-134a) A/C system and HFC-134a (R-134a) components. If lubricant other than that specified is used, compressor malfunction is likely to occur. ● The specified HFC-134a (R-134a) lubricant rapidly absorbs moisture from the atmosphere. The following handling precautions must be observed: – When removing refrigerant components from a vehicle, immediately cap (seal) the component to minimize the entry of moisture from the atmosphere. – When installing refrigerant components to a vehicle, do not remove the caps (unseal) until just before connecting the components. Connect all refrigerant loop components as quickly as possible to minimize the entry of moisture into system. – Only use the specified lubricant from a sealed container. Immediately reseal containers of lubricant. Without proper sealing, lubricant will become moisture saturated and should not be used. – Avoid breathing A/C refrigerant and lubricant vapor or mist. Exposure may irritate eyes, nose and throat. Use only approved recovery/recycling equipment to discharge HFC-134a (R-134a) refrigerant. If accidental system discharge occurs, ventilate work area before resuming service. Additional health and safety information may be obtained from refrigerant and lubricant manufacturers. – Do not allow lubricant (Nissan A/C System Oil Type R) to come in contact with styrofoam parts. Damage may result. General Refrigerant Precautions BJS000AL WARNING: ● Do not release refrigerant into the air. Use approved recovery/recycling equipment to capture the refrigerant every time an air conditioning system is discharged. ATC-4 PRECAUTIONS ● ● ● ● ● ● ● Always wear eye and hand protection (goggles and gloves) when working with any refrigerant or air conditioning system. Do not store or heat refrigerant containers above 52°C. Do not heat a refrigerant container with an open flame; if container warming is required, place the bottom of the container in a warm pail of water. Do not intentionally drop, puncture, or incinerate refrigerant containers. Keep refrigerant away from open flames: poisonous gas will be produced if refrigerant burns. Refrigerant will displace oxygen, therefore be certain to work in well ventilated areas to prevent suffocation. Do not pressure test or leak test HFC-134a (R-134a) service equipment and/or vehicle air conditioning systems with compressed air during repair. Some mixtures of air and HFC-134a (R-134a) have been shown to be combustible at elevated pressures. These mixtures, if ignited, may cause injury or property damage. Additional health and safety information may be obtained from refrigerant manufacturers. Lubricant Precautions ● ● – – – ● ● B C D E BJS000AM Use only specified lubricant for the HFC-134a (R-134a) A/C system and HFC-134a (R-134a) components. F If lubricant other than that specified is used, compressor malfunction is likely to occur. The specified HFC-134a (R-134a) lubricant rapidly absorbs moisture from the atmosphere. The following handling precautions must be observed: When removing refrigerant components from a vehicle, immediately cap (seal) the component to minimize G the entry of moisture from the atmosphere. When installing refrigerant components to a vehicle, do not remove the caps (unseal) until just before connecting the components. Connect all refrigerant loop components as quickly as possible to minimize the H entry of moisture into system. Only use the specified lubricant from a sealed container. Immediately reseal containers of lubricant. WithI out proper sealing, lubricant will become moisture saturated and should not be used. Avoid breathing A/C refrigerant and lubricant vapor or mist. Exposure may irritate eyes, nose and throat. Use only approved recovery/recycling equipment to discharge HFC-134a (R-134a) refrigerant. If accidental system discharge occurs, ventilate work area before resuming service. Additional health and safety ATC information may be obtained from refrigerant and lubricant manufacturers. Do not allow lubricant (Nissan A/C System Oil Type R) to come in contact with styrofoam parts. Damage may result. K Precautions for Refrigerant Connection BJS000AN A new type refrigerant connection has been introduced to all refrigerant lines except the following location. ● Expansion valve to evaporator ● Refrigerant pressure sensor to condenser FEATURES OF NEW TYPE REFRIGERANT CONNECTION ● A The O-ring has been relocated. It has also been provided with a groove for proper installation. This eliminates the chance of the O-ring being caught in, or damaged by, the mating part. The sealing direction of the O-ring is now set vertically in relation to the contacting surface of the mating part to improve sealing characteristics. ATC-5 L M PRECAUTIONS ● The reaction force of the O-ring will not occur in the direction that causes the joint to pull out, thereby facilitating piping connections. SHA815E O-RING AND REFRIGERANT CONNECTION CAUTION: The new and former refrigerant connections use different O-ring configurations. Do not confuse Orings since they are not interchangeable. If a wrong O-ring is installed, refrigerant will leak at, or around, the connection. O-Ring Part Numbers and Specifications (CR Engine Models) Connection type New Piping connection point Part number Qty. Low-pressure flexible hose to heater & cooling unit 92473 BC700 1 High-pressure pipe to heater & cooling unit 92471 BC700 1 Condenser to high-pressure flexible hose 92472 BC700 1 Condenser to high-pressure pipe 92471 BC700 1 Compressor to low-pressure flexible hose 92474 BC700 1 Compressor to high-pressure flexible hose 92472 BC700 1 Liquid tank to condenser pipe 92471 N8210 1 — – Inlet 92477 AX000 1 Outlet 92477 AX005 1 Refrigerant pressure sensor Former Expansion valve to evaporator Remarks O-Ring Part Numbers and Specifications (HR Engine Models) Connection type New Part number Qty. Low-pressure flexible hose to heater & cooling unit Piping connection point 92473 N8210 1 High-pressure pipe to heater & cooling unit 92471 N8210 1 Condenser to high-pressure flexible hose 92472 N8210 1 Condenser to high-pressure pipe 92471 N8210 1 Compressor to low-pressure flexible hose 92474 N8210 1 Compressor to high-pressure flexible hose 92472 N8210 1 Liquid tank to condenser pipe 92471 N8210 1 — – Inlet 92477 AX000 1 Outlet 92477 AX005 1 Refrigerant pressure sensor Former Expansion valve to evaporator ATC-6 Remarks PRECAUTIONS O-Ring Part Numbers and Specifications (K9K Engine Models) Connection type New Piping connection point Part number Qty. Low-pressure flexible hose to heater & cooling unit 92473 N8210 1 Low-pressure flexible hose to Low-pressure pipe 92473 N8210 1 High-pressure pipe to heater & cooling unit 92471 N8210 1 Condenser to high-pressure flexible hose 92472 N8210 1 Condenser to high-pressure pipe 92471 N8210 1 Compressor to low-pressure flexible hose 92474 N8210 1 Compressor to high-pressure flexible hose 92472 N8210 1 Liquid tank to condenser pipe 92471 N8210 1 — – Inlet 92477 AX000 1 Outlet 92477 AX005 1 Refrigerant pressure sensor Former Expansion valve to evaporator Remarks A B C D E WARNING: Make sure all refrigerant is discharged into the recycling equipment and the pressure in the system is F less than atmospheric pressure. Then gradually loosen the discharge side hose fitting and remove it. CAUTION: G When replacing or cleaning refrigerant cycle components, observe the following. ● When the compressor is removed, store it in the same position as it is when mounted on the car. Malfunction to do so will cause lubricant to enter the low-pressure chamber. H ● When connecting tubes, always use a torque wrench and a back-up wrench. ● After disconnecting tubes, immediately plug all openings to prevent entry of dirt and moisture. ● When installing an air conditioner in the vehicle, connect the pipes as the final stage of the operaI tion. Do not remove the seal caps of pipes and other components until just before required for connection. ● Allow components stored in cool areas to warm to working area temperature before removing seal ATC caps. This prevents condensation from forming inside A/C components. ● Thoroughly remove moisture from the refrigeration system before charging the refrigerant. ● Always replace used O-rings. K ● When connecting tube, apply lubricant to circle of the O-rings shown in illustration. Be careful not to apply lubricant to threaded portion. Gasoline engine Name Parts number ● ● ● Nissan A/C System Oil Type R KLH00 - PAGR0 K9K engine Nissan A/C System Oil Type S KLH00 - PAGS0 O-ring must be closely attached to dented portion of tube. When replacing the O-ring, be careful not to damage O-ring and tube. Connect tube until you hear it click, then tighten the nut or bolt by hand until snug. Make sure that the O-ring is installed to tube correctly. ATC-7 L M PRECAUTIONS ● After connecting line, perform leak test and make sure that there is no leakage from connections. When the refrigerant leaking point is found, disconnect that line and replace the O-ring. Then tighten connections of seal seat to the specified torque. RHA861F Precautions for Servicing Compressor ● ● ● ● ● ● BJS000AO Plug all openings to prevent moisture and foreign matter from entering. When the compressor is removed, store it in the same position as it is when mounted on the car. When replacing or repairing compressor, follow “Maintenance of Lubricant Quantity in Compressor” exactly. Refer to ATC-17, "Maintenance of Lubricant Quantity in Compressor" . Keep friction surfaces between clutch and pulley clean. If the surface is contaminated, with lubricant, wipe it off by using a clean waste cloth moistened with thinner. After compressor service operation, turn the compressor shaft by hand more than five turns in both directions. This will equally distribute lubricant inside the compressor. After the compressor is installed, let the engine idle and operate the compressor for one hour. After replacing the compressor magnet clutch, apply voltage to the new one and check for usual operation. Precautions for Service Equipment BJS000AP RECOVERY/RECYCLING EQUIPMENT Be certain to follow the manufacturer’s instructions for machine operation and machine maintenance. Never introduce any refrigerant other than that specified into the machine. ELECTRONIC LEAK DETECTOR Be certain to follow the manufacturer’s instructions for tester operation and tester maintenance. ATC-8 PRECAUTIONS VACUUM PUMP A The lubricant contained inside the vacuum pump is not compatible with the specified lubricant for HFC-134a (R-134a) A/C systems. The vent side of the vacuum pump is exposed to atmospheric pressure. So the vacuum pump lubricant may migrate out of the pump into the service hose. This is possible when the pump is switched off after evacuation (vacuuming) and hose is connected to it. To prevent this migration, use a manual valve placed near the hoseto-pump connection, as follows. ● Usually vacuum pumps have a manual isolator valve as part of the pump. Close this valve to isolate the service hose from the pump. ● For pumps without an isolator, use a hose equipped with a manual shut-off valve near the pump end. Close the valve to isolate the hose from the pump. ● If the hose has an automatic shut-off valve, disconnect the hose from the pump. As long as the hose is connected, the valve is open and lubricating oil may migrate. Some one-way valves open when vacuum is applied and close under a no vacuum condition. Such valves may restrict the pump’s ability to pull a deep vacuum and are not recommended. B C D E F G RHA270DA H MANIFOLD GAUGE SET Be certain that the gauge face indicates HFC-134a or R-134a. Be sure the gauge set has 1/2″-16 ACME threaded connections for service hoses. Confirm the set has been used only with refrigerant HFC-134a (R-134a) and specified lubricants. I ATC K SHA533D SERVICE HOSES L Be certain that the service hoses display the markings described (colored hose with black stripe). All hoses must include positive shutoff devices (either manual or automatic) near the end of the hoses opposite the manifold gauge. M RHA272D ATC-9 PRECAUTIONS SERVICE COUPLERS Never attempt to connect HFC-134a (R-134a) service couplers to a CFC-12 (R-12) A/C system. The HFC-134a (R-134a) couplers will not properly connect to the CFC-12 (R-12) system. However, if an improper connection is attempted, discharging and contamination may occur. Shut-off valve rotation A/C service valve Clockwise Open Counterclockwise Close RHA273D REFRIGERANT WEIGHT SCALE Verify that no refrigerant other than HFC-134a (R-134a) and specified lubricants have been used with the scale. If the scale controls refrigerant flow electronically, the hose fitting must be 1/2″-16 ACME. RHA274D CALIBRATING ACR4 WEIGHT SCALE Calibrate the scale every three months. To calibrate the weight scale on the ACR4: 1. Press “Shift/Reset” and “Enter” at the same time. 2. Press “8787” . “A1” will be displayed. 3. Remove all weight from the scale. 4. Press “0” , then press “Enter” . “0.00” will be displayed and change to “A2” . 5. Place a known weight (dumbbell or similar weight), between 4.5 and 8.6 kg (10 and 19 lb) on the center of the weight scale. 6. Enter the known weight using four digits. (Example 10 lb = 10.00, 10.5 lb = 10.50) 7. Press “Enter” — the display returns to the vacuum mode. 8. Press “Shift/Reset” and “Enter” at the same time. 9. Press “6” — the known weight on the scale is displayed. 10. Remove the known weight from the scale. “0.00” will be displayed. 11. Press “Shift/Reset” to return the ACR4 to the program mode. CHARGING CYLINDER Using a charging cylinder is not recommended. Refrigerant may be vented into air from cylinder’s top valve when filling the cylinder with refrigerant. Also, the accuracy of the cylinder is generally less than that of an electronic scale or of quality recycle/recharge equipment. ATC-10 PRECAUTIONS Precautions for Leak Detection Dye ● ● ● ● ● ● ● ● ● ● ● BJS000AQ The A/C system contains a fluorescent leak detection dye used for locating refrigerant leaks. An ultraviolet (UV) lamp is required to illuminate the dye when inspecting for leaks. Always wear fluorescence enhancing UV safety goggles to protect your eyes and enhance the visibility of the fluorescent dye. The fluorescent dye leak detector is not a replacement for an electronic refrigerant leak detector. The fluorescent dye leak detector should be used in conjunction with an electronic refrigerant leak detector to pinpoint refrigerant leaks. For your safety and your customer’s satisfaction, read and follow all manufacture’s operating instructions and precautions prior to performing the work. A compressor shaft seal should not be repaired because of dye seepage. The compressor shaft seal should only be repaired after confirming the leak with an electronic refrigerant leak detector. Always remove any remaining dye from the leak area after repairs are complete to avoid a misdiagnosis during a future service. Do not allow dye to come into contact with painted body panels or interior components. If dye is spilled, clean immediately with the approved dye cleaner. Fluorescent dye left on a surface for an extended period of time cannot be removed. Do not spray the fluorescent dye cleaning agent on hot surfaces (engine exhaust manifold, etc.). Do not use more than one refrigerant dye bottle (1/4 ounce /7.4 cc) per A/C system. Leak detection dyes for HFC-134a (R-134a) and CFC-12 (R-12) A/C systems are different. Do not use HFC-134a (R-134a) leak detection dye in CFC-12 (R-12) A/C system or CFC-12 (R-12) leak detector dye in HFC-134a (R-134a) A/C system or A/C system damage may result. The fluorescent properties of the dye will remain for over three (3) years unless a compressor malfunction occurs. A B C D E F G H IDENTIFICATION I NOTE: Vehicles with factory installed fluorescent dye have a green label. Vehicles without factory installed fluorescent dye have a blue label. ATC IDENTIFICATION LABEL FOR VEHICLE Vehicles with factory installed fluorescent dye have this identification label on the front side of hood. K L M MJIB0432E ATC-11 PREPARATION PREPARATION HFC-134a (R-134a) Service Tools and Equipment PFP:00002 BJS000AS Never mix HFC-134a (R-134a) refrigerant and/or its specified lubricant with CFC-12 (R-12) refrigerant and/or its lubricant. Separate and non-interchangeable service equipment must be used for handling each type of refrigerant/lubricant. Refrigerant container fittings, service hose fittings and service equipment fittings (equipment which handles refrigerant and/or lubricant) are different between CFC-12 (R-12) and HFC-134a (R-134a). This is to avoid mixed use of the refrigerants/lubricant. Adapters that convert one size fitting to another must never be used: refrigerant/lubricant contamination will occur and compressor malfunction will result. Tool number Tool name Description Container color: Light blue Container marking: HFC-134a (R134a) Fitting size: Thread size HFC-134a (R-134a) refrigerant ● Large container 1/2″ -16 ACME S-NT196 Type: Polyalkylene glycol oil (PAG), type R (DH-PR) Application: HFC-134a (R-134a) vane rotary compressors (Nissan only) Lubricity: 40 m (1.4 Imp fl oz.) KLH00-PAGR0 Nissan A/C System Oil Type R (DH-PR) S-NT197 Recovery/Recycling/ Recharging equipment (ACR4) Function: Refrigerant recovery and recycling and recharging RJIA0195E Power supply: DC 12V (Cigarette lighter) Electrical leak detector SHA705EB ATC-12 PREPARATION Tool number Tool name Description (J-43926) Refrigerant dye leak detection kit Kit includes: (J-42220) UV lamp and UV safety goggles (J-41459) HFC-134a (R-134a) dye injector Use with J-41447, 1/4 ounce bottle (J-41447) HFC-134a (R-134a) fluorescent leak detection dye (Box of 24, 1/4 ounce bottles) (J-43872) Refrigerant dye cleaner A B C Power supply: DC 12V (Battery terminal) D ZHA200H E Power supply: DC 12V (Battery terminal) For checking refrigerant leak when fluorescent dye is installed in A/C system Includes: UV lamp and UV safety goggles (J-42220) UV lamp and UV safety goggles SHA438F Application: For HFC-134a (R-134a) PAG oil Container: 1/4 ounce (7.4 cc) bottle (Includes self-adhesive dye identification labels for affixing to vehicle after charging system with dye.) (J-41447) HFC-134a (R-134a) fluorescent leak detection dye (Box of 24, 1/4 ounce bottles) SHA439F F G H I ATC (J-41459) HFC-134a (R-134a) dye injector Use with J-41447, 1/4 ounce bottle For injecting 1/4 ounce of fluorescent leak detection dye into A/C system K L SHA440F M (J-43872) Refrigerant dye cleaner For cleaning dye spills SHA441F Identification: ● Manifold gauge set (with hoses and couplers) The gauge face indicates HFC-134a (R-134a). Fitting size: Thread size ● RJIA0196E ATC-13 1/2″ -16 ACME PREPARATION Tool number Tool name Description Hose color: Service hoses ● High-pressure side hose ● Low-pressure side hose ● Utility hose Service couplers High-pressure side coupler ● Low-pressure side coupler Low hose: Blue with black stripe ● High hose: Red with black stripe ● Utility hose: Yellow with black stripe or green with black stripe Hose fitting to gauge: S-NT201 ● ● ● 1/2″ -16 ACME Hose fitting to service hose: ● M14 x 1.5 fitting is optional or permanently attached. S-NT202 For measuring of refrigerant Fitting size: Thread size Refrigerant weight scale ● 1/2″ -16 ACME S-NT200 Capacity: Vacuum pump (Including the isolator valve) ● Air displacement: 4 CFM ● Micron rating: 20 microns ● Oil capacity: 482 g (17 oz.) Fitting size: Thread size S-NT203 ● 1/2″ -16 ACME Commercial Service Tools BJS000AT Tool name Description Power tool For loosening bolts and nuts PBIC0190E ATC-14 REFRIGERATION SYSTEM REFRIGERATION SYSTEM Refrigerant Cycle PFP:KA990 A BJS000AU REFRIGERANT FLOW The refrigerant flows in the standard pattern, that is, through the compressor, the condenser with liquid tank, through the evaporator, and back to the compressor. The refrigerant evaporation through the evaporator is controlled by an externally equalized expansion valve, located inside the evaporator case. FREEZE PROTECTION B C Under usual operating conditions, when the A/C is switched ON, the compressor runs continuously, and the evaporator pressure, and therefore, temperature is controlled by the compressor to prevent freeze up. Refrigerant System Protection BJS000AV D REFRIGERANT PRESSURE SENSOR The refrigerant system is protected against excessively high- or low-pressures by the refrigerant pressure sensor, located on the condenser. If the system pressure rises above, or falls below the specifications, the refrigerant pressure sensor detects the pressure inside the refrigerant line and sends the voltage signal to the ECM. ECM makes the A/C relay go OFF and stops the compressor when pressure on the high-pressure side detected by refrigerant pressure sensor is over about 2,746 kPa (27.46 bar, 28.0 kg/cm2 , 398 psi), or below about 134 kPa (1.34 bar, 1.4 kg/cm2 , 20 psi). PRESSURE RELIEF VALVE The refrigerant system is also protected by a pressure relief valve, located in the rear head of the compressor. When the pressure of refrigerant in the system increases to an unusual level [more than 3.8MPa (38 bar, 38.76 kg/cm2 , 551 psi)], the release port on the pressure relief valve automatically opens and releases refrigerant into the atmosphere. E F G H I ATC K L M MJIB0355E ATC-15 REFRIGERATION SYSTEM Component Layout BJS000AW MJIB0368E 1. Defroster nozzle 2. Side defroster duct 3. Side ventilator duct 4. A/C unit 5. Center ventilator duct 6. Front floor duct 7. Rear floor duct ATC-16 LUBRICANT LUBRICANT Maintenance of Lubricant Quantity in Compressor PFP:KLG00 A BJS000AX The lubricant in the compressor circulates through the system with the refrigerant. Add lubricant to compressor when replacing any component or after a large refrigerant leakage occurred. It is important to maintain the specified amount. If lubricant quantity is not maintained properly, the following malfunctions may result: ● Lack of lubricant: May lead to a seized compressor. ● Excessive lubricant: Inadequate cooling (thermal exchange interference) B C LUBRICANT D Gasoline engine Name Nissan A/C System Oil Type R Parts number K9K engine Nissan A/C System Oil Type S KLH00 - PAGR0 KLH00 - PAGS0 E LUBRICANT RETURN OPERATION Adjust the lubricant quantity according to the test group shown below. F 1. CHECK LUBRICANT RETURN OPERATION Can lubricant return operation be performed? ● A/C system works properly. ● There is no evidence of a large amount of lubricant leakage. CAUTION: If excessive lubricant leakage is noted, do not perform the lubricant return operation. OK or NG OK >> GO TO 2. NG >> GO TO 3. 2. PERFORM LUBRICANT RETURN OPERATION, PROCEEDING AS FOLLOWS 1. – – – – – 2. 3. Start engine, and set the following conditions: Engine speed: Idling to 1,200 rpm A/C switch: ON Blower speed: Max. position Temp. control: Optional (Set so that intake air temperature is 25 to 30°C.) Intake position: Recirculation (REC) Perform lubricant return operation for about 10 minutes. Stop engine. >> GO TO 3. 3. CHECK REPLACEMENT PART Should the compressor be replaced? YES >> GO TO ATC-18, "LUBRICANT ADJUSTING PROCEDURE FOR COMPRESSOR REPLACEMENT" . NO >> GO TO ATC-18, "LUBRICANT ADJUSTING PROCEDURE FOR COMPONENTS REPLACEMENT EXCEPT COMPRESSOR" . ATC-17 G H I ATC K L M LUBRICANT LUBRICANT ADJUSTING PROCEDURE FOR COMPONENTS REPLACEMENT EXCEPT COMPRESSOR After replacing any of the following major components, add the correct amount of lubricant to the system. Amount of lubricant to be added Lubricant to be added to system Part replaced Amount of lubricant m (Imp fl oz.) Remarks Evaporator 35 (1.2) - Condenser 15 (0.5) - Liquid tank 5 (0.2) - 30 (1.1) Large leak - Small leak *1 In case of refrigerant leak *1: If refrigerant leak is small, no addition of lubricant is needed. LUBRICANT ADJUSTING PROCEDURE FOR COMPRESSOR REPLACEMENT 1. 2. 3. 4. 5. 6. 7. Before connecting ACR4 to vehicle, check ACR4 gauges. No refrigerant pressure should be displayed. If NG, recover refrigerant from equipment lines. Discharge refrigerant into the refrigerant recovery/recycling equipment. Measure lubricant discharged into the recovery/recycling equipment. Drain the lubricant from the old (removed) compressor into a graduated container and recover the amount of lubricant drained. Drain the lubricant from the new compressor into a separate, clean container. Measure an amount of new lubricant installed equal to amount drained from old compressor. Add this lubricant to new compressor through the suction port opening. Measure an amount of new lubricant equal to the amount recovered during discharging. Add this lubricant to new compressor through the suction port opening. If the liquid tank also needs to be replaced, add another 5 m (0.2 Imp fl oz.) of lubricant at this time. Do not add this 5 m (0.2 Imp fl oz.) of lubricant only when replaces the compressor. ATC-18 LUBRICANT A B C D E F G H I SJIA0596E ATC K L M ATC-19 AIR CONDITIONER CONTROL AIR CONDITIONER CONTROL System Construction PFP:27500 BJS000AY AIR MIX DOOR CONTROL (AUTOMATIC TEMPERATURE CONTROL) The air mix door is automatically controlled so that in-vehicle temperature is maintained at a predetermined value by the temperature setting, ambient temperature, in-vehicle temperature and amount of sunload. FAN SPEED CONTROL Blower speed is automatically controlled by the temperature setting, ambient temperature, in-vehicle temperature, intake temperature, amount of sunload and air mix door position. With fan control dial set to AUTO switch is pressed, the blower motor starts to gradually increase air flow volume. When engine coolant temperature is low, the blower motor operation is delayed to prevent cool air from flowing. INTAKE DOOR CONTROL The intake doors are automatically controlled by the temperature setting, ambient temperature, in-vehicle temperature, intake temperature, amount of sunload and ON-OFF operation of the compressor. OUTLET DOOR CONTROL The outlet door is automatically controlled by the temperature setting, ambient temperature, in-vehicle temperature, intake temperature and amount of sunload. ATC-20 AIR CONDITIONER CONTROL MAGNET CLUTCH CONTROL A B C D E F SJIA0703E When A/C switch, AUTO switch or DEF switch is pressed, auto amp. inputs compressor ON signal to BCM. BCM sends compressor ON signal to ECM, via CAN communication line. ECM judges whether compressor can be turned ON, based on each sensor status (refrigerant-pressure sensor signal, throttle angle, etc.). If it judges compressor can be turned ON, it sends compressor ON signal to IPDM E/R, via CAN communication line. Upon receipt of compressor ON signal from ECM, IPDM E/R turns air conditioner relay ON to operate compressor. G H I SELF-DIAGNOSTIC SYSTEM The self-diagnostic system is built into the auto amp. to quickly locate the cause of symptoms. ATC K L M ATC-21 AIR CONDITIONER CONTROL Description of Control System BJS000AZ The control system consists of input sensors, switches, the auto amp. (microcomputer) and outputs. The relationship of these components is shown in the figure below: SJIA0712E Control Operation BJS000B0 MJIB0369E 1. Fan SW 2. MODE SW 3. Fresh (FRE) SW 4. Reciculation (REC) SW 5. AUTO SW 6. Temperature control SW ATC-22 AIR CONDITIONER CONTROL 7. Defroster (DEF) SW 10. A/C SW 8. Rear window defogger SW 9. Display screen A 11. OFF SW DISPLAY SCREEN Displays the operational status of the system. B AUTO SWITCH ● ● The compressor, intake doors, air mix doors, outlet doors and blower speed are automatically controlled so that the in-vehicle temperature will reach, and be maintained at the set temperature selected by the operator. When pressing AUTO switch, air inlet, air outlet, fan speed, and discharge air temperature are automatically controlled. (Inlet is automatically controlled only when FRE or REC switch is OFF.) C D TEMPERATURE CONTROL SWITCH (POTENTIO TEMPERATURE CONTROL) Increases or decreases the set temperature. E RECIRCULATION (REC) SWITCH ● ● When REC switch is ON, REC switch indicator turns ON, air inlet is fixed to REC, and compressor will turn ON. When FRE switch is turned ON, air outlet switches to D/F or DEF position, or when compressor is turned from ON to OFF, REC switch is automatically turned OFF (fixed to FRE mode). FRESH (FRE) SWITCH ● ● F G When FRE switch is ON, FRE switch indicator turns ON, and air inlet is fixed to FRE. When REC switch is turned ON, FRE switch is automatically turned OFF (fixed to REC mode). FRE mode can be re-entered by pressing FRE switch again. H DEFROSTER (DEF) SWITCH Positions the air outlet doors to the defrost position. Also positions the intake doors to the outside air position, and compressor will turn ON. I REAR WINDOW DEFOGGER SWITCH When illumination is ON, rear window is defogged. ATC OFF SWITCH The compressor and blower are OFF, the intake doors are set to the outside air position, and the air outlet doors are set to the foot position. K A/C SWITCH The compressor is ON or OFF. (Pressing the A/C switch when the A/C switch is ON will turn off the A/C switch and compressor.) L MODE SWITCH Controls the air discharge outlets. When air outlet switches to D/F position, compressor will turn ON and fixed to REC mode. FAN SWITCH Manually control the blower speed. Four speeds are available for manual control (as shown on the display screen). ATC-23 M AIR CONDITIONER CONTROL Discharge Air Flow BJS000JB MJIB0511E ATC-24 AIR CONDITIONER CONTROL System Description BJS000B4 A SWITCHES AND THEIR CONTROL FUNCTION B C D E F G H I MJIB0507E ATC K L M SJIA0717E CAN Communication System Description BJS000B5 CAN (Controller Area Network) is a serial communication line for real time application. It is an on-vehicle multiplex communication line with high data communication speed and excellent error detection ability. Many electronic control units are equipped onto a vehicle, and each control unit shares information and links with other control units during operation (not independent). In CAN communication, control units are connected with 2 communication lines (CAN-H line, CAN-L line) allowing a high rate of information transmission with less wiring. Each control unit transmits/receives data but selectively reads required data only. For details, refer to LAN-27, "CAN Communication Unit" . ATC-25 TROUBLE DIAGNOSIS TROUBLE DIAGNOSIS CONSULT-II Function (BCM) PFP:00004 BJS000B6 CONSULT-II can display diagnostic item using the diagnostic test modes shown following. System part Check item, diagnosis mode BCM Data monitor Description Displays BCM input data in real time. CONSULT-II BASIC OPERATION Refer to GI-36, "CONSULT-II Start Procedure" . DATA MONITOR Operation Procedure 1. Touch “AIR CONDITIONER” on “SELECT TEST ITEM” screen. MJIB0465E 2. Touch “DATA MONITOR” on “SELECT DIAG MODE” screen. MJIB0466E 3. Touch either “ALL SIGNALS” or “SELECTION FROM MENU” on “DATA MONITOR” screen. All signals Monitors all the items. Selection from menu Selects and monitors the individual item selected. 4. 5. 6. When “SELECTION FROM MENU” is selected, touch items to be monitored. When “ALL SIGNALS” is selected, all the items will be monitored. Touch “START”. Touch “RECORD” while monitoring, then the status of the monitored item can be recorded. To stop recording, touch “STOP”. RJIA1111E Display Item List Monitor item name “operation or unit” Contents IGN ON SW “ON/OFF” Displays “IGN Position (ON)/OFF, ACC Position (OFF)” status as judged from ignition switch signal. FAN ON SIG “ON/OFF” Displays “FAN (ON)/FAN (OFF)” status as judged from blower fan motor switch signal. AIR COND SW “ON/OFF” Displays “COMP (ON)/COMP (OFF)” status as judged from air conditioner switch signal. ATC-26 TROUBLE DIAGNOSIS How to Perform Trouble Diagnosis for Quick and Accurate Repair BJS000B7 A WORK FLOW B C D SHA900E *1 ATC-55, "Operational Check" E SYMPTOM TABLE Symptom A/C system does not come on. Reference Page Go to Trouble Diagnosis Procedure for A/C System. Air outlet does not change. ATC-57, "Power Supply and Ground Circuit for Auto Amp." Go to Trouble Diagnosis Procedure for Mode Door Motor. ATC-60, "Mode Door Motor Circuit" Go to Trouble Diagnosis Procedure for Air Mix Door Motor. ATC-64, "Air Mix Door Motor Circuit" Go to Trouble Diagnosis Procedure for Intake Door Motor. ATC-68, "Intake Door Motor Circuit" Blower motor operation is malfunctioning under out of starting fan speed control. Go to Trouble Diagnosis Procedure for Blower Motor. ATC-71, "Blower Motor Circuit" Magnet clutch does not engage. Go to Trouble Diagnosis Procedure for Magnet Clutch. ATC-78, "Magnet Clutch Circuit" Insufficient cooling Go to Trouble Diagnosis Procedure for Insufficient Cooling. ATC-86, "Insufficient Cooling" Insufficient heating Go to Trouble Diagnosis Procedure for Insufficient Heating. ATC-94, "Insufficient Heating" Noise Go to Trouble Diagnosis Procedure for Noise. ATC-96, "Noise" Self-diagnosis cannot be performed. Go to Trouble Diagnosis Procedure for Self-diagnosis. Memory function does not operate. Go to Trouble Diagnosis Procedure for Memory Function. Mode door motor does not operate normally. Intake door does not change. Intake door motor does not operate normally. G H Discharge air temperature does not change. Air mix door motor does not operate normally. F I ATC Blower motor operation is malfunctioning. ATC-27 ATC-97, "Selfdiagnosis" ATC-98, "Memory Function" K L M TROUBLE DIAGNOSIS Component Parts and Harness Connector Location BJS000B8 ENGINE COMPARTMENT MJIB0478E 1. Compressor (CR & HR engine F28) (K9K engine F129) 2. Ambient sensor E17 4. Condenser 5. Liquid tank ATC-28 3. Refrigerant pressure sensor (CR & HR engine E21) (K9K engine E65) TROUBLE DIAGNOSIS PASSENGER COMPARTMENT A B C D E F G H I ATC K L M MJIB0479E 1. Power transistor M30, M31 2. Intake door motor M28 3. Controller (Auto amp.) M64, M65 4. Blower motor M56 5. Sunload sensor M43 6. In-vehicle sensor M43 7. Air mix door motor M51 8. Intake sensor M44 9. Mode door motor M50 ATC-29 TROUBLE DIAGNOSIS Circuit Diagram BJS000B9 MJWA0273E ATC-30 TROUBLE DIAGNOSIS Wiring Diagram —A/C— CR Engine Models BJS000BA A B C D E F G H I ATC K L M MJWA0274E ATC-31 TROUBLE DIAGNOSIS MJWA0275E ATC-32 TROUBLE DIAGNOSIS A B C D E F G H I ATC K L M MJWA0276E ATC-33 TROUBLE DIAGNOSIS MJWA0277E ATC-34 TROUBLE DIAGNOSIS Wiring Diagram —A/C—HR Engine Models BJS000JD A B C D E F G H I ATC K L M MJWA0278E ATC-35 TROUBLE DIAGNOSIS MJWA0279E ATC-36 TROUBLE DIAGNOSIS A B C D E F G H I ATC K L M MJWA0280E ATC-37 TROUBLE DIAGNOSIS MJWA0281E ATC-38 TROUBLE DIAGNOSIS Wiring Diagram —A/C— K9K Engine Models BJS000EZ A B C D E F G H I ATC K L M MJWA0282E ATC-39 TROUBLE DIAGNOSIS MJWA0283E ATC-40 TROUBLE DIAGNOSIS A B C D E F G H I ATC K L M MJWA0284E ATC-41 TROUBLE DIAGNOSIS MJWA0285E ATC-42 TROUBLE DIAGNOSIS Wiring Diagram —PTC/H— K9K Engine LHD Models BJS000F0 A B C D E F G H I ATC K L M MJWA0286E PTC heater function is intended to improve the heating performance with CTP electrical system for air heating system which is broken down into several stages controlled by relays. ATC-43 TROUBLE DIAGNOSIS Auto Amp. Terminals and Reference Value BJS000BB Measure voltage between each terminal and ground by following terminals and reference value for auto amp. MJIB0370E PIN CONNECTOR TERMINAL LAYOUT MJIB0371E TERMINALS AND REFERENCE VALUE FOR AUTO AMP. Terminal No. Wire color 1 LG Item Power supply for BAT Ignition switch Voltage (V) Condition - OFF Battery voltage At idle (after warming up, approx. 80°C) 4 BR Engine coolant temperature sensor signal ON CAUTION: The wave forms vary depending on coolant temperature. SKIB3651J 5 B Illumination ground ON - Approx. 0 7 G Power supply for IGN 2 OFF - Battery voltage 10 B Ground ON - Approx. 0 12 SB FAN ON signal ON FAN speed: 1st step (manual) ZJIA0583J 13 P Compressor ON signal ON A/C switch: ON (Blower motor operates.) ZJIA0584J ATC-44 TROUBLE DIAGNOSIS Terminal No. 14 Wire color W Item Rear window defogger ON signal Ignition switch ON Voltage (V) Condition When rear window defogger switch is depressed. Approx. 0 When rear window defogger switch is released. Approx. 5 A B C 15 GR Blower PWM ON FAN speed: 1st step (manual) D ZJIA0863J 16 V 17 O 19 BR 20 SB 21 LG 22 Y Illumination signal Power supply for IGN 1 ON Light switch: ON Approx. 12 Light switch: OFF Approx. 0 ON - E Battery voltage F Air mix door motor drive signal ON Immediately after temperature adjustment switch operation G HAK0627D 23 GR 24 W 25 P 26 V Mode door motor drive signal ON H I Immediately after mode switch operation ATC HAK0627D Approx. 0 FRE→REC Approx. 12 G Intake door motor drive signal 28 LG In-vehicle sensor - - - 29 O Intake sensor - - - 30 SB Ambient sensor - - - 31 P Sunload sensor - - - 32 R Rear window defogger feedback signal ON 33 R Sensor ground ON 36 B Intake door motor drive signal ON ON REC or FRE switch REC→FRE 27 Rear window defogger: ON Approx. 12 Rear window defogger: OFF Approx. 0 REC or FRE switch ATC-45 Approx. 0 REC→FRE Approx. 12 FRE→REC Approx. 0 K L M TROUBLE DIAGNOSIS Self-diagnosis Function BJS000BC DESCRIPTION The self-diagnostic system diagnoses sensors, door motors, blower motor, etc. by system line. Refer to applicable sections (items) for details. Shifting from usual control to the self-diagnostic system is accomplished by starting the engine (turning the ignition switch ON) and pressing OFF switch for at least 5 seconds. The OFF switch must be pressed within 10 seconds after starting the engine (ignition switch is turned ON). This system will be canceled by either pressing AUTO switch or turning the ignition switch OFF. Shifting from one step to another is accomplished by means of pushing temperature control switch, as required. ATC-46 TROUBLE DIAGNOSIS Additionally shifting from STEP-5 to AUXILIARY MECHANISM is accomplished by means of pushing fan switch (UP: ). A B C D E F G H I ATC K L M MJIB0372E ATC-47 TROUBLE DIAGNOSIS FUNCTION CONFIRMATION PROCEDURE 1. SET IN SELF-DIAGNOSTIC MODE 1. 2. Turn ignition switch ON. Set in self-diagnostic mode as follows. Within 10 seconds after starting engine (ignition switch is turned ON.), press OFF switch for at least 5 seconds. CAUTION: If battery voltage drops below 12V during diagnosis STEP-3, door motor speed becomes slower and as a result, the system may generate an error even when operation is usual. To avoid this, start engine before performing this diagnosis. >> GO TO 2. 2. STEP-1: LED AND DISPLAY ARE CHECKED Check display screen (1) and LED illumination (2). OK or NG OK >> GO TO 3. NG >> Malfunction OFF switch or AUTO amp. Refer to ATC97, "Self-diagnosis" . MJIB0373E 3. CHECK TO ADVANCE SELF-DIAGNOSIS STEP-2 Press temperature control switch (UP: ). Advance to self-diagnosis STEP-2? YES >> GO TO 4. NO >> Replace auto amp. (Temperature control switch is malfunctioning.) 4. CHECK TO RETURN SELF-DIAGNOSIS STEP-1 Press temperature control switch (DOWN: ). Return to self-diagnosis STEP-1? YES >> GO TO 5. NO >> Replace auto amp. (Temperature control switch is malfunctioning.) 5. STEP-2: SENSOR CIRCUITS ARE CHECKED FOR OPEN OR SHORT CIRCUIT Press temperature control switch (UP: ). Does code No. 20 appear on the display? YES >> GO TO 6. NO >> GO TO 13. SJIA0737E ATC-48 TROUBLE DIAGNOSIS 6. STEP-3: AIR MIX DOOR AND MODE DOOR POSITIONS ARE CHECKED A Press temperature control switch (UP: ). Does code No. 30 appear on the display? YES >> GO TO 7. NO >> GO TO 14. B C D SJIA0738E 7. STEP-4: OPERATION OF EACH DOOR MOTOR IS CHECKED E 1. 2. F Press temperature control switch (UP: ). Press (DEF) switch. Code No. of each door motor test is indicated on the display. >> GO TO 8. G H RHA495A 8. CHECK ACTUATORS I Refer to the following chart and confirm discharge air flow, air temperature, blower motor voltage, compressor, ionizer and indicator (ION mode) operation. ATC K L MJIB0374E M 41 42 43 44 45 46 Mode door position Code No. VENT B/L 1 B/L 2 FOOT D/F DEF Intake door position REC REC FRE FRE FRE FRE Air mix door position FULL COLD FULL COLD 50% 50% FULL HOT FULL HOT Blower motor voltage 5V 10.5V 8.5V 8.5V 8.5V Battery voltage Compressor ON ON ON OFF OFF ON Fan ON signal 12V 12V 12V 1V 1V 12V ATC-49 TROUBLE DIAGNOSIS Checks must be made visually, by listening to any noise, or by touching air outlets with your hand, etc. for improper operation. OK or NG OK >> GO TO 9. NG >> ● Air outlet does not change. Go to Mode Door Motor Circuit. Refer to ATC-60, "Mode Door Motor Circuit" . ● Intake door does not change. Go to Intake Door Motor Circuit. Refer to ATC-68, "Intake Door Motor Circuit" . ● Blower motor operation is malfunctioning. Go to Blower Motor Circuit. Refer to ATC-71, "Blower Motor Circuit" . ● Magnet clutch does not engage. Go to Magnet Clutch Circuit. Refer to ATC-78, "Magnet Clutch Circuit" . ● Discharge air temperature does not change. Go to Air Mix Door Motor Circuit. Refer to ATC-64, "Air Mix Door Motor Circuit" . 9. STEP-5: TEMPERATURE OF EACH SENSOR IS CHECKED 1. 2. Press temperature control switch (UP: Code No. 5 appears on the display. ). >> GO TO 10. 10. CHECK AMBIENT SENSOR Press (DEF) switch one time. Temperature detected by ambient sensor is indicated on the display. NOTE: If temperature shown on display greatly differs from actual temperature, check sensor circuit first, then inspect sensor. OK or NG OK >> GO TO 11. NG >> Go to Ambient Sensor Circuit. Refer to ATC-99, "Ambient Sensor Circuit" . SJIA0744E 11. CHECK IN-VEHICLE SENSOR Press (DEF) switch second time. Temperature detected by invehicle sensor is indicated on the display. NOTE: If temperature shown on display greatly differs from actual temperature, check sensor circuit first, then inspect sensor. OK or NG OK >> GO TO 12. NG >> Go to In-vehicle Sensor Circuit. Refer to ATC-102, "Invehicle Sensor Circuit" . SJIA0746E ATC-50 TROUBLE DIAGNOSIS 12. CHECK INTAKE SENSOR A Press (DEF) switch third time. Temperature detected by intake sensor is indicated on the display. NOTE: If temperature shown on display greatly differs from actual temperature, check sensor circuit first, then inspect sensor. OK or NG OK >> 1. Turn ignition switch OFF or AUTO switch ON. 2. INSPECTION END NG >> Go to Intake Sensor Circuit. Refer to ATC-108, "Intake Sensor Circuit" . B C D SJIA0748E 13. CHECK MALFUNCTIONING SENSOR E Refer to the following chart for malfunctioning code No. (If two or more sensors malfunction, corresponding code No. blink respectively twice.) *1: Perform self-diagnosis STEP-2 under sunshine. When performing indoors, aim a light (more than 60W) at sunload sensor, otherwise code No.25 will indicate despite that sunload sensor is functioning properly. F Code No. Malfunctioning sensor (Including circuits) 21 / AUTO 21 Ambient sensor *2 22 / AUTO 22 In-vehicle sensor *3 24 / AUTO 24 Intake sensor *4 25 / AUTO 25 Sunload sensor *1 *5 Intake door motor PBR *6 26 / AUTO 26 G Reference page H I *2: ATC-99, "DIAGNOSTIC PROCEDURE FOR AMBIENT SENSOR" . *3: ATC-102, "DIAGNOSTIC PROCEDURE FOR IN-VEHICLE SENSOR" . *4: ATC-108, "DIAGNOSTIC PROCEDURE FOR INTAKE SENSOR" . *5: ATC-105, "DIAGNOSTIC PROCEDURE FOR SUNLOAD SENSOR" . *6: ATC-70, "DIAGNOSTIC PROCEDURE FOR INTAKE DOOR MOTOR" . ATC K L M SJIA0752E >> INSPECTION END ATC-51 TROUBLE DIAGNOSIS 14. CHECK MALFUNCTIONING DOOR MOTOR POSITION SWITCH Air mix and/or mode door motor is/are malfunctioning. Door motor corresponding to the DTC Code No.*1 *2 31, 32, 33, 34 35, 36, 37, 38 Corresponding door motor Air mix door Mode door DTC for an inoperative harness Corresponding door motor Air mix door motor Mode door motor Corresponding terminal (Door motor side) 3 4 1 6 3 4 1 6 Corresponding terminal (Auto amp. side) 19 22 21 20 23 26 25 24 Code number for short circuit AUTO31 AUTO32 AUTO33 AUTO34 AUTO35 AUTO36 AUTO37 AUTO38 Code number for open circuit 31 32 33 34 35 36 37 38 Reference Page *3 *4 (If two or more air mix or mode doors are out of order, corresponding code numbers blink respectively twice.) *1: If air mix door motor harness connector is disconnected, the following display pattern will appear. 31→32→33→34→Return to 31 *2: If mode door motor harness connector is disconnected, the following display pattern will appear. 35→36→37→38→Return to 35 *3: ATC-64, "Air Mix Door Motor Circuit" . *4: ATC-60, "Mode Door Motor Circuit" . NOTE: ● If all four terminals of each door motor show an open circuit, there is probably a disconnected connector or an open circuit in actuator drive power supply harness. ● If a short circuit occurs in the harness between terminal for each door motor and drive signal, although it cannot be detected by self-diagnosis, the door motor will vibrate when it operate. SJIA0951E Door Motor Starting Position Reset ● Pressing the DEF switch during STEP-3 will send a reset signal to air mix door and mode door motor to reset them to the starting position. During reset: The 30 and DEF switch LED will blinks. (For approx. 9 seconds) SJIA0952E ATC-52 TROUBLE DIAGNOSIS A B C SJIA0757E D >> INSPECTION END E F G H I ATC K L M ATC-53 TROUBLE DIAGNOSIS AUXILIARY MECHANISM: TEMPERATURE SETTING TRIMMER The trimmer compensates for differences in range of ±3°C between temperature setting (displayed digitally) and temperature felt by driver. Operating procedures for this trimmer are as follows: 1. Begin self-diagnosis STEP-5 mode. Refer to ATC-46, "Self-diagnosis Function" . 2. 3. 4. Press fan switch (UP: ) to set system in auxiliary mode. Display shows 0°C in auxiliary mechanism. Press temperature control switch as desired. Temperature will change at a rate of 1°C each time a switch is pressed. SJIA0761E When battery cable is disconnected or battery voltage is 9.0V or less, trimmer operation is canceled. Set temperature returns to the initial condition, i.e. 0°C. ATC-54 TROUBLE DIAGNOSIS Operational Check BJS000BD A The purpose of the operational check is to confirm that the system operates properly. Conditions : Engine running at usual operating temperature B CHECKING MEMORY FUNCTION 1. Press temperature control switch (UP: ) until 32°C is displayed. 2. Press OFF switch. 3. Turn the ignition switch OFF. 4. Turn the ignition switch ON. 5. Press the AUTO switch. 6. Confirm that the set temperature remains at previous temperature. 7. Press OFF switch. If NG, go to trouble diagnosis procedure for ATC-98, "Memory Function" . If OK, continue the check. C D E MJIB0375E F CHECKING BLOWER 1. Press fan switch (UP: ). Blower should operate on low speed. The fan symbol should have one blade lit. G 2. Press fan switch (UP: ), and continue checking blower speed and fan symbol until all speeds are checked. 3. Leave blower on max. speed. If NG, go to trouble diagnosis procedure for ATC-71, "Blower Motor Circuit" . If OK, continue the check. H I MJIB0376E ATC CHECKING DISCHARGE AIR 1. 2. Press MODE switch and DEF switch. Each position indicator should change shape. K L M MJIB0377E 3. Confirm that discharge air comes out according to the air distribution table. Refer to ATC-24, "Discharge Air Flow" . Intake door position is checked in the next step. If NG, go to trouble diagnosis procedure for ATC-60, "Mode Door Motor Circuit" . If OK, continue the check. NOTE: Confirm that the compressor clutch is engaged (sound or visual inspection) and intake door position is at FRESH when the DEF is selected. MJIB0374E ATC-55 TROUBLE DIAGNOSIS CHECKING RECIRCULATION 1. Press recirculation (REC) switch one time. Recirculation LED should illuminate. 2. Press fresh (FRE) switch one time. Fresh LED should illuminate. 3. Listen for intake door position change (you should hear blower sound change slightly). If NG, go to trouble diagnosis procedure for ATC-68, "Intake Door Motor Circuit" . If OK, continue the check. MJIB0378E CHECKING TEMPERATURE INCREASE 1. Press temperature control switch (UP: ) until 32°C is displayed. 2. Check for hot air at discharge air outlets. If NG, go to trouble diagnosis procedure for ATC-94, "Insufficient Heating" . If OK, continue the check. MJIB0379E CHECKING TEMPERATURE DECREASE 1. Press temperature control switch (DOWN: ) until 18°C is displayed. 2. Check for cold air at discharge air outlets. If NG, go to trouble diagnosis procedure for ATC-86, "Insufficient Cooling" . If OK, continue the check. MJIB0380E CHECK A/C SWITCH 1. 2. Press AUTO and A/C switches. A/C switch LED will turn ON. ● Confirm that the compressor clutch engages (sound or visual inspection). If NG, go to trouble diagnosis procedure for ATC-78, "Magnet Clutch Circuit" . If OK, continue the check. MJIB0381E ATC-56 TROUBLE DIAGNOSIS CHECKING AUTO MODE 1. 2. ● ● ● Press AUTO switch. Display should indicate AUTO. ● Confirm that discharge air and blower speed will depend on ambient, in-vehicle, and set temperatures. If NG, go to trouble diagnosis procedure for ATC-57, "Power Supply and Ground Circuit for Auto Amp." , then if necessary, trouble diagnosis procedure for ATC-78, "Magnet Clutch Circuit" . If all operational checks are OK (symptom cannot be duplicated), go to Incident Simulation Tests in GI-25, "How to Perform MJIB0382E Efficient Diagnosis for an Electrical Incident" and perform tests as outlined to simulate driving conditions environment. If symptom appears, refer to ATC-27, "SYMPTOM TABLE" and perform applicable trouble diagnosis procedures. Power Supply and Ground Circuit for Auto Amp. A B C D E BJS000BE F SYMPTOM: A/C system does not come on. INSPECTION FLOW G H I ATC K L M MJIB0383E *1 ATC-58, "DIAGNOSTIC PROCEDURE FOR A/C SYSTEM" *2 ATC-55, "Operational Check" ATC-57 TROUBLE DIAGNOSIS COMPONENT DESCRIPTION Auto Amp. (Automatic Amplifier) The auto amp. has a built-in microcomputer which processes information sent from various sensors needed for air conditioner operation. The air mix door motor, mode door motor, intake door motor, blower motor and compressor are then controlled. The auto amp. is unitized with control mechanisms. Signal from various switches and Potentio Temperature Control (PTC) are directly entered into auto amp. Self-diagnostic functions are also built into auto amp. to provide quick check of malfunctions in the auto air conditioner system. MJIB0370E Potentio Temperature Control (PTC) The PTC is built into the auto amp. It can be set at an interval of 1°C in the 18°C to 32°C temperature range by pressing temperature control switch. The set temperature is displayed. MJIB0384E DIAGNOSTIC PROCEDURE FOR A/C SYSTEM SYMPTOM: A/C system does not come on. SJIA0785E ATC-58 TROUBLE DIAGNOSIS 1. CHECK POWER SUPPLY CIRCUIT FOR AUTO AMP. 1. 2. 3. A Turn ignition switch OFF. Disconnect auto amp. connector. Check voltage between auto amp. harness connector and ground. Terminals B Ignition switch position C (+) Connector Auto amp.: M64 OFF ACC ON 1 Battery voltage Battery voltage Battery voltage 7 Approx. 0V Approx. 0V Battery voltage Approx. 0V Approx. 0V Battery voltage Terminal (-) Ground 17 D MJIB0433E E OK or NG OK >> GO TO 2. NG >> Check 10A fuses (Nos. 5, 7 and 19, located in the fuse block). Refer to PG-95, "FUSE BLOCK" . ● If fuses are OK, check harness for open circuit. Repair or replace if necessary. ● If fuses are NG, replace fuse and check harness for short circuit. Repair or replace if necessary. F G 2. CHECK GROUND CIRCUIT FOR AUTO AMP. H 1. 2. I Turn ignition switch OFF. Check continuity between auto amp. harness connector and ground. Connector Auto amp.: M64 Terminal 10 Continuity Ground ATC Yes OK or NG OK >> Replace auto amp. NG >> Repair or replace harness. K MJIB0434E L M ATC-59 TROUBLE DIAGNOSIS Mode Door Motor Circuit BJS000BF SYMPTOM: ● Air outlet does not change. ● Mode door motor does not operate normally. INSPECTION FLOW MJIB0385E *1 ATC-24, "Discharge Air Flow" *4 *7 *2 ATC-55, "Operational Check" *3 ATC-48, "FUNCTION CONFIRMATION PROCEDURE", see No. 1. ATC-48, "FUNCTION CONFIRMA*5 TION PROCEDURE", see No. 5 to 7. ATC-99, "Ambient Sensor Circuit" *6 ATC-102, "In-vehicle Sensor Circuit" ATC-105, "Sunload Sensor Circuit" ATC-125, "AIR MIX DOOR MOTOR" *9 ATC-48, "FUNCTION CONFIRMATION PROCEDURE", see No. 13. *8 ATC-60 TROUBLE DIAGNOSIS *10 ATC-48, "FUNCTION CONFIRMATION PROCEDURE" see No. 14. *11 ATC-126, "MODE DOOR MOTOR" *12 ATC-27, "SYMPTOM TABLE" A *13 ATC-108, "Intake Sensor Circuit" SYSTEM DESCRIPTION Component Parts B Mode door control system components are: ● Auto amp. ● Mode door motor ● In-vehicle sensor ● Ambient sensor ● Sunload sensor C D System Operation The auto amp. receives data from each of the sensors. When a drive signal is input from auto amp. to door motor, a step motor built into the door motor rotates according to the drive signal, and then stops at the position of target door. Mode door changes to manual select mode by pressing MODE/DEF switch of the controller. That allows mode door to be fixed. Pressing AUTO switch allows automatic control by auto amp., and mode door is fixed in the FOOT position by pressing OFF switch. During automatic operation of mode door, mode door position (VENT, B/L, FOOT) is selected according to the temperature of discharge air calculated by auto amp. based on the target opening angle of air mix door and the amount of sunload. And only when ambient temperature is extremely low with the mode door in the FOOT position, D/F is selected and prevents windshield fogging. E F G H I ATC K L M SJIA0788E ATC-61 TROUBLE DIAGNOSIS Drive System of Step Motor Type Door Motor SJIA0971E ● ● Motor is actuated in sequence by energizing four drive coils. Rotation direction can be changed by changing pattern of excitation. Mode Door Control Specification RHA384HA COMPONENT DESCRIPTION Mode Door Motor The mode door motor is attached to the A/C unit assembly. It rotates so that air is discharged from the outlet set by the auto amp. Motor rotation is conveyed to a link which activates the mode door. MJIB0463E ATC-62 TROUBLE DIAGNOSIS DIAGNOSTIC PROCEDURE FOR MODE DOOR MOTOR A 1. CHECK MODE DOOR MOTOR 1. 2. 3. Turn ignition switch OFF. Disconnect mode door motor connector. Check continuity between mode door motor connector terminal. Connector Terminals B Continuity C Yes D 1 3 Mode door motor: M50 2 4 6 SJIA0948E OK or NG OK >> GO TO 2. NG >> Replace mode door motor. E 2. CHECK CIRCUIT CONTINUITY BETWEEN AUTO AMP. AND MODE DOOR MOTOR F 1. 2. G Disconnect auto amp. connector. Check continuity between auto amp. harness connector (A) and mode door motor harness connector (B). A Connector B Terminal Connector 23 Auto amp.: M65 Terminal H Continuity 3 24 Mode door motor: M50 25 26 I 6 Yes 1 MJIB0386E 4 ATC OK or NG OK >> GO TO 3. NG >> Repair harness or connector. K 3. CHECK CIRCUIT CONTINUITY BETWEEN AUTO AMP. AND GROUND L Check continuity between auto amp. harness connector and ground. Connector Terminal Continuity 23 Auto amp.: M65 24 M Ground No 25 26 OK or NG OK >> Replace auto amp. NG >> Repair harness or connector. MJIB0387E ATC-63 TROUBLE DIAGNOSIS Air Mix Door Motor Circuit BJS000BG SYMPTOM: ● Discharge air temperature does not change. ● Air mix door motor does not operate. INSPECTION FLOW MJIB0388E *1 ATC-48, "FUNCTION CONFIRMATION PROCEDURE", see No. 1. *2 ATC-99, "Ambient Sensor Circuit" *4 ATC-105, "Sunload Sensor Circuit" *5 ATC-64, "Air Mix Door Motor Circuit" *6 ATC-48, "FUNCTION CONFIRMATION PROCEDURE", see No. 13. *7 ATC-48, "FUNCTION CONFIRMATION PROCEDURE", see No. 14. *8 ATC-64, "Air Mix Door Motor Circuit" *9 ATC-55, "Operational Check" *10 ATC-27, "SYMPTOM TABLE" *11 ATC-108, "Intake Sensor Circuit" ATC-64 *3 ATC-102, "In-vehicle Sensor Circuit" *12 ATC-48, "FUNCTION CONFIRMATION PROCEDURE", see No. 5 to 7. TROUBLE DIAGNOSIS SYSTEM DESCRIPTION Component Parts A Air mix door control system components are: ● Auto amp. ● Air mix door motor ● In-vehicle sensor ● Intake sensor ● Ambient sensor ● Sunload sensor B C D System Operation The auto amp. receives data from each of the sensors. When setting a target temperature by using temperature button, auto amp. corrects preset temperature, performs an arithmetical operation based on signals from sensors and determines opening angle of target air mix door. Air mix door is constantly controlled so as to keep optimum opening angle of air mix door based on target and present opening angles of air mix door. Air mix door is fixed in the full cold position when preset temperature is set to 18°C, and full hot position when set to 32°C. E F G H I ATC SJIA0789E Drive System of Step Motor Type Door Motor K L M SJIA0970E ● ● Motor is actuated in sequence by energizing four drive coils. Rotation direction can be changed by changing pattern of excitation. ATC-65 TROUBLE DIAGNOSIS Air Mix Door Control Specification RHA457H COMPONENT DESCRIPTION Air Mix Door Motor The air mix door motor is attached to the A/C unit assembly. It rotates so that the air mix door is opened or closed to a position set by the auto amp. Motor rotation is conveyed through a shaft and the air mix door position is then feedback to the auto amp. by PBR builtin air mix door motor. MJIB0464E ATC-66 TROUBLE DIAGNOSIS DIAGNOSTIC PROCEDURE FOR AIR MIX DOOR MOTOR A 1. CHECK AIR MIX DOOR MOTOR 1. 2. 3. Turn ignition switch OFF. Disconnect air mix door motor connector. Check continuity between air mix door motor connector terminals. B C Connector Terminals Continuity 1 Air mix motor: M51 D 3 2 Yes 4 6 SJIA0948E E OK or NG OK >> GO TO 2. NG >> Replace air mix door motor. F 2. CHECK CIRCUIT CONTINUITY BETWEEN AUTO AMP. AND AIR MIX DOOR MOTOR 1. 2. Disconnect auto amp. connector. Check continuity between auto amp. harness connector (A) and air mix door motor harness connector (B). A Connector H B Terminal Connector 19 Terminal Continuity 3 20 Auto amp.: M65 G Air mix door motor: M51 21 22 I 6 Yes 1 MJIB0389E 4 OK or NG OK >> GO TO 3. NG >> Repair harness or connector. ATC K 3. CHECK CIRCUIT CONTINUITY BETWEEN AUTO AMP. AND GROUND L Check continuity between auto amp. harness connector and ground. Connector Terminal Continuity M 19 Auto amp.: M65 20 Ground No 21 22 OK or NG OK >> Replace auto amp. NG >> Repair harness or connector. MJIB0390E ATC-67 TROUBLE DIAGNOSIS Intake Door Motor Circuit BJS000BH SYMPTOM: ● Intake door does not change. ● Intake door motor does not operate normally. INSPECTION FLOW MJIB0391E *1 ATC-48, "FUNCTION CONFIRMATION PROCEDURE", see No. 1. *2 ATC-99, "Ambient Sensor Circuit" *3 ATC-102, "In-vehicle Sensor Circuit" *4 ATC-105, "Sunload Sensor Circuit" *5 ATC-64, "Air Mix Door Motor Circuit" *6 ATC-48, "FUNCTION CONFIRMATION PROCEDURE", see No. 13. *7 ATC-124, "INTAKE DOOR MOTOR" *8 ATC-55, "Operational Check" *9 ATC-48, "FUNCTION CONFIRMATION PROCEDURE", see No. 5 to 7. *10 ATC-27, "SYMPTOM TABLE" *11 ATC-108, "Intake Sensor Circuit" ATC-68 TROUBLE DIAGNOSIS SYSTEM DESCRIPTION Component Parts A Intake door control system components are: ● Auto amp. ● Intake door motor ● In-vehicle sensor ● Ambient sensor ● Sunload sensor ● Intake sensor ● ECM B C D System Operation Suction opening is basically fixed in the position FRESH when DEF switch, FRE switch, or OFF switch (only at the time of REC switch OFF) is pressed or when A/C switch is OFF. It is fixed in the position RECIRCULATION when REC switch is pressed. It is automatically controlled at all other times. During automatic control of suction opening, any of FRESH, 20% FRESH and RECIRCULATION is selected according to the target opening angle of air mix door calculated by auto amp. based on the in-vehicle temperature, ambient temperature and the amount of solar radiation. E F G H I ATC K L SJIA0790E Intake Door Control Specification M RHA383H ATC-69 TROUBLE DIAGNOSIS COMPONENT DESCRIPTION Intake Door Motor The intake door motor is attached to the A/C unit assembly. It rotates so that air is drawn from inlets set by the auto amp. Motor rotation is conveyed to a lever which activates the intake door. SJIA0814E DIAGNOSTIC PROCEDURE FOR INTAKE DOOR MOTOR 1. CHECK POWER SUPPLY FOR INTAKE DOOR MOTOR 1. 2. Turn ignition switch ON. Check voltage between intake door motor harness connector. Terminals Terminal Connector Intake door motor: M28 Condition (+) (−) 1 2 FRE → REC 2 1 REC → FRE Voltage (Approx.) 12 V OK or NG OK >> Replace intake door motor. NG >> GO TO 2. MJIB0392E 2. CHECK CIRCUIT CONTINUITY BETWEEN AUTO AMP. AND INTAKE DOOR MOTOR 1. 2. 3. 4. Turn ignition switch OFF. Disconnect auto amp. connector. Disconnect intake door motor connector. Check continuity between auto amp. harness connector (A) and intake door motor harness connector (B). A Connector Auto amp.: M65 B Terminal Connector Terminal 27 Intake door motor: M28 1 36 Continuity 2 Yes OK or NG OK >> GO TO 3. NG >> Repair harness or connector. 3. CHECK CIRCUIT CONTINUITY BETWEEN AUTO AMP. AND GROUND OK or NG OK >> Replace auto amp. NG >> Repair harness or connector. ATC-70 MJIB0393E TROUBLE DIAGNOSIS Blower Motor Circuit BJS000BI A SYMPTOM: Blower motor operation is malfunctioning. INSPECTION FLOW B C D E F G H I ATC K L M MJIB0394E *1 ATC-55, "Operational Check" *2 ATC-48, "FUNCTION CONFIRMATION PROCEDURE", see No. 1. *3 ATC-48, "FUNCTION CONFIRMATION PROCEDURE", see No. 5. *4 ATC-48, "FUNCTION CONFIRMA- *5 TION PROCEDURE", see No. 7. ATC-48, "FUNCTION CONFIRMATION PROCEDURE", see No. 13. *6 ATC-73, "DIAGNOSTIC PROCEDURE FOR BLOWER MOTOR" ATC-71 TROUBLE DIAGNOSIS *7 ATC-27, "SYMPTOM TABLE" *8 ATC-99, "Ambient Sensor Circuit" *9 *10 ATC-105, "Sunload Sensor Circuit" *11 ATC-108, "Intake Sensor Circuit" ATC-102, "In-vehicle Sensor Circuit" *12 CR(WITH EURO–OBD): EC-166 CR(WITHOUT EURO–OBD): EC-565 HR(WITH EURO–OBD): EC-947 HR(WITHOUT EURO–OBD): EC-1361 K9K: EC-1727 *For further information refer to EC-21, "APPLICATION NOTICE" . SYSTEM DESCRIPTION Component Parts Fan speed control system components are: ● Auto amp. ● In-vehicle sensor ● Ambient sensor ● Sunload sensor ● Intake sensor System Operation MJIB0395E Automatic Mode In the automatic mode, the blower motor speed is calculated by the auto amp. based on input from in-vehicle sensor, sunload sensor, intake sensor and ambient sensor. The blower motor is applied voltage ranges from approximately 3.0 volts (lowest speed) to 12 volts (highest speed). The control blower speed (in the range of 3.0 to 12V), auto amp. supplies a gate voltage to the power transistor. Based on this voltage, auto amp. controls voltage supplied to the blower motor. Starting Fan Speed Control Start up from COLD SOAK Condition (Automatic mode) In a cold start up condition where the engine coolant temperature is below 56°C, the blower will not operate for a short period of time (up to 150 seconds). The exact start delay time varies depending on the ambient and engine coolant temperature. In the most extreme case (very low ambient) the blower starting delay will be 150 seconds as described above. After this delay, the blower will operate at low speed until the engine coolant temperature rises above 56°C, at which time the blower speed will increase to the objective speed. Start up from usual or HOT SOAK Condition (Automatic mode) ATC-72 TROUBLE DIAGNOSIS The blower will begin operation momentarily after the A/C switch is pushed. The blower speed will gradually rise to the objective speed over a time period of 3 seconds or less (actual time depends on the objective blower speed). A Blower Speed Compensation Sunload When the in-vehicle temperature and the set temperature are very close, the blower will be operating at low speed. The low speed will vary depending on the sunload. During conditions of low or no sunload, the blower low speed is usual low speed (approx. 4.0V). During high sunload conditions, auto amp. causes the blower speed to increase (approx. 6.5V). B C Fan Speed Control Specification D E F SJIA0792E G DIAGNOSTIC PROCEDURE FOR BLOWER MOTOR SYMPTOM: Blower motor operation is malfunctioning. H I ATC MJIB0396E K 1. CHECK POWER SUPPLY FOR BLOWER MOTOR 1. 2. 3. Disconnect blower motor connector. Turn ignition switch ON. Check voltage between blower motor harness connector and ground. Terminals (+) (−) Connector Terminal Blower motor: M56 1 Ground Voltage (Approx.) Battery voltage MJIB0516E OK or NG OK >> GO TO 2. NG >> Check power supply circuit and 15A fuses (Nos. 18 and 20, located in the fuse block). Refer to PG-95, "FUSE BLOCK" . ● If fuses are OK, check harness for open circuit. Repair or replace if necessary. ● If fuses are OK, check blower relay. Replace if necessary. ● If fuses are NG, replace fuse and check harness for short circuit. Repair or replace if necessary. ATC-73 L M TROUBLE DIAGNOSIS 2. CHECK CIRCUIT POWER SUPPLY FOR POWER TRANSISTOR 1. 2. 3. 4. 5. Turn ignition switch OFF. Connect blower motor connector. Disconnect power transistor connector. Turn ignition switch ON. Check voltage between power transistor harness connector (A), (B) and ground. Terminals (−) Voltage (Approx.) Ground Battery voltage (+) Connector Terminal A Power transistor: M30 1 B Power transistor: M31 4 MJIB0397E OK or NG OK >> GO TO 3. NG >> ● Terminal 1 - Ground: Repair harness or connector. ● Terminal 4 - Ground: GO TO 5. 3. CHECK GROUND CIRCUIT FOR POWER TRANSISTOR 1. 2. Turn ignition switch OFF. Check continuity between power transistor harness connector and ground. Connector Power transistor: M30 Terminal 2 Continuity Ground Yes OK or NG OK >> GO TO 4. NG >> Repair harness or connector. MJIB0398E ATC-74 TROUBLE DIAGNOSIS 4. CHECK FOR AUTO AMP. OUTPUT 1. 2. A Reconnect power transistor connector. Turn ignition switch ON. B C D MJIB0399E 3. Change the fan speed from Lo to Hi, and confirm the duty ratios between power transistor harness connector and ground using an oscilloscope. Usual terminal 6 drive signal duty ratios are shown in the table below. E F G H I ATC K SJIA0944E OK or NG OK >> GO TO 5. NG >> ● Fan speed is stuck at speed 4: GO TO 7. ● Fan speed is stuck at speed 1: GO TO 8. L M 5. CHECK BLOWER MOTOR 1. 2. 3. Turn ignition switch OFF. Remove blower motor connector. Check continuity between blower motor connector terminals. Connector Blower motor: M56 Terminal 1 Continuity 2 Yes OK or NG OK >> GO TO 6. NG >> Replace blower motor. MJIB0517E ATC-75 TROUBLE DIAGNOSIS 6. CHECK CIRCUIT CONTINUITY BETWEEN BLOWER MOTOR AND POWER TRANSISTOR Check continuity between blower motor harness connector (A) and power transistor harness connector (B). A B Continuity Connector Terminal Connector Terminal Blower motor: M56 2 Power transistor: M31 4 Yes OK or NG OK >> GO TO 7. NG >> Repair harness or connector. MJIB0518E 7. CHECK CIRCUIT CONTINUITY BETWEEN AUTO AMP. AND POWER TRANSISTOR 1. 2. 3. 4. Turn ignition switch OFF. Disconnect power transistor connector. Disconnect auto amp. connector. Check continuity between auto amp. harness connector (A) and power transistor harness connector (B). A B Connector Terminal Connector Terminal Auto amp.: M64 15 Power transistor: M31 6 Continuity Yes MJIB0401E OK or NG OK >> Replace power transistor. NG >> Repair harness or connector. 8. CHECK FOR AUTO AMP. OUT PUT 2 1. 2. 3. 4. Turn ignition switch OFF. Disconnect auto amp. connector. Turn ignition switch ON. Check output signal between auto amp. harness connector and ground. Terminals (+) Connector (−) Condition Voltage (Approx.) Terminal MJIB0402E Auto amp.: M64 15 Ground Fan speed: 1st ZJIA0863J OK or NG OK >> Replace auto amp. NG >> Replace power transistor. ATC-76 TROUBLE DIAGNOSIS COMPONENT INSPECTION Blower Motor A Confirm smooth rotation of the blower motor (1). ● Ensure that there are no foreign particles inside the A/C unit assembly. B C D SJIA0735E E F G H I ATC K L M ATC-77 TROUBLE DIAGNOSIS Magnet Clutch Circuit BJS000BJ SYMPTOM: Magnet clutch does not engage. INSPECTION FLOW MJIB0403E *1 ATC-48, "FUNCTION CONFIRMATION PROCEDURE", see No. 1. *2 ATC-99, "Ambient Sensor Circuit" *3 ATC-48, "FUNCTION CONFIRMATION PROCEDURE", see No. 13. *4 ATC-79, "DIAGNOSTIC PROCEDURE FOR MAGNET CLUTCH" *5 ATC-91, "TROUBLE DIAGNOSIS FOR UNUSUAL PRESSURE" *6 ATC-55, "Operational Check" *7 ATC-48, "FUNCTION CONFIRMA*8 TION PROCEDURE", see No. 5 to 7. ATC-27, "SYMPTOM TABLE" *9 ATC-108, "Intake Sensor Circuit" ATC-78 TROUBLE DIAGNOSIS SYSTEM DESCRIPTION A Auto amp. controls compressor operation by intake air temperature and signal from ECM. Low Temperature Protection Control Auto amp. will turn compressor ON or OFF as determined by a signal detected by intake sensor. When intake air temperatures are higher than 3.5°C (38°F), the compressor turns ON. The compressor turns OFF when intake air temperatures are lower than 2°C (36°F). B C D E SJIA0802E DIAGNOSTIC PROCEDURE FOR MAGNET CLUTCH F SYMPTOM: Magnet clutch does not engage when A/C switch is ON. G H I ATC K MJIB0404E L 1. CHECK INTAKE SENSOR CIRCUIT Check intake sensor. Refer to ATC-48, "FUNCTION CONFIRMATION PROCEDURE" , see No. 12. OK or NG OK >> GO TO 2. NG >> Malfunctioning intake sensor: Refer to ATC-108, "Intake Sensor Circuit" . 2. PERFORM AUTO ACTIVE TEST Refer to PG-22, "Auto Active Test" . Does the magnet clutch operate? YES >> ● WITH CONSULT-II GO TO 6. ● WITHOUT CONSULT-II GO TO 7. NO >> GO TO 3. ATC-79 M TROUBLE DIAGNOSIS 3. CHECK POWER SUPPLY COMPRESSOR 1. 2. 3. 4. 5. Turn ignition switch OFF. Disconnect compressor connector. Start the engine. Press AUTO switch and A/C switch ON. Check voltage between compressor harness connector and ground. Terminals (+) Engine CR and HR K9K Voltage (Approx.) (−) Connector MJIB0405E Terminal Compressor: F28 Ground 1 Compressor: F129 12V OK or NG OK >> GO TO 5. NG >> Check power supply circuit and 10A fuse (No. 51, located in the fuse block), and GO TO 4. Refer to PG-32, "IPDM E/R Terminal Arrangement" . ● If fuse is OK, GO TO 4. ● If fuse is NG, replace fuse and GO TO 4. 4. CHECK CIRCUIT CONTINUITY BETWEEN IPDM E/R AND COMPRESSOR 1. 2. 3. Turn ignition switch OFF. Disconnect IPDM E/R connector. Check continuity between compressor harness connector (A) and IPDM E/R harness connector (B). A Engine Connector CR and HR Compressor: F28 K9K 4. Continuity Terminal Connector Terminal 1 IPDM E/R: E7 41 Compressor: F129 Yes MJIB0406E Check continuity between compressor harness connection (A) and ground. Engine CR and HR K9K 5. B Connector Compressor: F28 Terminal Continuity Ground 1 No Compressor: F129 Check continuity between compressor harness connector and ground. Engine K9K Connector Terminal Compressor: F129 2 Ground Continuity Yes OK or NG OK >> GO TO 5. NG >> Repair harness or connector. MJIA0205E ATC-80 TROUBLE DIAGNOSIS 5. CHECK MAGNET CLUTCH A Check for operation sound when applying battery voltage direct current to terminal. OK or NG OK >> 1. Replace IPDM E/R. 2. Go to self-diagnosis procedure ATC-48, "FUNCTION CONFIRMATION PROCEDURE" and perform selfdiagnosis STEP-4. Confirm that magnet clutch operation usual. NG >> 1. Replace compressor. 2. Go to self-diagnosis procedure ATC-48, "FUNCTION CONFIRMATION PROCEDURE" and perform selfdiagnosis STEP-4. Confirm that magnet clutch operation usual. B C D MJIB0407E E 6. CHECK BCM INPUT (COMPRESSOR ON) SIGNAL F Check compressor ON/OFF signal. Refer to ATC-26, "CONSULT-II Function (BCM)" . A/C SW ON A/C SW OFF : AIR COND SW ON : AIR COND SW OFF G OK or NG OK >> GO TO 9. NG >> GO TO 7. H RJIA1111E I 7. CHECK CIRCUIT CONTINUITY BETWEEN AUTO AMP. AND BCM. 1. 2. 3. A 4. ATC Turn ignition switch OFF. Disconnect auto amp. harness connector. Check continuity between auto amp. harness connector (A) and BCM harness connector. K B Connector Terminal Connector Terminal Auto amp.: M64 13 BCM: M58 61 Continuity Yes Check continuity between auto amp.harness connector (A) and ground. A Connector Terminal Auto amp.: M64 13 Ground L Continuity No OK or NG OK >> GO TO 8. NG >> Repair harness or connector. ATC-81 M MJIB0408E TROUBLE DIAGNOSIS 8. CHECK VOLTAGE FOR AUTO AMP. (COMPRESSOR ON SIGNAL) 1. 2. 3. Reconnect auto amp. harness connector and BCM harness connector. Turn ignition switch ON. Confirm compressor ON signal between auto amp. harness connector and ground. Terminals (+) Connector (-) Condition Voltage (Approx.) Terminal MJIB0409E Auto amp.: M64 Ground 13 A/C switch: ON (Blower motor operates.) ZJIA0584J OK or NG OK >> GO TO 9. NG >> Replace auto amp. ATC-82 TROUBLE DIAGNOSIS 9. CHECK REFRIGERANT PRESSURE SENSOR A WITH CONSULT-II Start the engine. Check the voltage of refrigerant pressure sensor. CR(WITH EURO–OBD): Refer to EC-112, "CONSULT-II Reference Value in Data Monitor Mode" . CR(WITHOUT EURO–OBD): Refer to EC-527, "CONSULT-II Reference Value in Data Monitor Mode" . HR(WITH EURO–OBD): Refer to EC-902, "CONSULT-II Reference Value in Data Monitor" . HR(WITHOUT EURO–OBD): Refer to EC-1321, "CONSULT-II Reference Value in Data Monitor" . K9K: Refer to EC-1694, "CONSULT-II Reference Value in Data Monitor Mode" . *For further information refer to EC-21, "APPLICATION NOTICE" . WITHOUT CONSULT-II 1. Start the engine. 2. Check voltage between ECM harness connector and ground. 1. 2. B C D E Terminals Engine (+) Connector ECM: F2 69 HR ECM: F51 41 K9K ECM: F134 89 ● NG >> ● ● ● ● ● Condition Voltage (Approx.) F Ground A/C switch: ON (Blower motor operates.) 1-4V G Terminal CR OK or NG OK >> ● (-) H WITH CONSULT-II GO TO 10. WITHOUT CONSULT-II GO TO 11. CR (WITH EURO–OBD): Refer to EC-443 . CR (WITHOUT EURO–OBD): Refer to EC-794 . HR (WITH EURO–OBD): Refer to EC-1231 . HR (WITHOUT EURO–OBD): Refer to EC-1590 . K9K: Refer to EC-1811 . I ATC K MJIB0410E 10. CHECK BCM INPUT (FAN ON) SIGNAL L Check FAN ON/OFF signal. Refer to ATC-26, "CONSULT-II Function (BCM)" . FAN SW ON FAN SW OFF M : FAN ON SIG ON : FAN ON SIG OFF OK or NG OK >> GO TO 13. NG >> GO TO 11. RJIA1111E ATC-83 TROUBLE DIAGNOSIS 11. CHECK CIRCUIT CONTINUITY BETWEEN AUTO AMP. AND BCM 1. 2. 3. Turn ignition switch OFF. Disconnect auto amp. connector and BCM connector. Check continuity between auto amp. harness connector (A) and BCM harness connector (B). A B Connector Terminal Connector Terminal Auto amp.: M64 12 BCM: M58 50 4. Continuity Yes Check continuity between auto amp.harness connector (A) and ground. MJIB0411E A Connector Terminal Auto amp.: M64 12 Ground Continuity No OK or NG OK >> GO TO 12. NG >> Repair harness or connector. 12. CHECK VOLTAGE FOR AUTO AMP. (FAN ON SIGNAL) 1. 2. 3. Reconnect auto amp. connector and BCM connector. Turn ignition switch ON. Confirm fan ON signal between auto amp. harness connector and ground using oscilloscope. Terminals (+) Connector (−) Condition Voltage (Approx.) Terminal MJIB0412E Auto amp.: M64 Ground 12 Fan speed: 1st ZJIA0583J OK or NG OK >> Replace auto amp. NG >> Replace BCM. 13. CHECK CAN COMMUNICATION Check CAN communication. Refer to BCS-17, "CAN Communication Inspection With CONSULT-II (Self-Diagnosis)" . ● BCM – ECM ● ECM – IPDM E/R OK or NG OK >> INSPECTION END NG >> Repair or replace malfunction part(s). ATC-84 TROUBLE DIAGNOSIS COMPONENT INSPECTION Refrigerant Pressure Sensor A The refrigerant pressure sensor (1) is attached to the condenser. B C D MJIB0457E Make sure that the A/C refrigerant pressure and the sensor output voltage are within the specified range as shown in the A/C operating condition figure. CR(WITH EURO–OBD): Refer to EC-443 . CR(WITHOUT EURO–OBD): Refer to EC-794 . HR(WITH EURO–OBD): Refer to EC-1231 . HR(WITHOUT EURO–OBD): Refer to EC-1590 . K9K: Refer to EC-1811 . *For further information refer to EC-21, "APPLICATION NOTICE" . E F G H RJIA2954E I ATC K L M ATC-85 TROUBLE DIAGNOSIS Insufficient Cooling BJS000BK SYMPTOM: Insufficient cooling INSPECTION FLOW MJIB0413E *1 ATC-48, "FUNCTION CONFIRMATION PROCEDURE", see No. 1. *2 ATC-64, "Air Mix Door Motor Circuit" *3 *4 ATC-54, "AUXILIARY MECHANISM: TEMPERATURE SETTING TRIMMER" *5 ATC-48, "FUNCTION CONFIRMATION PROCEDURE", see No. 13. ATC-86 *6 ATC-90, "Test Reading" ATC-71, "Blower Motor Circuit" TROUBLE DIAGNOSIS *7 ATC-78, "Magnet Clutch Circuit" *8 ATC-88, "PERFORMANCE TEST DIAGNOSIS" *11 CR: EM-14, "Checking drive Belts" *10 ATC-48, "FUNCTION CONFIRMATION PROCEDURE", see No. 5 to 7. HR: EM-114, "Checking Drive Belts" K9K: EM-242, "Checking Drive Belts" *For further information refer to EC-21, "APPLICATION NOTICE" . *9 ATC-55, "Operational Check" A *12 CR(WITH EURO–OBD): EC-345 CR(WITHOUT EURO–OBD): EC-662 HR(WITH EURO–OBD): EC-1130 HR(WITHOUT EURO–OBD): EC-1451 K9K: EC-1864 B C D E F G H I ATC K L M ATC-87 TROUBLE DIAGNOSIS PERFORMANCE TEST DIAGNOSIS RJIA1601E *1 ATC-90, "PERFORMANCE CHART" *2 *4 ATC-64, "Air Mix Door Motor Circuit" ATC-90, "PERFORMANCE CHART" *3 ATC-88 ATC-91, "TROUBLE DIAGNOSIS FOR UNUSUAL PRESSURE" TROUBLE DIAGNOSIS A B C D E F G H I ATC K L M RJIA3107E *1 ATC-141, "CHECK DISC TO PULLEY CLEARANCE" *2 ATC-71, "Blower Motor Circuit" ATC-89 *3 CR: EM-14, "Checking drive Belts" HR: EM-114, "Checking Drive Belts" K9K: EM-242, "Checking Drive Belts" TROUBLE DIAGNOSIS PERFORMANCE CHART Test Condition Testing must be performed as follows: Vehicle condition Indoors or in the shade (in a well-ventilated place) Doors Closed Door window Open Hood Open TEMP. Max. COLD Mode switch (Ventilation) set Recirculation (REC) switch (Recirculation) set Max. speed set Fan (blower) speed Engine speed Idle speed Operate the air conditioning system for 10 minutes before taking measurements. Test Reading Recirculating-to-discharge Air Temperature Table Inside air (Recirculating air) at blower assembly inlet Relative humidity % Discharge air temperature at center ventilator °C (°F) Air temperature °C (°F) 50 - 60 60 - 70 20 (68) 7.2 - 9.1 (45 - 48) 25 (77) 11.4 - 13.8 (53 - 57) 30 (86) 15.5 - 18.4 (60 - 65) 35 (95) 20.3 - 23.7 (69 - 75) 20 (68) 9.1 - 10.9 (48 - 52) 25 (77) 13.8 - 16.2 (57 - 61) 30 (86) 18.4 - 21.3 (65 - 70) 35 (95) 23.7 - 27.1 (75 - 81) Ambient Air Temperature-to-operating Pressure Table Ambient air Relative humidity % 50 - 70 High-pressure (Discharge side) Low-pressure (Suction side) Air temperature °C (°F) kPa (bar, kg/cm2 , psi) kPa (bar, kg/cm2 , psi) 20 (68) 843 - 1,036 *1 (11.08 - 13.63, 8.6 - 10.6, 122 - 150) 159.0 - 194.0 (1.59 - 1.94, 1.62 - 1.98, 23.1 - 28.1) 25 (77) 1,094 - 1,338 *1 (10.94 - 13.38, 11.2 - 13.6, 159 - 194) 196.3 - 240.0 (1.96 - 2.40, 2.00 - 2.45, 28.5 - 34.8) 30 (86) 1,298 - 1,590 *1 (12.98 - 15.90, 13.2 - 16.2, 188 - 231) 248.0 - 302.7 (2.48 - 3.03, 2.53 - 3.09, 36.0 - 43.9) 35 (95) 1,383 - 1,688 *2 (13.83 - 16.88, 14.1 - 17.2, 201 - 245) 308.8 - 377.4 (3.09 - 3.77, 3.15 - 3.85, 44.8 - 54.7) 40 (104) 1,628 - 1,988 *2 (16.28 - 19.88, 16.6 - 20.3, 236 - 288) 377.4 - 461.2 (3.77 - 4.61, 3.85 - 4.70, 54.7 - 66.8) *1: In the motor fan low-speed control *2: In the motor fan high-speed control ATC-90 TROUBLE DIAGNOSIS TROUBLE DIAGNOSIS FOR UNUSUAL PRESSURE Whenever system’s high and/or low side pressure(s) is/are unusual, diagnose using a manifold gauge. The marker above the gauge scale in the following tables indicates the standard (usual) pressure range. Since the standard (usual) pressure, however, differs from vehicle, refer to above table (Ambient air temperature-tooperating pressure table). A B Both High- and Low-pressure Sides are Too High Gauge indication Refrigerant cycle Probable cause Pressure is reduced soon after water is splashed on condenser. Air suction by cooling fan is insufficient. Excessive refrigerant charge in refrigeration cycle. Insufficient condenser cooling performance. ↓ 1. Condenser fins are clogged. Corrective action Reduce refrigerant until specified pressure is obtained. D ● Clean condenser. ● Check and repair cooling fan if necessary. 2. Improper fan rotation of cooling fan. Both high- and low-pressure sides are too high. ● Low-pressure pipe is not cold. ● When compressor is stopped high-pressure value quickly drops by approximately 196 kPa (1.96 bar, 2 kg/cm2 , 28 psi). It then decreases gradually thereafter. AC359A Engine tends to overheat. ● ● An area of the low-pressure pipe is colder than areas near the evaporator outlet. Plates are sometimes covered with frost. C E F Poor heat exchange in condenser (After compressor operation stops, high-pressure decreases too slowly.). ↓ Air in refrigeration cycle. Evacuate repeatedly and recharge system. Engine cooling systems malfunction. Check and repair each engine cooling system. ● Excessive liquid refrigerant on lowpressure side. ● Excessive refrigerant discharge flow. ● Expansion valve is open a little compared with the specification. G H I ATC Replace expansion valve. K ↓ Improper expansion valve adjustment. L High-pressure Side is Too High and Low-pressure Side is Too Low Gauge indication Refrigerant cycle Probable cause Corrective action M High-pressure side is too high and low-pressure side is too low. Upper side of condenser and high-pressure side are hot, however, liquid tank is not so hot. High-pressure tube or parts located between compressor and condenser are clogged or crushed. AC360A ATC-91 ● Check and repair or replace malfunctioning parts. ● Check lubricant for contamination. TROUBLE DIAGNOSIS High-pressure Side is Too Low and Low-pressure Side is Too High Gauge indication High-pressure side is too low and low-pressure side is too high. Refrigerant cycle Probable cause Corrective action High- and low-pressure sides become equal soon after compressor operation stops. Compressor pressure operation is improper. ↓ Damaged inside compressor packings. Replace compressor. No temperature difference between high- and low-pressure sides. Compressor pressure operation is improper. ↓ Damaged inside compressor packings. Replace compressor. AC356A Both High- and Low-pressure Sides are Too Low Gauge indication Refrigerant cycle ● Liquid tank inlet and expansion valve are frosted. ● Temperature of expansion valve inlet is extremely low as compared with areas near liquid tank. ● AC353A There is a big temperature difference between liquid tank outlet and inlet. Outlet temperature is extremely low. ● ● Both high- and low-pressure sides are too low. Probable cause Expansion valve inlet may be frosted. Liquid tank inside is slightly clogged. High-pressure pipe located between liquid tank and expansion valve is clogged. Corrective action ● Replace liquid tank. ● Check lubricant for contamination. ● Check and repair malfunctioning parts. ● Check lubricant for contamination. Temperature difference occurs somewhere in highpressure side. Expansion valve and liquid tank are warm or only cool when touched. There is a big temperature difference between expansion valve inlet and outlet while the valve itself is frosted. Low refrigerant charge. ↓ Leaking fittings or components Expansion valve closes a little compared with the specification. ↓ 1. Improper expansion valve adjustment. 2. Malfunctioning expansion valve. Check refrigerant for leaks. Refer to ATC-147, "Checking for Refrigerant Leaks" . ● Remove foreign particles by using compressed air. ● Replace expansion valve. ● Check lubricant for contamination. ● Check and repair malfunctioning parts. ● Check lubricant for contamination. ● Check intake sensor circuit. Refer to ATC-108, "Intake Sensor Circuit" . ● Replace compressor. ● Repair evaporator fins. ● Replace evaporator. ● Refer to ATC-71, "Blower Motor Circuit" . 3. Outlet and inlet may be clogged. An area of the low-pressure pipe is colder than areas near the evaporator outlet. Air flow volume is not enough or is too low. Low-pressure pipe is clogged or crushed. Evaporator is frozen. ATC-92 TROUBLE DIAGNOSIS Low-pressure Side Sometimes Becomes Negative Gauge indication Low-pressure side sometimes becomes negative. Refrigerant cycle ● ● AC354A Air conditioning system does not function and does not cyclically cool the compartment air. The system constantly functions for a certain period of time after compressor is stopped and restarted. Probable cause Refrigerant does not discharge cyclically. ↓ Moisture is frozen at expansion valve outlet and inlet. ↓ Water is mixed with refrigerant. Corrective action A B ● Drain water from refrigerant or replace refrigerant. ● Replace liquid tank. C D Low-pressure Side Becomes Negative Gauge indication Refrigerant cycle Probable cause Corrective action Leave the system at rest until no frost is present. Start it again to check whether or not the malfunction is caused by water or foreign particles. ● Low-pressure side becomes negative. Liquid tank or front/rear side of expansion valve’s pipe is frosted or dewed. High-pressure side is closed and refrigerant does not flow. ↓ Expansion valve or liquid tank is frosted. ● AC362A ● If water is the cause, initially cooling is okay. Then the water freezes causing a blockage. Drain water from refrigerant or replace refrigerant. If due to foreign particles, remove expansion valve and remove the particles with dry and compressed air (not shop air). If either of the above methods cannot correct the malfunction, replace expansion valve. ● Replace liquid tank. ● Check lubricant for contamination. E F G H I ATC K L M ATC-93 TROUBLE DIAGNOSIS Insufficient Heating BJS000BL SYMPTOM: Insufficient heating INSPECTION FLOW MJIB0414E *1 ATC-55, "Operational Check" *2 ATC-48, "FUNCTION CONFIRMATION PROCEDURE", see No. 1. *3 ATC-48, "FUNCTION CONFIRMATION PROCEDURE", see No. 5 to 7. *4 ATC-64, "Air Mix Door Motor Circuit" *5 ATC-48, "FUNCTION CONFIRMATION PROCEDURE", see No. 13. *6 ATC-71, "Blower Motor Circuit" ATC-94 TROUBLE DIAGNOSIS *7 ATC-64, "Air Mix Door Motor Circuit" *8 CR(WITH EURO–OBD): EC-166 *9 CR'WITHOUT EURO–OBD): EC-565 HR(WITH EURO–OBD): EC-947 HR(WITHOUT EURO–OBD): EC-1361 K9K: EC-1727 *10 CR: CO-15 or CO-16 HR: CO-34 or CO-35 K9K: CO-53 *For further information refer to EC-21, "APPLICATION NOTICE" . CR: CO-9 HR: CO-28 K9K: CO-49 A B C D E F G H I ATC K L M ATC-95 TROUBLE DIAGNOSIS Noise BJS000BM SYMPTOM: Noise INSPECTION FLOW SJIA0843E ATC-96 TROUBLE DIAGNOSIS *1 ATC-55, "Operational Check" *4 CR: EM-14, "Checking drive Belts" HR: EM-114, "Checking Drive Belts" K9K: EM-242, "Checking Drive Belts" *2 ATC-141, "CHECK DISC TO PULLEY CLEARANCE" *3 ATC-17, "Maintenance of Lubricant Quantity in Compressor" A B Self-diagnosis BJS000BN C SYMPTOM: Self-diagnosis cannot be performed. INSPECTION FLOW D E F G H I ATC K L M MJIB0415E *1 ATC-57, "Power Supply and Ground Circuit for Auto Amp." *2 ATC-99, "Ambient Sensor Circuit" *3 ATC-102, "In-vehicle Sensor Circuit" *4 ATC-105, "Sunload Sensor Circuit" *5 ATC-108, "Intake Sensor Circuit" *6 ATC-64, "Air Mix Door Motor Circuit" *7 ATC-55, "Operational Check" *8 ATC-27, "SYMPTOM TABLE" ATC-97 TROUBLE DIAGNOSIS Memory Function BJS000BO SYMPTOM: Memory function does not operate. INSPECTION FLOW MJIB0416E *1 ATC-57, "Power Supply and Ground Circuit for Auto Amp." *2 ATC-55, "Operational Check" ATC-98 *3 ATC-48, "FUNCTION CONFIRMATION PROCEDURE", see No. 5. TROUBLE DIAGNOSIS Ambient Sensor Circuit BJS000BP A COMPONENT DESCRIPTION Ambient Sensor The ambient sensor (1) is attached on the radiator core support upper. It detects ambient temperature and converts it into a resistance value which is then input into the auto amp. B C D MJIB0467E AMBIENT TEMPERATURE INPUT PROCESS The auto amp. includes a processing circuit for the ambient sensor input. However, when the temperature detected by the ambient sensor increases quickly, the processing circuit retards the auto amp. function. It only allows the auto amp. to recognize an ambient temperature increase of 0.33°C (0.6°F) per 100 seconds. As an example, consider stopping for a few minutes after high speed driving. Although the actual ambient temperature has not changed, the temperature detected by the ambient sensor will increase. This is because the heat from the engine compartment can radiate to the front grille area, location of the ambient sensor. E F G DIAGNOSTIC PROCEDURE FOR AMBIENT SENSOR SYMPTOM: Ambient sensor circuit is open or shorted. (21 or AUTO 21 is indicated on auto amp. As a result of performing self-diagnosis STEP-2.) H I ATC SJIA0807E 1. CHECK VOLTAGE BETWEEN AMBIENT SENSOR AND GROUND 1. 2. 3. 4. L Turn ignition switch OFF. Disconnect ambient sensor connector. Turn ignition switch ON. Check voltage between ambient sensor harness connector and ground. M Terminals (+) (−) Connector Terminal Ambient sensor: E17 4 Voltage (Approx.) Ground 5V OK or NG OK >> GO TO 2. NG >> GO TO 4. ATC-99 K MJIB0417E TROUBLE DIAGNOSIS 2. CHECK CIRCUIT CONTINUITY BETWEEN AMBIENT SENSOR AND AUTO AMP. 1. 2. 3. Turn ignition switch OFF. Disconnect auto amp. connector. Check continuity between ambient sensor harness connector (A) and auto amp. harness connector (B). A B Connector Terminal Connector Terminal Ambient sensor: E17 3 Auto amp.: M65 33 Continuity Yes OK or NG OK >> GO TO 3. NG >> Repair harness or connector. MJIB0418E 3. CHECK AMBIENT SENSOR Refer to ATC-114, "AMBIENT SENSOR" . OK or NG OK >> 1. Replace auto amp. 2. Go to self-diagnosis ATC-48, "FUNCTION CONFIRMATION PROCEDURE" and perform selfdiagnosis STEP-2. Confirm that code No. 20 is displayed. NG >> 1. Replace ambient sensor. 2. Go to self-diagnosis ATC-48, "FUNCTION CONFIRMATION PROCEDURE" and perform selfdiagnosis STEP-2. Confirm that code No. 20 is displayed. 4. CHECK CIRCUIT CONTINUITY BETWEEN AMBIENT SENSOR AND AUTO AMP. 1. 2. 3. Turn ignition switch OFF. Disconnect auto amp. connector. Check continuity between ambient sensor harness connector (A) and auto amp. harness connector (B). A 4. B Connector Terminal Connector Terminal Ambient sensor: E17 4 Auto amp.: M65 30 Continuity Yes Check continuity between ambient sensor harness connector (A) and ground. A MJIB0419E Continuity Connector Terminal Ambient sensor: E17 4 Ground No OK or NG OK >> 1. Replace auto amp. 2. Go to self-diagnosis ATC-48, "FUNCTION CONFIRMATION PROCEDURE" diagnosis STEP-2. Confirm that code No. 20 is displayed. NG >> Repair harness or connector. ATC-100 and perform self- TROUBLE DIAGNOSIS COMPONENT INSPECTION Ambient Sensor A After disconnecting ambient sensor connector E32, measure resistance between terminals 1 and 2 at sensor side, using the table below. B Temperature °C (°F) Resistance kΩ −15 (5) 12.73 −10 (14) 9.92 −5 (23) 7.80 0 (32) 6.19 5 (41) 4.95 10 (50) 3.99 15 (59) 3.24 20 (68) 2.65 25 (77) 2.19 30 (86) 1.81 35 (95) 1.51 40 (104) 1.27 45 (113) 1.07 C D E F G MJIB0468E If NG, replace ambient sensor. H I ATC K L M ATC-101 TROUBLE DIAGNOSIS In-vehicle Sensor Circuit BJS000BQ COMPONENT DESCRIPTION In-vehicle Sensor The in-vehicle sensor (1) is located on instrument lower finisher. It converts variations in temperature of compartment air drawn from the aspirator into a resistance value. It is then input into the auto amp. MJIB0420E Aspirator The aspirator (1) is located on passenger’s side of A/C unit assembly. It produces vacuum pressure due to air discharged from the A/C unit, continuously taking compartment air in the aspirator. MJIB0421E RJIA1402E DIAGNOSTIC PROCEDURE FOR IN-VEHICLE SENSOR SYMPTOM: In-vehicle sensor circuit is open or shorted. (22 or AUTO 22 is indicated on auto amp. as a result of performing self-diagnosis STEP-2.) SJIA0815E ATC-102 TROUBLE DIAGNOSIS 1. CHECK VOLTAGE BETWEEN IN-VEHICLE SENSOR AND GROUND 1. 2. 3. 4. A Turn ignition switch OFF. Disconnect in-vehicle sensor connector. Turn ignition switch ON. Check voltage between in-vehicle sensor harness connector and ground. B C Terminals (+) Voltage (Approx.) (−) Connector D Terminal Ground In-vehicle sensor: M43 1 SJIA0816E 5V E OK or NG OK >> GO TO 2. NG >> GO TO 4. F 2. CHECK CIRCUIT CONTINUITY BETWEEN IN-VEHICLE SENSOR AND AUTO AMP. 1. 2. 3. Turn ignition switch OFF. Disconnect auto amp. connector. Check continuity between in-vehicle sensor harness connector (A) and auto amp. harness connector (B). A B G H Continuity Connector Terminal Connector Terminal In-vehicle sensor: M43 2 Auto amp.: M65 33 I Yes OK or NG OK >> GO TO 3. NG >> Repair harness or connector. MJIB0422E 3. CHECK IN-VEHICLE SENSOR ATC K Refer to ATC-115, "IN-VEHICLE SENSOR" . OK or NG OK >> 1. Replace auto amp. 2. Go to self-diagnosis ATC-48, "FUNCTION CONFIRMATION PROCEDURE" and perform selfdiagnosis STEP-2. Confirm that code No. 20 is displayed. NG >> 1. Replace in-vehicle sensor. 2. Go to self-diagnosis ATC-48, "FUNCTION CONFIRMATION PROCEDURE" and perform selfdiagnosis STEP-2. Confirm that code No. 20 is displayed. ATC-103 L M TROUBLE DIAGNOSIS 4. CHECK CIRCUIT CONTINUITY BETWEEN IN-VEHICLE SENSOR AND AUTO AMP. 1. 2. 3. Turn ignition switch OFF. Disconnect auto amp. connector. Check continuity between in-vehicle sensor harness connector (A) and auto amp. harness connector (B). A 4. B Connector Terminal Connector Terminal In-vehicle sensor: M43 1 Auto amp.: M65 28 Continuity Yes Check continuity between in-vehicle sensor harness connector (A) and ground. A MJIB0423E Continuity Connector Terminal In-vehicle sensor: M43 1 Ground No OK or NG OK >> 1. Replace auto amp. 2. Go to self-diagnosis ATC-48, "FUNCTION CONFIRMATION PROCEDURE" and perform selfdiagnosis STEP-2. Confirm that code No. 20 is displayed. NG >> Repair harness or connector. COMPONENT INSPECTION In-vehicle Sensor After disconnecting in-vehicle sensor connector M41, measure resistance between terminals 1 and 2 at sensor side, using the table below. Temperature °C (°F) Resistance kΩ −15 (5) 12.73 −10 (14) 9.92 −5 (23) 7.80 0 (32) 6.19 5 (41) 4.95 10 (50) 3.99 15 (59) 3.24 20 (68) 2.65 25 (77) 2.19 30 (86) 1.81 35 (95) 1.51 40 (104) 1.27 45 (113) 1.07 MJIB0424E If NG, replace in-vehicle sensor. ATC-104 TROUBLE DIAGNOSIS Sunload Sensor Circuit BJS000BR A COMPONENT DESCRIPTION Sunload Sensor The sunload sensor (1) is located on the instrument upper mask. It detects sunload entering through windshield by means of a photo diode. The sensor converts the sunload into a current value which is then input into the auto amp. B C D MJIB0431E SUNLOAD INPUT PROCESS The auto amp. also includes a processing circuit which averages the variations in detected sunload over a period of time. This prevents drastic swings in the ATC system operation due to small or quick variations in detected sunload. For example, consider driving along a road bordered by an occasional group of large trees. The sunload detected by the sunload sensor will vary whenever the trees obstruct the sunlight. The processing circuit averages the detected sunload over a period of time, so that the (insignificant) effect of the trees momentarily obstructing the sunlight does not cause any change in the ATC system operation. On the other hand, shortly after entering a long tunnel, the system will recognize the change in sunload, and the system will react accordingly. E F G H DIAGNOSTIC PROCEDURE FOR SUNLOAD SENSOR SYMPTOM: Sunload sensor circuit is open or shorted. (25 or AUTO 25 is indicated on auto amp. as a result of performing self-diagnosis STEP-2.) I ATC K SJIA0820E L 1. CHECK VOLTAGE BETWEEN SUNLOAD SENSOR AND GROUND 1. 2. 3. 4. M Turn ignition switch OFF. Disconnect sunload sensor connector. Turn ignition switch ON. Check voltage between sunload sensor harness connector and ground. Terminals (+) (−) Connector Terminal Sunload sensor: M23 1 Voltage (Approx.) Ground 5V OK or NG OK >> GO TO 2. NG >> GO TO 4. ATC-105 SJIA0821E TROUBLE DIAGNOSIS 2. CHECK CIRCUIT CONTINUITY BETWEEN SUNLOAD SENSOR AND AUTO AMP. 1. 2. 3. Turn ignition switch OFF. Disconnect auto amp. connector. Check continuity between sunload sensor harness connector (A) and auto amp. harness connector (B). A B Connector Terminal Connector Terminal Sunload sensor: M23 2 Auto amp.: M65 33 Continuity Yes OK or NG OK >> GO TO 3. NG >> Repair harness or connector. MJIB0422E 3. CHECK SUNLOAD SENSOR 1. Reconnect sunload sensor connector and auto amp. connector. 2. Refer to ATC-116, "SUNLOAD SENSOR" . OK or NG OK >> 1. Replace auto amp. 2. Go to self-diagnosis ATC-48, "FUNCTION CONFIRMATION PROCEDURE" and perform self-diagnosis STEP-2. Confirm that code No. 20 is displayed. NG >> 1. Replace sunload sensor. 2. Go to self-diagnosis ATC-48, "FUNCTION CONFIRMATION PROCEDURE" and perform self-diagnosis STEP-2. Confirm that code No. 20 is displayed. MJIA0089E 4. CHECK CIRCUIT CONTINUITY BETWEEN SUNLOAD SENSOR AND AUTO AMP. 1. 2. 3. Turn ignition switch OFF. Disconnect auto amp. connector. Check continuity between sunload sensor harness connector (B) and auto amp. harness connector (B). A 4. B Connector Terminal Connector Terminal Sunload sensor: M23 1 Auto amp.: M65 31 Continuity Yes Check continuity between sunload sensor harness connector (A) and ground. MJIB0425E A Connector Terminal Sunload sensor: M23 1 Ground Continuity No OK or NG OK >> 1. Replace auto amp. 2. Go to self-diagnosis ATC-48, "FUNCTION CONFIRMATION PROCEDURE" and perform selfdiagnosis STEP-2. Confirm that code No. 20 is displayed. NG >> Repair harness or connector. ATC-106 TROUBLE DIAGNOSIS COMPONENT INSPECTION Sunload Sensor A Measure voltage between auto amp. harness connector M65 terminal 31 and ground. If NG, replace sunload sensor (1). B C D E F G MJIB0469E ● H When checking sunload sensor, select a place where sun shines directly on it. I ATC K L M SHA930E ATC-107 TROUBLE DIAGNOSIS Intake Sensor Circuit BJS000BS COMPONENT DESCRIPTION Intake Sensor The intake sensor (1) is located on the A/C unit. It converts temperature of air that through the evaporator (2) into a resistance value which is then input to the auto amp. MJIB0459E DIAGNOSTIC PROCEDURE FOR INTAKE SENSOR SYMPTOM: Intake sensor circuit is open or shorted. (24 or AUTO 24 is indicated on auto amp. as a result of performing self-diagnosis STEP-2.) SJIA0824E 1. CHECK VOLTAGE BETWEEN INTAKE SENSOR AND GROUND 1. 2. 3. 4. Turn ignition switch OFF. Disconnect intake sensor connector. Turn ignition switch ON. Check voltage between intake sensor harness connector and ground. Terminals (+) (−) Connector Terminal Intake sensor: M44 1 Ground Voltage (Approx.) 5V OK or NG OK >> GO TO 2. NG >> GO TO 4. ATC-108 SJIA0825E TROUBLE DIAGNOSIS 2. CHECK CIRCUIT CONTINUITY BETWEEN INTAKE SENSOR AND AUTO AMP. 1. 2. 3. A Turn ignition switch OFF. Disconnect auto amp. connector. Check continuity between intake sensor harness connector (A) and auto amp. harness connector (B). A B B Connector Terminal Connector Terminal Intake sensor: M44 2 Auto amp.: M65 33 C Continuity Yes D OK or NG OK >> GO TO 3. NG >> Repair harness or connector. MJIB0426E E 3. CHECK INTAKE SENSOR Refer to ATC-117, "INTAKE SENSOR" . OK or NG OK >> 1. Replace auto amp. 2. Go to self-diagnosis ATC-48, "FUNCTION CONFIRMATION PROCEDURE" and perform selfdiagnosis STEP-2. Confirm that code No. 20 is displayed. NG >> 1. Replace intake sensor. 2. Go to self-diagnosis ATC-48, "FUNCTION CONFIRMATION PROCEDURE" and perform selfdiagnosis STEP-2. Confirm that code No. 20 is displayed. 4. CHECK CIRCUIT CONTINUITY BETWEEN INTAKE SENSOR AND AUTO AMP. 1. 2. 3. B Connector Terminal Intake sensor: M44 1 4. Connector Auto amp.: M65 ATC K Continuity 29 Yes L MJIB0427E Continuity Connector Terminal Intake sensor: M44 1 H Terminal Check continuity between intake sensor harness connector (A) and ground. A G I Turn ignition switch OFF. Disconnect auto amp. connector. Check continuity between intake sensor harness connector (A) and auto amp. harness connector (B). A F Ground No OK or NG OK >> 1. Replace auto amp. 2. Go to self-diagnosis ATC-48, "FUNCTION CONFIRMATION PROCEDURE" and perform selfdiagnosis STEP-2. Confirm that code No. 20 is displayed. NG >> Repair harness or connector. ATC-109 M TROUBLE DIAGNOSIS COMPONENT INSPECTION Intake Sensor After disconnecting intake sensor connector (1) M44, measure resistance between terminals 1 and 2 at sensor side, using the table below. Temperature °C (°F) Resistance kΩ −15 (5) 12.34 −10 (14) 9.62 −5 (23) 7.56 0 (32) 6.00 5 (41) 4.80 10 (50) 3.87 15 (59) 3.15 20 (68) 2.57 25 (77) 2.12 30 (86) 1.76 35 (95) 1.47 40 (104) 1.23 45 (113) 1.04 MJIB0470E If NG, replace intake sensor. ATC-110 TROUBLE DIAGNOSIS Engine Coolant Temperature Circuit BJS000BT Symptom: Low engine coolant temperature startup airflow control cannot be cancelled, or the mode cannot be switched to low engine coolant temperature startup airflow control. Inspection Procedure A B 1. COMBINATION METER FUNCTION INSPECTION Is engine coolant temperature gauge operating normally? OK or NG OK >> GO TO 2. NG >> GO TO DI-19, "Check Water Temperature Warning/indicator Lamp" of Combination Meter. C D 2. HARNESS INSPECTION 1. 2. 3. E Turn ignition switch OFF. Disconnect auto amp. connector and combination meter connector. Check continuity between auto amp. harness connector (A) and combination meter harness connector (B). A B F G Continuity Connector Terminal Connector Terminal Auto amp.: M64 4 Combination meter: M27 35 Yes MJIB0428E 4. H Check continuity between auto amp. harness connector (A) and ground. I A Connector Terminal Auto amp.: M64 4 Ground Continuity No ATC OK or NG OK >> GO TO 3. NG >> Repair harness and connector. K 3. ENGINE COOLANT TEMPERATURE SIGNAL INSPECTION L After warming up engine, check voltage waveform between combination meter harness connector and ground. Terminals (+) Connector Combination meter: M27 M (−) Condition Voltage (approx.) Terminal 35 Ground After warming up, approx. 80°C. MJIB0429E SKIB3651J OK or NG OK >> Replace auto amp. NG >> Replace combination meter. ATC-111 CONTROLLER CONTROLLER Removal and Installation of Controller PFP:28074 BJS000BU REMOVAL 1. 2. 3. Remove controller mounting clips (A) using remover tool. Disconnect controller harness connector and front passenger air bag OFF indicator harness connector. Remove controller (1). ZJIA0790J INSTALLATION Installation is basically the reverse order of removal. Disassembly and Assembly of Controller BJS000BV ZJIA0791J 1. Controller assembly 4. TEMP ring 5. A/C finisher 6. A/C button 7. TEMP button 8. REC button 9. LCD ring 10. Rear DEF button 2. FRE button 11. AUTO button 3. MODE ring 12. FAN button 13. MODE button DISASSEMBLY 1. Remove rear DEF button (1) using screwdriver (A). ZJIA0792J ATC-112 CONTROLLER 2. Remove A/C button (1) using screwdriver (A). A B C ZJIA0793J D 3. Remove FRE button (1) and REC button (2) using screwdriver. E F G ZJIA0794J ASSEMBLY Assembly is basically the reverse order of disassembly. H I ATC K L M ATC-113 AMBIENT SENSOR AMBIENT SENSOR Removal and Installation PFP:27722 BJS000BY REMOVAL 1. 2. Remove front grille (left side). Refer to EI-10, "Removal and Installation" . Disconnect ambient sensor connector, and then remove ambient sensor (1). MJIB0467E INSTALLATION Installation is basically the reverse order of removal. ATC-114 IN-VEHICLE SENSOR IN-VEHICLE SENSOR Removal and Installation PFP:27720 A BJS000BZ REMOVAL 1. 2. Remove instrument lower finisher. Refer to IP-4, "INSTRUMENT PANEL ASSEMBLY" . Remove mounting screw (A), and then remove in-vehicle sensor (1) from instrument lower finisher (2). B C D E MJIB0430E INSTALLATION Installation is basically the reverse order of removal. F G H I ATC K L M ATC-115 SUNLOAD SENSOR SUNLOAD SENSOR Removal and Installation PFP:27721 BJS000C0 REMOVAL 1. 2. Remove instrument upper mask. Refer to IP-4, "INSTRUMENT PANEL ASSEMBLY" . Disconnect sunload sensor connector, and then remove sunload sensor (1). MJIB0431E INSTALLATION Installation is basically the reverse order of removal. ATC-116 INTAKE SENSOR INTAKE SENSOR Removal and Installation PFP:27723 A BJS000C1 REMOVAL 1. 2. Remove evaporator. Refer to ATC-145, "Removal and Installation for Evaporator" . CAUTION: Cap or wrap the joint of the pipe with suitable material such as vinyl tape to avoid the entry of air. Remove intake sensor (1) from evaporator (2). B C D E MJIB0459E F INSTALLATION Installation is basically the reverse order of removal. CAUTION: ● Replace O-rings for A/C piping with new ones, and then apply compressor oil to it when installing it. ● Mark the mounting position of intake sensor. ● When recharging refrigerant, check for leaks. G H I ATC K L M ATC-117 A/C UNIT ASSEMBLY A/C UNIT ASSEMBLY Removal and Installation PFP:27110 BJS000C2 REMOVAL 1. 2. 3. 4. 5. Use a refrigerant collecting equipment (for HFC-134a) to discharge refrigerant. Drain coolant from cooling system. CR: Refer to CO-28, "Changing Engine coolant" . HR: Refer to CO-28, "Changing Engine coolant" . K9K: Refer to CO-49, "Changing Engine Coolant" . Remove cowl top cover. Refer to EI-12, "Removal and Installation" . Remove lower dash insulator. Remove mounting bolt (A), and then disconnect low-pressure flexible hose (1) and high-pressure pipe (2) from evaporator. CAUTION: Cap or wrap the joint of the pipe with suitable material such as vinyl tape to avoid the entry of air. MJIB0471E 6. Remove clamps (A), and then disconnect heater hoses (1) from heater core. MJIB0472E 7. 8. Remove console box assembly. Refer to IP-4, "INSTRUMENT PANEL ASSEMBLY" . Remove mounting nuts (A) and harness clamps (B), and then remove instrument stay (1). MJIB0473E ATC-118 A/C UNIT ASSEMBLY 9. Disconnect intake sensor connector (1). A B C MJIB0474E D 10. 11. 12. 13. Remove instrument panel & pad. Refer to IP-4, "INSTRUMENT PANEL ASSEMBLY" . Remove side ventilator ducts. Refer to ATC-132, "Removal of Side Ventilator Ducts" . Remove center ventilator ducts. Refer to ATC-132, "Removal of Center Ventilator Ducts" . Remove A/C unit assembly mounting bolts (A), steering member mounting bolts (B), steering column mounting nuts (C) and harness clips. E F G H I ATC K MJIB0435E 14. Remove steering member, and then remove A/C unit assembly. L M ATC-119 A/C UNIT ASSEMBLY INSTALLATION Installation is basically the reverse order of removal. CAUTION: ● Replace O-rings for A/C piping with new ones, and then apply compressor oil to it when installing it. ● When recharging refrigerant, check for leaks. NOTE: ● When filling radiator with coolant. CR: Refer to CO-9, "Changing Engine coolant" . HR: Refer to CO-28, "Changing Engine coolant" . K9K: Refer to CO-49, "Changing Engine Coolant" . ● Recharge the refrigerant. A/C unit assembly mounting bolt Tightening torque : 6.9 N·m (0.7 kg-m, 61 in-lb) Steering member mounting bolt Tightening torque : 12 N·m (1.25 kg-m, 9 ft-lb) Steering column mounting nut Tightening torque : 12 N·m (1.25 kg-m, 9 ft-lb) ATC-120 A/C UNIT ASSEMBLY Disassembly and Assembly BJS000C3 A B C D E F G H I ATC K L M MJIB0480E 1. Center defroster duct 2. Seal 3. Intake case 4. Insulator 5. Nut 6. Blower motor 7. Air conditioner filter Ventilator-defroster door lever 8. Evaporator assembly 9. 10. Foot door lever 11. Air mix door link 12. Main link 13. Foot door link 14. Rod 15. Rod holder 16. Rod 17. Mode door motor 18. Foot duct assembly (RH) ATC-121 A/C UNIT ASSEMBLY 19. Aspirator 20. Heater cover 21. Lower blower case 22. Heater core assembly 23. Power transistor 24. Foot duct assembly (LH) 25. Intake door lever 26. Rod holder 27. Rod 28. Intake door motor 29. Air mix door motor 30. Rod 31. Rod holder 32. Air mix door lever 33. Heater pipe packing 34. Heater hose cover 35. Cover 36. Expansion valve assembly 37. O-ring 38. Evaporator valve block 39. Expansion valve cover 40. Intake sensor 41. Drain hose 42. Blower case (RH) 43. Blower case (LH) 44. Ventilator-defroster door 45. Air mix door 1 46. Air mix door 2 47. Foot door 48. Foot door link ATC-122 BLOWER MOTOR BLOWER MOTOR Removal and Installation PFP:27226 A BJS000C4 REMOVAL 1. 2. 3. 4. Remove instrument panel & pad. Refer to IP-4, "INSTRUMENT PANEL ASSEMBLY" . Remove side ventilator duct (right). Refer to ATC-132, "Removal of Side Ventilator Ducts" . Disconnect blower motor connector (1). Push flange holding hook (A), and then remove blower motor (2) from A/C unit assembly (3). CAUTION: When blower fan and blower motor are assembled, the balance is adjusted, so do not replace the individual parts. B C D E MJIB0440E INSTALLATION F Installation is basically the reverse order of removal. CAUTION: Correctly install blower motor flange holding hook in A/C unit assembly. G H I ATC K L M ATC-123 INTAKE DOOR MOTOR INTAKE DOOR MOTOR Removal and Installation PFP:27730 BJS000C5 REMOVAL 1. 2. 3. Remove instrument lower finisher and instrument lower cover (LH). Refer to IP-4, "INSTRUMENT PANEL ASSEMBLY" . Disconnect connector (A). Remove mounting screws (B), and then remove intake door motor (1). MJIB0441E INSTALLATION Installation is basically the reverse order of removal. CAUTION: After installing door motor, perform door motor starting position reset by following self-diagnosis STEP-3. Refer to ATC-46, "Self-diagnosis Function" . ATC-124 AIR MIX DOOR MOTOR AIR MIX DOOR MOTOR Removal and Installation PFP:27732 A BJS000C6 REMOVAL 1. 2. 3. Remove instrument lower finisher. Refer to IP-4, "INSTRUMENT PANEL ASSEMBLY" . Remove console box assembly. Refer to IP-4, "INSTRUMENT PANEL ASSEMBLY" . Remove mounting nuts (A) and harness clamps (B), and then remove instrument stay (1). B C D E MJIB0442E 4. 5. F Remove mounting screws (A), and then remove air mix door motor (1). Disconnect air mix door motor connector. G H I MJIB0443E INSTALLATION ATC Installation is basically the reverse order of removal. CAUTION: After installing door motor, perform door motor starting position reset by following self-diagnosis STEP-3. Refer to ATC-46, "Self-diagnosis Function" . K L M ATC-125 MODE DOOR MOTOR MODE DOOR MOTOR Removal and Installation PFP:27731 BJS000C7 REMOVAL 1. 2. 3. Remove glove box assembly and instrument lower cover (RH). Refer to IP-4, "INSTRUMENT PANEL ASSEMBLY" . Remove mounting screws (A), and then remove mode door motor (1). Disconnect mode door motor connector. MJIB0444E INSTALLATION Installation is basically the reverse order of removal. CAUTION: After installing door motor, perform door motor starting position reset by following self-diagnosis STEP-3. Refer to ATC-46, "Self-diagnosis Function" . ATC-126 POWER TRANSISTOR POWER TRANSISTOR Removal and Installation PFP:27761 A BJS000C8 REMOVAL 1. 2. Remove A/C unit assembly. Refer to ATC-118, "A/C UNIT ASSEMBLY" . Remove mounting screws (A), and then remove power transistor (1). B C D E MJIB0445E INSTALLATION Installation is basically the reverse order of removal. F G H I ATC K L M ATC-127 HEATER CORE HEATER CORE Removal and Installation PFP:27140 BJS000C9 REMOVAL 1. 2. 3. 4. Remove A/C unit assembly. Refer to ATC-118, "A/C UNIT ASSEMBLY" . Remove foot duct (left). Refer to ATC-132, "Removal of Foot Ducts" . Remove mounting screws (A). Slide heater core (1) to leftward. MJIB0439E INSTALLATION Installation is basically the reverse order of removal. CAUTION: After installing door motor, perform door motor starting position reset by following self-diagnosis STEP-3. Refer to ATC-46, "Self-diagnosis Function" . ATC-128 AIR CONDITIONER FILTER AIR CONDITIONER FILTER Removal and Installation PFP:27277 A BJS000CA FUNCTION Air inside passenger compartment is kept clean at either recirculation or fresh mode by installing air conditioner filter into A/C unit assembly. B C D SJIA0651E E REPLACEMENT TIMING Replace air conditioner filter. Refer to MA-55, "CHASSIS AND BODY MAINTENANCE" . Caution label is fixed inside glove box. F REPLACEMENT PROCEDURES 1. 2. 3. 4. 5. G Remove glove box assembly. Refer to IP-4, "INSTRUMENT PANEL ASSEMBLY" . Compress air conditioner filter downward while sliding it to the right side of the vehicle. Turn the bottom of air conditioner filter upward, and then remove it. Replace with new one and reinstall on A/C unit assembly. Reinstall glove box assembly. H I ATC MJIB0446E K L M ATC-129 DUCTS AND GRILLES DUCTS AND GRILLES Removal and Installation PFP:27860 BJS000CB REMOVAL MJIB0447E 1. Side defroster duct (right) 2. Defroster nozzle 3. Side defroster duct (left) 4. Side defroster grille (left) 5. Instrument side panel (left) 6. Instrument panel & pad 7. Side ventilator assembly (left) 8. Cluster lid C 9. Side ventilator assembly (right) 10. Instrument finisher E 11. Instrument side panel (right) Removal of Center Ventilator Grilles 1. 2. Remove cluster lid C. Refer to IP-4, "INSTRUMENT PANEL ASSEMBLY" . Remove center ventilator grilles (1) mounting screws (A) using a screwdriver (B), and then remove center ventilator grilles (1). MJIB0448E ATC-130 DUCTS AND GRILLES Removal of Side Ventilator Grilles 1. Remove instrument pad assembly (left). Refer to IP-4, "INSTRUMENT PANEL ASSEMBLY" . 2. Side ventilator grille (left) (1) mounting pawl ( side ventilator grille (left)(1) is pulled out. A ) is pushed, and B C D MJIB0449E 3. Remove instrument pad assembly (right). Refer to IP-4, "INSTRUMENT PANEL ASSEMBLY" . 4. Side ventilator grille (right) (1) mounting pawl ( and side ventilator grille (right)(1) is pulled out. E ) is pushed, F G H MJIB0450E Removal of Defroster Nozzle and Ducts 1. 2. Remove instrument upper finisher. Refer to IP-4, "INSTRUMENT PANEL ASSEMBLY" . Remove mounting screws (A) and then remove side defroster duct (right) (1) and side defroster duct (left) (2). I ATC K L M MJIB0451E 3. Remove mounting screws (B), and then remove defroster nozzle (3). ATC-131 DUCTS AND GRILLES Removal of Side Ventilator Ducts 1. 2. Remove instrument panel & pad. Refer to IP-4, "INSTRUMENT PANEL ASSEMBLY" . Remove mounting screws (A) and clip (B), and then remove side ventilator duct (left) (1). MJIB0475E 3. Remove mounting screw (A) and clip (B), and then remove side ventilator duct (right) (1). MJIB0476E Removal of Center Ventilator Ducts 1. 2. Remove instrument panel & pad. Refer to IP-4, "INSTRUMENT PANEL ASSEMBLY" . Remove mounting screws (A), and then remove center ventilator ducts (1). MJIB0477E Removal of Foot Ducts 1. 2. 3. Remove A/C unit assembly. Refer to ATC-118, "A/C UNIT ASSEMBLY" . Remove intake door motor (2). Refer to ATC-124, "INTAKE DOOR MOTOR" . Remove mounting screws (A), and then remove foot duct (left) (1). MJIB0452E ATC-132 DUCTS AND GRILLES 4. Remove mounting screws (A), and then remove foot duct (right) (1). A B C MJIB0453E D Removal of Floor Ducts E F G H I MJIB0454E 1. 2. 1. Front floor duct 4. Rear floor duct (right) 2. Rear floor duct (left) 3. ATC Clip K Remove front seats and center console assembly. Refer to SE-8, "Removal and Installation" "INSTRUMENT PANEL ASSEMBLY" . Disengage claws (A), and then remove front floor duct (1). and IP-4, L M MJIB0455E 3. Peel back floor trim to a point where floor duct is visible. ATC-133 DUCTS AND GRILLES 4. Remove mounting clips (A), and then remove rear floor duct (left) (1) and rear floor duct (right) (2). MJIB0456E INSTALLATION Installation is basically the reverse order of removal. ATC-134 REFRIGERANT LINES REFRIGERANT LINES HFC-134a (R-134a) Service Procedure PFP:92600 A BJS000CC SETTING OF SERVICE TOOLS AND EQUIPMENT Discharging Refrigerant B WARNING: Avoid breathing A/C refrigerant and lubricant vapor or mist. Exposure may irritate eyes, nose and throat. Use only approved recovery/recycling equipment to discharge HFC-134a (R-134a) refrigerant. If accidental system discharge occurs, ventilate work area before resuming service. Additional health and safety information may be obtained from refrigerant and lubricant manufacturers. C D E F G H I SHA539DE Evacuating System and Charging Refrigerant ATC K L M SHA540DC ATC-135 REFRIGERANT LINES RJIA2143E *1 ATC-17, "LUBRICANT RETURN OPERATION" *4 ATC-88, "PERFORMANCE TEST DIAGNOSIS" *2 ATC-147, "Checking for Refrigerant Leaks" ATC-136 *3 ATC-149, "CHECKING PROCEDURE" REFRIGERANT LINES Components BJS000CD A CR ENGINE MODELS B C D E F G H I MJIB0436E 1. High-pressure flexible hose 2. Radiator (Condenser) 3. Liquid tank 4. Compressor 5. High-pressure pipe 6. Low-pressure flexible hose ATC K L M ATC-137 REFRIGERANT LINES HR ENGINE MODELS MJIB0437E 1. High-pressure flexible hose 2. Radiator (Condenser) 3. Liquid tank 4. Compressor 5. High-pressure pipe 6. Low-pressure flexible hose 7. Service valve (High pressure) 8. Service valve (Low pressure) 9. Refrigerant pressure sensor 10. Condenser ATC-138 REFRIGERANT LINES K9K ENGINE MODELS A B C D E F G H I ATC K L MJIB0438E 1. High-pressure flexible hose 2. Refrigerant pressure sensor 3. Liquid tank 4. Radiator (Condenser) 5. Condenser 6. Compressor 7. Service valve (Low pressure) 8. Low-pressure flexible hose 9. High-pressure pipe 10. Service valve (High pressure) ATC-139 M REFRIGERANT LINES Removal and Installation of Compressor BJS000CE REMOVAL 1. 2. 3. Use a refrigerant collecting equipment (for HFC-134a) to discharge the refrigerant. Remove engine undercover, using power tools. Remove low-pressure flexible hose mounting nut and high-pressure flexible hose mounting bolt from compressor. MJIB0273E 4. 5. 6. CAUTION: Cap or wrap the joint of the pipe with suitable material such as vinyl tape to avoid the entry of air. Remove A/C compressor belt. CR: Refer to EM-14, "DRIVE BELTS" . HR: Refer to EM-114, "DRIVE BELTS" . K9K: Refer to EM-242, "DRIVE BELTS" . Disconnect compressor connector. Remove mounting bolts from compressor, using power tools. MJIB0134E 7. Remove compressor downward of the vehicle. INSTALLATION Installation is basically the reverse order of removal. CAUTION: ● Replace O-rings of low-pressure flexible hose and high-pressure flexible hose with a new ones, and then apply compressor oil to it when installing it. ● When recharging refrigerant, check for leaks. Compressor mounting bolt Tightening torque : 20.0 N·m (2.05 kg-m, 14.8 ft-lb) ATC-140 REFRIGERANT LINES CHECK DISC TO PULLEY CLEARANCE A Check clearance around entire periphery of clutch disc. Disc to pulley clearance : 0.3 - 0.6 mm (0.012 - 0.024 in) B If specified clearance is not obtained, replace compressor. C RHA087E Removal and Installation for Pipe and Hose D BJS000I9 REMOVAL 1. 2. 3. 4. 5. 6. 7. E Use recovery/recycling recharging equipment [for HFC-134a (R-134a)] to discharge refrigerant. Remove the low-pressure flexible hose bracket mounting bolt and nut. Remove the high-pressure pipe and low-pressure flexible hose mounting bolts (air conditioner unit side). F CAUTION: Seal the connecting points of the pipe and hose with caps and vinyl tape, etc. to prevent them from being exposed to the atmosphere. G Remove the low-pressure flexible hose mounting bolt or nut (compressor side) and then remove the lowpressure flexible hose. CAUTION: H Seal the connecting points of the hose with caps and vinyl tape, etc. to prevent them from being exposed to the atmosphere. Remove the front bumper and air guide (RH). Refer to EI-4, "Removal and Installation" and BL-13, I "Removal and Installation" . Remove the high-pressure pipe mounting bolt (liquid tank side) and then remove the high-pressure pipe. CAUTION: ATC Seal the connecting points of the pipe with caps and vinyl tape, etc. to prevent them from being exposed to the atmosphere. Remove the high-pressure flexible hose mounting bolts and then remove the high-pressure flexible hose. K CAUTION: Seal the connecting points of the hoses with caps and vinyl tape, etc. to prevent them from being exposed to the atmosphere. L INSTALLATION CAUTION: ● Replace the O-rings on the high-pressure pipe, low-pressure flexible hose, and high-pressure flexible hose with new ones, and apply compressor lubricant to O-rings before installing. ● When charging refrigerant, check for refrigerant leaks. High-pressure pipe mounting bolt Tightening torque : 4.4 N·m (0.45 kg-m, 39.0 in-lb) Low-pressure flexible hose and high-pressure pipe mounting bolts (evaporator side) Tightening torque : 4.4 N·m (0.45 kg-m, 39.0 in-lb) Low-pressure flexible hose mounting bolt (compressor side) Tightening torque : 13.7 N·m (1.4 kg-m, 10.1 ft-lb) Low-pressure flexible hose bracket mounting bolt/nut Tightening torque : 4.2 N·m (0.43 kg-m, 37.2 in-lb) High-pressure flexible hose mounting bolt Tightening torque : 13.7 N·m (1.4 kg-m, 10.1 ft-lb) ATC-141 M REFRIGERANT LINES Removal and Installation for Refrigerant Pressure Sensor BJS000IA MJIB0457E 1. Refrigerant pressure sensor 4. Air guide 2. Condenser 3. Liquid tank REMOVAL AND INSTALLATION 1. 2. 3. Use refrigerant collecting equipment (for HFC134a) to discharge refrigerant. Remove the front bumper and air guide (RH) (4). Refer to EI-4, "Removal and Installation" and BL-13, "Removal and Installation" . Use a adjustable wrench A or other tool to hold the refrigerant pressure sensor mounting block, and then remove the refrigerant pressure sensor from the condenser (CR and HR engine models) or the high-pressure flexible hose (K9K engine models). CAUTION: ● Be careful when working so as not to damage the condenser core. ● When installing refrigerant pressure sensor, apply compressor lubricant to the O-rings. Refrigerant pressure sensor Tightening torque : 10.8 N·m (1.1 kg-m, 8.0 ft-lb) Removal and Installation for Condenser (Models without Integrated Condenser) BJS000IB REMOVAL 1. 2. 3. 4. Use refrigerant collecting equipment (for HFC134a) to discharge refrigerant. Remove the front bumper and air guide (RH). Refer to EI-4, "Removal and Installation" and BL-13, "Removal and Installation" . Disconnect the high-pressure flexible hose and high-pressure pipe from the condenser. CAUTION: Seal the connecting points of the pipes with caps and vinyl tape, etc. to prevent them from being exposed to the atmosphere. Disconnect the refrigerant pressure sensor connector, and then remove the harness clip (CR engine models). MJIA0059E ATC-142 REFRIGERANT LINES 5. 6. 7. Use cord, etc., to hold the condenser and radiator to each radiator core support upper. NOTE: To prevent the condenser and radiator from being dropped when the radiator core lower support is removed. Remove the mounting bolts, and then remove the radiator core lower support. Remove the condenser from underneath the vehicle. CAUTION: Do not damage the condenser core. A B C MJIA0060E D INSTALLATION CAUTION: ● Replace O-rings on the high-pressure pipe and high-pressure flexible hose with new ones. Apply compressor lubricant to O-rings when installing them. ● When charging refrigerant, check for refrigerant leaks. High-pressure flexible hose bolt Tightening torque : 13.7 N·m (1.4 kg-m, 10.1 ft-lb) High-pressure pipe mounting bolt Tightening torque : 4.4 N·m (0.45 kg-m, 39.0 in-lb) Radiator core lower support mounting bolts. Tightening torque : 51.1 N·m (5.3 kg-m, 37.7 ft-lb) E F G H Removal and Installation for Condenser (Models with Integrated Condenser) BJS000IC REMOVAL 1. 2. 3. 4. I Use refrigerant collecting equipment (for HFC134a) to discharge refrigerant. Remove the front bumper and air guide (RH). Refer to EI-4, "Removal and Installation" and BL-13, "Removal and Installation" . ATC Disconnect the high-pressure flexible hose from the condenser. Disconnect the high-pressure pipe from the liquid tank. CAUTION: K Seal the connecting points of the pipes with caps and vinyl tape, etc. to prevent them from being exposed to the atmosphere. L Remove the radiator assembly. CR: Refer to CO-12, "Removal and Installation" . HR: Refer to CO-31, "Removal and Installation" . M CAUTION: MJIA0214E Do not damage the radiator and condenser core. INSTALLATION CAUTION: ● Replace O-rings on the high-pressure pipe and high-pressure flexible hose with new ones. Apply compressor lubricant to O-rings when installing them. ● When charging refrigerant, check for refrigerant leaks. ATC-143 REFRIGERANT LINES Removal and Installation for Liquid Tank (HR Engine with A/T Models) BJS000ID REMOVAL 1. 2. 3. 4. Use refrigerant collecting equipment (for HFC134a) to discharge refrigerant. Remove condenser. Refer to ATC-142, "Removal and Installation for Condenser (Models without Integrated Condenser)" . Clean around the liquid tank to remove foreign material and corrosion. Remove the liquid tank bracket (upper/lower) mounting bolts. MJIA0061E 5. 6. Lift up the liquid tank bracket, and remove it from the condenser protruding area. Lift up the liquid tank and remove it. CAUTION: Seal the connecting points of the pipes with caps and vinyl tape, etc. to prevent them from being exposed to the atmosphere. MJIA0062E INSTALLATION Install the liquid tank, and then install liquid tank bracket to the condenser. CAUTION: ● Make sure the liquid tank bracket is correctly inserted into the condenser's protruding area (the liquid tank bracket does not move below the center of the liquid tank). ● Replace the condenser pipe O-rings with new ones. Apply a coat of compressor lubricant to the O-rings prior to installation. MJIA0063E Liquid tank bracket (upper) mounting bolt Tightening torque : 3.38 N·m (0.35 kg-m, 30.0 in-lb) Liquid tank bracket (lower) mounting bolt Tightening torque : 5.74 N·m (0.58 kg-m, 50.8 in-lb) Removal and Installation for Liquid Tank (Except HR Engine with A/T Models) BJS000IE REMOVAL 1. 2. 3. 4. 5. Use refrigerant collecting equipment (for HFC134a) to discharge refrigerant. Clean around the liquid tank to remove foreign material and corrosion. Remove the high-pressure pipe from the liquid tank. Remove the condenser pipe mounting bolt from the liquid tank, and remove pipe from the condenser protruding area. Remove the liquid tank bracket bolts and then remove the liquid tank. MJIA0215E ATC-144 REFRIGERANT LINES CAUTION: Seal the connecting points of the pipes with caps and vinyl tape, etc. to prevent them from being exposed to the atmosphere. A INSTALLATION Install the liquid tank, and then install liquid tank bracket to the condenser. CAUTION: Replace the condenser pipe O-rings with new ones. Apply a coat of compressor lubricant to the Orings prior to installation. Removal and Installation for Evaporator B C BJS000IF REMOVAL 1. Use refrigerant collecting equipment (for HFC134a) to discharge refrigerant. 2. Remove the A/C unit. Refer to ATC-118, "A/C UNIT ASSEMBLY" . CAUTION: Seal the connecting points of the pipes with caps and vinyl tape, etc. to prevent them from being exposed to the atmosphere. 3. Remove the air conditioner filter, mode door motor, and foot duct (RH). Refer to ATC-129, "AIR CONDITIONER FILTER" , ATC-126, "MODE DOOR MOTOR" and ATC-132, "Removal of Foot Ducts" . 4. Remove the lower blower case and expansion valve cover. 5. Slide the evaporator (1) and lower blower case (2) downward, and remove the intake sensor (3). 6. Remove the evaporator from the lower blower case. D E F G H I MJIB0462E ATC INSTALLATION CAUTION: ● Replace low-pressure flexible hose and high-pressure pipe O-rings with new ones. Apply a coat of compressor lubricant prior to installation. ● When installing a new evaporator, install the thermistor of intake air temperature in the same position as the removed intake sensor. ● When removing and installing the intake sensor, do not rotate the thermistor insertion part. Mounting bolts for the low-pressure flexible hoses and high-pressure pipes. Tightening torque : 4.4 N·m (0.45 kg-m, 39.0 in-lb) Removal and Installation for Expansion Valve L M BJS000IG REMOVAL 1. Use refrigerant collecting equipment (for HFC134a) to discharge refrigerant. 2. Disconnect the low-pressure flexible hose and high-pressure pipe from the evaporator. CAUTION: Seal the connecting points of the pipes with caps and vinyl tape, etc. to prevent them from being exposed to the atmosphere. 3. Remove the two bolts from the expansion valve, and then remove the expansion valve. MJIB0460E ATC-145 K REFRIGERANT LINES INSTALLATION CAUTION: Replace the removed O-rings with new ones. Apply a coat of compressor lubricant to the O-rings prior to installation. Expansion valve mounting bolts Tightening torque : 4.0 N·m (0.41 kg-m, 35.4 in-lb) Mounting bolts for the low-pressure flexible hoses and high-pressure pipes. Tightening torque : 4.4 N·m (0.45 kg-m, 39.0 in-lb) ATC-146 REFRIGERANT LINES Checking for Refrigerant Leaks BJS000CN Perform a visual inspection of all refrigeration parts, fittings, hoses and components for signs of A/C lubricant leakage, damage and corrosion. A/C lubricant leakage may indicate an area of refrigerant leakage. Allow extra inspection time in these areas when using either an electronic refrigerant leak detector or fluorescent dye leak detector. If dye is observed, confirm the leak with an electronic refrigerant leak detector. It is possible a prior leak was repaired and not properly cleaned. When searching for leaks, do not stop when one leak is found but continue to check for additional leaks at all system components and connections. When searching for refrigerant leaks using an electronic leak detector, move the probe along the suspected leak area at 1 to 2 inches per second and no further than 1/4 inch from the component. CAUTION: Moving the electronic leak detector probe slower and closer to the suspected leak area will improve the chances of finding a leak. Checking System for Leaks Using the Fluorescent Leak Detector A B C D E BJS000CO 1. Check A/C system for leaks using the UV lamp and safety goggles [SST: J-42220] in a low sunlight area (area without windows preferable). Illuminate all components, fittings and lines. The dye will appear as a F bright green/yellow area at the point of leakage. Fluorescent dye observed at the evaporator drain opening indicates an evaporator core assembly (tubes, core or expansion valve) leak. 2. If the suspected area is difficult to see, use an adjustable mirror or wipe the area with a clean shop rag or G cloth, with the UV lamp for dye residue. 3. After the leak is repaired, remove any residual dye using dye cleaner [SST: J-43872] to prevent future misdiagnosis. H 4. Perform a system performance check and verify the leak repair with an approved electronic refrigerant leak detector. NOTE: I Other gases in the work area or substances on the A/C components, for example, anti-freeze, windshield washer fluid, solvents and lubricants, may falsely trigger the leak detector. Make sure the surfaces to be checked are clean. Clean with a dry cloth or blow off with shop air. ATC Do not allow the sensor tip of the detector to contact with any substance. This can also cause false readings and may damage the detector. Dye Injection BJS000CP (This procedure is only necessary when recharging the system or when the compressor has seized and was replaced.) 1. 2. 3. 4. 5. 6. 7. Check A/C system static (at rest) pressure. Pressure must be at least 345 kPa (3.45 bar, 3.52 kg/cm2 , 50 psi). Pour one bottle (1/4 ounce / 7.4 cc) of the A/C refrigerant dye into the injector tool [SST: J-41459]. Connect the injector tool to the A/C low-pressure side service fitting. Start engine and switch A/C ON. When the A/C operating (compressor running), inject one bottle (1/4 ounce / 7.4 cc) of fluorescent dye through the low-pressure service valve using dye injector tool J-41459 (refer to the manufacture’s operating instructions). With the engine still running, disconnect the injector tool from the service fitting. CAUTION: Be careful the A/C system or replacing a component, pour the dye directly into the open system connection and proceed with the service procedures. Operate the A/C system for a minimum of 20 minutes to mix the dye with the system oil. Depending on the leak size, operating conditions and location of the leak, it may take from minutes to days for the dye to penetrate a leak and become visible. ATC-147 K L M REFRIGERANT LINES Electronic Refrigerant Leak Detector BJS000CQ PRECAUTIONS FOR HANDLING LEAK DETECTOR When performing a refrigerant leak check, use an A/C electrical leak detector (SST) or equivalent. Ensure that the instrument is calibrated and set properly per the operating instructions. The leak detector is a delicate device. In order to use the leak detector properly, read the operating instructions and perform any specified maintenance. SHA705EB 1. Position probe approximately 5 mm (3/16 in) away from point to be checked. SHA707EA 2. When testing, circle each fitting completely with probe. SHA706E 3. Move probe along component approximately 25 to 50 mm (1 to 2 in)/sec. SHA708EA ATC-148 REFRIGERANT LINES CHECKING PROCEDURE To prevent inaccurate or false readings, make sure there is no refrigerant vapor, shop chemicals, or cigarette smoke in the vicinity of the vehicle. Perform the leak test in calm area (low air/wind movement) so that the leaking refrigerant is not dispersed. 1. Turn engine OFF. 2. Connect a suitable A/C manifold gauge set to the A/C service ports. 3. 4. Check if the A/C refrigerant pressure is at least 345 kPa (3.45 bar, 3.52 kg/cm2 , 50 psi) above 16°C. If less than specification, recover/evacuate and recharge the system with the specified amount of refrigerant. NOTE: At temperatures below 16°C, leaks may not be detected since the system may not reach 345 kPa (3.45 bar, 3.52 kg/cm2 , 50 psi). Perform the leak test from the high-pressure side (compressor discharge a to evaporator inlet f) to the low-pressure side (evaporator drain hose g to shaft seal k). Refer to ATC-137, "Components" . Perform a leak check for the following areas carefully. Clean the component to be checked and move the leak detected probe completely around the connection/component. Compressor Check the fitting of high- and low-pressure flexible hoses, relief valve and shaft seal. A B C D E F Condenser Check the fitting of high-pressure flexible hose and pipe, refrigerant pressure sensor. G Liquid tank Check the refrigerant connection. H Service valves I Check all around the service valves. Ensure service valve caps are secured on the service valves (to prevent leaks). NOTE: After removing A/C manifold gauge set from service valves, wipe any residue from valves to prevent any ATC false readings by leak detector. 5. 6. 7. 8. a. b. c. d. e. 9. Cooling unit (Evaporator) With engine OFF, turn blower fan on “High” for at least 15 seconds to dissipate any refrigerant trace in the cooling unit. Wait a minimum of 10 minutes accumulation time (refer to the manufacturer’s recommended procedure for actual wait time) before inserting the leak detector probe into the drain hose. Keep the probe inserted for at least 10 seconds. Use caution not to contaminate the probe tip with water or dirt that may be in the drain hose. If a leak detector detects a leak, verify at least once by blowing compressed air into area of suspected leak, then repeat check as outlined above. Do not stop when one leak is found. Continue to check for additional leaks at all system components. If no leaks are found, perform steps 7-10. Start engine. Set the heater A/C control as follows; A/C switch: ON MODE door position: VENT (Ventilation) Intake door position: Recirculation Temperature control dial: Max. cold Fan speed: High Run engine at 1,500 rpm for at least 2 minutes. ATC-149 K L M REFRIGERANT LINES 10. Turn engine off and perform leak check again following steps 4 through 6 above. Refrigerant leaks should be checked immediately after stopping the engine. Begin with the leak detector at the compressor. The pressure on the high-pressure side will gradually drop after refrigerant circulation stops and pressure on the low-pressure side will gradually rise, as shown in the graph. Some leaks are more easily detected when pressure is high. 11. Before connecting ACR4 to vehicle, check ACR4 gauges. No refrigerant pressure should be displayed. If pressure is displayed, recover refrigerant from equipment lines. 12. Discharge A/C system using approved refrigerant recovery equipment. Repair the leaking fitting or component if necessary. 13. Evacuate and recharge A/C system and perform the leak test to confirm no refrigerant leaks. 14. Perform A/C performance test to ensure system works properly. ATC-150 SHA839E SERVICE DATA AND SPECIFICATIONS (SDS) SERVICE DATA AND SPECIFICATIONS (SDS) COMPRESSOR Model PFP:00030 A BJS000IH CR engine models HR engine models K9K engine models ZEXEL VALEO CLIMATE CONTROL make KC59G CR-10 SANDEN make SD6V12 Type Vane rotary Displacement Max. cm3 (cu in)/rev Min. Cylinder bore × stroke mm (in) Variable volume piston 80 (4.88) Theoretical displacement 96 (5.86) Theoretical displacement 125.1 (7.63) 6.2 (0.38) 5 vanes, φ51.0 × 7.28 5 vanes, φ50.2 × 8.5 — Direction of rotation Poly V (4grooves) V-Ribbed (7 grooves) E Poly V (6 grooves) LUBRICANT BJS000J9 F CR engine models HR engine models K9K engine models ZEXEL VALEO CLIMATE CONTROL make KC59G CR-10 SANDEN make SD6V12 Name Part number Capacity m (lmp fl oz) Nissan A/C System Oil Type R Nissan A/C System Oil Type S KLH00-PAGR0 KLH00-PAGS0 Total in system — — 135 (4.75) Compressor (Service part) charging amount — — 135 (4.75) REFRIGERANT Model G H I BJS000JA ATC CR engine models HR engine models K9K engine models ZEXEL VALEO CLIMATE CONTROL make KC59G CR-10 SANDEN make SD6V12 K 0.55 ± 0.05 (1.21 ± 0.11) L Type Capacity kg (lb) C D Clockwise (viewed from drive end) Drive belt Model B HFC-134a (R-134a) 0.475 ± 0.025 (1.04 ± 0.055) 0.475 ± 0.025 (1.04 ± 0.055) ENGINE IDLING SPEED BJS000IK M Refer to EC-449, "SERVICE DATA AND SPECIFICATIONS (SDS)" . CR (with EURO−OBD). Refer to EC-801, "SERVICE DATA AND SPECIFICATIONS (SDS)" . CR (without EURO−OBD). Refer to EC-1237, "SERVICE DATA AND SPECIFICATIONS (SDS)" . HR (with EURO−OBD). Refer to EC-1597, "SERVICE DATA AND SPECIFICATIONS (SDS)" . HR (without EURO−OBD). Refer to EC-1870, "SERVICE DATA AND SPECIFICATIONS (SDS)" .K9K. BELT TENSION BJS000IL Refer to EM-14, "Tension Adjustment" . (CR engine models). Refer to EM-114, "Tension Adjustment" . (HR engine models). Refer to EM-242, "Tension Adjustment" . (K9K engine models). ATC-151 SERVICE DATA AND SPECIFICATIONS (SDS) ATC-152 AUDIO, VISUAL & TELEPHONE SYSTEM K ELECTRICAL SECTION AV AUDIO, VISUAL & TELEPHONE SYSTEM A B C D CONTENTS PRECAUTIONS .......................................................... 2 Precautions for Supplemental Restraint System (SRS) “AIR BAG” and “SEAT BELT PRE-TENSIONER” .................................................................. 2 AUDIO ......................................................................... 3 System Description .................................................. 3 SPEED DEPENDENT VOLUME SYSTEM ........... 3 Component parts Location ....................................... 3 Wiring Diagram —AUDIO— ..................................... 4 Terminals and Reference Value for Audio Unit ......... 6 Symptom Chart ........................................................ 8 Steering Switch Resistance Check .......................... 9 Removal and Installation of Audio Unit .................... 9 REMOVAL ............................................................. 9 INSTALLATION ..................................................... 9 Removal and Installation of Front Door Speaker ..... 9 REMOVAL ............................................................. 9 INSTALLATION ..................................................... 9 Removal and Installation of Rear Door Speaker ..... 9 REMOVAL ............................................................. 9 INSTALLATION ................................................... 10 Removal and Installation of Tweeter ...................... 10 REMOVAL ........................................................... 10 INSTALLATION ................................................... 10 AUDIO ANTENNA .................................................... 11 Location of Antenna ................................................ 11 Removal and Installation of Roof Antenna ............. 11 REMOVAL ........................................................... 11 INSTALLATION ................................................... 11 E F G H I J AV L M AV-1 PRECAUTIONS PFP:00011 PRECAUTIONS Precautions for Supplemental Restraint System (SRS) “AIR BAG” and “SEAT BELT PRE-TENSIONER” BKS001AK The Supplemental Restraint System such as “AIR BAG” and “SEAT BELT PRE-TENSIONER”, used along with a front seat belt, helps to reduce the risk or severity of injury to the driver and front passenger for certain types of collision. Information necessary to service the system safely is included in the SRS and SB section of this Service Manual. WARNING: ● To avoid rendering the SRS inoperative, which could increase the risk of personal injury or death in the event of a collision which would result in air bag inflation, all maintenance must be performed by an authorized NISSAN/INFINITI dealer. ● Improper maintenance, including incorrect removal and installation of the SRS, can lead to personal injury caused by unintentional activation of the system. For removal of Spiral Cable and Air Bag Module, see the SRS section. ● Do not use electrical test equipment on any circuit related to the SRS unless instructed to in this Service Manual. SRS wiring harnesses can be identified by yellow and/or orange harnesses or harness connectors. AV-2 AUDIO AUDIO System Description PFP:28111 A BKS001AL Refer to Owner’s Manual for audio system operating instructions. B SPEED DEPENDENT VOLUME SYSTEM Volume level of this system turns up and down automatically in proportion to the vehicle speed. And the control level can be selected by the customer. C Component parts Location BKS001C2 D E F G H I J AV SKIB8381E L M AV-3 AUDIO Wiring Diagram —AUDIO— BKS001AM MKWA4265E AV-4 AUDIO A B C D E F G H I J AV L M MKWA4266E AV-5 AUDIO Terminals and Reference Value for Audio Unit Terminal No. (wire color) (+) (–) 4 (B) Ground Item Ground Signal input/ output — BKS001AO Condition Voltage Ignition switch Operation ON — Press MODE switch 10 (L) Ground Remote control A Input ON Ground Remote control B Input ON Approx. 1.7 V Press VOL UP switch Approx. 3.3 V — Remote control GND — ON 21 (B) 22 (O) Audio signal rear RH Output ON Approx. 5 V Press SEEK DOWN switch Approx. 1.7 V Press VOL DOWN switch Approx. 3.3 V Except for above 12 (R) Approx. 0 V Press SEEK UP switch Except for above 11 (W) Approx. 0 V — Approx. 5 V Approx. 0 V Receive audio signal SKIA0177E 23 (W) 24 (R) Audio signal front RH Output ON Receive audio signal SKIA0177E 25 (V) 26 (P) Audio signal front LH Output ON Receive audio signal SKIA0177E 27 (G) 28 (GR) Audio signal rear LH Output ON Receive audio signal SKIA0177E 31 (R) Ground Vehicle speed signal (2-pulse) Input ON 34 (LG) Ground Battery power supply Input OFF When vehicle speed is approx. 40 km/h (25 MPH) ELF1080D AV-6 — Battery voltage AUDIO Terminal No. (wire color) (+) 36 (V) Item (–) Ground Illumination signal 37 (L) Ground ACC power 38 (B) Ground Ground Signal input/ output Input Condition A Voltage Ignition switch ON Operation Lighting switch is ON (position 1). Approx. 12 V Turn lighting switch OFF. Approx. 0 V Input ACC — Battery voltage — ON — Approx. 0 V B C D E F G H I J AV L M AV-7 AUDIO Symptom Chart ● ● BKS001C3 The majority of the audio malfunctions are the result of outside causes (bad CD/cassette, electromagnetic interference, etc.). Check the symptoms below to diagnose the malfunction. The vehicle itself can be a source of noise if noise prevention parts or electrical equipment is malfunctioning. Check if noise is caused and/or changed by engine speed, ignition switch turned to each position, and operation of each piece of electrical equipment, and then determine the cause. NOTE: ● CD-R is not guaranteed to play because they can contain compressed audio (MP3, WMA) or could be incorrectly mastered by the customer on a computer. ● Check if the CDs carry the Compact Disc Logo. If not, the disc is not mastered to the “red book” Compact Disc Standard and may not play. Symptom Probable malfunction location ● Audio unit power supply circuit ● Audio unit ● Remote control signal circuit between steering switch and combination switch (spiral cable) ● Remote control signal circuit between combination switch (spiral cable) and audio unit ● Steering wheel audio control switch ● Combination switch (spiral cable) ● Audio unit ● Audio unit ● Audio signal circuit between audio unit and speaker ● Speaker ● Tweeter ● Audio unit ● Antenna feeder ● Roof antenna ● Audio unit ● Vehicle speed signal circuit between combination meter and audio unit ● Audio unit ● Combination meter Audio system does not work properly. Audio steering wheel switch does not operate properly. No sound can be heard from all speakers. No sound can be heard from one or several speakers. No sound can be heard from radio or noise is caught. Speed dependent volume system does not function. NOTE: Noise resulting from variations in field strength, such as fading noise and multi-path noise, or external noise from trains and other sources, is not a malfunction. ● Fading noise: This noise occurs because of variations in the field strength in a narrow range due to mountains or buildings blocking the signal. ● Multi-path noise: This noise results from a time difference between the broadcast waves directly from the station arriving at the antenna and the waves reflected by mountains or buildings. AV-8 AUDIO Steering Switch Resistance Check BKS001AP A Check continuity between steering switch harness connector terminals 14, 15 and 16. Resistance value 14 − 16 MODE ON SEEK UP ON VOL UP ON :0−1Ω : 164 − 166 Ω : 646 − 658 Ω 15 − 16 SEEK DOWN ON VOL DOWN ON : 164 − 166 Ω : 646 − 658 Ω B Removal and Installation of Audio Unit C D SKIB8537E BKS001AU E REMOVAL 1. 2. Remove cluster lid C. Refer to IP-8, "K. Cluster Lid C" . Remove screws (A) and remove audio unit (1) and bracket. F G H SKIB3963J I INSTALLATION Install in the reverse order of removal. J Removal and Installation of Front Door Speaker BKS001AV REMOVAL 1. 2. Remove front door finisher. Refer to EI-20, "DOOR FINISHER" . Remove screws (A) and remove speaker (1). AV L M SKIB3965J INSTALLATION Install in the reverse order of removal. Removal and Installation of Rear Door Speaker REMOVAL 1. Remove rear side finisher. Refer to EI-20, "DOOR FINISHER" . AV-9 BKS001AW AUDIO 2. Remove screws (A) and remove speaker (1). SKIB3965J INSTALLATION Install in the reverse order of removal. Removal and Installation of Tweeter BKS001AZ REMOVAL 1. 2. Remove corner cover inner. Refer to GW-96, "DOOR MIRROR" . Remove screws (A) and remove tweeter. SKIB8634E INSTALLATION Install in the reverse order of removal. AV-10 AUDIO ANTENNA AUDIO ANTENNA Location of Antenna PFP:28200 A BKS001B0 B C D E F G H I SKIB8382E Removal and Installation of Roof Antenna BKS001B1 J REMOVAL 1. 2. : Vehicle front Remove headliner. Refer to EI-30, "HEADLINER" . Remove roof antenna mounting nut (A) and antenna feeder (1). Then remove roof antenna. AV L M SKIB8635E INSTALLATION Install in the reverse order of removal. Roof Antenna mounting nut : 4.0 N·m (0.41 kg-m, 35 in-lb) AV-11 AUDIO ANTENNA AV-12 BODY CONTROL SYSTEM K ELECTRICAL SECTION BCS BODY CONTROL SYSTEM A B C D CONTENTS PRECAUTIONS .......................................................... 2 Precautions for Supplemental Restraint System (SRS) “AIR BAG” and “SEAT BELT PRE-TENSIONER” .................................................................. 2 Maintenance Information .......................................... 2 RHD MODELS ...................................................... 2 LHD MODELS ....................................................... 2 BCM (BODY CONTROL MODULE) ........................... 3 System Description .................................................. 3 BCM FUNCTION ................................................... 3 COMBINATIONSWITCHREADING FUNCTION..... 3 SYSTEMS CONTROLLED BY BCM ..................... 3 SYSTEMS CONTROLLED BY BCM AND IPDM E/R ........................................................................ 3 SYSTEMS CONTROLLED BY BCM AND INTELLIGENT KEY UNIT ................................................ 3 INPUT/OUTPUT .................................................... 4 CAN COMMUNICATION CONTROL .................... 5 BCM STATUS CONTROL ..................................... 5 CAN Communication ................................................ 6 SYSTEM DESCRIPTION ...................................... 6 CAN Communication Unit ......................................... 6 Schematic ................................................................. 7 CONSULT-II Function (BCM) ................................... 9 CONSULT–II INSPECTION PROCEDURE ........... 9 ITEMS OF EACH PART ........................................ 9 Configuration .......................................................... 10 DESCRIPTION .................................................... 10 READ CONFIGURATION PROCEDURE ............ 10 WRITE CONFIGURATION PROCEDURE .......... 13 CAN Communication Inspection With CONSULTII (Self-Diagnosis) ................................................... 17 Removal and Installation of BCM ........................... 17 REMOVAL ........................................................... 17 INSTALLATION ................................................... 18 E F G H I J BCS L M BCS-1 PRECAUTIONS PFP:00011 PRECAUTIONS Precautions for Supplemental Restraint System (SRS) “AIR BAG” and “SEAT BELT PRE-TENSIONER” BKS0026F The Supplemental Restraint System such as “AIR BAG” and “SEAT BELT PRE-TENSIONER”, used along with a front seat belt, helps to reduce the risk or severity of injury to the driver and front passenger for certain types of collision. Information necessary to service the system safely is included in the SRS and SB section of this Service Manual. WARNING: ● To avoid rendering the SRS inoperative, which could increase the risk of personal injury or death in the event of a collision which would result in air bag inflation, all maintenance must be performed by an authorized NISSAN/INFINITI dealer. ● Improper maintenance, including incorrect removal and installation of the SRS, can lead to personal injury caused by unintentional activation of the system. For removal of Spiral Cable and Air Bag Module, see the SRS section. ● Do not use electrical test equipment on any circuit related to the SRS unless instructed to in this Service Manual. SRS wiring harnesses can be identified by yellow and/or orange harnesses or harness connectors. Maintenance Information BKS0026G If any of following part is replaced, always replace with new* one. If it's not (or fail to do so), the electrical system may not be operated properly. *: New one means a virgin control unit that has never been energized on-board. RHD MODELS ● ● ● ● ● ● BCM (Models without Intelligent Key system) Intelligent Key unit (Models with Intelligent Key system) ECM IPDM E/R Combination meter EPS control unit LHD MODELS ● ● ● BCM (Models without Intelligent Key system) Intelligent Key unit (Models with Intelligent Key system) ECM BCS-2 BCM (BODY CONTROL MODULE) BCM (BODY CONTROL MODULE) System Description PFP:284B2 A BKS0026R BCM (Body Control Module) controls the operation of various electrical units installed on the vehicle. BCM FUNCTION B BCM has a combination switch reading function for reading the operation of combination switches (light, wiper washer, turn signal) in addition to the function for controlling the operation of various electrical components. Also, it functions as an interface that receives signals from the A/C auto amplifier, and sends signals to ECM using CAN communication. C COMBINATION SWITCH READING FUNCTION BCM reads combination switch (headlamp, wiper and washer, turn signal) status, and controls various electrical components according to the results. BCM reads information of 20 switches and 5 diagnostic results by combining five output terminals (Output 1 5) and five input terminals (Input 1 - 5). Refer to LT-114, "COMBINATION SWITCH" . SYSTEMS CONTROLLED BY BCM ● ● ● ● ● ● ● ● ● Power door lock system. Refer to BL-16, "POWER DOOR LOCK SYSTEM" . Super lock system. Refer to BL-59, "POWER DOOR LOCK — SUPER LOCK —" . Multi-remote control system. Refer toBL-111, "MULTI-REMOTE CONTROL SYSTEM" . Power window system. Refer to GW-32, "POWER WINDOW SYSTEM" . Interior room lamp timer. Refer to LT-150, "INTERIOR ROOM LAMP" . Warning chime. Refer to DI-52, "WARNING CHIME" . Turn signal and hazard warning lamps. Refer to LT-98, "TURN SIGNAL AND HAZARD WARNING LAMPS" . Rear wiper. Refer to WW-49, "REAR WIPER AND WASHER SYSTEM" . Rear fog lamp. Refer to LT-88, "REAR FOG LAMP" . SYSTEMS CONTROLLED BY BCM AND IPDM E/R ● ● ● ● ● ● NATS (Nissan Anti-Theft System). Refer to BL-215, "NATS (Nissan Anti-Theft System)" . Front wiper. Refer to WW-4, "FRONT WIPER AND WASHER SYSTEM" . Front washer. Refer toWW-4, "FRONT WIPER AND WASHER SYSTEM" . Rear window defogger. Refer to GW-12, "REAR WINDOW DEFOGGER" . Front fog lamp. Refer to LT-73, "FRONT FOG LAMP" . Headlamp washer. Refer to WW-73, "HEADLAMP WASHER" . D E F G H I J BCS L SYSTEMS CONTROLLED BY BCM AND INTELLIGENT KEY UNIT ● Intelligent Key system. Refer toBL-130, "INTELLIGENT KEY SYSTEM" . BCS-3 M BCM (BODY CONTROL MODULE) INPUT/OUTPUT System Multi-remote control system Intelligent Key system Power door lock system/ Super lock system Input Remote controller Output ● Door lock actuator ● Back door release actuator ● Turn signal lamp (LH, RH) ● Door lock actuator ● Back door release actuator ● Turn signal lamp ● Combination meter ● Door lock actuator ● Back door release actuator ● Power window main switch ● Front power window switch (passenger side) Intelligent Key unit ● Key switch ● Door lock/unlock switch ● Door switches Power supply (IGN) to power window system Ignition power supply ● Power window main switch Power supply (BAT) to power window system Battery power supply ● Front power window switch (passenger side) Headlamp Combination switch IPDM E/R (headlamp relay) Tail lamp Combination switch IPDM E/R (tail lamp relay) Rear fog lamp Combination switch Rear combination lamp (Refer fog) Turn signal lamp Combination switch Hazard warning lamp ● Key switch ● Intelligent Key unit (key switch signal) ● Remote controller ● Door lock/unlock switch ● Front door switch (driver side) ● Door switches ● Key switch ● Intelligent Key unit (key switch signal) ● Front door switch (driver side) ● Combination switch ● Key switch ● Intelligent Key unit (key switch signal) ● Front door switch (driver side) ● Combination switch ● Combination meter ● Rain sensor Light warning chime Front wiper with rain sensor Turn signal lamps ● Combination meter ● Turn signal lamps ● Combination meter Hazard switch Interior room lamp timer Ignition key warning chime ● Interior room lamp Combination meter (warning buzzer) Combination meter (warning buzzer) IPDM E/R (front wiper relays) Front washer Combination switch Washer motor Rear wiper Combination switch Rear wiper motor Rear washer Combination switch Washer motor Headlamp washer Headlamp washer switch Headlamp washer relay (via IPDM E/R) ● A/C auto amp. (Rear window defogger switch) (with auto amp). ● Heater control panel (Rear window defogger switch) (with manual A/C). Rear window defogger BCS-4 IPDM E/R (rear window defogger relay) BCM (BODY CONTROL MODULE) System Input Output A/C switch signal A/C auto amp. ECM Blower fan switch signal A/C auto amp. ECM A CAN COMMUNICATION CONTROL B CAN communication is capable of dealing with a lot of information through the two communication lines (CAN L line, CAN H line) connecting control units in the system. Also each control unit functions to transmit and receive data, and reads necessary information only. C BCM STATUS CONTROL BCM changes its status depending on the operation status in order to save power consumption. D 1. CAN communication status ● With ignition switch ON, CAN communicates with other control units normally. ● Control by BCM is being operated properly. E ● When ignition switch is OFF, switching to sleep mode is possible. ● Even when ignition switch is OFF, if CAN communication with IPDM E/R and combination meter is active, CAN communication status is active. F 2. Pre-sleep status ● This is the status to stop CAN communication when ignition switch is turned OFF. ● It transmits sleep request signal to IPDM E/R and combination meter. G ● Two seconds after CAN communication with another control unit stops, it switches to CAN communication inactive status. H 3. CAN communication inactive status ● With ignition switch OFF, CAN communication is not active. ● With ignition switch OFF, control performed only by BCM is active. I ● Two seconds after CAN communication with another control unit stops, it switches to CAN communication inactive status. 4. Sleep status J ● BCM is activated with low-current-consumption mode. ● CAN communication is not active. ● When CAN communication operation is detected, it switches to CAN communication status. BCS ● When control performed only by BCM is required by switch, it shifts to CAN communication inactive mode. ● It changes combination switch reading function. L M BCS-5 BCM (BODY CONTROL MODULE) CAN Communication BKS0026S SYSTEM DESCRIPTION CAN (Controller Area Network) is a serial communication line for real time application. It is an on-vehicle multiplex communication line with high data communication speed and excellent error detection ability. Many electronic control units are equipped onto a vehicle, and each control unit shares information and links with other control units during operation (not independent). In CAN communication, control units are connected with 2 communication lines (CAN H line, CAN L line) allowing a high rate of information transmission with less wiring. Each control unit transmits/receives data but selectively reads required data only. CAN Communication Unit BKS0026T Refer to LAN-21, "CAN COMMUNICATION" . BCS-6 BCM (BODY CONTROL MODULE) Schematic BKS0026U A B C D E F G H I J BCS L M MKWA4378E BCS-7 BCM (BODY CONTROL MODULE) MKWA4379E BCS-8 BCM (BODY CONTROL MODULE) CONSULT-II Function (BCM) BKS0026V CONSULT-II can display each diagnostic item using the diagnostic modes shown following. Data is received and transmitted via the control module communication line. BCM diagnostic test item Check item, diagnostic test mode Inspection by part Content A B WORK SUPPORT Setting of each function can be changed. SELF-DIAGNOSTIC RESULTS BCM performs self-diagnosis of CAN communication. DATA MONITOR Displays the input data of BCM in real time. CAN DIAG SUPPORT MNTR The results of transmit/receive diagnosis of CAN communication can be read. ACTIVE TEST Gives a drive signal to a load to check the operation. ECU PART NUMBER Displays BCM parts number CONFIGURATION Performs BCM configuration read/write functions. C D E F CONSULT–II INSPECTION PROCEDURE Refer to GI-36, "CONSULT-II Start Procedure" . G ITEMS OF EACH PART ×:Applicable Diagnostic test mode (Inspection by part) System and item “TEST ITEM” screen WORK SUPPORT SELFDIAG RESULT S ACTIVE TEST × × × × KEY WARN ALM × × LIGHT WARN ALM × × Back door warning chime BACK DR OPEN WARN × × Door warning indicator DOOR WARNING IND × × INT LAMP × × MULTI REMOTE ENT × Power door lock system DOOR LOCK Rear window defogger REAR DEFOGGER Ignition key warning chime Light warning chime BUZZER Interior room lamp timer Multi-remote control system Headlamp Wiper Turn signal lamp Hazard warning lamp × DATA MONITOR CAN DIAG SUPPORT MNTR HEAD LAMP × × × WIPER × × × FLASHER × × × × A/C switch signal Blower fan switch signal AIR CONDITIONER × Intelligent Key system INTELLIGENT KEY × COMB SW × Combination switch Theft warning system (Dealer option) BCM THEFT ALM H ECU PARTS NUMBER J BCS L M × × BCM BCS-9 × × I × BCM (BODY CONTROL MODULE) Configuration BKS0026W DESCRIPTION There are two CONFIGURATION functions, as follows. READ CONFIGURATION is a function for confirming vehicle configuration written on BCM. WRITE CONFIGURATION is a function for writing a vehicle configuration to BCM. CAUTION: ● When replacing BCM, completely perform WRITE CONFIGURATION with CONSULT-II. ● Orderly complete the procedure of WRITE CONFIGURATION. ● If you set incorrect WRITE CONFIGURATION, vehicle operation will not be correct. ● Configuration is different by each vehicle model, confirm configuration in each case. READ CONFIGURATION PROCEDURE CAUTION: If CONSULT-II is used with no connection of CONSULT CONVERTER, malfunctions might be detected in self-diagnosis depending on control unit which carry out CAN communication. 1. With the ignition switch OFF, connect CONSULT-II and CONSULT-II CONVERTER to the data link connector, then turn the ignition switch ON. PAIA0070E 2. Touch “START(NISSAN BASED VHCL)”. BCIA0029E 3. Touch “BCM” on “SELECT SYSTEM” screen. If “BCM” is not indicated, go to GI-38, "CONSULT-II Data Link Connector (DLC) Circuit" . BCIA0030E BCS-10 BCM (BODY CONTROL MODULE) 4. Touch “BCM” on “SELECT TEST SYSTEM” screen. A B C MKIB0394E D 5. Touch “CONFIGURATION” on “SELECT DIAG MODE” screen. E F G MKIB2357E 6. Touch “E11”, and “OK” on “VEHICLE SELECT” screen. For canceling, touch “CANCEL” on “VEHICLE SELECT” screen. NOTE: Confirm vehicle model on GI-47, "IDENTIFICATION PLATE" . H I J MKIB2358E 7. BCS Touch “READ CONFIGURATION” on “SELECT CINFIG ITEM” screen. L M MKIB2362E BCS-11 BCM (BODY CONTROL MODULE) 8. Configuration of brand-new BCM are printed out automatically. Configuration of brand-new BCM before executing “WRITE CONFIGURATION” is as follows. MANUAL SET ITEM ITEM SET VAL HANDLE LHD DTRL OFF I-KEY WITHOUT RAIN SENSOR WITHOUT AIR COND HEATER PTC HEATER WITHOUT THEFT ALARM WITHOUT RETRACT H/TOP WITHOUT AUTO SET ITEM RR DEF SET YET H/L WASH FREQ 5 DONGLE OFF SUPER LOCK WITH DOOR LCK SET 1 5 DOOR LCK SET 2 7 LIT OFF TIMER ON AUTO LT BEEP WITH AUTO LT TIMER — MKIB2359E 9. TURN SIG TIME WITHOUT DTRL SW LBEAM WITHOUT DTRL SW RELAY WITH RR ADD WIPE WITHOUT Touch “BACK” on “ READ CONFIGURATION“screen. MKIB0775E BCS-12 BCM (BODY CONTROL MODULE) WRITE CONFIGURATION PROCEDURE CAUTION: If CONSULT-II is used with no connection of CONSULT CONVERTER, malfunctions might be detected in self-diagnosis depending on control unit which carry out CAN communication. 1. With the ignition switch OFF, connect CONSULT-II and CONSULT-II CONVERTER to the data link connector, then turn the ignition switch ON. A B C D PAIA0070E 2. E Touch “START(NISSAN BASED VHCL)”. F G H BCIA0029E 3. I Touch “BCM” on “SELECT SYSTEM” screen. If “BCM” is not indicated, go to GI-38, "CONSULT-II Data Link Connector (DLC) Circuit" . J BCS L BCIA0030E 4. Touch “BCM” on “SELECT TEST SYSTEM” screen. M MKIB0394E BCS-13 BCM (BODY CONTROL MODULE) 5. Touch “CONFIGURATION” on “SELECT DIAG MODE” screen. MKIB2357E 6. Touch “E11”, and “OK” on “VEHICLE SELECT” screen. For canceling, touch “CANCEL” on “VEHICLE SELECT” screen. NOTE: Confirm vehicle model on GI-47, "IDENTIFICATION PLATE" . MKIB2358E 7. Touch “WRITE CONFIGURATION” on “SELECT CONFIG ITEM” screen. MKIB2362E 8. Touch “YES”. For canceling, touch “NO”. MKIB0762E BCS-14 BCM (BODY CONTROL MODULE) 9. Select the configuration for the vehicle on “WRITE CONFIGURATION”screen based on the following ITEM LIST. < ITEM LIST> ITEM SET VAL NOTE LHD For LHD models RHD For RHD models ON With day time light system*1 OFF Without day time light system*1 WITH With Intelligent Key system WITHOUT Without Intelligent Key system WITH With rain sensor*1 WITHOUT Without rain sensor*1 AUTO A/C With auto A/C*1 MANUAL A/C With manual A/C*1 HEATER Heater*1 WITH With PTC heater*2 WITHOUT Without PTC heater*2 WITH With theft warning system*3 WITHOUT Without theft warning system*3 RETRACT H/ WITH With retractable hard top TOP*4 WITHOUT Without retractable hard top HANDLE DTRL (Day time Running Light) I-KEY (Intelligent Key system) A B C MKIB0769E D RAIN SENSOR AIR COND E F G PTC HEATER THEFT ALARM H I *1: Refer to bottom illustration to specify the items for “SET VAL”. *2: Models with PTC heater have PTC heater relays. Refer to Harness Layout, PG-59, "ENGINE ROOM HARNESS/K9K ENGINE MODELS" , to confirm whether PTC heater relays are equipped or not. *3: Confirm with the customer if the vehicle is equipped with the optional parts. *4: Always select “WITHOUT”, because retractable hard top is not equipped to E11. J BCS L M MKIB2315E 1. Daytime light relay 4. A/C button 2. Light and rain sensor For canceling, touch “CANCEL”. 10. Touch “CONFIG” on “WRITE CONFIGURATION“screen. BCS-15 3. In-vehicle sensor (for Auto A/C) BCM (BODY CONTROL MODULE) CAUTION: Make sure to touch “CONFIG” even if the indicated configuration of brand new BCM is same as the desirable configuration. If not, configuration which is set automatically by selecting vehicle model can not be memorized. 11. Touch “OK” on “WRITE CONFIGURATION”screen. When touched “CANCEL”, go to previous screen. MKIB0770E 12. Wait until the next screen during setting. MKIB0771E 13. WRITE CONFIGURATION results are printed out automatically. Check “WRITE CONFIGURATION” is correctly executed by comparing sheet automatically printed out with desirable configuration. MKIB2360E BCS-16 BCM (BODY CONTROL MODULE) 14. Touch “OK” on “WRITE CONFIGURATION“screen. WRITE CONFIGURATION is completed. A B C MKIB0773E D CAN Communication Inspection With CONSULT-II (Self-Diagnosis) BKS0026X 1. CHECK SELF-DIAGNOSTIC RESULT E CAUTION: If CONSULT-II is used with no connection of CONSULT-II CONVERTER, malfunctions might be detected in self-diagnosis depending on control unit which carry out CAN communication. 1. Connect to CONSULT-II, and select “BCM” on “SELECT SYSTEM” screen. 2. Select “BCM” on “SELECT TEST ITEM” screen. 3. Touch “SELF-DIAG RESULTS”, on “SELECT DIAG MODE” screen. 4. Check display content in self-diagnostic results. CONSULT-II display code Diagnosis item F G H TRANSMIT DIAG ECM I IPDM E/R U1000 METER / M&A I-KEY J VDC / TCS / ABS Contents displayed BCS No malfunction>>INSPECTION END Malfunction in CAN communication system>>After printing the monitor items, go to “CAN System”. Refer to LAN-3, "Precautions When Using CONSULT-II" . Removal and Installation of BCM BKS0026Y CAUTION: Always replace with new* BCM when the BCM replacement is required. *: New one means virgin control unit that has never been energized on-board. M REMOVAL NOTE: If possible, before removing BCM, retrieve current BCM configuration to use for reference when configuring brand-new BCM after installation. Refer to BCS-10, "Configuration" . 1. Remove instrument upper panel. Refer to IP-4, "INSTRUMENT PANEL ASSEMBLY" . 2. Disconnect BCM connector. 3. Remove BCM. MKIB2365E BCS-17 L BCM (BODY CONTROL MODULE) INSTALLATION ● Install in the reverse order of removal. BCS-18 BODY, LOCK & SECURITY SYSTEM I BODY SECTION BL BODY, LOCK & SECURITY SYSTEM A B C D CONTENTS PRECAUTIONS .......................................................... 5 Precautions for Supplemental Restraint System (SRS) “AIR BAG” and “SEAT BELT PRE-TENSIONER” .................................................................. 5 Maintenance Information .......................................... 5 RHD MODELS ...................................................... 5 LHD MODELS ....................................................... 5 Precautions .............................................................. 5 CLIP AND FASTENER ............................................... 6 List of Table .............................................................. 6 HOOD ......................................................................... 7 Fitting Adjustment .................................................... 7 FRONT END HEIGHT ADJUSTMENT AND LATERAL/LONGITUDINAL CLEARANCE ADJUSTMENT .................................................................... 7 SURFACE MISMATCH ADJUSTMENT ................ 7 Removal and Installation .......................................... 8 REMOVAL ............................................................. 8 INSTALLATION ..................................................... 9 Removal and Installation of Hood Lock Control ....... 9 REMOVAL ............................................................. 9 INSTALLATION ................................................... 10 Hood Lock Control Inspection .................................11 RADIATOR CORE SUPPORT .................................. 13 Removal and Installation ........................................ 13 REMOVAL ........................................................... 13 INSTALLATION ................................................... 14 FRONT FENDER ...................................................... 15 Removal and Installation ........................................ 15 REMOVAL ........................................................... 15 INSTALLATION ................................................... 15 POWER DOOR LOCK SYSTEM .............................. 16 Component Parts and Harness Connector Location... 16 System Description ................................................ 17 OPERATION ....................................................... 17 DOOR LOCK AND UNLOCK SWITCH OPERATION .................................................................... 18 BACK DOOR SWITCH OPERATION ................. 18 BACK DOOR RELEASE ACTUATOR OPERATION .................................................................... 18 BL-1 BACK DOOR SWITCH OPERATION .................. 18 KEY REMINDER SYSTEM ................................. 18 UNLOCK LINK FUNCTION ................................. 18 BACK DOOR OPENER OPERTION ................... 19 AUTO RE-LOCK FUNCTION .............................. 19 ANTI-HIJACK FUNCTION ................................... 19 CAN Communication .............................................. 19 SYSTEM DESCRIPTION .................................... 19 CAN Communication Unit ....................................... 19 Schematic (Without Intelligent Key System) ........... 20 Wiring Diagram — D/LOCK — (Without Intelligent Key System) ........................................................... 21 Schematic (With Intelligent Key System) ................ 26 Wiring Diagram — D/LOCK — (With Intelligent Key System) .................................................................. 27 Terminal and Reference Value for BCM ................. 33 CONSULT- II Inspection Procedure ........................ 34 CONSULT- II Application Items .............................. 34 WORK SUPPORT ............................................... 34 DATA MONITOR ................................................. 34 ACTIVE TEST ..................................................... 34 Work Flow ............................................................... 35 TROUBLE DIAGNOSES CHART BY SYMPTOM/WITHOUT INTELLIGENT KEY SYSTEM... 35 TROUBLE DIAGNOSES CHART BY SYMPTOM/WITH INTELLIGENT KEY SYSTEM .......... 36 Check Power Supply and Ground Circuit of BCM... 37 Check Door Lock / Unlock Switch .......................... 38 Check Key Switch /Without Intelligent Key System... 39 Check Key Switch and Ignition Knob Switch/With Intelligent Key System ............................................ 40 Check Door Lock Actuator Circuit .......................... 41 Check Door Lock Actuator ...................................... 42 DRIVER SIDE ..................................................... 42 PASSENGER SIDE ............................................. 43 REAR LH SIDE ................................................... 44 REAR RH SIDE ................................................... 45 Check Door Switch ................................................. 46 DRIVER SIDE ..................................................... 46 PASSENGER SIDE ............................................. 48 E F G H BL J K L M REAR LH SIDE .................................................... 50 REAR RH SIDE ................................................... 52 BACK DOOR SWITCH ........................................ 53 Check Back Door Switch ........................................ 55 Check Back Door Release Actuator ....................... 57 Check Door Lock/Unlock Switch Indicator .............. 58 POWER DOOR LOCK — SUPER LOCK — ............ 59 ComponentParts and Harness Connector Location... 59 System Description ................................................. 60 OPERATION ........................................................ 60 DOOR LOCK AND UNLOCK SWITCH OPERATION .................................................................... 61 BACK DOOR SWITCH OPERATION .................. 61 BACK DOOR RELEASE ACTUATOR OPERATION .................................................................... 61 BACK DOOR SWITCH OPERATION .................. 61 KEY REMINDER SYSTEM ................................. 61 UNLOCK LINK FUNCTION ................................. 61 BACK DOOR OPENER OPERTION ................... 61 AUTO RE-LOCK FUNCTION .............................. 62 ANTI-HIJACK FUNCTION ................................... 62 SUPER LOCK OPERATION ............................... 62 OUTLINE ............................................................. 62 OPERATION ........................................................ 62 CAN Communication .............................................. 63 SYSTEM DESCRIPTION .................................... 63 CAN Communication Unit ....................................... 63 Schematic –S/LOCK – (Without Intelligent Key System) ........................................................................ 64 Wiring Diagram — S/LOCK — (Without Intelligent Key System) ........................................................... 65 Schematic – S/LOCK – (With Intelligent Key System) ........................................................................ 71 Wiring Diagram — S/LOCK — (With Intelligent Key System) .................................................................. 72 Terminal and Reference Value for BCM ................. 78 CONSULT- II Inspection Procedure ........................ 79 CONSULT- II Application Items .............................. 79 WORK SUPPORT ............................................... 79 DATA MONITOR .................................................. 79 ACTIVE TEST ..................................................... 79 Work Flow ............................................................... 79 Trouble Diagnoses .................................................. 81 PRELIMINARY CHECK/WITHOUT INTELLIGENT KEY SYSTEM ........................................... 81 SYMPTOM CHART/WITHOUT INTELLIGENT KEY SYSTEM ...................................................... 82 PRELIMINARY CHECK/WITH INTELLIGENT KEY SYSTEM ...................................................... 83 SYMPTOM CHART/WITH INTELLIGENT KEY SYSTEM .............................................................. 84 Check Power Supply and Ground Circuit ............... 85 Check Door Lock / Unlock Switch .......................... 86 Check Key Switch /Without Intelligent Key System... 87 Check Key Switch And Ignition Knob Switch/With Intelligent Key System ............................................ 88 Check Power Door Lock / Unlock Output Signal ... 89 Check Super Lock Output Signal ........................... 90 Check Door Lock Actuator ...................................... 91 DRIVER SIDE ......................................................91 PASSENGER SIDE .............................................92 REAR LH SIDE ....................................................93 REAR RH SIDE ...................................................94 Check Super Lock Actuator ....................................95 DRIVER SIDE ......................................................95 PASSENGER SIDE .............................................96 REAR LH SIDE ....................................................97 REAR RH SIDE ...................................................98 Check Door Switch .................................................99 DRIVER SIDE ......................................................99 PASSENGER SIDE ........................................... 101 REAR LH SIDE .................................................. 103 REAR RH SIDE ................................................. 105 Check Back Door Switch ...................................... 107 Check Back Door Release Actuator ..................... 109 MULTI-REMOTE CONTROL SYSTEM ................... 111 ComponentParts and Harness Connector Location. 111 System Description ............................................... 112 INPUTS .............................................................. 112 OUTLINE ........................................................... 112 Schematic ............................................................. 114 Wiring Diagram — MULTI — ................................ 115 Terminal and Reference Value for BCM ................ 119 CONSULT- II Inspection Procedure ...................... 120 CONSULT- II Application Items ............................. 120 DATA MONITOR ................................................ 120 Work Flow ............................................................. 120 Trouble Diagnosis Chart by Symptom .................. 121 Check Remote controller ...................................... 122 Check Door Switch ............................................... 122 DOOR SWITCH DRIVER SIDE ......................... 122 DOOR SWITCH PASSENGER SIDE ................123 DOOR SWITCH REAR LH ................................ 124 DOOR SWITCH REAR RH ................................ 125 BACK DOOR RELEASE ACTUATOR (BACK DOOR SWITCH) ................................................ 126 Key Switch Check ................................................. 127 Hazard Reminder Check ....................................... 128 Remote Controller Battery Replacement .............. 129 INTELLIGENT KEY SYSTEM ................................. 130 ComponentParts and Harness Connector Location.130 System Description ............................................... 132 DOOR LOCK FUNCTION .................................. 132 REMOTE CONTROL ENTRY FUNCTIONS ...... 133 ENGINE STARTUP FUNCTION ........................ 134 WARNING AND ALARM FUNCTION ................ 135 CHANGE SETTINGS FUNCTION ..................... 137 INTELLIGENT KEY REGISTRATION ................ 137 STEERING LOCK UNIT REGISTRATION ......... 137 Schematic —I/KEY— ............................................ 138 Wiring Diagram — I/KEY— ................................... 139 Terminals and Reference Value for INTELLIGENT KEY UNIT ............................................................. 149 Terminals and Reference Value for Steering Lock unit ........................................................................ 151 Terminal and Reference Value for BCM ................ 151 Trouble Diagnosis Procedure ................................ 153 PRELIMINALY CHECK ...................................... 153 BL-2 WORK FLOW .................................................... 154 CONSULT-II Function (INTELLIGENT KEY) ........ 155 CONSULT-II Inspection Procedure ...................... 155 BASIC OPERATION ......................................... 155 CONSULT-II Application Items ............................. 155 SELF-DIAGNOSTIC RESULTS ........................ 155 DATA MONITOR ............................................... 155 ACTIVE TEST ................................................... 156 WORK SUPPORT ............................................. 156 Trouble Diagnosis Symptom Chart ...................... 157 KEY WARNING LAMP (GREEN) ILLUMINATES. 157 KEY WARNING LAMP (RED) ILLUMINATES ... 157 KEY WARNING LAMP DOES NOT ILLUMINATE. 158 SELF-DIAGNOSIS RESULTS ARE NOT DISPLAYED ............................................................ 158 ENGINE START CONDITION CHECK ............. 158 DOOR LOCK/UNLOCK FUNCTION MALFUNCTION .................................................................. 159 REMOTE KEYLESS ENTRY FUNCTION MALFUNCTION ........................................................ 159 HAZARD AND BUZZER REMINDER FUNCTION MALFUNCTION ....................................... 161 WARNING CHIME FUNCTION MALFUNCTION. 161 WARNING LAMP FUNCTION MALFUNCTION. 163 Check CAN Communication System ................... 163 Check Power Supply and Ground Circuit ............. 164 Check Ignition Switch Signal Circuit ..................... 164 Check Key Switch (Intelligent Key Unit Input) ...... 165 Check Key Switch (BCM Input) ............................ 167 Check Ignition Knob Switch ................................. 168 Check Door Request Switch ................................ 170 Check Back Door Request Switch ....................... 172 Check Door Switch ............................................... 174 DRIVER SIDE ................................................... 174 PASSENGER SIDE ........................................... 176 REAR LH SIDE ................................................. 178 REAR RH SIDE ................................................. 180 BACK DOOR SWITCH ..................................... 181 Check Intelligent Key Warning Buzzer Circuit ...... 183 Check Outside Key Antenna (Driver Side and Passenger Side) ......................................................... 184 Check Outside Key Antenna (Back Door) ............ 185 Check Inside Key Antenna ................................... 187 Check Steering Lock Unit ..................................... 188 Check Warning Lamp ........................................... 191 Check Warning Buzzer in Combination Meter ..... 191 Check Hazard Function ........................................ 191 Check Headlamp Function ................................... 191 Check Stop Lamp Switch ..................................... 192 Removal and Installation of Intelligent key unit .... 193 REMOVAL ......................................................... 193 INSTALLATION ................................................. 193 Intelligent Key Inspection ..................................... 193 INTELLIGENT KEY DISASSEMBLY AND ASSEMBLY ....................................................... 193 REMOTE CONTROLLER BATTERY INSPECTION .................................................................. 194 DOOR ..................................................................... 195 Fitting Adjustment ................................................ 195 FRONT DOOR .................................................. 195 REAR DOOR ..................................................... 196 STRIKER ADJUSTMENT .................................. 196 Removal and Installation ...................................... 196 REMOVAL OF FRONT DOOR .......................... 196 INSTALLATION ................................................. 196 REMOVAL OF REAR DOOR ............................ 197 INSTALLATION ................................................. 197 Front Door Weatherstrip ....................................... 198 REMOVAL ......................................................... 198 INSTALLATION ................................................. 198 Front Door Weatherstrip ....................................... 199 REMOVAL ......................................................... 199 INSTALLATION ................................................. 199 FRONT DOOR LOCK ............................................. 200 Component Parts Location ................................... 200 Removal and Installation ...................................... 200 REMOVAL ......................................................... 200 Disassembly and Assembly .................................. 203 DOOR KEY CYLINDER ASSEMBLY ................ 203 OUTSIDE HANDLE ........................................... 203 REAR DOOR LOCK ............................................... 204 Component Parts Location ................................... 204 Removal and Installation ...................................... 204 REMOVAL ......................................................... 204 BACK DOOR .......................................................... 207 Fitting Adjustment ................................................. 207 VERTICAL/LATERAL CLEARANCE (SURFACE DIFFERENCE) ADJUSTMENT ......................... 207 Back Door Assembly ............................................ 208 REMOVAL ......................................................... 208 INSTALLATION ................................................. 208 INSPECTION .................................................... 208 Back Door Striker .................................................. 208 REMOVAL ......................................................... 208 INSTALLATION ................................................. 209 Back Door Stay Assembly .................................... 209 REMOVAL ......................................................... 209 INSTALLATION ................................................. 209 RemovalandInstallationofBackDoorWeatherstrip. 210 REMOVAL ......................................................... 210 INSTALLATION ................................................. 210 BACK DOOR LOCK ............................................... 211 Removal and Installation ...................................... 211 BACK DOOR LOCK ASSEMBLY ...................... 211 BACK DOOR HANDLE ASSEMBLY ................. 211 FUEL FILLER LID OPENER ................................... 212 Removal and Installation of Fuel Filler Lid Opener. 212 REMOVAL ......................................................... 212 INSTALLATION ................................................. 213 THEFT WARNING SYSTEM ................................... 214 Wiring Diagram — THEFT — / PRWIRE .............. 214 NATS (NISSAN ANTI-THEFT SYSTEM) ................ 215 Component Parts and Harness Connector Location (Hatchback) .......................................................... 215 System Description ............................................... 217 OPERATING DESCRIPTION ............................ 217 SECURITY INDICATOR .................................... 217 System Composition ............................................. 218 BL-3 A B C D E F G H BL J K L M ECM Re-communicating Function ........................ 218 Wiring Diagram —NATS— ................................... 219 WITHOUT INTELLIGENT KEY SYSTEM .......... 219 WITH INTELLIGENT KEY SYSTEM ................. 220 Terminals and Reference Value for Steering Lock Unit/With Intelligent Key System .......................... 222 Terminals and Reference Value for Intelligent Key Unit/With Intelligent Key System .......................... 222 Terminals and Reference Value for BCM/Without Intelligent Key System .......................................... 223 CONSULT-II .......................................................... 224 CONSULT-II INSPECTION PROCEDURE ........ 224 CONSULT-II DIAGNOSTIC TEST MODE FUNCTION .................................................................. 224 CHECK RESULT ITEM CHART FOR NATS IMMU FUNCTION ............................................. 225 Diagnosis Procedure ............................................ 226 WORK FLOW .................................................... 226 BL-4 Trouble Diagnosis Symptom Chart ....................... 227 MODELS WITHOUT INTELLIGENT KEY SYSTEM ................................................................... 227 MODELS WITH INTELLIGENT KEY SYSTEM .228 Security Indicator Inspection ................................. 228 Diagnostic Procedure 1 ......................................... 229 Diagnostic Procedure 2 ......................................... 229 MODELS WITHOUT INTELLIGENT KEY SYSTEM ................................................................... 229 MODELS WITH INTELLIGENT KEY SYSTEM .231 Diagnostic Procedure 3 ......................................... 233 Diagnostic Procedure 4 ......................................... 233 Diagnostic Procedure 5 ......................................... 234 Diagnostic Procedure 6 ......................................... 234 Diagnostic Procedure 7 ......................................... 236 Removal and Installation NATS Antenna Amp. ..... 237 REMOVAL .......................................................... 237 INSTALLATION .................................................. 237 PRECAUTIONS PRECAUTIONS PFP:00001 Precautions for Supplemental Restraint System (SRS) “AIR BAG” and “SEAT BELT PRE-TENSIONER” A BIS000HV The Supplemental Restraint System such as “AIR BAG” and “SEAT BELT PRE-TENSIONER”, used along with a front seat belt, helps to reduce the risk or severity of injury to the driver and front passenger for certain types of collision. Information necessary to service the system safely is included in the SRS and SB section of this Service Manual. WARNING: ● To avoid rendering the SRS inoperative, which could increase the risk of personal injury or death in the event of a collision which would result in air bag inflation, all maintenance must be performed by an authorized NISSAN/INFINITI dealer. ● Improper maintenance, including incorrect removal and installation of the SRS, can lead to personal injury caused by unintentional activation of the system. For removal of Spiral Cable and Air Bag Module, see the SRS section. ● Do not use electrical test equipment on any circuit related to the SRS unless instructed to in this Service Manual. SRS wiring harnesses can be identified by yellow and/or orange harnesses or harness connectors. Maintenance Information B C D E F BIS000HW If any of following part is replaced, always replace with new* one. If it's not (or fail to do so), the electrical system may not be operated properly. *: New one means a virgin control unit that has never been energized on-board. G RHD MODELS H ● ● ● ● ● ● BCM (Models without Intelligent Key system) Intelligent Key unit (Models with Intelligent Key system) ECM IPDM E/R Combination meter EPS control unit BL J LHD MODELS ● ● ● BCM (Models without Intelligent Key system) Intelligent Key unit (Models with Intelligent Key system) ECM L Precautions ● ● K BIS000HX After installing removed lids or doors, be sure to adjust hinges and mount points so that lids or doors can open and close properly. Confirm parts for proper lubrication, damage or wear. Lubricate, repair or replace as necessary. BL-5 M CLIP AND FASTENER CLIP AND FASTENER List of Table Symbol No. PFP:76906 BIS000HY Shape Removal and installation PIIA1350J PIIA1354J MIIB0153E BL-6 HOOD HOOD Fitting Adjustment PFP:F5100 A BIS000HZ B C D E F G H BL J K L PIIB5563J FRONT END HEIGHT ADJUSTMENT AND LATERAL/LONGITUDINAL CLEARANCE ADJUSTMENT 1. Remove hood lock. Rotate bumper rubber to adjust height until hood becomes 1 to 1.5 mm lower than the fender. 2. Position hood lock and engage striker. Check hood lock and striker for looseness. Tighten lock bolts to the specified torque. CAUTION: Adjust the clearance between hood and other parts so that the dimensional difference left and right is as follows. Hood (B) - Headlamp (B) Hood (C) - Headlamp (C) : 1.5 mm or less : 1.0 mm or less PIIB5564J SURFACE MISMATCH ADJUSTMENT 1. Release hood lock, and adjust surface level difference of hood, fender, and headlamp according to the fitting standard dimension, using RH and LH bumper rubbers. BL-7 M HOOD Hood (C) - Fender (C) 2. 3. 4. 5. : -1.0 - 1.0 mm Install hood lock, and move hood lock laterally until the centers of striker and lock become vertical when viewed from the front. Make sure the secondary latch is securely engaged with the secondary striker from either the dead weight of the hood (free-fall from approx. 200 mm height), or by applying light pressure (approx. 3 kg). CAUTION: Do not drop hood from a height of 300 mm or more. Move hood lock-up and down until striker smoothly engages the lock when the hood is closed. After adjustment, tighten lock bolts to the specified torque. Removal and Installation BIS000I0 PIIB5565J 1. Hood hinge 2. Hood stay 3. Radiator core seal rubber 4. Hood assembly 5. Hood lock 6. Hood stay holder REMOVAL Hood Assembly 1. 2. Disconnect washer hose at the connecting point. Remove hinge nuts on hood and remove hood assembly. PIIB2529J Hood Hinge 1. 2. 3. Remove front fender. Refer to BL-15, "Removal and Installation" . Remove cowl top cover. Remove hood assembly. BL-8 HOOD 4. Remove bolts and then remove hood hinge. A B C PIIB2530J D INSTALLATION ● ● ● Perform installation in the reverse order of removal while being careful of the following items while performing the work. Apply Anti-Corrosion Wax M-97 Super or comparable product to the hood hinge, hood ledge, and hood assembly. After installing, perform hood fitting adjustment. Refer to BL-7, "Fitting Adjustment" . Removal and Installation of Hood Lock Control E F BIS000I1 G H BL J K L M PIIB5566J 1. Hood lock cable 2. Clip 3. Clip 4. Radiator core support upper 5. Washer hose 6. Hood legge reinforcement REMOVAL Hood Lock 1. Remove front bumper. Refer to EI-10, "Removal and Installation" . BL-9 HOOD 2. Remove hood lock bolts. PIIB2532J 3. Remove hood lock cable from hood lock. Hood Lock Mounting Reinforcement 1. 2. 3. Remove front bumper. Refer to EI-4, "Removal and Installation" . Remove crash zone censor. Remove bolts, and then remove hood lock mounting reinforcement. PIIB5569J Hood Lock Cable 1. 2. 3. 4. 5. 6. Remove front bumper. Refer to EI-10, "Removal and Installation" . Remove fender protector. Refer to EI-14, "Removal and Installation" . Remove hood lock, and remove hood lock cable from hood lock. Remove radiator core upper support and hood ledge clips, and then remove hood lock cable. Remove hood opener on bottom right or left of instrument panel, and then remove hood lock cable. Remove grommet on lower dashboard, and pull out hood lock cable from passenger room side. CAUTION: While pulling the cable, be careful not to damage (peel) hood opener cable outer surface on edges of body through hole. PIIB2534J INSTALLATION ● ● Perform installation in the reverse order of removal while being careful of the following items while performing the work. After installing, perform hood fitting adjustment. Refer to BL-7, "Fitting Adjustment" . Hood Lock Mounting Reinforcement ● When installing hood lock mounting reinforcement, loosen hood bolts, and then tighten bolts in the order shown in the figure. BL-10 HOOD Bolt No. 1 to 5. Tightening torque (N·m, (kgm)) : 20.6 - 26.5 (2.1 - 2.7) A B C PIIB5568J D Hood Lock Cable 1. 2. 3. Pass hood lock cable through the opening while keeping the winding radius 100 mm or larger. After confirming grommet is properly positioned, push it securely into the hole. Apply sealant (POS seal) to area on the grommet indicated with the * mark. E F G PIIA0173E 4. 5. H Install cable securely to lock. After installing, check hood lock adjustment and hood opener operation. BL J K PIIB5570J Hood Lock Control Inspection BIS000I2 CAUTION: If hood lock cable is bent or deformed, replace it. 1. Confirm hood lock secondary latch securely engages secondary striker by releasing it from a height of approximately 200 mm. PIIB6101J 2. While operating the hood opener carefully, make sure the front end of the hood is lifted by approximately 20 mm. Also, make sure the hood opener returns to the original position. BL-11 L M HOOD 3. Inspect hood lock grease, and if insufficient, apply grease to the area shown in the figure. PIIB5571J BL-12 RADIATOR CORE SUPPORT RADIATOR CORE SUPPORT Removal and Installation PFP:62500 A BIS000I3 B C D E F G PIIB5572J 1. Radiator core support upper 2. Air guide (LH) 3. Air guide (RH) 4. bamper reinforcement 5. Food lock mounting reinforcement 6. Radiator core support upper H REMOVAL Radiator Core Upper Support 1. 2. 3. 4. 5. 6. 7. 8. 9. BL Remove crash zone sensor. Remove air duct. Remove bumper reinforcement. Remove food lock assembly. Remove air guide. Remove clip from washer tunk inlet, and then remove washer tunk inlet. Remove ambient sencor. Riemove horn. Remove bolts, and then remove radiator core upper support. J K L Radiator Core Lower Support 1. 2. 3. 4. 5. Remove front bamper reinforcement. Refer to EI-10, "Removal and Installation" . Remove under cover. Remove front bumper lower clip. Refer to EI-4, "Removal and Installation" . Tie cord to all radiator core upper supports of the radiator and condenser. NOTE: To prevent the compressor and radiator from being dropped when the radiator core lower support is removed. Remove bolts, and then remove radiator core lower supports. M PIIB5573J 6. Remove air guide (RH) bottom clips, and remove radiator core lower supports from passenger room. BL-13 RADIATOR CORE SUPPORT INSTALLATION Install in the reverse order of removal. BL-14 FRONT FENDER FRONT FENDER Removal and Installation PFP:63100 A BIS000I4 B C D E F G PIIB5574J 1. Front fender H REMOVAL 1. 2. 3. 4. 5. 6. Remove side turn signal lamp. Refer to LT-111, "Removal and Installation of Side Turn Signal Lamp" . Remove front bumper. Refer to LT-32, "Removal and Installation" . Remove headlamps. Refer to LT-32, "Removal and Installation" . Remove front fender finisher. Remove fender protector front front side clip. Remove bolts and then front fender. BL J INSTALLATION K Install in the reverse order of removal. L M BL-15 POWER DOOR LOCK SYSTEM POWER DOOR LOCK SYSTEM Component Parts and Harness Connector Location PFP:24814 BIS000I5 MIIB1367E BL-16 POWER DOOR LOCK SYSTEM 1. BCM (Body Control Module) M57, M58, M59 2. Front door lock actuator Driver side: D11 Passenger side: D28 3. Rear door lock actuator RH: D65 LH: D45 A 4. Front door switch RH: B29 LH: B14 5. Rear door switch RH: B42 LH: B19 6. Key switch and ignition knob switch connector M34 (With Intelligent Key system) B Key switch connector M33 (Without Intelligent Key system) 8. Intelligent Key unit M60 (With Intelligent Key system) 9. 7. 10. Back door switch D104 11. Back door release actuator B46 System Description Door lock/unlock switch M54 C 12. Door lock relay M20 (With Intelligent Key system) BIS000I7 OPERATION D Power is supplied (Without Intelligent Key System) ● through to 40A fusible link (letter J , located in the fusible link box) E ● to BCM terminal 74 and 79. ● through 10A fuse [No.9, located in the fuse box (J/B)] F ● to key switch terminal 2. Power is supplied (With Intelligent Key System) ● through to 40A fusible link (letter J , located in the fusible link box) G ● to BCM terminal 74 and 79. ● through 10A fuse [No.13, located in the fuse box (J/B)] ● to key switch and ignition knob switch terminal 1 and 3. H When the key switch is ON (Ignition key is inserted in ignition key cylinder), power is supplied (Without Intelligent Key system) ● through key switch terminal 1 BL ● to BCM terminal 3. When the key switch is ON (Ignition key is inserted in ignition key cylinder), power is supplied. (With Intelligent Key system) J ● through key switch and ignition knob switch terminal 4 ● to BCM terminal 3. ● to Intelligent Key unit terminal 7. K When the ignition switch is ON or START, power is supplied ● through 10A fuse [No. 5, located in the fuse block (J/B)] L ● to BCM terminal 24. Ground is supplied ● through BCM terminals 2 and 70 M ● to body ground M21 and M66. When the front door switch LH (LHD Models) or RH (RHD Models) is ON (door is open), ground is supplied ● through BCM terminal 29 ● through front door switch LH (LHD Models) or RH (RHD Models) terminal 1 ● to front door switch LH (LHD Models) or RH (RHD Models) case ground. When the front door switch RH (LHD Models) or LH (RHD Models) is ON (door is open), ground is supplied ● through BCM terminal 30 ● through front door switch RH (LHD Models) or LH (RHD Models) terminal 1 ● to front door switch RH (LHD Models) or LH (RHD Models) case ground. When the rear door switch LH is ON (door is open), ground is supplied ● through BCM terminal 59 ● through rear door switch LH terminal 1 ● to rear door switch LH case ground. BL-17 POWER DOOR LOCK SYSTEM When the rear door switch RH is ON (door is open), ground is supplied ● through BCM terminal 60 ● through rear door switch RH terminal 1 ● to rear door switch RH case ground. DOOR LOCK AND UNLOCK SWITCH OPERATION When door lock/unlock switch is in LOCK position, ground is supplied ● through BCM terminal 6. ● through door lock/unlock switch terminal 1 and 3 ● to body grounds M21 and M66 With power and ground supplied, doors are locked. When door lock/unlock switch is in UNLOCK position, ground is supplied ● through BCM terminal 25 ● through door lock/unlock switch terminal 2 and 3 ● to body grounds M21 and M66 With power and ground supplied, all doors are unlocked. Lock/unlock switch indicated by LED when key in switch is on or on with timer. BACK DOOR SWITCH OPERATION When the back door switch is turn on, back door is opened Ground is supplied ● through BCM terminal 5 ● through back door switch terminal 1 and 2 ● to body ground B13, B28, B38 and B48. BACK DOOR RELEASE ACTUATOR OPERATION When the back door release actuator receives a release signal from BCM Ground is supplied ● through BCM terminal 68 ● through back door release actuator terminal 4 and 3 ● to body ground B13, B28, B38 and B48. BACK DOOR SWITCH OPERATION When the back door switch is opened, ground is supplied ● through BCM terminal 10 ● through back door switch terminal 2 and 1 ● to body ground B13, B28, B38 and B48. KEY REMINDER SYSTEM If the ignition key is in the ignition key cylinder and driver door is open, setting door lock/unlock switch, key or remote controller to “LOCK” locks the door once but then immediately unlocks all doors. UNLOCK LINK FUNCTION When this function is activated, if the car is locked by door lock/unlock switch, opening the driver or passenger side door from the inside handle will override the lock state and unlock the whole car. (This function will be deactivate if anti-hijack function is activated.) Selectable Function Door Lock/unlock switch How to change setting Press unlock for more than 4 seconds Contents Unlock link activate/deactivate How to confirm Buzzer should sound for 0.2 seconds BL-18 POWER DOOR LOCK SYSTEM BACK DOOR OPENER OPERTION Back door can be opened with back door switch: When all door are unlocked, or When back door request switch is pushed (With Intelligent Key system). AUTO RE-LOCK FUNCTION The BCM is equipped with an auto re-lock function, when no further user action occurs after an full or partial unlock, the doors will automatically re-lock after 2 minutes (default value). The 2 minutes timer of auto re-lock will be reset if unlock button from the key fob is pressed. The auto re-lock function will not be activated under the following states. ● Key switch is ON ● Mechanical key is inserted ● Any door is opened NOTE: For the Intelligent Key system models, this function will be deactivated. A B C D E ANTI-HIJACK FUNCTION With the anti-hijack function enabled, the first unlock request send from key fob will partially unlock only the driver side door (released super lock if equipped). Then if a second unlock signal is send, then all remaining doors will be unlocked. CAN Communication F BIS000I8 SYSTEM DESCRIPTION G CAN (Controller Area Network) is a serial communication line for real time application. It is an on-vehicle multiplex communication line with high data communication speed and excellent error detection ability. Many electronic control units are equipped onto a vehicle, and each control unit shares information and links with other control units during operation (not independent). In CAN communication, control units are connected with 2 communication lines (CAN H line, CAN L line) allowing a high rate of information transmission with less wiring. Each control unit transmits/receives data but selectively reads required data only. H CAN Communication Unit BL BIS000I9 Refer to LAN-27, "CAN Communication Unit" . J K L M BL-19 POWER DOOR LOCK SYSTEM Schematic (Without Intelligent Key System) BIS000IA MIWA0688E BL-20 POWER DOOR LOCK SYSTEM Wiring Diagram — D/LOCK — (Without Intelligent Key System) BIS000IB A B C D E F G H BL J K L M MIWA0689E BL-21 POWER DOOR LOCK SYSTEM MIWA0690E BL-22 POWER DOOR LOCK SYSTEM A B C D E F G H BL J K L M MIWA0691E BL-23 POWER DOOR LOCK SYSTEM MIWA0692E BL-24 POWER DOOR LOCK SYSTEM A B C D E F G H BL J K L M MIWA0693E BL-25 POWER DOOR LOCK SYSTEM Schematic (With Intelligent Key System) BIS000IC MIWA0694E BL-26 POWER DOOR LOCK SYSTEM Wiring Diagram — D/LOCK — (With Intelligent Key System) BIS000ID A B C D E F G H BL J K L M MIWA0695E BL-27 POWER DOOR LOCK SYSTEM MIWA0696E BL-28 POWER DOOR LOCK SYSTEM A B C D E F G H BL J K L M MIWA0697E BL-29 POWER DOOR LOCK SYSTEM MIWA0698E BL-30 POWER DOOR LOCK SYSTEM A B C D E F G H BL J K L M MIWA0699E BL-31 POWER DOOR LOCK SYSTEM MIWA0700E BL-32 POWER DOOR LOCK SYSTEM Terminal and Reference Value for BCM BIS000IE A Terminal Wire color 2 B 3 O GR* 5 Y 6 LG 10 P Signal Input/ Output Condition Voltage (V) (Approx.) — — 0 Key switch Input Key inserted (ON) → key removed from Ignition key cylinder (OFF) Battery voltage → 0 Back door switch Input Back door switch open operation Door lock / unlock switch (Lock signal) Input Item Ground Back door switch Input Lock operation (ON) 0 Other than above (OFF) 5 Open (ON) → Close (OFF) Input/ Output 19* L CAN-H 24 O Ignition power supply Input 25 BR Door lock/unlock switch (Unlock signal) Input 5→0 — B C D 0→5 — Ignition switch (ON or START position) Battery voltage Unlock operation (ON) 0 Other than above (OFF) 5 29 LG Front door switch LH Input Door open (ON) → close (OFF) 0 → Battery voltage 30 BR Front door switch RH Input Door open (ON) → close (OFF) 0 → Battery voltage 32 V Door lock status indicator Output Goes OFF→ Illuminates (Ignition switch ON and all door closed) 0 → Battery voltage Input/ Output — — E F G H 39* R CAN-L 59 G Rear door switch LH Input Door open (ON) → close (OFF) 0 → Battery voltage 60 L Rear door switch RH Input Door open (ON) → close (OFF) 0 → Battery voltage 67 Y Door lock actuator unlock (Passenger and rear LH, RH doors) Output Door lock / unlock switch Unlock operation 0 → Battery voltage J 68 O Back door release actuator Output Door lock/unlock switch (Back door release switch) Open operation Battery voltage → 0 K 70 B Ground (Power) — — 0 74 Y Battery power supply (BCM) Input — Battery voltage 76 BR Door lock actuator unlock (DR side door) Output Door lock / unlock switch Unlock operation 0 → Battery voltage 77 SB Door lock actuator lock signal (All doors) Output Door lock/unlock switch & remote controller lock operation 0 → Battery voltage 79 Y Battery power supply (Power) Input — *: With Intelligent Key system BL-33 Battery voltage BL L M POWER DOOR LOCK SYSTEM CONSULT- II Inspection Procedure BIS000IF Refer to GI-36, "CONSULT-II Start Procedure" . CONSULT- II Application Items BIS000IG WORK SUPPORT Supported Item Description SECURITY DOOR LOCK SET Anti-hijack function mode can be changed in this mode. AUTO LOCK SET Auto locking function mode can be changed in this mode. Security Door Lock Set Anti hijack function ON OFF Activation Deactivation Auto Lock Set Auto locking function MODE1 MODE2 MODE3 MODE4 MODE5 MODE6* MODE7* MODE8* 1 minute 2 minutes 3 minutes 4 minutes 5 minutes – – – *: These mode are not supported. DATA MONITOR Monitored Item Description IGN ON SW Indicates [ON/OFF] condition of ignition switch. PUSH SW (*1) Indicates [ON/OFF] condition of ignition knob switch. KEY IN SW (*2) Indicates [ON/OFF] condition of key switch. CDL LOCK SW Indicates [ON/OFF] condition of lock signal from door lock/ unlock switch. CDL UNLOCK SW Indicates [ON/OFF] condition of unlock signal from door lock/ unlock switch. DOOR SW-DR Indicates [ON/OFF] condition of front door switch (driver side). DOOR SW-AS Indicates [ON/OFF] condition of front door switch (passenger side). DOOR SW-RR Indicates [ON/OFF] condition of rear door switch LH. DOOR SW-RL Indicates [ON/OFF] condition of rear door switch RH. BACK DOOR SW Indicates [ON/OFF] condition of back door switch. TRNK OPNR SW Indicates [ON/OFF] condition of back door switch. *1: Models with Intelligent Key System. *2: Models without Intelligent Key System. ACTIVE TEST Monitored Item Description DOOR LOCK This test is able to check all door lock actuator (except for back door) lock / unlock operation. These actuator lock / unlock when “LOCK” or “UNLOCK” on CONSULT-II screen is touched. DOOR LOCK IND This test is able to check door lock / unlock switch's indicator illumination. TRUNK / BACK DOOR This test is able to check back door release actuator open operation. These actuator open when “OPEN” on CONSUT-II screen is touched. BL-34 POWER DOOR LOCK SYSTEM Work Flow 1. 2. 3. 4. 5. BIS000IH Check the symptom and customer's requests. Understand the outline of system. Refer to BL-17, "System Description" . According to the trouble diagnosis, repair or replace the cause of the malfunction. Refer to BL-35, "TROUBLE DIAGNOSES CHART BY SYMPTOM/WITHOUT INTELLIGENT KEY SYSTEM" or BL-36, "TROUBLE DIAGNOSES CHART BY SYMPTOM/WITH INTELLIGENT KEY SYSTEM" . Does power door lock system operate normally? YES: GO TO 5. NO: GO TO 2. INSPECTION END. TROUBLE DIAGNOSES CHART BY SYMPTOM/WITHOUT INTELLIGENT KEY SYSTEM NOTE: Always check the “Work Flow” before troubleshooting. Refer to BL-35, "Work Flow" . Symptom Power door lock does not operate with door lock / unlock switch. Malfunctioning system BL-37 2. Check door lock / unlock switch. BL-38 3. Check front door lock actuator (driver side). BL-42 BCS-17 1. Check door lock actuator. BL-42 Front door lock actuator (driver side) does not operate. (All other door lock actuators operate properly) 1. Check front door lock actuator (driver side). BL-42 1. Check door lock actuator circuit. BL-41 2. Replace BCM. 2. Check door switch. 3. Replace BCM. Back door does not open. But power door lock operates properly. F G BCS-17 BL-39 BL-55 2. Check back door release actuator. BL-57 1. Check door lock/unlock switch indicator. 2. Replace BCM. BL BL-46 BCS-17 1. Check back door switch. 3. Replace BCM. Door lock/unlock switch indicator does not illuminate. (All other door lock system is “OK”) D H 1. Check key switch. Key reminder system does not operate. C E Specific door lock actuator does not operate. All door lock actuator (except driver side) does not operate. B Refer to page 1. Check power supply and ground circuit of BCM. 4. Replace BCM. A BCS-17 J K BL-58 BCS-17 L M BL-35 POWER DOOR LOCK SYSTEM TROUBLE DIAGNOSES CHART BY SYMPTOM/WITH INTELLIGENT KEY SYSTEM NOTE: Always check the “Work Flow” before troubleshooting. Refer to BL-35, "Work Flow" . Symptom Power door lock does not operate with door lock / unlock switch. Malfunctioning system Refer to page 1. Check power supply and ground circuit of BCM. BL-37 2. Check door lock / unlock switch. BL-38 3. Check door lock actuator (driver side). BL-42 4. Replace BCM. BCS-17 Specific door lock actuator does not operate. 1. Check door lock actuator. BL-42 Front door lock actuator (driver side) does not operate. (All other door lock actuators operate properly) 1. Check front door lock actuator (driver side). BL-42 1. Check door lock actuator circuit. BL-41 All door lock actuator (except driver side) does not operate. Key reminder system does not operate. 2. Replace BCM. 1. Check key switch. BL-40 2. Check door switch. BL-46 3. Replace BCM. Back door does not open. But power door lock operates properly. BCS-17 1. Check back door switch. BL-55 2. Check back door release actuator. BL-57 3. Replace BCM. Door lock/unlock switch indicator does not illuminate. (All other door lock system is “OK”) BCS-17 1. Check door lock/unlock switch indicator. 2. Replace BCM. BL-36 BCS-17 BL-58 BCS-17 POWER DOOR LOCK SYSTEM Check Power Supply and Ground Circuit of BCM BIS000II First perform the “SELF-DIAG RESULTS” in “BCM” with CONSULT-II, then perform the each trouble diagnosis of malfunction system indicated “SELF-DIAG RESULTS” of “BCM”, Refer toBCS-9, "CONSULT-II Function (BCM)". 1. FUSE INSPECTION Check 10A fuse [No.5, located in fuse block (J/B)] ● Check 40A fusible link (letter J located in the fuse and fusible link box). ● Check 10A fuse [No.9, located in fuse block (J/B)] (Without Intelligent Key system) ● Check 10A fuse [No.13, located in fuse block (J/B)] (With Intelligent Key system) NOTE: Refer to BL-16, "Component Parts and Harness Connector Location" . OK or NG OK >> GO TO 2. NG >> PG-4, "POWER SUPPLY ROUTING CIRCUIT"If fuse is blown out, be sure to eliminate cause of malfunction before installing new fuse. Refer to. A B ● 2. CHECK POWER SUPPLY CIRCUIT 1. 2. Turn ignition switch ON. Check voltage between BCM connector M57, M59 terminals 24, 74, 79 and ground. 24 – Ground 74 – Ground 79 – Ground C D E F G : Battery voltage : Battery voltage : Battery voltage H BL OK or NG OK >> GO TO 3. NG >> Check BCM power supply circuit for open or short. J MIIB1111E K 3. CHECK GROUND CIRCUIT 1. 2. 3. Turn ignition switch OFF. Disconnect BCM connector. Check continuity between BCM connector M57, M59 terminals 2, 70 and ground. 2 – Ground 70 – Ground L :Continuity should exist. :Continuity should exist. M OK or NG OK >> Power supply and ground circuit is OK. NG >> Check BCM ground circuit for open or short. MIIB0093E BL-37 POWER DOOR LOCK SYSTEM Check Door Lock / Unlock Switch BIS000IJ 1. CHECK DOOR LOCK / UNLOCK SWITCH SIGNAL With CONSULT- II Check door lock / unlock switch input signal (“CDL LOCK SW” “CDL UNLOCK SW”) in “DATA MONITOR” mode with CONSULT- II. When door lock/unlock switch is turned to LOCK: CDL LOCK SW Þ ON When door lock/unlock switch is turned to UNLOCK: CDL UNLOCK SW Þ ON SIIA1566E Without CONSULT- II Operate door lock / unlock switch, check voltage between BCM connector M57 terminal 6, 25 and ground. Terminals (Wire color) Connector (+) (-) 6 M57 Ground 25 Condition Voltage (V) (Approx.) Lock 0 Neutral / Unlock 5 Unlock 0 Neutral / Lock 5 OK or NG OK >> Door lock / unlock switch is OK. NG >> GO TO 2. MIIB0317E 2. CHECK DOOR LOCK/UNLOCK SWITCH 1. 2. 3. Turn ignition switch OFF. Disconnect door lock / unlock switch connector. Check continuity between door lock / unlock switch terminals. Terminals Door lock/ unlock switch 2 3 1 Condition Continuity Unlock Yes Neutral / Lock No Lock Yes Neutral / Unlock No OK or NG OK >> Check the following. ● Ground circuit for door lock / unlock switch ● Harness for open or short between BCM and door lock / unlock switch. NG >> Replace door lock / unlock switch. BL-38 MIIB1369E POWER DOOR LOCK SYSTEM Check Key Switch /Without Intelligent Key System BIS000IK 1. CHECK KEY SWITCH INPUT SIGNAL A With CONSULT-II Check key switch input signal “KEY IN SW” in “DATA MONITOR” mode with CONSULT- II. B When key is inserted in ignition key cylinder: KEY IN SW Þ ON When key is removed from ignition key cylinder: KEY IN SW Þ OFF C D Without CONSULT- II Check voltage between BCM connector and ground. Connector M57 Terminal (Wire color) (+) (-) 3 Ground Condition Voltage (V) (Approx.) Key is inserted Battery voltage Key is removed 0 E F OK or NG OK >> Key switch is OK. NG >> GO TO 2. G MIIB0499E H 2. CHECK KEY SWITCH 1. 2. 3. Turn ignition switch OFF. Disconnect key switch connector. Check continuity between key switch terminals. Terminals Key switch 1 2 BL Condition Continuity Key is inserted YES Key is removed NO OK or NG? OK >> Check the following. ● 10A fuse [No. 9, located in fuse block (J/B)]. ● Harness for open or short between key switch and fuse. ● Harness for open or short between BCM and key switch. NG >> Replace key switch. BL-39 J K L MIIB1370E M POWER DOOR LOCK SYSTEM Check Key Switch and Ignition Knob Switch/With Intelligent Key System BIS000IL 1. KEY SWITCH AND IGNITION KNOB SWITCH INSPECTION With CONSULT-II Display “PUSH SW” on DATA MONITOR screen, and check if ONOFF display is linked to ignition knob switch operation. When ignition knob is pushed When ignition knob is released : PUSH SW ON : PUSH SW OFF PIIB1360E Without CONSULT- II Check voltage between BCM connector and ground. Connector Terminal (Wire color) M57 (+) (-) 3 Ground Condition Voltage (V) (Approx.) Key is inserted Battery voltage Key is removed 0 OK or NG OK >> Key switch is OK. NG >> GO TO 2. MIIB0499E 2. KEY SWITCH POWER SUPPLY CIRCUIT INSPECTION 1. 2. 3. Remove mechanical key from ignition knob. Disconnect key switch and ignition knob switch connector. Check voltage between key switch and ignition knob switch connector and ground. Key switch and ignition knob switch connector Terminal M34 2 Ground Voltage (V) (Approx.) Battery voltage OK or NG OK >> GO TO 3. NG >> Repair or replace key switch power supply circuit. PIIB6598E BL-40 POWER DOOR LOCK SYSTEM 3. KEY SWITCH OPERATION INSPECTION 1. 2. A Insert mechanical key into ignition knob. Check continuity between key switch and ignition knob switch connector M34 terminal. B Terminal Key switch and ignition knob switch 3 Condition Continuity Key is inserted Yes Key is removed No 4 C OK or NG OK >> GO TO 4. NG >> Replace key switch. D MIIB1372E E 4. KEY SWITCH CIRCUIT INSPECTION 1. 2. Disconnect Intelligent Key unit connector. Check continuity between Intelligent Key unit connector and key switch and ignition knob switch connector. A Intelligent Key unit connector M60 3. Terminal Key switch and ignition knob switch connector Terminal 7 M34 4 Continuity H Yes BL Check continuity between key switch connector and ground. J Key switch and ignition knob switch connector Terminal M34 4 Continuity MIIB1373E Ground K No OK or NG OK >> Key switch is OK. NG >> Repair or replace harness between Intelligent Key unit and key switch and ignition knob switch. Check Door Lock Actuator Circuit M Disconnect BCM connector. Check continuity between BCM connector M59 terminal 67 and front door lock actuator (passenger side) connector D28 terminal 2. 67 – 2 : Continuity should exist. Check continuity between BCM connector M59 terminal 67 and ground. 67 – Ground L BIS000IM 1. CHECK HARNESS CONTINUITY 3. G B B 1. 2. F : Continuity should not exist. OK or NG OK >> Check the condition of the harness and the connector. NG >> Repair or replace harness. MIIB0412E BL-41 POWER DOOR LOCK SYSTEM Check Door Lock Actuator BIS000IN DRIVER SIDE 1. CHECK DOOR LOCK ACTUATOR 1. 2. 3. Turn ignition switch OFF. Disconnect front door lock actuator (driver side) connector. Operate door lock / unlock switch, check voltage between front door lock actuator (driver side) connector D11 terminal 4, 5 and ground. Terminals (Wire color) Connector (+) (-) 5 D11 4 Ground Condition Voltage (V) (Approx.) Unlock 0 → Battery voltage → 0 Lock 0 → Battery voltage → 0 MIIB0396E OK or NG OK >> Replace front door lock actuator (driver side). NG >> GO TO 2. 2. CHECK HARNESS CONTINUITY 1. 2. Disconnect BCM connector. Check continuity between BCM connector M59 terminals 76, 77 and front door lock actuator (driver side) connector D11 terminals 4, 5. 76 – 5 77 – 4 3. : Continuity should exist. : Continuity should exist. Check continuity between BCM connector M59 terminals 76, 77 and ground. 76 – Ground 77 – Ground : Continuity should not exist. : Continuity should not exist. OK or NG OK >> Check the condition of the harness and the connector. NG >> Repair or replace harness. BL-42 MIIB0397E POWER DOOR LOCK SYSTEM PASSENGER SIDE A 1. CHECK DOOR LOCK ACTUATOR 1. 2. 3. Turn ignition switch OFF. Disconnect front door lock actuator (passenger side) connector. Operate door lock / unlock switch, check voltage between front door lock actuator (passenger side) connector D28 terminal 2, 3 and ground. Connector Terminals (Wire color) (+) 3 D28 2 C Condition Voltage (V) (Approx.) Lock 0 → Battery voltage → 0 Unlock 0 → Battery voltage → 0 (-) Ground B D E MIIB0398E OK or NG OK >> Replace front door lock actuator (passenger side). NG >> GO TO 2. G 2. CHECK HARNESS CONTINUITY 1. 2. H Disconnect BCM connector. Check continuity between BCM connector M59 terminals 67, 77 and front door lock actuator (passenger side) connector D28 terminals 2, 3. BL 67 – 2 77 – 3 3. F : Continuity should exist. : Continuity should exist. J Check continuity between BCM connector M59 terminals 67, 77 and ground. 67 – Ground 77 – Ground : Continuity should not exist. : Continuity should not exist. OK or NG OK >> Check the condition of the harness and the connector. NG >> Repair or replace harness. K L MIIB0399E M BL-43 POWER DOOR LOCK SYSTEM REAR LH SIDE 1. CHECK DOOR LOCK ACTUATOR 1. 2. 3. Turn ignition switch OFF. Disconnect rear door lock actuator LH connector. Operate door lock / unlock switch, check voltage between rear door lock actuator LH connector D45 terminal 4, 5 and ground. Connector Terminals (Wire color) (+) 4 D45 5 Condition Voltage (V) (Approx.) Lock 0 → Battery voltage → 0 Unlock 0 → Battery voltage → 0 (-) Ground MIIB0324E OK or NG OK >> Replace rear door lock actuator LH. NG >> GO TO 2. 2. CHECK HARNESS CONTINUITY 1. 2. Disconnect BCM connector. Check continuity between BCM connector M59 terminals 67, 77 and rear door lock actuator LH connector D45 terminals 4, 5. 67– 5 77– 4 3. : Continuity should exist. : Continuity should exist. Check continuity between BCM connector M59 terminals 67, 77 and ground. 67 – Ground 77 – Ground : Continuity should not exist. : Continuity should not exist. OK or NG OK >> Check the condition of the harness and the connector. NG >> Repair or replace harness. BL-44 MIIB0325E POWER DOOR LOCK SYSTEM REAR RH SIDE A 1. CHECK DOOR LOCK ACTUATOR 1. 2. 3. Turn ignition switch OFF. Disconnect rear door lock actuator RH connector. Operate door lock / unlock switch, check voltage between rear door lock actuator RH connector D65 terminal 2, 3 and ground. Connector Terminals (Wire color) (+) 2 D65 3 C Condition Voltage (V) (Approx.) Unlock 0 → Battery voltage → 0 Lock 0 → Battery voltage → 0 (-) Ground B D E MIIB0326E OK or NG OK >> Replace rear door lock actuator RH. NG >> GO TO 2. G 2. CHECK HARNESS CONTINUITY 1. 2. H Disconnect BCM connector. Check continuity between BCM connector M59 terminals 67, 77 and rear door lock actuator RH connector D65 terminals 2, 3. BL 67 – 2 77 – 3 3. F : Continuity should exist. : Continuity should exist. J Check continuity between BCM connector M59 terminals 67, 77 and ground. 67 – Ground 77 – Ground : Continuity should not exist. : Continuity should not exist. OK or NG OK >> Check the condition of the harness and the connector. NG >> Repair or replace harness. K L MIIB0327E M BL-45 POWER DOOR LOCK SYSTEM Check Door Switch BIS000IO DRIVER SIDE 1. CHECK DOOR SWITCH INPUT SIGNAL With CONSULT- II Check door switch “DOOR SW-DR” in “DATA MONITOR” mode with CONSULT- II. When front door (driver side) is opened: DOOR SW-DR Þ ON When front door (driver side) is close: DOOR SW-DR Þ OFF MIIB1050E Without CONSULT- II Check voltage between BCM connector and ground. Connector M57 Terminals (Wire color) (+) (-) 29 Ground Condition Voltage (V) (Approx.) Open 0 Close Battery voltage OK or NG OK >> Front door switch LH is OK. NG >> GO TO 2. MIIB0342E 2. CHECK HARNESS CONTINUITY 1. 2. 3. Turn ignition switch OFF. Disconnect BCM and front door switch LH connector. Check continuity between BCM connector M57 terminal 29 and front door switch LH connector B14 terminal 1. 29 – 1 4. : Continuity should exist. Check continuity between BCM connector M57 terminal 29 and ground. 29 – Ground : Continuity should not exist. OK or NG OK >> GO TO 3. NG >> Repair or replace harness. MKIB0849E BL-46 POWER DOOR LOCK SYSTEM 3. CHECK DOOR SWITCH A Check continuity between door switch terminal 1 and body ground part of door switch. Terminal 1 Body ground part of door switch Condition Continuity Pushed No Released Yes B OK or NG OK >> GO TO 4. NG >> Replace door switch. C D PIIA3351E E 4. CHECK BCM OUTPUT SIGNAL 1. 2. Connect BCM connector. Check voltage between BCM connector M57 terminal 29 and ground. 29 – Ground F : Battery voltage OK or NG OK >> Check door switch ground condition. NG >> Replace BCM. G H BL MIIB0342E J K L M BL-47 POWER DOOR LOCK SYSTEM PASSENGER SIDE 1. CHECK DOOR SWITCH INPUT SIGNAL With CONSULT- II Check door switch “DOOR SW-AS” in “DATA MONITOR” mode with CONSULT- II. When front door (passenger side) is opened: DOOR SW-AS Þ ON When front door (passenger side) is close: DOOR SW-AS Þ OFF MIIB1051E Without CONSULT- II Check voltage between BCM connector M57 terminal 30 and ground. Terminal (Wire color) Connector M48 (+) (-) 30 Ground Condition Voltage (V) (Approx.) Open 0 Close Battery voltage OK or NG OK >> Front door switch RH is OK. NG >> GO TO 2. MIIB0344E 2. CHECK HARNESS CONTINUITY 1. 2. 3. Turn ignition switch OFF. Disconnect BCM and front door switch RH connector. Check continuity between BCM connector M57 terminal 30 and front door switch RH connector B29 terminal 1. 30 – 1 4. : Continuity should exist. Check continuity between BCM connector M57 terminal 30 and ground. 30 – Ground : Continuity should not exist. OK or NG OK >> GO TO 3. NG >> Repair or replace harness. MKIB0850E BL-48 POWER DOOR LOCK SYSTEM 3. CHECK DOOR SWITCH A Check continuity between door switch terminal 1 and body ground of door switch. Terminal 1 Ground Condition Continuity Pushed No Released Yes B OK or NG OK >> GO TO 4. NG >> Replace door switch. C D PIIA3351E E 4. CHECK BCM OUTPUT SIGNAL 1. 2. Connect BCM connector. Check voltage between BCM connector M57 terminal 30 and ground. 30 – Ground F : Battery voltage OK or NG OK >> Check door switch ground condition. NG >> Replace BCM. G H BL MIIB0344E J K L M BL-49 POWER DOOR LOCK SYSTEM REAR LH SIDE 1. CHECK DOOR SWITCH INPUT SIGNAL With CONSULT- II Check door switch “DOOR SW-RL” in “DATA MONITOR” mode with CONSULT- II. When rear door (LH side) is opened: DOOR SW-RL Þ ON When rear door (LH side) is close: DOOR SW-RL Þ OFF MIIB1052E Without CONSULT- II Check voltage between BCM connector M58 terminal 59 and ground. Terminal (Wire color) Connector M58 (+) (-) 59 Ground Condition Voltage (V) (Approx.) Open 0 Close Battery voltage OK or NG OK >> Rear door switch LH is OK. NG >> GO TO 2. MIIB0346E 2. CHECK HARNESS CONTINUITY 1. 2. 3. Turn ignition switch OFF. Disconnect BCM and rear door switch LH connector. Check continuity between BCM connector and rear door switch LH connector. A 4. B Continuity BCM connector Terminal Rear door switch LH Terminal M58 59 B19 1 Yes Check continuity between BCM connector and ground. A Continuity BCM connector Terminal M58 59 Ground No OK or NG OK >> GO TO 3. NG >> Repair or replace harness. BL-50 MIIB1374E POWER DOOR LOCK SYSTEM 3. CHECK DOOR SWITCH A Check continuity between door switch terminal 1 and body ground of door switch. Terminals 1 Ground Condition Continuity Pushed NO Released YES B C OK or NG OK >> GO TO 4. NG >> Replace door switch. D PIIA3351E E 4. CHECK BCM OUTPUT SIGNAL 1. 2. Connect BCM connector. Check voltage between BCM connector M58 terminal 59 and ground. 59 – Ground F : Battery voltage OK or NG OK >> Check door switch ground condition. NG >> Replace BCM. G H BL MIIB0346E J K L M BL-51 POWER DOOR LOCK SYSTEM REAR RH SIDE 1. CHECK DOOR SWITCH INPUT SIGNAL With CONSULT- II Check door switch “DOOR SW-RR” in “DATA MONITOR” mode with CONSULT- II. When rear door (RH side) is opened: DOOR SW-RR Þ ON When rear door (RH side) is close: DOOR SW-RR Þ OFF MIIB1053E Without CONSULT- II Check voltage between BCM connector and ground. Terminal (Wire color) Connector M58 (+) (-) 60 Ground Condition Voltage (V) (Approx.) Open 0 Close Battery voltage OK or NG OK >> Rear door switch RH is OK. NG >> GO TO 2. MIIB0348E 2. CHECK HARNESS CONTINUITY 1. 2. 3. Turn ignition switch OFF. Disconnect BCM and rear door switch RH connector. Check continuity between BCM connector and rear door switch RH connector. A 4. B Continuity BCM connector Terminal Rear door switch RH Terminal M58 60 B42 1 Yes Check continuity between BCM connector and ground. A Continuity BCM connector Terminal M58 60 Ground No OK or NG OK >> GO TO 3. NG >> Repair or replace harness. BL-52 MIIB1375E POWER DOOR LOCK SYSTEM 3. CHECK DOOR SWITCH A Check continuity between door switch terminal 1 and body ground of door switch. Terminal 1 Ground Condition Continuity Pushed NO Released YES B OK or NG OK >> GO TO 4. NG >> Replace door switch. C D PIIA3351E E 4. CHECK BCM OUTPUT SIGNAL 1. 2. Connect BCM connector. Check voltage between BCM connector M58 terminal 60 and ground. 60 – Ground F : Battery voltage OK or NG OK >> Check door switch ground condition. NG >> Replace BCM. G H BL MIIB0348E BACK DOOR SWITCH J 1. CHECK BACK DOOR SWITCH INPUT SIGNAL 1. 2. Turn ignition switch OFF. Check voltage between BCM connector M57 terminal 10 and ground. Terminal (+) (–) 10 Ground Back door condition Voltage (V) Approx. Closed 5 Open 0 K L M OK or NG OK >> Back door switch circuit is OK. NG >> GO TO 2 MIIB0314E BL-53 POWER DOOR LOCK SYSTEM 2. CHECK BACK DOOR SWITCH HARNESS 1. 2. Disconnect back door switch connector. Check voltage between back door switch connector and ground. (Check harness for open.) Back door switch connector Terminal B46 2 Voltage (V) (Approx.) Ground Battery voltage MIIB1376E 3. 4. Disconnect BCM connector. Check continuity between back door switch connector and ground. (Check harness for short.) Back door switch connector Terminal B46 2 Continuity Ground No OK or NG OK >> GO TO 3. NG >> Repair or replace harness. MIIB1377E 3. CHECK BACK DOOR SWITCH Check continuity between back door switch terminal. Terminal Back door switch 1 2 Rear door condition Continuity Closed No Opened Yes OK or NG OK >> GO TO 4. NG >> Replace back door release actuator (back door switch). MIIB1378E 4. CHECK BACK DOOR SWITCH GROUND HARNESS Check continuity between back door switch connector and ground. Back door switch connector Terminal B46 1 Continuity Ground Yes OK or NG OK >> Check harness connection. NG >> Replace back door switch. MIIB1379E BL-54 POWER DOOR LOCK SYSTEM Check Back Door Switch BIS000IP 1. CHECK BACK DOOR SWITCH INPUT SIGNAL A With CONSULT- II Check back door switch “TRNK OPNR SW” in “DATA MONITOR” mode with CONSULT- II. B Back door switch is pushed TRNK OPNR SW : ON Back door switch is released TRNK OPNR SW : OFF C D E MIIB0350E Without CONSULT- II Check voltage between BCM connector and ground. Terminal (Wire color) Connector (+) (-) 5 Ground M57 F Condition Voltage (V) (Approx.) Pushed 0 Released 5 G H OK or NG OK >> Back door switch is OK. NG >> GO TO 2. BL MIIB0719E 2. CHECK HARNESS CONTINUITY J 1. 2. 3. K Turn ignition switch OFF. Disconnect BCM and back door switch connector. Check continuity between BCM connector and back door switch connector. A 4. BCM connector M57 B L Continuity Terminal Back door switch connector Terminal 5 D104 1 M Yes Check continuity between BCM connector and ground. A Continuity BCM connector Terminal M57 5 Ground No OK or NG OK >> GO TO 3. NG >> Repair or replace harness. BL-55 MIIB1380E POWER DOOR LOCK SYSTEM 3. CHECK BACK DOOR SWITCH Check continuity between back door switch terminals. Terminals Back door switch 1 2 Condition Continuity Pushed Yes Released No OK or NG OK >> GO TO 4. NG >> Replace back door switch. MIIB1381E 4. CHECK BCM OUTPUT SIGNAL 1. 2. Connect BCM connector. Check voltage between BCM connector M57 terminal 5 and ground. 5 – Ground : Approx. 5V OK or NG OK >> Check the condition of the harness and the connector. NG >> Replace BCM. MIIB0351E BL-56 POWER DOOR LOCK SYSTEM Check Back Door Release Actuator BIS000IQ 1. CHECK BCM OUTPUT SIGNAL A Check back door release output signal Perform (“TRUNK/BACK DOOR”) in “ACTIVE TEST” mode with CONSULT-II. B When “ACTIVE TEST” is executed, does the back door open? C OK or NG OK >> Back door release output is OK. NG >> GO TO 2. D E MIIB0354E 2. CHECK BACK DOOR RELEASE ACTUATOR 1. 2. 3. F Turn ignition switch OFF. Disconnect back door release actuator connector. Operate back door switch, check voltage between back door release actuator connector B46 terminal 4 and ground. Terminal Connector back door switch connector B46 (+) (-) 4 Ground Condition Voltage (V) (Approx.) Pushed 0 → Battery voltage →0 G H BL OK or NG OK >> GO TO 4. NG >> GO TO 3. J MIIB1382E K 3. CHECK HARNESS CONTINUITY 1. 2. Disconnect BCM connector. Check continuity between BCM connector and back door release actuator connector. A 3. BCM connector M59 L B Terminal Back door release actuator connector Terminal 68 B46 4 M Continuity Yes Check continuity between BCM connector and ground. A BCM connector Terminal M59 68 Ground Continuity MIIB1383E No OK or NG OK >> Replace BCM. NG >> Repair or replace harness. BL-57 POWER DOOR LOCK SYSTEM 4. CHECK GROUND CIRCUIT Check continuity between back door release actuator connector and ground. Back door release actuator connector Terminal B46 3 Ground Continuity Yes OK or NG OK >> Replace back door release actuator. NG >> Repair or replace harness. MIIB1384E Check Door Lock/Unlock Switch Indicator BIS00160 1. CHECK DOOR LOCK/UNLOCK SWITCH INDICATOR Check continuity between door lock/unlock switch indicator harness connector terminals 3 and 5. Terminals Continuity (+) (-) 5 3 Yes 3 5 No OK or NG OK >> Check harness for open or short between BCM and door lock/unlock switch. NG >> replace door lock/unlock switch. BL-58 MIIB1442E POWER DOOR LOCK — SUPER LOCK — POWER DOOR LOCK — SUPER LOCK — Component Parts and Harness Connector Location PFP:24814 A BIS000IW B C D E F G H BL J K L M MIIB1367E BL-59 POWER DOOR LOCK — SUPER LOCK — 1. BCM (Body control Module) M57,M58, M59 2. Front door lock actuator Driver side: D11 Passenger side: D28 3. Rear door lock actuator RH: D65 LH: D45 4. Front door switch RH: B29 LH: B14 5. Rear door switch RH: B42 LH: B19 6. Key switch and ignition knob switch connector M34 (With Intelligent Key system) 7. Key switch connector M33 (without Intelligent Key system) 8. Intelligent Key unit M60 (With Intelligent Key system) 9. Door lock/unlock switch M54 10. back door switch D104 11. Back door release actuator B46 System Description 12. Door lock relay M20 (With Intelligent Key system) BIS000IY OPERATION Power is supplied (Without Intelligent Key System) ● through to 40A fusible link (letter J , located in the fusible link box) ● to BCM terminal 74 and 79. ● through 10A fuse [No.9, located in the fuse box (J/B)] ● to key switch terminal 2. Power is supplied (With Intelligent Key System) ● through to 40A fusible link (letter J , located in the fusible link box) ● to BCM terminal 74 and 79. ● through 10A fuse [No.13, located in the fuse box (J/B)] ● to key switch and ignition knob switch terminal 1 and 3. When the key switch is ON (Ignition key is inserted in ignition key cylinder), power is supplied (Without Intelligent Key system) ● through key switch terminal 1 ● to BCM terminal 3. When the key switch is ON (Ignition key inserted key cylinder), power is supplied (With Intelligent Key system) ● through key switch and ignition knob switch terminal 4 ● to BCM terminal 3. ● to Intelligent Key unit terminal 7. When the ignition switch is ON or START, power is supplied ● through 10A fuse [No. 5, located in the fuse block (J/B)] ● to BCM terminal 24. Ground is supplied ● through BCM terminals 2 and 70 ● to body ground M21 and M66. When the front door switch LH (LHD Models) or RH (RHD Models) is ON (door is open), ground is supplied ● through BCM terminal 29 ● through front door switch LH (LHD Models) or RH (RHD Models) terminal 1 ● to front door switch LH (LHD Models) or RH (RHD Models) case ground. When the front door switch RH (LHD Models) or LH (RHD Models) is ON (door is open), ground is supplied ● through BCM terminal 30 ● through front door switch RH (LHD Models) or LH (RHD Models) terminal 1 ● to front door switch RH (LHD Models) or LH (RHD Models) case ground. When the rear door switch LH is ON (door is open), ground is supplied ● through BCM terminal 59 ● through rear door switch LH terminal 1 ● to rear door switch LH case ground. When the rear door switch RH is ON (door is open), ground is supplied ● through BCM terminal 60 BL-60 POWER DOOR LOCK — SUPER LOCK — ● ● through rear door switch RH terminal 1 to rear door switch RH case ground. A DOOR LOCK AND UNLOCK SWITCH OPERATION When door lock/unlock switch is in LOCK position, ground is supplied ● through BCM terminal 6. ● through door lock/unlock switch terminal 2 and 3 ● to body grounds M21 and M66 With power and ground supplied, doors are locked. When door lock/unlock switch is in UNLOCK position, ground is supplied ● through BCM terminal 25 ● through door lock/unlock switch terminal 2 and 3 ● to body grounds M21and M66 With power and ground supplied, all doors are unlocked. Lock/unlock switch indicated by LED when key in switch is on or on with timer. BACK DOOR SWITCH OPERATION B C D E F When the back door switch is turn on, back door is opened Ground is supplied ● through BCM terminal 5 ● through back door switch terminal 1 and 2 ● to body ground B13, B28, B38 and B48. G BACK DOOR RELEASE ACTUATOR OPERATION H When the back door release actuator receives a release signal from BCM Ground is supplied ● through BCM terminal 68 ● through back door release actuator terminal 4 and 3 ● to body ground B13, B28, B38 and B48. BL J BACK DOOR SWITCH OPERATION When the back door switch is opened, ground is supplied ● through BCM terminal 10 ● through back door switch terminal 2 and 1 ● to body ground B13, B28, B38 and B48. K L KEY REMINDER SYSTEM ● If the ignition key is in the ignition key cylinder and driver door is open, setting door lock/unlock switch, key or remote controller to “LOCK” locks the door once but then immediately unlocks all doors. UNLOCK LINK FUNCTION When this function is activated, if the car is locked by door lock/unlock switch, opening the driver or passenger side door from the inside handle will override the lock state and unlock the whole car. (This function will be deactivate if anti-hijack function is activated.) Selectable Function Door Lock/unlock switch How to change setting Press unlock for more than 4 seconds Contents Unlock link activate/deactivate How to confirm Buzzer should sound for 0.2 seconds BACK DOOR OPENER OPERTION Back door can be opened with back door switch: When all door are unlocked, or When back door request switch is pushed (With Intelligent Key system). BL-61 M POWER DOOR LOCK — SUPER LOCK — AUTO RE-LOCK FUNCTION The BCM is equipped with an auto re-lock function, when no further user action occurs after an full or partial unlock, the doors will automatically re-lock after 2 minutes (default value). The 2 minutes timer of auto re-lock will be reset if unlock button from the key fob is pressed. The auto re-lock function will not be activated under the following states. ● Key switch is ON ● Mechanical key is inserted ● Any door is opened NOTE: For the Intelligent Key system models, this function will be deactivated. ANTI-HIJACK FUNCTION With the anti-hijack function enabled, the first unlock request send from key fob will partially unlock only the driver side door (released super lock if equipped). Then if a second unlock signal is send, then all remaining doors will be unlocked. SUPER LOCK OPERATION When super lock is set, ground is supplied ● through BCM terminals 75 ● through each super lock actuators terminals 1 and 2 ● to BCM terminal 76 When super lock is released, ground is supplied ● through BCM terminal 76 ● through each super lock actuators terminals 2 and 1 ● to BCM terminals 75 Door lock and unlock switch operation When door lock/unlock switch is in LOCK position, ground is supplied OUTLINE Power door lock system with super lock and key reminder is controlled by BCM (Body Control Module). Super lock has a higher anti-theft performance than conventional power door lock systems. When super lock is in released condition, lock/unlock switch operation locks or unlocks door. When super lock is in set condition, door operation cannot lock nor unlock door. OPERATION Power Door Lock / Unlock and Super Lock Set / Release Operation by Remote Controller or Intelligent Key ● ● Pressing remote controller LOCK button will lock all doors and set super lock. (Super lock will not be set while key is inserted in the ignition key cylinder.) Pressing remote controller UNLOCK button once will unlock driver door and release super lock. Then, if an unlock signal is sent from the remote controller again, all other doors will be unlocked. Power Door Lock / Unlock and Super Lock Release Operation by Door Key Cylinder With the key inserted into driver door key cylinder, turning it to UNLOCK will unlock the door and release super lock. Power Door Lock and Super Lock Release Operation When the super lock is set, turning the ignition key switch to ON will release the super lock. All doors will unlock once, but then immediately lock again. BL-62 POWER DOOR LOCK — SUPER LOCK — CAN Communication BIS000IZ SYSTEM DESCRIPTION A CAN (Controller Area Network) is a serial communication line for real time application. It is an on-vehicle multiplex communication line with high data communication speed and excellent error detection ability. Many electronic control units are equipped onto a vehicle, and each control unit shares information and links with other control units during operation (not independent). In CAN communication, control units are connected with 2 communication lines (CAN H line, CAN L line) allowing a high rate of information transmission with less wiring. Each control unit transmits/receives data but selectively reads required data only. B CAN Communication Unit C BIS000J0 Refer to LAN-27, "CAN Communication Unit" . D E F G H BL J K L M BL-63 POWER DOOR LOCK — SUPER LOCK — Schematic – S/LOCK – (Without Intelligent Key System) BIS000J1 MIWA0701E BL-64 POWER DOOR LOCK — SUPER LOCK — Wiring Diagram — S/LOCK — (Without Intelligent Key System) BIS000J2 A B C D E F G H BL J K L M MIWA0702E BL-65 POWER DOOR LOCK — SUPER LOCK — MIWA0703E BL-66 POWER DOOR LOCK — SUPER LOCK — A B C D E F G H BL J K L M MIWA0704E BL-67 POWER DOOR LOCK — SUPER LOCK — MIWA0705E BL-68 POWER DOOR LOCK — SUPER LOCK — A B C D E F G H BL J K L M MIWA0706E BL-69 POWER DOOR LOCK — SUPER LOCK — MIWA0707E BL-70 POWER DOOR LOCK — SUPER LOCK — Schematic – S/LOCK – (With Intelligent Key System) BIS000J3 A B C D E F G H BL J K L M MIWA0708E BL-71 POWER DOOR LOCK — SUPER LOCK — Wiring Diagram — S/LOCK — (With Intelligent Key System) BIS000J4 MIWA0709E BL-72 POWER DOOR LOCK — SUPER LOCK — A B C D E F G H BL J K L M MIWA0710E BL-73 POWER DOOR LOCK — SUPER LOCK — MIWA0711E BL-74 POWER DOOR LOCK — SUPER LOCK — A B C D E F G H BL J K L M MIWA0712E BL-75 POWER DOOR LOCK — SUPER LOCK — MIWA0713E BL-76 POWER DOOR LOCK — SUPER LOCK — A B C D E F G H BL J K L M MIWA0714E BL-77 POWER DOOR LOCK — SUPER LOCK — Terminal and Reference Value for BCM Terminal Wire color 2 B 3 O (GR) 5 Y 6 LG 10 Item Ground BIS000J5 Signal Input/ Output Condition Voltage (V) (Approx.) — — 0 Key switch Input Key inserted (ON) → key removed from IGN key cylinder (OFF) Back door switch Input Release switch open operation Door lock / unlock switch (Lock signal) Input P Back door switch Input (19) L CAN-H 24 O IGN power supply Input 25 BR Door lock/unlock switch (Unlock signal) Input Battery voltage → 0 5→0 Lock operation (ON) 0 Other than above (OFF) 5 Open (ON) → Close (OFF) Input/ Output — 0→5 — Ignition switch (ON or START position) Battery voltage Unlock operation (ON) 0 Other than above (OFF) 5 29 BR Front door switch RH Input Door open (ON) → close (OFF) 0 → Battery voltage 30 LG Front door switch LH Input Door open (ON) → close (OFF) 0 → Battery voltage 32 V Door lock status indicator Output Goes OFF→ Illuminates (Ignition switch ON and all door closed) 0 → Battery voltage (39) Y CAN-L Input/ Output 59 G Rear door switch LH Input Door open (ON) → close (OFF) 0 → Battery voltage 60 L Rear door switch RH Input Door open (ON) → close (OFF) 0 → Battery voltage 67 Y Door lock actuator & super lock actuator unlock signal (Passenger and rear LH, RH doors) Output Door lock / unlock switch & remote controller unlock operation * 0 → Battery voltage 68 O Back door release actuator Output Door lock/unlock switch (Back door release switch) Open operation Battery voltage → 0 70 B Ground (Power) 74 Y BAT power supply (BCM) 75 O Super lock actuator lock signal (All doors) Output Remote controller lock operation 0 → Battery voltage 76 BR Door lock actuator & super lock actuator unlock signal (Driver side) Output Door lock / unlock switch & remote controller unlock operation * 0 → Battery voltage 77 SB Door lock actuator lock signal (All doors) Output Door lock/unlock switch & remote controller lock operation 0 → Battery voltage 79 Y BAT power supply (PW) — — — — 0 Input — Battery voltage Input (): With Intelligent Key system models *: Door lock actuator operation activated by door lock/unlock switch. BL-78 — Battery voltage POWER DOOR LOCK — SUPER LOCK — CONSULT- II Inspection Procedure BIS000J6 A Refer to GI-36, "CONSULT-II Start Procedure" . CONSULT- II Application Items BIS000J7 WORK SUPPORT B Supported Item Description SECURITY DOOR LOCK SET Anti-hijack function mode can be changed in this mode. AUTO LOCK SET Auto re-locking function mode can be changed in this mode. C Security Door Lock Set D Anti hijack function ON OFF Activation Deactivation E Auto Lock Set Auto locking function MODE1 MODE2 MODE3 MODE4 MODE5 MODE6* MODE7* MODE8* 1 minute 2 minutes 3 minutes 4 minutes 5 minutes – – – F *: These mode are not supported. DATA MONITOR G Monitored Item Description IGN ON SW Indicates [ON/OFF] condition of ignition switch. PUSH SW (*1) Indicates [ON/OFF] condition ignition knob switch. KEY IN SW (*2) Indicates [ON/OFF] condition of key switch. CDL LOCK SW Indicates [ON/OFF] condition of lock signal from door lock/ unlock switch. CDL UNLOCK SW Indicates [ON/OFF] condition of unlock signal from door lock/ unlock switch. DOOR SW-DR Indicates [ON/OFF] condition of front door switch (driver side). DOOR SW-AS Indicates [ON/OFF] condition of front door switch (passenger side). DOOR SW-RR Indicates [ON/OFF] condition of rear door switch (RH). DOOR SW-RL Indicates [ON/OFF] condition of rear door switch (LH). BACK DOOR SW Indicates [ON/OFF] condition of back door switch. TRNK OPNR SW Indicates [ON/OFF] condition of back door switch. H BL J K L *1: Models with Intelligent Key system. *2: Models without Intelligent Key system. ACTIVE TEST M Monitored Item Description DOOR LOCK This test is able to check all door lock actuator (except for back door) lock / unlock operation. Actuators lock / unlock when “LOCK” or “UNLOCK” on CONSULT-II screen is touched. SUPER LOCK This test is able to check super lock actuator lock / unlock operation. Actuators lock / unlock when “LOCK” or “UNLOCK” on CONSULT-II screen is touched. DOOR LOCK IND This test is able to check door lock / unlock switch's illumination. TRUNK / BACK DOOR This test is able to check back door release actuator open operation. These actuator open when “OPEN” on CONSUT-II screen is touched. Work Flow 1. 2. 3. 4. BIS000J8 Check the symptom and customer's requests. Understand the outline of system. Refer to BL-17, "System Description" . According to the trouble diagnosis, repair or replace the cause of the malfunction. Refer to BL-35, "TROUBLE DIAGNOSES CHART BY SYMPTOM/WITHOUT INTELLIGENT KEY SYSTEM" or BL-36, "TROUBLE DIAGNOSES CHART BY SYMPTOM/WITH INTELLIGENT KEY SYSTEM" . Does power door lock system operate normally? BL-79 POWER DOOR LOCK — SUPER LOCK — 5. YES: GO TO 5. NO: GO TO 2. INSPECTION END. BL-80 POWER DOOR LOCK — SUPER LOCK — Trouble Diagnoses BIS000J9 A PRELIMINARY CHECK/WITHOUT INTELLIGENT KEY SYSTEM B C D E F G H BL J K L M MIIB1440E BL-81 POWER DOOR LOCK — SUPER LOCK — SYMPTOM CHART/WITHOUT INTELLIGENT KEY SYSTEM NOTE: Before starting trouble diagnosis below, perform Preliminary Check BL-81, "PRELIMINARY CHECK/ WITHOUT INTELLIGENT KEY SYSTEM" . Symptom numbers in the symptom chart correspond with those of Preliminary check. Symptom Diagnosis/service procedure Reference page 1. Check power supply and ground circuit BL-85 2. Check door lock/unlock switch BL-86 3. Check door switch (except back door switch) BL-99 4. Check front door lock actuator (driver side) BL-91 1. Check front door lock actuator (driver side) BL-92 1. Check front door lock actuator (driver side) BL-91 2. Check front door lock actuator (passenger side) BL-92 3. Check rear door lock actuator LH BL-93 4. Check rear door lock actuator RH BL-94 1. Check key switch BL-87 2. Check super lock actuator (driver side) BL-95 1. Check super lock actuator (driver side) BL-95 2. Check super lock actuator (passenger side) BL-96 3. Check super lock actuator (rear LH) BL-97 4. Check super lock actuator (rear RH) BL-98 1.Check ignition switch ON circuit BL-85 SYMPTOM 7 Key reminder system does not operate. 1. Check key switch BL-87 SYMPTOM 8 Door lock indicator does not illuminate. 1. Check door lock/unlock switch indicator lamp SYMPTOM 1 Power door lock does not operate by using door lock/ unlock switch. SYMPTOM 2 All door lock actuators except driver side does not operate using door lock/unlock switch. SYMPTOM 3 Specific door lock actuator does not operate using door lock/unlock switch. SYMPTOM 4 Super lock does not operate by using Key fob. SYMPTOM 5 Specific super lock actuator does not operate. SYMPTOM 6 Super lock cannot be released by ignition switch. 2. If above systems are OK, replace BCM. 2. If above systems are OK, replace BCM. BL-82 BCS-17 BL-58 BCS-17 POWER DOOR LOCK — SUPER LOCK — PRELIMINARY CHECK/WITH INTELLIGENT KEY SYSTEM A B C D E F G H BL J K L M MIIB1441E BL-83 POWER DOOR LOCK — SUPER LOCK — SYMPTOM CHART/WITH INTELLIGENT KEY SYSTEM NOTE: Before starting trouble diagnosis below, perform Preliminary Check BL-83, "PRELIMINARY CHECK/ WITH INTELLIGENT KEY SYSTEM" . Symptom numbers in the symptom chart correspond with those of Preliminary check. Symptom Diagnosis/service procedure Reference page 1. Check power supply and ground circuit BL-85 2. Check door lock/unlock switch BL-86 3. Check door switch (except back door switch) BL-99 4. Check front door lock actuator (driver side) BL-95 1. Check front door lock actuator (driver side) BL-96 1. Check front door lock actuator (driver side) BL-95 2. Check front door lock actuator (passenger side) BL-96 3. Check rear door lock actuator LH BL-97 4. Check rear door lock actuator RH BL-98 1. Check key switch and ignition knob switch BL-88 2. Check super lock actuator (driver side) BL-95 1. Check super lock actuator (driver side) BL-95 2. Check super lock actuator (passenger side) BL-96 3. Check super lock actuator (rear LH) BL-97 4. Check super lock actuator (rear RH) BL-98 1. Check ignition switch ON circuit BL-85 SYMPTOM 7 Key reminder system does not operate. 1. Check key switch and ignition switch BL-88 SYMPTOM 8 Door lock indicator does not illuminate. 1. Check door lock/unlock switch indicator lamp SYMPTOM 1 Power door lock does not operate by using door lock/ unlock switch. SYMPTOM 2 All door lock actuators except driver side does not operate using door lock/unlock switch. SYMPTOM 3 Specific door lock actuator does not operate using door lock/unlock switch. SYMPTOM 4 Super lock does not operate by using Intelligent Key. SYMPTOM 5 Specific super lock actuator does not operate. SYMPTOM 6 Super lock cannot be released by ignition switch. 2. If above systems are OK, replace BCM. 2. If above systems are OK, replace BCM. BL-84 BCS-17 BL-58 BCS-17 POWER DOOR LOCK — SUPER LOCK — Check Power Supply and Ground Circuit BIS000JA First perform the “SELF-DIAG RESULTS” in “BCM” with CONSULT-II, then perform the each trouble diagnosis of malfunction system indicated “SELF-DIAG RESULTS” of “BCM”, Refer to BCS-9, "CONSULT-II Function (BCM)" . 1. FUSE INSPECTION Check 10A fuse [No.5, located in fuse block (J/B)] ● Check 40A fusible link (letter J located in the fuse and fusible link box). ● Check 10A fuse [No.9, located in fuse block (J/B)] (Without Intelligent Key system) ● Check 10A fuse [No.13, located in fuse block (J/B)] (With Intelligent Key system) NOTE: Refer to BL-59, "Component Parts and Harness Connector Location" . OK or NG OK >> GO TO 2 NG >> If fuse is blown out, be sure to eliminate cause of malfunction before installing new fuse. Refer to PG-4, "POWER SUPPLY ROUTING CIRCUIT" . A B ● 2. CHECK POWER SUPPLY CIRCUIT 1. 2. Turn ignition switch ON. Check voltage between BCM connector M57, M59 terminals 24, 79 and ground. 24 – Ground 74 – Ground 79 – Ground C D E F G :Battery voltage. :Battery voltage. :Battery voltage. H BL OK or NG OK >> GO TO 3 NG >> Check BCM power supply circuit for open or short. J MIIB1111E K 3. CHECK GROUND CIRCUIT 1. 2. 3. Turn ignition switch OFF. Disconnect BCM connector. Check continuity between BCM connector M57, M59 terminals 2, 70 and ground. 2 – Ground 70 – Ground L :Continuity should exist. :Continuity should exist. M OK or NG OK >> Power supply and ground circuit is OK. NG >> Check BCM ground circuit for open or short. MIIB0093E BL-85 POWER DOOR LOCK — SUPER LOCK — Check Door Lock / Unlock Switch BIS000JB 1. CHECK DOOR LOCK / UNLOCK SWITCH SIGNAL With CONSULT- II Check door lock / unlock switch input signal (“CDL LOCK SW” “CDL UNLOCK SW”) in “DATA MONITOR” mode with CONSULT- II. When door lock/unlock switch is turned to LOCK: CDL LOCK SW Þ ON When door lock/unlock switch is turned to UNLOCK: CDL UNLOCK SW Þ ON SIIA1566E Without CONSULT- II Operate door lock / unlock switch, check voltage between BCM connector and ground. Terminals (Wire color) Connector (+) (-) 6 M57 Ground 25 Condition Voltage (V) (Approx.) Lock 0 Neutral / Unlock 5 Unlock 0 Neutral / Lock 5 OK or NG OK >> Door lock / unlock switch is OK. NG >> GO TO 2. MIIB0721E 2. CHECK DOOR LOCK/UNLOCK SWITCH 1. 2. 3. Turn ignition switch OFF. Disconnect door lock / unlock switch connector. Check continuity between door lock / unlock switch terminals. Terminals Door lock/ unlock switch 2 3 1 Condition Continuity Unlock YES Neutral / Lock NO Lock YES Neutral / Unlock NO OK or NG OK >> Check the following. ● Ground circuit for door lock / unlock switch ● Harness for open or short between BCM and door lock / unlock switch. NG >> Replace door lock / unlock switch. BL-86 MIIB1369E POWER DOOR LOCK — SUPER LOCK — Check Key Switch /Without Intelligent Key System BIS000JC 1. CHECK KEY SWITCH INPUT SIGNAL A With CONSULT-II Check key switch input signal “KEY ON SW” in “DATA MONITOR” mode with CONSULT- II. B When key is inserted in ignition key cylinder: KEY IN SW Þ ON When key is removed from ignition key cylinder: KEY IN SW Þ OFF C D Without CONSULT- II Check voltage between BCM connector and ground. Connector M57 Terminal (Wire color) (+) (-) 3 Ground Condition Voltage (V) (Approx.) Key is inserted Battery voltage Key is removed 0 E F OK or NG OK >> Key switch is OK. NG >> GO TO 2. G MIIB0499E H 2. CHECK KEY SWITCH (INSERT) 1. 2. 3. Turn ignition switch OFF. Disconnect key switch connector. Check continuity between key switch terminals. Terminals Key switch 1 2 BL Condition Continuity Key is inserted YES Key is removed NO OK or NG? OK >> Check the following. ● 10A fuse [No. 9, located in fuse block (J/B)]. ● Harness for open or short between key switch and fuse. ● Harness for open or short between BCM and key switch. NG >> Replace key switch. BL-87 J K L MIIB1370E M POWER DOOR LOCK — SUPER LOCK — Check Key Switch And Ignition Knob Switch/With Intelligent Key System BIS000JD 1. KEY SWITCH AND IGNITION KNOB SWITCH INSPECTION With CONSULT-II Display “PUSH SW” on DATA MONITOR screen, and check if ONOFF display is linked to ignition knob switch operation. When ignition knob is pushed When ignition knob is released : PUSH SW ON : PUSH SW OFF PIIB1360E Without CONSULT- II Check voltage between BCM connector and ground. Connector Terminal (Wire color) M57 (+) (-) 3 Ground Condition Voltage (V) (Approx.) Key is inserted Battery voltage Key is removed 0 OK or NG OK >> Key switch is OK. NG >> GO TO 2. MIIB0499E 2. KEY SWITCH POWER SUPPLY CIRCUIT INSPECTION 1. 2. 3. Remove mechanical key from ignition knob. Disconnect key switch and ignition knob switch connector. Check voltage between key switch and ignition knob switch connector and ground. Key switch and ignition knob switch connector Terminal M34 2 Ground Voltage (V) (Approx.) Battery voltage OK or NG OK >> GO TO 3. NG >> Repair or replace key switch power supply circuit. PIIB6598E BL-88 POWER DOOR LOCK — SUPER LOCK — 3. KEY SWITCH OPERATION INSPECTION 1. 2. A Insert mechanical key into ignition knob. Check continuity between key switch and ignition knob switch connector M34 terminal. B Terminal Key switch and ignition knob switch 3 4 Condition Continuity Key is inserted Yes Key is removed No C OK or NG OK >> GO TO 4. NG >> Replace key switch. D MIIB1372E E 4. KEY SWITCH CIRCUIT INSPECTION 1. 2. Disconnect Intelligent Key unit connector. Check continuity between Intelligent Key unit connector and key switch and ignition knob switch connector. A Intelligent Key unit connector M60 3. F G B Terminal Key switch and ignition knob switch connector Terminal 7 M34 4 Continuity H Yes BL Check continuity between key switch connector and ground. B J Key switch and ignition knob switch connector Terminal M34 4 Continuity MIIB1373E Ground K No OK or NG OK >> Key switch is OK. NG >> Repair or replace harness between Intelligent Key unit and key switch and ignition knob switch. Check Power Door Lock / Unlock Output Signal BIS000JE 1. CHECK POWER DOOR LOCK OUTPUT SIGNAL M Operate door lock / unlock switch, check voltage between BCM connector and ground. Connector Terminals (Wire color) (+) 67 M59 76 77 Condition Voltage (V) (Approx.) Unlock 0 → Battery voltage→ 0 Unlock 0 → Battery voltage→ 0 Lock 0 → Battery voltage→ 0 (-) Ground OK or NG OK >> Check the condition of the harness and the connector. NG >> Replace BCM. MIIB0319E BL-89 L POWER DOOR LOCK — SUPER LOCK — Check Super Lock Output Signal BIS000JF 1. CHECK SUPER LOCK OUTPUT SIGNAL Operate remote controller, check voltage between BCM connector and ground. Terminals (Wire color) Connector M59 (+) (-) 75 Ground Condition Lock button is pressed. Voltage (V) (Approx.) 0 → Battery voltage→ 0 OK or NG OK >> Check the condition of the harness and connector. NG >> Replace BCM. MIIB0722E BL-90 POWER DOOR LOCK — SUPER LOCK — Check Door Lock Actuator BIS000JG A DRIVER SIDE 1. CHECK DOOR LOCK ACTUATOR 1. 2. 3. Turn ignition switch OFF. Disconnect front door lock actuator (driver side) connector. Operate door lock / unlock switch, check voltage between front door lock actuator (driver side) connector and ground. Terminals (Wire color) Connector (+) (-) 2 D11 3 Ground Condition Voltage (V) (Approx.) Unlock 0 → Battery voltage → 0 Lock 0 → Battery voltage → 0 B C D E F MIIB0320E OK or NG OK >> Replace front door lock actuator (driver side). NG >> GO TO 2. G 2. CHECK HARNESS CONTINUITY 1. 2. Disconnect BCM connector. Check continuity between BCM connector M59 terminals 76, 77 and front door lock actuator (driver side) BL connector D11 terminals 2, 3. 76 – 2 77 – 3 3. H : Continuity should exist. : Continuity should exist. J Check continuity between BCM connector M59 terminals 76, 77 and ground. 76 – Ground 77 – Ground K : Continuity should not exist. : Continuity should not exist. OK or NG OK >> Check the condition of the harness and the connector. NG >> Repair or replace harness. BL-91 L MIIB0321E M POWER DOOR LOCK — SUPER LOCK — PASSENGER SIDE 1. CHECK DOOR LOCK ACTUATOR 1. 2. 3. Turn ignition switch OFF. Disconnect front door lock actuator (passenger side) connector. Operate door lock / unlock switch, check voltage between front door lock actuator (passenger side) connector and ground. Connector Terminals (Wire color) (+) 4 D28 5 Condition Voltage (V) (Approx.) Lock 0 → Battery voltage → 0 Unlock 0 → Battery voltage → 0 (-) Ground MIIB0322E OK or NG OK >> Replace front door lock actuator (passenger side). NG >> GO TO 2. 2. CHECK HARNESS CONTINUITY 1. 2. Disconnect BCM connector. Check continuity between BCM connector M59 terminals 67, 77 and front door lock actuator (passenger side) connector D28 terminals 4, 5. 67 – 5 77 – 4 3. : Continuity should exist. : Continuity should exist. Check continuity between BCM connector M59 terminal 67, 77 and ground. 67 – Ground 77 – Ground : Continuity should not exist. : Continuity should not exist. OK or NG OK >> Check the condition of the harness and the connector. NG >> Repair or replace harness. BL-92 MIIB0323E POWER DOOR LOCK — SUPER LOCK — REAR LH SIDE A 1. CHECK DOOR LOCK ACTUATOR 1. 2. 3. Turn ignition switch OFF. Disconnect rear door lock actuator LH connector. Operate door lock / unlock switch, check voltage between rear door lock actuator LH connector and ground. Connector Terminals (Wire color) (+) 4 D45 5 C Condition Voltage (V) (Approx.) Lock 0 → Battery voltage → 0 Unlock 0 → Battery voltage → 0 (-) Ground B D E MIIB0324E OK or NG OK >> Replace rear door lock actuator LH. NG >> GO TO 2. G 2. CHECK HARNESS CONTINUITY 1. 2. H Disconnect BCM connector. Check continuity between BCM connector M59 terminals 67, 77 and rear door lock actuator LH connector D45 terminals 4, 5. BL 67 – 5 77 – 4 3. F : Continuity should exist. : Continuity should exist. J Check continuity between BCM connector M59 terminals 67, 77 and ground. 67 – Ground 77 – Ground : Continuity should not exist. : Continuity should not exist. OK or NG OK >> Check the condition of the harness and the connector. NG >> Repair or replace harness. K L MIIB0325E M BL-93 POWER DOOR LOCK — SUPER LOCK — REAR RH SIDE 1. CHECK DOOR LOCK ACTUATOR 1. 2. 3. Turn ignition switch OFF. Disconnect rear door lock actuator RH connector. Operate door lock / unlock switch, check voltage between rear door lock actuator RH connector and ground. Connector Terminals (Wire color) (+) 2 D65 3 Condition Voltage (V) (Approx.) Unlock 0 → Battery voltage → 0 Lock 0 → Battery voltage → 0 (-) Ground MIIB0326E OK or NG OK >> Replace rear door lock actuator RH. NG >> GO TO 2. 2. CHECK HARNESS CONTINUITY 1. 2. Disconnect BCM connector. Check continuity between BCM connector M59 terminals 67, 77 and rear door lock actuator RH connector D65 terminals 2, 3. 67 – 2 77 – 3 3. : Continuity should exist. : Continuity should exist. Check continuity between BCM connector M59 terminals 67, 77 and ground. 67 – Ground 77 – Ground : Continuity should not exist. : Continuity should not exist. OK or NG OK >> Check the condition of the harness and the connector. NG >> Repair or replace harness. BL-94 MIIB0327E POWER DOOR LOCK — SUPER LOCK — Check Super Lock Actuator BIS000JH A DRIVER SIDE 1. CHECK SUPER LOCK ACTUATOR 1. 2. 3. Turn ignition switch OFF. Disconnect front door lock actuator (driver side) connector. Operate door lock / unlock switch, check voltage between front door lock actuator (driver side) connector and ground. Terminal (Wire color) Connector D11 (+) 1 (-) Ground Condition Lock button is pressed. Voltage (V) (Approx.) B C D 0 → Battery voltage → 0 E F MIIB0333E OK or NG OK >> Replace front door lock actuator (driver side). NG >> GO TO 2. G 2. CHECK HARNESS CONTINUITY 1. 2. Disconnect BCM connector. Check continuity between BCM connector M59 terminal 75 and front door lock actuator (driver side) con- BL nector D11 terminal 1. 75 – 1 3. H : Continuity should exist. J Check continuity between BCM connector M59 terminal 75 and ground. 75 – Ground : Continuity should not exist. K OK or NG OK >> Check the condition of the harness and the connector. NG >> Repair or replace harness. L MIIB0334E M BL-95 POWER DOOR LOCK — SUPER LOCK — PASSENGER SIDE 1. CHECK DOOR LOCK ACTUATOR 1. 2. 3. Turn ignition switch OFF. Disconnect front door lock actuator (passenger side) connector. Operate remote controller, check voltage between front door lock actuator (passenger side) connector and ground. Connector Terminal (Wire color) D28 (+) (-) 6 Ground Condition Lock button is pressed. Voltage (V) (Approx.) 0 → Battery voltage → 0 MIIB0335E OK or NG OK >> Replace front door lock actuator (passenger side). NG >> GO TO 2. 2. CHECK HARNESS CONTINUITY 1. 2. Disconnect BCM connector. Check continuity between BCM connector M59 terminal 75 and front door lock actuator (passenger side) connector D45 terminal 6. 75 – 6 3. : Continuity should exist. Check continuity between BCM connector M59 terminal 75 and ground. 75 – Ground : Continuity should not exist. OK or NG OK >> Check the condition of the harness and the connector. NG >> Repair or replace harness. MIIB0336E BL-96 POWER DOOR LOCK — SUPER LOCK — REAR LH SIDE A 1. CHECK DOOR LOCK ACTUATOR 1. 2. 3. Turn ignition switch OFF. Disconnect rear door lock actuator LH connector. Operate remote controller, check voltage between rear door lock actuator LH connector and ground. Connector Terminal (Wire color) D45 (+) (-) 6 Ground Voltage (V) (Approx.) Condition Lock button is pressed. B C 0 → Battery voltage → 0 D E MIIB0337E F OK or NG OK >> Replace rear door lock actuator LH. NG >> GO TO 2. G 2. CHECK HARNESS CONTINUITY 1. 2. Disconnect BCM connector. Check continuity between BCM connector M59 terminal 75 and rear door lock actuator LH connector D45 terminal 6. 75 – 6 3. BL : Continuity should exist. Check continuity between BCM connector M59 terminal 75 and ground. 75 – Ground H J : Continuity should not exist. OK or NG OK >> Check the condition of the harness and the connector. NG >> Repair or replace harness. K MIIB0338E L M BL-97 POWER DOOR LOCK — SUPER LOCK — REAR RH SIDE 1. CHECK DOOR LOCK ACTUATOR 1. 2. 3. Turn ignition switch OFF. Disconnect rear door lock actuator RH connector. Operate remote controller, check voltage between rear door lock actuator RH connector and ground. Connector Terminal (Wire color) D65 (+) (-) 1 Ground Voltage (V) (Approx.) Condition Lock button is pressed. 0 → Battery voltage → 0 MIIB0339E OK or NG OK >> Replace rear door lock actuator RH. NG >> GO TO 2. 2. CHECK HARNESS CONTINUITY 1. 2. Disconnect BCM connector. Check continuity between BCM connector M59 terminal 75 and rear door lock actuator RH connector D65 terminal 1. 75 – 1 3. : Continuity should exist. Check continuity between BCM connector M59 terminal 75 and ground. 75 – Ground : Continuity should not exist. OK or NG OK >> Check the condition of the harness and the connector. NG >> Repair or replace harness. MIIB0340E BL-98 POWER DOOR LOCK — SUPER LOCK — Check Door Switch BIS000JI A DRIVER SIDE 1. CHECK DOOR SWITCH INPUT SIGNAL B With CONSULT- II Check door switch “DOOR SW-DR” in “DATA MONITOR” mode with CONSULT- II. Monitor item Condition DOOR SW-DR C OPEN : ON CLOSE :OFF D E MIIB1050E F Without CONSULT- II Check voltage between BCM connector and ground. Connector M57 Terminal (Wire color) (+) (-) 29 Ground Condition Voltage (V) (Approx.) OPEN 0 CLOSE Battery voltage G H OK or NG OK >> Front door switch RH is OK. NG >> GO TO 2. BL MIIB0342E J 2. CHECK HARNESS CONTINUITY 1. 2. 3. Turn ignition switch OFF. Disconnect BCM and front door switch RH connector. Check continuity between BCM connector M57 terminal 29 and front door switch RH connector B29 terminal 1. 29 – 1 4. L : Continuity should exist. Check continuity between BCM connector M57 terminal 29 and ground. 29 – Ground K M : Continuity should not exist. OK or NG OK >> GO TO 3. NG >> Repair or replace harness. MIIB0343E BL-99 POWER DOOR LOCK — SUPER LOCK — 3. CHECK DOOR SWITCH Check continuity between door switch terminal 1 and body ground part of door switch. Connector B29 Terminal 1 Body ground part of door switch Condition Continuity Pushed NO Released YES OK or NG OK >> GO TO 4. NG >> Replace door switch. PIIA3351E 4. CHECK BCM OUTPUT SIGNAL 1. 2. Connect BCM connector. Check voltage between BCM connector M57 terminal 29 and ground. 29 – Ground : Battery voltage OK or NG OK >> Check door switch ground condition. NG >> Replace BCM. MIIB0342E BL-100 POWER DOOR LOCK — SUPER LOCK — PASSENGER SIDE A 1. CHECK DOOR SWITCH INPUT SIGNAL With CONSULT- II Check door switch “DOOR SW-AS” in “DATA MONITOR” mode with CONSULT- II. Monitor item B Condition DOOR SW-AS OPEN : ON CLOSE : OFF C D E MIIB1051E F Without CONSULT- II Check voltage between BCM connector and ground. Terminal (Wire color) Connector M57 (+) (-) 30 Ground Condition Voltage (V) (Approx.) OPEN 0 CLOSE Battery voltage G H OK or NG OK >> Front door switch LH is OK. NG >> GO TO 2. BL MIIB0344E J 2. CHECK HARNESS CONTINUITY 1. 2. 3. Turn ignition switch OFF. Disconnect BCM and front door switch LH connector. Check continuity between BCM connector M57 terminal 30 and front door switch LH connector B14 terminal 1. 30 – 1 4. : Continuity should exist. Check continuity between BCM connector M57 terminal 30 and ground. 30 – Ground L M : Continuity should not exist. OK or NG OK >> GO TO 3. NG >> Repair or replace harness. MIIB0345E BL-101 K POWER DOOR LOCK — SUPER LOCK — 3. CHECK DOOR SWITCH Check continuity between door switch terminal 1 and body ground part of door switch. Connector B14 Terminal 1 Body ground part of door switch Condition Continuity Pushed NO Released YES OK or NG OK >> GO TO 4. NG >> Replace door switch. PIIA3351E 4. CHECK BCM OUTPUT SIGNAL 1. 2. Connect BCM connector. Check voltage between BCM connector M57 terminal 30 and ground. 30 – Ground : Battery voltage OK or NG OK >> Check door switch ground condition. NG >> Replace BCM. MIIB0344E BL-102 POWER DOOR LOCK — SUPER LOCK — REAR LH SIDE A 1. CHECK DOOR SWITCH INPUT SIGNAL With CONSULT- II Check door switch “DOOR SW-RL” in “DATA MONITOR” mode with CONSULT- II. Monitor item B Condition DOOR SW-RL OPEN ON CLOSE OFF C D E MIIB1052E F Without CONSULT- II Check voltage between BCM connector and ground. Terminal (Wire color) Connector M58 (+) (-) 59 Ground Condition Voltage (V) (Approx.) OPEN 0 CLOSE Battery voltage G H OK or NG OK >> Rear door switch LH is OK. NG >> GO TO 2. BL MIIB0346E J 2. CHECK HARNESS CONTINUITY 1. 2. 3. Turn ignition switch OFF. Disconnect BCM and rear door switch LH connector. Check continuity between BCM connector and rear door switch LH connector. A 4. K L B Continuity BCM connector Terminal Rear door switch LH Terminal M58 59 B19 1 M Yes Check continuity between BCM connector and ground. A Continuity BCM connector Terminal M58 59 Ground No OK or NG OK >> GO TO 3. NG >> Repair or replace harness. BL-103 MIIB1374E POWER DOOR LOCK — SUPER LOCK — 3. CHECK DOOR SWITCH Check continuity between door switch terminal 1 and body ground of door switch. Connector B19 Terminal 1 Body ground part of door switch Condition Continuity Pushed NO Released YES OK or NG OK >> GO TO 4. NG >> Replace door switch. PIIA3351E 4. CHECK BCM OUTPUT SIGNAL 1. 2. Connect BCM connector. Check voltage between BCM connector M58 terminal 59 and ground. 59 – Ground : Battery voltage OK or NG OK >> Check door switch ground condition. NG >> Replace BCM. MIIB0346E BL-104 POWER DOOR LOCK — SUPER LOCK — REAR RH SIDE A 1. CHECK DOOR SWITCH INPUT SIGNAL With CONSULT- II Check door switch “DOOR SW-RR” in “DATA MONITOR” mode with CONSULT- II. Monitor item B Condition DOOR SW-RR OPEN ON CLOSE OFF C D E MIIB1053E F Without CONSULT- II Check voltage between BCM connector and ground. Terminal (Wire color) Connector M58 (+) (-) 60 Ground Condition Voltage (V) (Approx.) OPEN 0 CLOSE Battery voltage G H OK or NG OK >> Rear door switch RH is OK. NG >> GO TO 2. BL MIIB0348E J 2. CHECK HARNESS CONTINUITY 1. 2. 3. Turn ignition switch OFF. Disconnect BCM and rear door switch RH connector. Check continuity between BCM connector and rear door switch RH connector. A 4. K L B Continuity BCM connector Terminal Rear door switch RH Terminal M58 60 B42 1 M Yes Check continuity between BCM connector and ground. A Continuity BCM connector Terminal M58 60 Ground No OK or NG OK >> GO TO 3. NG >> Repair or replace harness. BL-105 MIIB1375E POWER DOOR LOCK — SUPER LOCK — 3. CHECK DOOR SWITCH Check continuity between door switch terminal 1 and body ground of door switch. Connector B42 Terminal 1 Body ground part of door switch Condition Continuity Pushed NO Released YES OK or NG OK >> GO TO 4. NG >> Replace door switch. PIIA3351E 4. CHECK BCM OUTPUT SIGNAL 1. 2. Connect BCM connector. Check voltage between BCM connector M58 terminal 60 and ground. 60 – Ground : Battery voltage OK or NG OK >> Check door switch ground condition. NG >> Replace BCM. MIIB0348E BL-106 POWER DOOR LOCK — SUPER LOCK — Check Back Door Switch BIS000JJ 1. CHECK BACK DOOR SWITCH INPUT SIGNAL A With CONSULT- II Check back door switch “TRNK OPNR SW” in “DATA MONITOR” mode with CONSULT- II. B Back door switch is pushed TRNK OPNR SW : ON Back door switch is released TRNK OPNR SW : OFF C D E MIIB0350E Without CONSULT- II Check voltage between BCM connector and ground. Terminal (Wire color) Connector (+) (-) 5 Ground M57 F Condition Voltage (V) (Approx.) Pushed 0 Released 5 G H OK or NG OK >> Back door switch is OK. NG >> GO TO 2. BL MIIB0719E 2. CHECK HARNESS CONTINUITY J 1. 2. 3. K Turn ignition switch OFF. Disconnect BCM and back door switch connector. Check continuity between BCM connector and back door switch connector. A 4. BCM connector M57 B L Continuity Terminal Back door switch connector Terminal 5 D104 1 M Yes Check continuity between BCM connector and ground. A Continuity BCM connector Terminal M57 5 Ground No OK or NG OK >> GO TO 3. NG >> Repair or replace harness. BL-107 MIIB1380E POWER DOOR LOCK — SUPER LOCK — 3. CHECK BACK DOOR SWITCH Check continuity between back door switch terminals. Terminals Back door switch 1 2 Condition Continuity Pushed YES Released NO OK or NG OK >> GO TO 4. NG >> Replace back door switch. MIIB1381E 4. CHECK BCM OUTPUT SIGNAL 1. 2. Connect BCM connector. Check voltage between BCM connector M57 terminal 5 and ground. 5 – Ground : Approx. 5V OK or NG OK >> Check the condition of the harness and the connector. NG >> Replace BCM. MIIB0351E BL-108 POWER DOOR LOCK — SUPER LOCK — Check Back Door Release Actuator BIS000JK 1. CHECK BCM OUTPUT SIGNAL A Check back door release output signal Perform (“TRUNK/BACK DOOR”) in “ACTIVE TEST” mode with CONSULT-II. B When “ACTIVE TEST” is executed, does the back door open? C OK or NG OK >> Back door release output is OK. NG >> GO TO 2. D E MIIB0354E 2. CHECK BACK DOOR RELEASE ACTUATOR 1. 2. 3. F Turn ignition switch OFF. Disconnect back door release actuator connector. Operate back door switch, check voltage between back door release actuator connector and ground. Terminal Back door switch connector (+) (-) B46 4 Ground Condition Voltage (V) (Approx.) Pushed 0 → Battery voltage → 0 G H OK or NG OK >> GO TO 4. NG >> GO TO 3. BL J MIIB1382E 3. CHECK HARNESS CONTINUITY K 1. 2. L Disconnect BCM connector. Check continuity between BCM connector and back door release actuator connector. A 3. B BCM connector Terminal Back door release actuator connector Terminal M59 68 B46 4 Continuity M Yes Check continuity between BCM connector and ground. A BCM connector Terminal M59 68 Ground Continuity MIIB1383E No OK or NG OK >> Replace BCM. NG >> Repair or replace harness. BL-109 POWER DOOR LOCK — SUPER LOCK — 4. CHECK GROUND CIRCUIT Check continuity between back door release actuator connector and ground. Back door release actuator connector Terminal B46 3 Ground Continuity Yes OK or NG OK >> Replace back door release actuator. NG >> Repair or replace harness. MIIB1384E BL-110 MULTI-REMOTE CONTROL SYSTEM MULTI-REMOTE CONTROL SYSTEM Component Parts and Harness Connector Location PFP:28596 A BIS000JP B C D E F G H BL MIIB1368E 1. BCM (Body Control Module) M57, M58, M59 2. Front door switch RH: B29 (RHD/LHD models) LH: B14 (RHD/LHD models) 4. Back door release actuator B46 5. Key switch connector M33 (Without Intelligent Key system) 3. Rear door switch RH: B42 LH: B19 J K L M BL-111 MULTI-REMOTE CONTROL SYSTEM System Description BIS000JR INPUTS Power is supplied at all times ● through 40A fusible link (letter J , located in the fusible link box) ● to BCM terminals 74 and 79. ● through 10A fuse [No. 9, located in the fuse block (J/B)] ● to key switch terminal 2. When the key switch is ON (Ignition key is inserted in ignition key cylinder), power is supplied ● through key switch terminal 1 ● to BCM terminal 3. When the ignition switch is ON or START, power is supplied ● through 10A fuse [No. 5, located in the fuse block (J/B)] ● to BCM terminal 24. Ground is supplied ● through BCM terminals 2 and 70 ● to body grounds M21 and M66. When the front door switch LH (LHD Models) or RH (RHD Models) is ON (door is open), ground supplied ● through BCM terminal 29 ● through front door switch LH (LHD Models) or RH (RHD Models) terminal 1 ● to front door switch LH (LHD Models) or RH (RHD Models) case ground. When the front door switch RH (LHD Models) or LH (RHD Models) is ON (door is open), ground supplied ● through BCM terminal 30 ● through front door switch RH (LHD Models) or LH (RHD Models) terminal 1 ● to front door switch RH (LHD Models) or LH (RHD Models) case ground. When the rear door switch LH is ON (door is open), ground is supplied ● through BCM terminal 59 ● through rear door switch LH terminal 1 ● to rear door switch LH case ground. When the rear door switch RH is ON (door is open), ground is supplied ● through BCM terminal 60 ● through rear door switch RH terminal 1 ● to rear door switch RH case ground. When the back door release actuator (back door switch) is ON (back door is open), ground is supplied ● through BCM terminal 10 ● through back door release actuator (back door switch) terminals 2 and 1 ● to body grounds B13, B28, B38 and B48. Remote controller signal is inputted to BCM (The antenna of the system is combined with BCM). OUTLINE Power Door Lock Operation UNLOCK LINK FUNCTION When this function is activated, if the car is locked by door lock/unlock switch, opening the driver or passenger side door from the inside handle will override the lock state and unlock the whole car. (This function will be deactivate if anti-hijack function is activated.) Selectable Function Door Lock/unlock switch How to change setting Press unlock for more than 4 seconds Contents Unlock link activate/deactivate How to confirm Buzzer should sound for 0.2 seconds BL-112 MULTI-REMOTE CONTROL SYSTEM AUTO RE-LOCK FUNCTION The BCM is equipped with an auto re-lock function, when no further user action occurs after an full or partial unlock, the doors will automatically re-lock after 2 minutes (default value). The auto re-lock function will not be activated under the following states. ● Key switch is ON ● Mechanical key is inserted ● Any door is opened NOTE: the 2 minutes timer of auto re-lock will be reset if unlock button from the key fob is pressed. ANTI-HIJACK FUNCTION With the anti-hijack function enabled, the first unlock request send from key fob will partially unlock only the driver side door (released super lock if equipped). Then if a second unlock signal is send from the first, then all remaining doors will be unlocked. HOW TO CHANGE DOOR LOCK FUNCTION MODE With CONSULT-II Door lock function can be changed using “SECURITY DOOR LOCK SET” mode in “WORK SUPPORT” of “DOOR LOCK”. Refer to BL-34, "WORK SUPPORT" . Without CONSULT-II Press and hold the UNLOCK and LOCK button on remote controller for more than 4 second will switch the Anti-Hijack mode to ON or OFF. A B C D E F G Answer Back When the doors are locked or unlocked by remote controller, supply power to hazard warning lamp flashes as follows H ● LOCK operation: Flash once ● UNLOCK operation: Flash twice Answer back mode can be changed using “HAZARD LAMP SET” mode in “WORK SUPPORT” of “FLASHER”. BL Refer to LT-106, "WORK SUPPORT" . Remote Controller ID Code Entry A maximum of four remote controller can be entered. Dedicated remote controller ID registration procedure is not required. Remote controller ID registration must be completed in conjunction with immobilizer transponder ID registration. J K L M BL-113 MULTI-REMOTE CONTROL SYSTEM Schematic BIS000JS MIWA0715E BL-114 MULTI-REMOTE CONTROL SYSTEM Wiring Diagram — MULTI — BIS000JT A B C D E F G H BL J K L M MIWA0716E BL-115 MULTI-REMOTE CONTROL SYSTEM MIWA0717E BL-116 MULTI-REMOTE CONTROL SYSTEM A B C D E F G H BL J K L M MIWA0718E BL-117 MULTI-REMOTE CONTROL SYSTEM MIWA0719E BL-118 MULTI-REMOTE CONTROL SYSTEM Terminal and Reference Value for BCM BIS000JU A Signal Input/ Output Condition Voltage [V] (Approx.) — — 0 Key switch Input Key is removed from IGN key cylinder (OFF) → Key is inserted in IGN key cylinder (ON) 0 → Battery voltage P Back door actuator switch Input Back door or trunk lid open (ON) → Back door or trunk lid close (OFF) 0 → Battery voltage O IGN power supply Input Terminal Wire color 2 B Ground 3 O 10 24 29 30 LG (BR) BR (LG) Item Front door switch LH (LHD models) Front door switch RH (RHD models) Front door switch RH (LHD models) Input Ignition switch is in ON or START position Door open (ON) → Door close (OFF) B C Battery voltage D 0 → Battery voltage E Input Door open (ON) → Door close (OFF) 0 → Battery voltage Front door switch LH (RHD models) 59 G Rear door switch LH Input Door open (ON) → Door close (OFF) 0 → Battery voltage 60 L Rear door switch RH Input Door open (ON) → Door close (OFF) 0 → Battery voltage F G H When door lock operated using remote controller*1 BL 65 LG Answer back (Turn signal lamp LH) PIIA2486J Output J When door unlock operated using remote controller*1 K PIIA2487J L When door lock operated using remote con- M troller*1 66 W Answer back (Turn signal lamp RH) PIIA2486J Output When door unlock operated using remote controller*1 PIIA2487J 67 Y All door lock actuator unlock (Except driver side) Output Door lock/unlock switch UNLOCK operation 0 → Battery voltage 68 O Back door or trunk lid opener actuator Output Power window main switch (Back door or trunk lid release switch) OPEN operation Battery voltage → 0 BL-119 MULTI-REMOTE CONTROL SYSTEM Signal Input/ Output Condition Voltage [V] (Approx.) — — 0 Input — Battery voltage Terminal Wire color 70 B Ground 74 Y BAT power supply (fusible link) (BCM) 75*2 O Super lock set output (All door) Output Super lock operation (Set) 0 → Battery voltage 76 BR Door lock actuator unlock (Driver side) Output Door lock/unlock switch Unlock operation 0 → Battery voltage 77 SB Door lock actuator lock (ALL Door) Output Door lock/unlock switch LOCK operation 0 → Battery voltage 79 Y Item BAT power supply (fusible link) (Power window) Input — Battery voltage *1 : In the state that answer back operates *2 : Only the model equipped with super lock system (RHD Models) (): RHD models CONSULT- II Inspection Procedure BIS000JV Refer to GI-36, "CONSULT-II Start Procedure" . CONSULT- II Application Items BIS000JW DATA MONITOR Monitored Item Description MEMORY 1 Indicates [ON/OFF] condition of remote controller ID code registration. MEMORY 2 Indicates [ON/OFF] condition of remote controller ID code registration. MEMORY 3 Indicates [ON/OFF] condition of remote controller ID code registration. MEMORY 4 Indicates [ON/OFF] condition of remote controller ID code registration. Work Flow 1. 2. 3. 4. 5. BIS000JX Check the trouble symptom and customer's requests. Understand outline of system. Refer to BL-112, "System Description" . Confirm that power door lock system operates normally. Refer to BL-16, "POWER DOOR LOCK SYSTEM" . Refer to trouble diagnosis chart by symptom, repair or replace any malfunctioning parts. INSPECTION END BL-120 MULTI-REMOTE CONTROL SYSTEM Trouble Diagnosis Chart by Symptom BIS000JY First perform the “SELF-DIAG RESULTS” in “BCM” with CONSULT-II, when perform the each trouble diagnosis. Refer to BCS-9, "CONSULT-II Function (BCM)" . NOTE: ● Always check “Work Flow” before troubleshooting. Refer to BL-120, "Work Flow" . ● Always check remote controller battery before replacing remote controller. Diagnoses/service procedure Reference page 1. Check remote controller (Reproduce the malfunction using a specific remote controller.) BL-122 2. Replace remote controller. BL-113 3. Replace BCM. BCS-17 1. Check remote controller BL-122 2. Check key switch BL-127 Symptom All function of multi-remote control system do not operate. Door lock or unlock does not function with remote controller. (Power door lock system is “OK”) Answer back does not activate properly when pressing lock or unlock button of remote controller. Auto door lock operation does not activate properly. (All other remote keyless entry system function is “OK”.) A B C D 3. Replace remote controller. E F NOTE: If the result of remote controller function check with CONSULT-II is OK, remote controller is not malfunctioning. BL-113 4. Replace BCM. BCS-17 1. Check answer back mode.* *: Answer back mode can be changed. First check the hazard reminder setting. LT-106 2. Check hazard reminder BL-128 3. Replace BCM. BCS-17 G H 1. Check auto door lock operation mode.* *: Auto door lock operation can be changed. First check the auto door lock operation setting. BL-34 2. Check door switch BL-122 3. Replace BCM. BCS-17 BL J K L M BL-121 MULTI-REMOTE CONTROL SYSTEM Check Remote controller BIS000JZ 1. CHECK REMOTE CONTROLLER BATTERY Remove battery and measure voltage across battery positive and negative terminals, (+) and (−). Battery voltage : 2.5V – 3.0V NOTE: Remote controller does not function if battery is not set correctly. SEL237W OK or NG OK >> Replace remote controller. NG >> Replace battery. Refer to BL-129, "Remote Controller Battery Replacement" . Check Door Switch BIS000K0 DOOR SWITCH DRIVER SIDE 1. CHECK DOOR SWITCH INPUT SIGNAL 1. 2. Turn ignition switch OFF. Check voltage between BCM connector M57 terminal 29 and ground. Terminal (+) (–) Driver door condition Voltage (V) Approx. Closed 5 Open 0 LHD Models RHD Models 29 Ground OK or NG OK >> Door switch circuit is OK. NG >> GO TO 2. MIIB0342E 2. CHECK DOOR SWITCH HARNESS 1. Check continuity between BCM connector M57 terminal 29 and driver door switch connector B14 (LHD Models) or B29 (RHD Models) terminal 1. Terminal LHD Models Continuity Yes 29 - 1 RHD Models 2. Yes Check continuity between BCM connector M57 terminal 29 and ground. Terminal LHD Models 29 Continuity Ground Continuity should not exist. RHD Models OK or NG OK >> GO TO 3. NG >> Repair or replace harness. BL-122 MKIB0851E MULTI-REMOTE CONTROL SYSTEM 3. CHECK DOOR SWITCH A Check continuity between driver door switch terminal 1 and ground part of door switch. Terminal Driver door switch condition Continuity Pushed No Released Yes 1 - Ground part of door switch B C OK or NG OK >> Check driver door switch ground condition. NG >> Replace driver door switch. D SIIA1589E DOOR SWITCH PASSENGER SIDE E 1. CHECK DOOR SWITCH INPUT SIGNAL 1. 2. Turn ignition switch OFF. Check voltage between BCM connector M57 terminal 30 and ground. Terminal (+) (–) Passenger door condition Voltage (V) Approx. Closed 5 Open 0 LHD Models RHD Models 30 Ground F G H OK or NG OK >> Door switch circuit is OK. NG >> GO TO 2 BL MIIB0344E 2. CHECK DOOR SWITCH HARNESS 1. Check continuity between BCM connector M57 terminal 30 and passenger door switch connector B29 (LHD Models) or B14 (RHD Models) terminal 1. Terminal K Continuity LHD Models L Yes 30 - 1 RHD Models 2. J Yes Check continuity between BCM connector M57 terminal 30 and ground. Terminal LHD Models 30 Continuity Ground Continuity should not exist. RHD Models OK or NG OK >> GO TO 3. NG >> Repair or replace harness. BL-123 M MKIB0852E MULTI-REMOTE CONTROL SYSTEM 3. CHECK DOOR SWITCH Check continuity between passenger door switch terminal 1 and ground part of door switch. Terminal Passenger door switch condition Continuity Pushed No Released Yes 1 - Ground part of door switch OK or NG OK >> Check passenger door switch ground condition. NG >> Replace passenger door switch. SIIA1589E DOOR SWITCH REAR LH 1. CHECK DOOR SWITCH INPUT SIGNAL 1. 2. Turn ignition switch OFF. Check voltage between BCM connector M58 terminal 59 and ground. Terminal (+) (–) 59 Ground Rear door LH condition Voltage (V) Approx. Closed 5 Open 0 OK or NG OK >> Door switch circuit is OK. NG >> GO TO 2 MIIB0346E 2. CHECK DOOR SWITCH HARNESS 1. Check continuity between BCM connector M58 terminal 59 and rear door switch LH connector B19 terminal 1. 59 – 1 2. : Continuity should exist. Check continuity between BCM connector M58 terminal 59 and ground 59 – Ground : Continuity should not exist. OK or NG OK >> GO TO 3. NG >> Repair or replace harness. MIIB0347E 3. CHECK DOOR SWITCH Check continuity between rear door switch LH terminal 1 and ground part of door switch. Terminal 1 - Ground part of door switch Rear door switch LH condition Continuity Pushed No Released Yes OK or NG OK >> Check rear door switch LH ground condition. NG >> Replace rear door switch LH. PIIA3351E BL-124 MULTI-REMOTE CONTROL SYSTEM DOOR SWITCH REAR RH A 1. CHECK DOOR SWITCH INPUT SIGNAL 1. 2. Turn ignition switch OFF. Check voltage between BCM connector M58 terminal 60 and ground. Terminal (+) (–) 60 Rear door RH condition Voltage (V) Approx. Closed 5 Open 0 Ground B C D OK or NG OK >> Door switch circuit is OK. NG >> GO TO 2 E MIIB0348E 2. CHECK DOOR SWITCH HARNESS 1. Check continuity between BCM connector and rear door switch RH connector. A 2. F BCM connector M58 G B Continuity Terminal Rear door switch RH Terminal 60 B42 1 H Yes Check continuity between BCM connector and ground BL A BCM connector Terminal M58 60 Continuity Ground MIIB1375E J No OK or NG OK >> GO TO 3. NG >> Repair or replace harness. K 3. CHECK DOOR SWITCH L Check continuity between rear door switch RH terminal 1 and ground part of door switch. Terminal 1 - Ground part of door switch Rear door switch RH condition Continuity Pushed No Released Yes M OK or NG OK >> Check rear door switch RH ground condition. NG >> Replace rear door switch RH. PIIA3351E BL-125 MULTI-REMOTE CONTROL SYSTEM BACK DOOR RELEASE ACTUATOR (BACK DOOR SWITCH) 1. CHECK BACK DOOR RELEASE ACTUATOR (BACK DOOR SWITCH) INPUT SIGNAL 1. 2. Turn ignition switch OFF. Check voltage between BCM connector M57 terminal 10 and ground. Terminal (+) (–) 10 Ground Back door condition Voltage (V) Approx. Closed 5 Open 0 OK or NG OK >> Back door switch circuit is OK. NG >> GO TO 2 MIIB0314E 2. CHECK BACK DOOR RELEASE ACTUATOR (BACK DOOR SWITCH) HARNESS 1. 2. Disconnect back door release actuator (back door switch) connector. Check voltage between back door release actuator (back door switch) connector and ground. (Check harness for open.) Back door switch connector Terminal B46 2 Voltage (V) (Approx.) Ground Battery voltage MIIB1376E 3. 4. Disconnect BCM connector. Check continuity between back door release actuator (back door switch) connector and ground. (Check harness for short.) Back door switch connector Terminal B46 2 Continuity Ground No OK or NG OK >> GO TO 3. NG >> Repair or replace harness. MIIB1377E 3. CHECK BACK DOOR SWITCH Check continuity between back door release actuator (back door switch) terminal 1 and 2. Terminal Back door switch 1 2 Rear door condition Continuity Closed No Opened Yes OK or NG OK >> GO TO 4. NG >> Replace back door release actuator (back door switch). MIIB1378E BL-126 MULTI-REMOTE CONTROL SYSTEM 4. CHECK BACK DOOR SWITCH GROUND HARNESS A Check continuity between back door release actuator (back door switch) connector and ground. B Back door switch connector Terminal B46 1 Continuity Ground Yes C OK or NG OK >> Check harness connection. NG >> Replace back door switch. D MIIB1379E Key Switch Check BIS000K1 1. CHECK KEY SWITCH INPUT SIGNAL Check voltage between BCM connector M57 terminal 3 and ground. Terminals (+) 3 Key switch condition Voltage (V) Approx. Key is inserted in IGN key cylinder (key switch is “ON”.) Battery voltage Key is removed from IGN key cylinder (Key switch is “OFF”.) 0 (–) Ground E F G OK or NG OK >> Key switch circuit is OK. NG >> GO TO 2 H BL MIIB0499E 2. CHECK KEY SWITCH (INSERT) J 1. 2. Disconnect key switch connector. Check continuity between key switch terminals. Terminals Key switch 1 2 Condition Continuity Key is inserted YES Key is removed NO OK or NG OK >> Check the following. ● 10A fuse [No. 9, located in fuse block (J/B)] ● Harness for open or short between key switch and fuse ● Harness for open or short between BCM and key switch NG >> Replace key switch. BL-127 K L M MIIB1370E MULTI-REMOTE CONTROL SYSTEM Hazard Reminder Check BIS000K2 1. CHECK HAZARD WARNING LAMP Check if hazard warning lamp flashes with hazard switch. Does hazard warning lamp operate? Yes >> GO TO 2 No >> Check hazard warning lamp circuit. Refer to LT-98, "TURN SIGNAL AND HAZARD WARNING LAMPS" . 2. CHECK HAZARD REMINDER OPERATION Check the following at when push the remote controller switch. Check voltage between BCM harness connector M59 terminal 65, 66 and ground. Remote controller Voltage (V) Approx. Pushing LOCK button MIIB0312E PIIA2486J Pushing UNLOCK button PIIA2487J OK or NG OK >> Check harness for open between BCM and hazard switch. NG >> Check harness for short between BCM and hazard switch. If check result is “OK”, replace BCM. If check result is “NG”, repair or replace harness. BL-128 MULTI-REMOTE CONTROL SYSTEM Remote Controller Battery Replacement 1. 2. 3. 4. A Remove installation screw on the rear of remote controller. Place the key with the lower case facing up. Set a screwdriver wrapped with tape into section A of the lower case and separate the lower case from the upper case. When replacing the circuit board assembly, remove circuit board assembly from the upper case. (Circuit board assembly: Switch rubber + Board surface) CAUTION: Be careful not to touch the printed circuits directly. When replacing the battery Remove battery from the lower case and replace it. Battery replacement 5. BIS000K3 B C D : Coin-type lithium battery (CR1620) CAUTION: When replacing battery, be sure to keep dirt, grease and other foreign materials off the electrode contact area. After replacement, fit the lower and upper cases together, part and tighten with the screw. CAUTION: After replacing the battery, be sure to check that door locking operates normally using the remote controller. E F G MIIB0308E H BL J K L M BL-129 INTELLIGENT KEY SYSTEM INTELLIGENT KEY SYSTEM Component Parts and Harness Connector Location PFP:285e2 BIS000K4 MIIB1436E 1. BCM M57, M58, M59 2. Intelligent Key unit M60 3. IPDM E/R E6, E10, E11, E12 4. Combination meter M27 5. Steering lock unit M37 6. Key switch and ignition knob switch M34 7. Door lock relay M20 8. Stop lamp switch E38: LHD CR engine and HR engine M/T models E60: LHD HR engine A/T models and K9K engine models M203: RHD CR engine and HR engine M/T models M204: RHD HR engine A/T models and K9K engine models BL-130 INTELLIGENT KEY SYSTEM A B C D E F G H BL J K L M MIIB1437E BL-131 INTELLIGENT KEY SYSTEM PIIB5851J 1. Inside key antenna (dash board) M47 2. Intelligent key warning buzzer D10 3. a: Door request switch (driver side) D12 Door request switch (passenger side) D29 b: Outside antenna (driver side) D13 Outside antenna (passenger side) D30 4. Inside key antenna (center console) B20 5. Inside key antenna (luggage room) B32 6. Outside antenna (back door) B43 7. Door request switch (back door) D102 System Description ● ● ● ● ● ● BIS000K6 The Intelligent Key system is a system that makes it possible to lock and unlock the door locks (door lock function) and start the engine (engine start function) by carrying the Intelligent Key, which operates based on the results of electrical key-ID verification using two-way communications between the Intelligent Key and the vehicle. Operation of the remote control buttons on the Intelligent Key also provides the same functions as the remote control entry system. (Remote control entry functions) As an ignition key warning function, when a door lock is locked or unlocked with door request switch or Intelligent Key button operation, the hazard lamps flashes and sound the Intelligent Key buzzer. Even if the vehicle or Intelligent Key battery runs out, the door locks can be locked and unlocked and the engine can be initiated by the mechanical key built-in the Intelligent Key. If Intelligent Key is lost, a new Intelligent Key can be registered. A maximum of 4 Intelligent Keys can be registered. It has been made possible to diagnose the system, change the function setting and register Intelligent Key with the CONSULT-II. DOOR LOCK FUNCTION Operation Description When the driver door, passenger door, or back door request switch is pressed, Intelligent Key unit sends a request signal from the transmission antenna corresponding to the pressed door request switch, key-ID verification is performed using two-way communication with Intelligent Key, and if ID is successfully verified, a door lock/unlock request signal is sent to BCM (Body Control Module) through CAN communication to lock/unlock the door lock. ● With the locking operation of door request switch, door lock actuators of all doors will be locked. Driver side door request switch operation ● When door request switch (driver side) is pressed, driver side door lock actuator will be unlocked. ● When door request switch (driver side) is pressed for the second time, within 5 seconds after the first the remaining doors will be unlock. ● BL-132 INTELLIGENT KEY SYSTEM Unlock mode can be changed using “WORK SUPPORT” mode in “LOCK/UNLOCK BY I-KEY”. Refer to BL-155, "CONSULT-II Function (INTELLIGENT KEY)" . Passenger side door request switch operation ● When door request switch (passenger side) is pressed, passenger side door will be unlocked. ● When door request switch (passenger side) is pressed for the second time, with in 5 seconds after the first operation, the remaining doors will be unlock. ● Unlock mode can be changed using “WORK SUPPORT” mode in “LOCK/UNLOCK BY I-KEY”. Refer to BL-155, "CONSULT-II Function (INTELLIGENT KEY)" . ● A B C Operation Condition Request switch operation Operating conditions (When all the conditions below are met) Door request switch (driver side) ● All doors closed (door switch: OFF) Door request switch (passenger side) ● Key switch OFF (key removed) ● Ignition knob switch: OFF (ignition knob switch not pressed) ● The Intelligent Key is in the antenna detection area for the door for which the door request switch was operated. Door request switch (back door) D E F Operation Range The antenna detection area for each door is about 80 cm (31.50 in) from the handle of each door (driver door, passenger door and back door). However, this operating range may differed by the ambient conditions. G Auto Door Lock Function When the door request switches are pressed and doors are locked or unlocked once, during this state, door lock will re-lock automatically unless the following conditions are met. H ● Mechanical key is inserted into ignition knob. ● Ignition knob is pressed. ● Any of the doors is opened. BL ● Intelligent Key button is operated within 30 seconds. Key Reminder Function As an operation confirmation, when the doors are lock or unlock by using door request switch or Intelligent Key, hazard lamps flashes and Intelligent Key warning buzzer sounds. Vehicle operation Hazard lamp Intelligent Key warning buzzer Door unlock operation Twice Twice Door lock operation Once Once Intelligent Key Lock-in Prevention Function When Intelligent Key is within the vehicle, a door is open or doors are locked using door lock and unlock switch, driver door lock knob or door request switch, Intelligent Key unit sends door unlock request signal to BCM via CAN communication to unlock all doors to prevent Intelligent Key from being locking in vehicle. CAUTION: The functions mentioned above are operable when the Intelligent Key is inside the vehicle. However, there may be times that the Intelligent Key cannot be detected in some blind spot of the inside key antennas. Thus engine start function system might not response when the Intelligent Key is placed on the instrument panel, rear parcel shelf or in the glove box. Furthermore, by placing the Intelligent Key in the door pocket and opening the door may interrupt the communication between the Intelligent Key and the antennas. REMOTE CONTROL ENTRY FUNCTIONS Door Lock Function ● ● Operating the button on the Intelligent Key sends the Intelligent Key-ID signals to the Intelligent Key unit. Intelligent Key unit conducts a verification of the received key-ID, and if the verification is accepted, a door lock or door unlock request signal is sent to BCM via CAN communication to lock/unlock the door lock. When door lock/unlock is performed using Intelligent Key button operation, confirmation is conducted by making hazard lamps flashes and Intelligent Key warning buzzer sounds. BL-133 J K L M INTELLIGENT KEY SYSTEM OPERATION CONDITION Intelligent Key operation Door lock operation Operation condition ● All doors closed ● Key switch OFF (key removed) ● Ignition knob switch: OFF (ignition knob not pressed) ● Key switch OFF (key removed) ● Ignition knob switch: OFF (ignition knob not pressed) Door unlock operation MT vehicle Key Interlock function In case of a MT vehicle is in motion and ignition knob is turned into lock position, steering lock unit pose a risk by activating the steering lock actuator. The key interlock function is designed to override the steering lock system and prevent situation mention above to occur. LOCK condition When the following condition had been fulfilled and then key interlock solenoid will be locked. (Steering lock inactive) ● When ignition switch is in ON position and engine revolution speed went above 500rpm. (1 second delay) UNLOCK condition When any of the following conditions had been fulfilled and then key interlock solenoid will be unlocked (Steering lock active) ● When vehicle speed is below 4 km/h and the ignition switch is turned from ON to OFF (1 second delay) ● When vehicle speed is over 4 km/h but less than 10 km/h and ignition switch is turned from ON to OFF. (3 seconds delay) Map Lamp Function When the following conditions is met: ● Condition of map lamp switch is DOOR position ● Door switch OFF (when all the doors are closed) Remote keyless entry system turns on interior lamp (for 30 seconds) once input of UNLOCK signal from Intelligent Key is received. For detailed description. Refer to LT-152, "INTERIOR ROOM LAMP TIMER OPERATION" . ENGINE STARTUP FUNCTION Operation Description ● ● ● When ignition knob is pressed, Intelligent Key unit sends request signal from inside key antenna, key-ID verification is conducted with Intelligent Key using two-way communication, and if verification is successful, an ignition rotation prohibition latch release signal is sent to steering lock unit and releases ignition knob rotation prohibition latch. (Ignition knob can now be turned) NOTE: When it becomes impossible to rotate the ignition knob, “KEY” warning lamp in combination meter lights up red. When key-ID verification is successful and ignition knob switch is in the ON state, Intelligent Key unit uses CAN communication to send engine start permission signal to BCM. When BCM receives engine start permission signal, it uses CAN communication to sent starter request signal to IPDM E/R so that the engine will start when ignition knob is rotated to START position. Operation Range Engine can be started when Intelligent Key is in side the vehicle. However, sometimes engine might not start when Intelligent Key is on instrument panel, rear parcel shelf, or in glove box. NOTE: Luggage room is not within the operation range, but sometimes it is possible to start the engine from there. Active Check Function Confirm whether or not ignition knob can be rotated by checking the color of warning lamp in combination meter. BL-134 INTELLIGENT KEY SYSTEM Condition Operation Ignition knob rotation possible “KEY” warning lamp in combination meter is lit up green. Ignition knob rotation not possible “KEY” warning lamp in combination meter is lit up red. A B WARNING AND ALARM FUNCTION Operation Description Warnings and alarms shown as follows and are given to the user as warning notice when using the combinations of Intelligent Key warning buzzer (driver door), inside vehicle buzzer (in combination meter), and warning lamps “KEY” and “LOCK.” ● Ignition switch return forgotten warning With the ignition in OFF or ACC position, if the driver door is opened, this warning is issued. ● Key left in ignition warning (when mechanical key is used) While the mechanical key in the ignition knob and the ignition switch is in the OFF, ACC, or LOCK position, if the driver door is opened, this warning is issued. ● Ignition switch OFF position warning (combination buzzer: when door closed) This warning is issued when the user forgets to return the ignition knob to the LOCK position. ● Ignition switch OFF position warning [Intelligent key warning buzzer (driver door): when door opened/ closed] This warning is issued when the user leaving the car without returning the ignition knob to the LOCK position. ● This warning is issued if the Intelligent Key is taken outside the car while the engine is running. (when door open → closed) ● This warning is issued if the Intelligent Key is taken outside the car through a window while the engine is running. (from window) ● Intelligent Key low battery warning This warning is issued when it detects that the battery in the Intelligent Key is running low. C D E F G H BL Operation Condition Warning and alarm names Ignition knob return forgotten warning Ignition key warning (When mechanical key used) Ignition knob OFF position warning (driver side door buzzer: when door closed) Ignition knob OFF position warning (E/G room buzzer: when door opened/closed) Operating conditions (when all the conditions below are met) ● The ignition switch is in the ACC, OFF, or LOCK position (knob pressed) ● The driver door is opened. ● The mechanical key is inserted in the ignition knob (key switch: ON) ● The ignition switch is in the ACC, OFF, or LOCK position. ● The driver door opened. ● The ignition switch is in the OFF or LOCK position (knob pressed) ● In the above state, when the ACC switch is switched from ON to OFF and 1 second passes. (However, this warning is not issued if the mechanical key is inserted in the ignition knob.) ● The ignition switch is in the OFF or LOCK position (knob pressed) ● In the above state, when the ACC switch is changed from ON to OFF and 1 second passes. (However, this warning is not issued if the mechanical key is inserted in the ignition knob.) ● Driver door open → closed When Any of the Following Conditions Are Met Warning for Intelligent Key taken outside the car (when door open → closed) ● When the ignition knob is pressed in so that it can be rotated (or has been rotated), if any of the doors has been opened, when all the doors are closed, the Intelligent Key unit compares the key-ID with the Intelligent Key using the inside key antenna (center console), if the results of the comparison are NG (the Intelligent Key is not found) ● When the ignition knob is pressed and rotated (or has been rotated), if any of the doors is open, the Intelligent Key unit compares the key-ID with that of the Intelligent Key every 5 seconds using the inside key antenna (center console), if the results of the comparison are NG (the Intelligent Key is not found) NOTE: However, this warning is not issued if the mechanical key is inserted in the ignition knob. BL-135 J K L M INTELLIGENT KEY SYSTEM Warning and alarm names Warning for Intelligent Key taken out from the window Operating conditions (when all the conditions below are met) When the ignition knob is pressed in so that it can be rotated (or has been rotated), if the vehicle speed is no greater than 5 km per hour, the Intelligent Key unit compares the key-ID with that of the Intelligent Key every 30 seconds using the inside key antenna (center console), if the results of the comparison are NG (the Intelligent Key is not found) Note: The default setting for this function is OFF. When any of the following conditions are met Intelligent Key Lock-in Prevention Warning ● When the Intelligent Key is inside the car and the ignition knob is not pressed, when an attempt is made to lock a door lock with a door request switch. NOTE: This warning is issued even if the Intelligent Key is not in the door antenna detection area corresponding to the door request switch was operated. Knob Return Forgotten Warning ● Door lock non-operation warning When the ignition knob is pressed, when an attempt is made to lock a door lock with a door request switch. NOTE: This warning is only issued if the Intelligent Key is in the door antenna detection area corresponding to the door request switch was operated. Door Ajar Alarm ● When any of the doors is open, when an attempt is made to lock a door with a door request switch. NOTE: This warning is only issued if the Intelligent Key is in the door antenna detection area corresponding to the specific door request switch was operated. Intelligent Key low battery prewarning This warning is issued when the battery of the Intelligent Key is running low. Warning Procedure Buzzer Warning and alarm names Warning lamp Inside car Outside car “KEY” “LOCK” Ignition switch return forgotten warning Buzzer: Continuous — — — Ignition key warning (When mechanical key is used) Buzzer: Continuous — — — Ignition switch OFF position warning (for inside car: when door closed) Buzzer (twice) — — Illuminate Ignition switch OFF position warning (for outside car: when door opened → closed) — Buzzer (3 seconds) — Illuminate Warning for removal of Intelligent Key to outside the car (when door open → closed) — Buzzer (3 seconds) Red illuminate — Warning for removal of Intelligent Key to outside the car (from window) Buzzer (3 seconds) — Red illuminate — Door lock non-operation warning — Buzzer (2 seconds) — — Intelligent Key low battery prewarning — — Green illuminate (30 seconds after ignition switch comes ON) — BL-136 INTELLIGENT KEY SYSTEM CHANGE SETTINGS FUNCTION The settings for each function can be changed with the CONSULT-II or Intelligent Key. A Changing Anti-Hijack Function Settings With the Intelligent Key Intelligent Key remote controller button and door request switch operations change the Anti-hijack function settings (enabled/disabled). Settings Change Procedure 1. Hold down both the LOCK and UNLOCK remote control buttons on the Intelligent Key at the same time for at least 10 seconds (The yardstick is that the Intelligent Key LED flashes 20 times.) 2. Within 3 seconds of releasing the Intelligent Key remote controller buttons, press the driver door request switch for once. 3. The KEY indicator in combination meter lights up for 3 seconds (Anti-hijack: enabled → disabled: lights up red, Anti-hijack: disabled → enabled: flashes green). This completes the setting procedure. B C D Changing Settings Using CONSULT-II E The settings for the Intelligent Key system functions can be changed using CONSULT-II (WORK SUPPORT). NOTE: Once a function setting is changed, it will remain effective even if the battery is disconnected. F INTELLIGENT KEY REGISTRATION Intelligent Key-ID registration is executed using the CONSULT-II. Up to 4 Intelligent Key can be registered. CAUTION: ● After a new Intelligent Key-ID is registered, be sure to check the function. ● When registering an additional Intelligent Key-ID, remove any registered Intelligent Keys out of the vehicle before starting. CONSULT-II can be used to check and delete Intelligent Key-IDs. For future information, see the CONSULT-II Operation Manual NATS. STEERING LOCK UNIT REGISTRATION Steering Lock Unit ID Registration CAUTION: The method for registering a steering lock unit ID depends on the status of the steering lock unit and Intelligent Key unit (new or old unit). After the registration procedures are completed ● Press and rotate the ignition knob while the registered Intelligent Key is within the vehicle to confirm the registration procedure. ● Press and rotate the ignition knob while the registered Intelligent Key is removed from the vehicle to confirm the registration procedure. For future information, see the CONSULT-II Operation Manual NATS. G H BL J K L M BL-137 INTELLIGENT KEY SYSTEM Schematic —I/KEY— BIS000K9 MIWA0720E BL-138 INTELLIGENT KEY SYSTEM Wiring Diagram — I/KEY— BIS000KA A B C D E F G H BL J K L M MIWA0721E BL-139 INTELLIGENT KEY SYSTEM MIWA0722E BL-140 INTELLIGENT KEY SYSTEM A B C D E F G H BL J K L M MIWA0723E BL-141 INTELLIGENT KEY SYSTEM MIWA0724E BL-142 INTELLIGENT KEY SYSTEM A B C D E F G H BL J K L M MIWA0725E BL-143 INTELLIGENT KEY SYSTEM MIWA0726E BL-144 INTELLIGENT KEY SYSTEM A B C D E F G H BL J K L M MIWA0727E BL-145 INTELLIGENT KEY SYSTEM MIWA0728E BL-146 INTELLIGENT KEY SYSTEM A B C D E F G H BL J K L M MIWA0729E BL-147 INTELLIGENT KEY SYSTEM MIWA0730E BL-148 INTELLIGENT KEY SYSTEM Terminals and Reference Value for INTELLIGENT KEY UNIT BIS000KB A Measuring condition Operation or conditions Voltage (V) (Approx.) Output LOCK — 5 CAN-H Input/ Output — — — Y CAN-L Input/ Output — — — P Intelligent Key warning buzzer Output Door request switch (driver side) Input Wire color 1 P Steering lock unit power supply 2 L 3 4 5 6 7 Signal Input/ Output Ignition knob position Terminal O O GR Item Ignition power supply Key switch Input Input C LOCK — Operate remote controller button or door request switch. 8 Door request switch operation: Press (ON). 0 Other than the above (OFF) 5 — Insert mechanical key into ignition key cylinder. Battery voltage Remove mechanical key from ignition key cylinder. 0 F G H ACC power supply Input ACC — Battery voltage 11 Y Battery power supply Input — — Battery voltage 12 B GND — — — 0 13 Y Inside key antenna (+) (Luggage room) BL Output LOCK Inside key antenna (-) (Luggage room) E Battery voltage L BR D Battery voltage Sound buzzer ON LOCK Buzzer OFF 10 14 B Output J Any door open → all doors shut (Door switch: ON → OFF) K SIIA1910J 15 V Inside key antenna (+) (Center console) Output Inside key antenna (-) (Center console) Output LOCK 16 LG L Any door open → Close (Door switch: ON → OFF) Ignition knob switch: ON (press ignition knob.) M SIIA1910J 17 B Out side antenna (+) Output 18 W Back door or trunk lid antenna (-) Output LOCK Back door request switch operation (Switch: ON) SIIA1910J 19 20 R Outside antenna (driver side) (+) W Outside antenna (driver side) (-) Output LOCK Driver door request signal operation (Switch: ON) Output SIIA1910J BL-149 INTELLIGENT KEY SYSTEM Measuring condition Terminal 25 26 Wire color LG R Item Signal Input/ Output Door request switch (passenger side) Input Stop lamp switch Input Ignition knob position — — Operation or conditions Door request switch operation: Press (ON) 0 Other than the above (OFF) 5 Brake pedal depressed (ON) Battery voltage Brake pedal not depressed (OFF) Press ignition knob. 27 29 31 32 O R Ignition knob switch Door request switch (back door) G Steering lock unit ground V Steering lock unit communication signal Input Input — Input/ Output — — 0 Battery voltage Return ignition knob to LOCK position. 0 Back door request switch operation: Press (ON) 0 Other than the above (OFF) 5 — LOCK Voltage (V) (Approx.) — 0 Press ignition knob with Intelligent Key inside vehicle. SIIA1911J Other than the above 35 P Inside key antenna (+) (Dashboard) Output Inside key antenna (-) (Dashboard) Output LOCK 36 L 5 Any door open → Close (Door switch: ON → OFF) Ignition knob switch: ON (Press ignition knob) SIIA1910J 37 BR Outside antenna (passenger side) (+) Output LOCK 38 Y Outside antenna (passenger side) (-) Passenger door request switch operation (Switch: ON) Output SIIA1910J 40 L Door lock relay Output — Press unlock button once (in all doors locked condition) BL-150 Battery voltage → 0 → Battery voltage INTELLIGENT KEY SYSTEM Terminals and Reference Value for Steering Lock unit BIS000KC A Measuring condition Terminal Wire color Item 1 Y Battery power supply 2 P Steering lock unit power supply Signal Input/ Output Ignition knob position Operation or conditions Voltage (V) (Approx.) Input LOCK — Battery voltage Input LOCK — 5 LOCK Press ignition knob with Intelligent Key inside vehicle. B C D 3 V Steering lock unit communication signal Input/ Output E SIIA1911J Other than the above 4 G Steering lock unit ground — — — 5 Terminal and Reference Value for BCM Terminal Wire color 2 B 3 GR 10 P Measuring condition — — 0 Key switch Input Mechanical key is removed from ignition knob (OFF) → Mechanical key is inserted in ignition knob (ON) 0 → Battery voltage Back door or trunk lid switch Input Back door or trunk lid open (ON) → Back door or trunk lid close (OFF) 0 → Battery voltage Ground 19 L CAN-H 24 O IGN power supply LG Front door switch LH (LHD models) BR Front door switch RH (RHD models) BR Front door switch RH (LHD models) LG Front door switch LH (RHD models) 29 30 BIS000KD Signal Input/ Output Item F 0 Voltage (V) (Approx.) Input/ Output — — Input Ignition knob ON or START position Battery voltage Input Door open (ON) → Door close (OFF) 0 → Battery voltage Input Door open (ON) → Door close (OFF) 0 → Battery voltage Input/ Output — — 39 R CAN-L 59 G Rear door switch LH Input Door open (ON) → Door close (OFF) 0 → Battery voltage 60 L Rear door switch RH Input Door open (ON) → Door close (OFF) 0 → Battery voltage BL-151 G H BL J K L M INTELLIGENT KEY SYSTEM Terminal Wire color Item Signal Input/ Output Measuring condition Voltage (V) (Approx.) When door lock operated using remote controller*1 65 LG Answer back (Turn signal lamp LH) PIIA2486J Output When door unlock operated using remote controller*1 PIIA2487J When door lock operated using remote controller*1 66 W Answer back (Turn signal lamp RH) PIIA2486J Output When door unlock operated using remote controller*1 PIIA2487J 67 Y Door lock actuator unlock (ALL Door) (Except driver side) Output Door lock/unlock switch UNLOCK operation 0 → Battery voltage 68 O Back door opener actuator Output Power window main switch (Back door release switch) OPEN operation Battery voltage → 0 70 B Ground 74 Y 75*2 — — 0 BAT power supply (fusible link) (BCM) Input — Battery voltage O Super lock set output (All door) Output Super lock operation (Set) 0 → Battery voltage 76 BR Door lock actuator unlock (Driver side) Output Door lock/unlock switch Unlock operation 0 → Battery voltage 77 SB Door lock actuator lock (ALL Door) Output Door lock/unlock switch LOCK operation 0 → Battery voltage 79 Y BAT power supply (fusible link) (Power window) Input — *1 : In the state that answer back operates *2 : Only the model equipped with super lock system (RHD Models) BL-152 Battery voltage INTELLIGENT KEY SYSTEM Trouble Diagnosis Procedure BIS0015E A PRELIMINALY CHECK B C D E F G H BL J K L M MIIB0940E *1: BL-193 *2: BL-157 *3: BL-158 *4: BL-157 *5: BL-155 *6: BL-158 *7: BL-158 *8: BL-154 *9: BL-226 BL-153 INTELLIGENT KEY SYSTEM WORK FLOW MIIB0941E *1: BL-16 *2: BL-59 *3: BL-159 *4: BL-159 *5: BL-161 *6: BL-135 *7: BL-161 *8: BL-163 BL-154 INTELLIGENT KEY SYSTEM CONSULT-II Function (INTELLIGENT KEY) BIS000KF A CONSULT-II can display each diagnostic item using the diagnostic test modes as shown below. Part to be diagnosed Test item, Diagnosis mode Intelligent Key Description B WORK SUPPORT Changes settings for each function. SELF-DIAG RESULTS Intelligent Key unit performs CAN communication diagnosis. DATA MONITOR Displays Intelligent Key unit input data in real time. CAN DIAGNOSTIC SUPPORT MONITOR The results of transmit/receive diagnosis of CAN Communication can be read. ACTIVE TEST Operation of electrical loads can be checked by sending driving signal to then. ECU PART NUMBER Displays Intelligent Key unit part No. C CONSULT-II Inspection Procedure BIS000KG CAUTION: If CONSULT-II is used with no connection CONSULT-II CONVERTER, malfunctions might be detected in self-diagnosis depending on control unit which performs CAN Communication. D E F BASIC OPERATION Refer to GI-36, "CONSULT-II Start Procedure" . G CONSULT-II Application Items BIS000KH SELF-DIAGNOSTIC RESULTS Self-diag results Description Diagnosis procedure Reference page CAN COMM Malfunction is detected in CAN communication. Check CAN communication system. BL-163 CAN COMM2 Intelligent Key unit internal malfunction Check CAN communication system. BL-163 STRG COMM Malfunction is detected in communication of Intelligent Key unit and steering lock unit. Check steering lock unit. BL-188 I-KEY C/U Intelligent Key unit internal malfunction Replace Intelligent Key unit. BL-193 IMMU NATS malfunction Check NATS. BL-215 DATA MONITOR H BL J K Monitor item Content PUSH SW Indicates [ON/OFF] condition of ignition knob switch. KEY SW Indicates [ON/OFF] condition of key switch. DR REQ SW Indicates [ON/OFF] condition of door request switch (driver side). AS REQ SW Indicates [ON/OFF] condition of door request switch (passenger side). BD/TR REQ SW Indicates [ON/OFF] condition of trunk opener request switch. IGN SW Indicates [ON/OFF] condition of ignition switch in ON position. ACC SW Indicates [ON/OFF] condition of ignition switch in ACC position. STOP LAMP SW Indicates [ON/OFF] condition of door unlock sensor. DOOR LOCK SIG* Indicates [ON/OFF] condition of door lock signal from Intelligent Key remote controller button. DOOR UNLOCK SIG* Indicates [ON/OFF] condition of door unlock signal from Intelligent Key remote controller button. DOOR SW DR* Indicates [OPEN/CLOSE] condition of front door switch driver side from BCM via CAN communication line. DOOR SW AS* Indicates [OPEN/CLOSE] condition of front door switch passenger side from BCM via CAN communication line. DOOR SW RR* Indicates [OPEN/CLOSE] condition of rear door switch LH from BCM via CAN communication line. DOOR SW RL* Indicates [OPEN/CLOSE] condition of rear door switch RH from BCM via CAN communication line. DOOR BK SW* Indicates [OPEN/CLOSE] condition of back door switch from BCM via CAN communication line. VEHICLE SPEED* Indicates [km/h] condition of vehicle speed. BL-155 L M INTELLIGENT KEY SYSTEM *: Select “SELECTION FROM MENU”. ACTIVE TEST Monitor item Description DOOR LOCK/UNLOCK This test is able to check all door lock actuators lock operation. These actuators lock when “LOCK” on CONSULT-II screen is touched. OUTSIDE BUZZER This test is able to check Intelligent Key warning buzzer operation. The buzzer will be activated on when “ON” on CONSULT-II screen is touched. INSIDE BUZZER This test is able to check buzzer (built in combination meter) operation. The buzzer will be activated on when either “TAKE OUT”, “KNOB” or “KEY” on CONSULT-II screen is touched. INDICATOR This test is able to check warning lamp operation. The lamp will be turned on when either “BLUE ON”, “BLUE IND”, “RED ON”, “RED IND”, “KNOB ON” or “KNOB IND” on CONSULT-II screen is touched. KEY LOCK SOLENOID This test is able to LOCK/UNLOCK the key lock solenoid. WORK SUPPORT Monitor item Description CONFIRM KEY FOB ID It can be checked whether Intelligent Key ID code is registered or not in this mode. LOW BAT OF KEY FOB WARN Intelligent Key low battery warning mode can be changed to operate (ON) or not operate (OFF) with this mode. SELECTIVE UNLOCK FUNCTION Selective unlock function mode can be changed to operate (ON) or not operate (OFF) with this mode. INTELLIGENT KEY FUNCTION All of the Intelligent Key functions can be changed to operate (ON) or not operate (OFF) with this mode. ANSWER BACK WITH I-KEY LOCK Answer back buzzer (external buzzer) function can be changed to operate (ON) or not operate (OFF) with this mode. ANSWER BACK WITH I-KEY UNLOCK Answer back buzzer (external buzzer) function (unlock operation) can be changed to operate (ON) or not operate (OFF) with this mode. AUTO RELOCK TIMER Auto door lock timer mode can select with this mode. ENGINE START BY I-KEY Engine start function mode can be changed to operate (ON) or not operate (OFF) with this mode. LOCK/UNLOCK BY I-KEY Door lock/unlock function by door request switch (driver side, passenger side and back door) mode can be changed to operate (ON) or not operate (OFF) with this mode. BL-156 INTELLIGENT KEY SYSTEM Trouble Diagnosis Symptom Chart BIS0015F A KEY WARNING LAMP (GREEN) ILLUMINATES NOTE: ● Before performing the diagnosis in the following table, check “Trouble Diagnosis Procedure”. Refer to BL153, "Trouble Diagnosis Procedure" ● Make sure that vehicle is under the condition shown in “Conditions of vehicle” before starting diagnosis, and check each symptom. ● If the following “symptoms” are detected, check systems shown in the “Diagnoses/service procedure” column in this order. B C Conditions of Vehicle (Operating Conditions) ● ● ● D Intelligent Key is registered. Key is not inserted in ignition switch. One or more registered Intelligent Keys are in the vehicle. Symptom Ignition switch does not turn on with Intelligent Key. [KEY warning lamp (green) illuminates.] Diagnosis/service procedure E Reference page 1. Check steering lock unit. BL-188 2. Replace Intelligent Key unit. BL-193 F KEY WARNING LAMP (RED) ILLUMINATES G NOTE: ● Before performing the diagnosis in the following table, check “Trouble Diagnosis Procedure”. Refer to BL153, "Trouble Diagnosis Procedure" . ● Make sure that vehicle is under the condition shown in “Conditions of vehicle” before starting diagnosis, H and check each symptom. ● If the following “symptoms” are detected, check systems shown in the “Diagnoses/service procedure” column in this order. BL Conditions of Vehicle (Operating Conditions) ● ● ● Intelligent Key is registered. Key is not inserted in ignition switch. One or more registered Intelligent Keys are in the vehicle. Symptom Ignition switch does not turn on with Intelligent Key. [KEY warning lamp (red) illuminates.] Diagnosis/service procedure J Reference page 1. Check inside key antenna. BL-187 2. Replace Intelligent Key unit. BL-193 K L M BL-157 INTELLIGENT KEY SYSTEM KEY WARNING LAMP DOES NOT ILLUMINATE NOTE: ● Before performing the diagnosis in the following table, check “Trouble Diagnosis Procedure”. Refer to BL153, "Trouble Diagnosis Procedure" . ● Make sure that vehicle is under the condition shown in “Conditions of vehicle” before starting diagnosis, and check each symptom. ● If the following “symptoms” are detected, check systems shown in the “Diagnoses/service procedure” column in this order. ● Check if ignition switch turns using mechanical key. If it turns, check if “ENGINE START BY I-KEY” in “WORK SUPPORT” mode is ON. Conditions of Vehicle (Operating Conditions) ● ● ● Intelligent Key is registered. Key is not inserted in ignition switch. One or more registered Intelligent Keys are in the vehicle. Symptom Diagnosis/service procedure Ignition switch does not turn on with Intelligent Key. (KEY warning lamp does not illuminate.) Reference page 1. Check Intelligent Key unit power supply and ground circuit. BL-164 2. Check ignition knob switch. BL-168 3. Check key switch. BL-165 4. Replace Intelligent Key unit. BL-193 SELF-DIAGNOSIS RESULTS ARE NOT DISPLAYED NOTE: ● Before performing the diagnosis in the following table, check “Trouble Diagnosis Procedure”. Refer to BL153, "Trouble Diagnosis Procedure" . ● Make sure that vehicle is under the condition shown in “Conditions of vehicle” before starting diagnosis, and check each symptom. ● If the following “symptoms” are detected, check systems shown in the “Diagnoses/service procedure” column in this order. Conditions of Vehicle (Operating Conditions) ● ● Intelligent Key is registered. Multiple mechanical keys are not set in a keyfob. (If mechanical keys are near the ignition switch, the operation may not work properly.) Symptom Ignition switch does not turn on with mechanical key. Diagnosis/service procedure Reference page 1. Check key switch. BL-165 2. Check NATS antenna amp. BL-233 ENGINE START CONDITION CHECK NOTE: ● Before performing the diagnosis in the following table, check “Trouble Diagnosis Procedure”. Refer to BL153, "Trouble Diagnosis Procedure" . ● If the following “symptoms” are detected, check systems shown in the ”Diagnoses/service procedure” column in this order. Symptom Engine start condition check Diagnosis/service procedure 1. Check stop lamp switch. BL-158 Reference page BL-192 INTELLIGENT KEY SYSTEM DOOR LOCK/UNLOCK FUNCTION MALFUNCTION NOTE: ● Before performing the diagnosis in the following table, check “Trouble Diagnosis Procedure”. Refer to BL153, "Trouble Diagnosis Procedure" . ● Make sure that vehicle is under the condition shown in “Conditions of vehicle” before starting diagnosis, and check each symptom. ● If the following “symptoms” are detected, check systems shown in the “Diagnosis/procedure” column in this order. A B C Conditions of Vehicle (Operating Conditions) ● ● ● “LOCK/UNLOCK BY I-KEY” is ON when setting on CONSULT-II. Ignition switch is not depressed. All doors are closed. Symptom Door lock/unlock do not operate by all request switch. Door lock/unlock does not operate by request switch (driver side). Door lock/unlock does not operate by request switch (passenger side). Door lock/unlock does not operate by back door request switch. Anti-hijack function does not operate by door request switch (driver side) (other door lock function operate). Anti-hijack function does not operate by back door request switch (other door lock function operate). Auto lock function does not operate. Key reminder function does not operate. Diagnosis/service procedure D Reference page 1. Check door switch. BL-174 2. Check key switch. BL-165 3. Check ignition knob switch. BL-168 4. Replace Intelligent Key unit. BL-193 1. Check door request switch (driver side). BL-170 2. Check outside key antenna (driver side). BL-184 3. Replace Intelligent Key unit. BL-193 1. Check door request switch (passenger side). BL-170 2. Check outside key antenna (passenger side). BL-184 3. Replace Intelligent Key unit. BL-193 1. Check back door request switch. BL-172 2. Check outside key antenna (back door). BL-185 3. Replace Intelligent Key unit. BL-193 1. Check “SELECTIVE UNLOCK FUNCTION” setting in “WORK SUPPORT”. BL-156 2. Replace BCM. BCS-17 1. Check “SELECTIVE UNLOCK FUNCTION” setting in “WORK SUPPORT”. BL-156 2. Replace BCM. BCS-17 1. Check “AUTO RELOCK TIMER” setting in “WORK SUPPORT”. BL-156 2. Check key switch. BL-165 3. Check ignition knob switch. BL-168 4. Check door switch. BL-174 5. Replace Intelligent Key unit. BL-193 1. Check door switch. BL-174 2. Check inside key antenna. BL-187 3. Check Intelligent Key battery inspection. BL-193 4. Replace Intelligent Key unit. BL-193 REMOTE KEYLESS ENTRY FUNCTION MALFUNCTION NOTE: ● Before performing the diagnosis in the following table, check “Trouble Diagnosis Procedure”. Refer to BL153, "Trouble Diagnosis Procedure" . ● Make sure that vehicle is under the condition shown in “Conditions of vehicle” before starting diagnosis, and check each symptom. BL-159 E F G H BL J K L M INTELLIGENT KEY SYSTEM ● If the following “symptoms” are detected, check systems shown in the “Diagnosis/service procedure” column in this order. Conditions of Vehicle (Operating Conditions) ● ● Ignition switch is not depressed. All doors are closed. Symptom All of the remote keyless entry functions do not operate. Anti-hijack function does not operate by Intelligent Key button. Auto lock function does not operate. Key reminder function does not operate. Diagnosis/service procedure Reference page 1. Check Intelligent Key battery inspection. BL-193 2. Replace Intelligent Key unit. BL-193 1. Check “SELECTIVE UNLOCK FUNCTION” setting in “WORK SUPPORT”. BL-156 2. Check Intelligent Key battery inspection. BL-193 3. Replace Intelligent Key unit. BL-193 1. Check “AUTO RELOCK TIMER” setting in “WORK SUPPORT”. BL-156 2. Check key switch. BL-165 3. Check ignition knob switch. BL-168 4. Check door switch. BL-174 5. Replace Intelligent Key unit. BL-193 1. Check door switch. BL-174 2. Check inside key antenna. BL-187 3. Check Intelligent Key battery inspection. BL-193 4. Replace Intelligent Key unit. BL-193 BL-160 INTELLIGENT KEY SYSTEM HAZARD AND BUZZER REMINDER FUNCTION MALFUNCTION NOTE: ● Before performing the diagnosis in the following table, check “Trouble Diagnosis Procedure”. Refer to BL153, "Trouble Diagnosis Procedure" . ● Make sure that vehicle is under the condition shown in “Conditions of vehicle” before starting diagnosis, and check each symptom. ● If the following “symptoms” are detected, check systems shown in the “Diagnosis/service procedure” column in this order. A B C Conditions of Vehicle (Operating Conditions) ● ● Ignition switch is not depressed. All doors are closed. D Symptom Diagnosis/service procedure Reference page Hazard reminder does not operate by request switch. (Buzzer reminder is operated.) 1. Check hazard function with hazard switch. 2. Replace Intelligent Key unit Hazard reminder does not operate by Intelligent Key button. (Buzzer reminder is operated.) 1. Check hazard function with hazard switch. 2. Replace Intelligent Key BL-193 1. Check “ANSWER BACK WITH I-KEY LOCK” or “ANSWER BACK WITH I-KEY UNLOCK” setting in “WORK SUPPORT”. BL-156 2. Check Intelligent Key warning buzzer. BL-183 3. Replace Intelligent Key unit. BL-193 Buzzer reminder does not operate properly by request switch. (Hazard reminder is operated.) LT-98 E BL-193 LT-98 F G H WARNING CHIME FUNCTION MALFUNCTION BL NOTE: ● Before performing the diagnosis in the following table, check “Trouble Diagnosis Procedure”. Refer to BL153, "Trouble Diagnosis Procedure" . ● Make sure that vehicle is under the condition shown in “Conditions of vehicle” before starting diagnosis, J and check each symptom. ● If the following “symptoms” are detected, check systems shown in the “Diagnosis/service procedure” column in this order. K Conditions of Vehicle (Operating Conditions) Each warning chime function is ON when setting on CONSULT-II. Symptom Ignition switch warning chime does not operate. Ignition key warning chime does not operate. (When mechanical key used) OFF position warning chime (For internal) does not operate. Diagnosis/service procedure Reference page 1. Check ignition knob switch. BL-168 2. Check door switch BL-174 3. Check key switch BL-165 4. Check warning buzzer in combination meter. BL-191 5. Replace Intelligent Key unit. BL-193 1. Check key switch (Intelligent Key unit input). BL-165 2. Check key switch (BCM input). BL-167 3. Check door switch. BL-174 4. Check warning buzzer in combination meter. BL-191 5. Replace Intelligent Key unit. BL-193 1. Check ignition switch signal circuit BL-164 2. Check ignition knob switch. BL-168 3. Check key switch BL-165 4. Check warning buzzer in combination meter. BL-191 5. Replace Intelligent Key unit. BL-193 BL-161 L M INTELLIGENT KEY SYSTEM Symptom OFF position warning chime (For external) does not operate. Take away warning chime does not operate. Take away warning chime (Take away from window) does not operate. Door lock operation warning chime does not operate. Diagnosis/service procedure Reference page 1. Check ignition switch signal circuit BL-164 2. Check ignition knob switch. BL-168 3. Check Intelligent Key warning buzzer. BL-183 4. Replace Intelligent Key unit. BL-193 1. Check door switch. BL-174 2. Check ignition switch signal circuit BL-164 3. Check Intelligent Key battery inspection BL-193 4. Check inside key antenna. BL-187 5. Check Intelligent Key warning buzzer. BL-191 6. Replace Intelligent Key unit. BL-193 1. Check “TAKE OUT FROM WINDOW WARN” setting in “WORK SUPPORT”. BL-156 2. Check inside key antenna. BL-187 3. Check key switch. BL-165 4. Check Intelligent Key battery inspection BL-193 5. Check warning buzzer in combination meter. BL-191 6. Replace Intelligent Key unit. BL-193 1. Check door switch BL-174 2. Check ignition knob switch BL-168 3. Check door request switch BL-170 4. Check back door request switch BL-172 4. Check outside key antenna BL-184 5. Check inside key antenna BL-187 6. Check Intelligent Key warning buzzer. BL-183 7. Replace Intelligent Key unit. BL-193 BL-162 INTELLIGENT KEY SYSTEM WARNING LAMP FUNCTION MALFUNCTION NOTE: ● Before performing the diagnosis in the following table, check “Trouble Diagnosis Procedure”. Refer to BL153, "Trouble Diagnosis Procedure" . ● If the following “symptoms” are detected, check systems shown in the “Diagnosis/service procedure” column in this order. Symptom Intelligent Key low battery warning does not operate. Diagnosis/service procedure Reference page 1. Check “LOW BAT OF KEY FOB WARN” setting in “WORK SUPPORT”. BL-156 2. Check Intelligent Key battery inspection. BL-193 3. Check warning lamp. BL-191 4. Replace Intelligent Key unit. BL-193 Take away warning lamp does not illuminate. (Take away warning chime is operated.) 1. Check warning lamp. BL-191 2. Replace Intelligent Key unit. BL-193 Ignition switch warning lamp does not illuminate. (Ignition switch warning chime is operated) 1. Check warning lamp. BL-191 2. Replace Intelligent Key unit. BL-193 Check CAN Communication System A B C D E F BIS0015G 1. CHECK SELF-DIAGNOSTIC RESULTS G CAUTION: If CONSULT-II is used with no connection of CONSULT-II CONVERTER, malfunctions might be detected in self-diagnosis depending on control unit which performs CAN communication. H ● ● ● ● With CONSULT-II Connect CONSULT-II, and turn ignition switch ON. Touch “INTELLIGENT KEY” on “SELECT SYSTEM” screen. Touch “SELF-DIAG RESULTS” on “SELECT DIAG MODE” screen. Check display content in self-diagnostic results. BL J CONSULT-II display item DTC code NO DTC IS DETECTED — CAN COMM U1000 CAN COMM2 U1010 OK or NG NO DTC IS DETECTED>> INSPECTION END CAN COMM [U1000]>> After printing “SELF-DIAGNOSIS RESULTS”, go to “CAN SYSTEM”, Refer to LAN3, "Precautions When Using CONSULT-II" . CAN COMM2 [U1010]>> Replace Intelligent Key unit. BL-163 K L M INTELLIGENT KEY SYSTEM Check Power Supply and Ground Circuit BIS00162 1. CHECK POWER SUPPLY CIRCUIT 1. 2. 3. Turn ignition switch OFF. Disconnect Intelligent Key unit connector. Check voltage between Intelligent Key unit harness connector and ground. Terminals (+) Intelligent Key unit connector Terminal M60 11 (–) Voltage (V) (Approx.) Ground Battery voltage OK or NG OK >> GO TO 2. NG >> Repair or replace Intelligent Key power supply circuit. PIIB6595E 2. CHECK GROUND CIRCUIT Check continuity between Intelligent Key unit harness connector and ground. Intelligent Key unit connector M60 Terminal Continuity Ground 12 Yes OK or NG OK >> Power supply and ground circuits are OK. NG >> Repair or replace the Intelligent Key unit ground circuit. PIIB6596E Check Ignition Switch Signal Circuit BIS0016K 1. CHECK IGNITION SWITCH SIGNAL 1. 2. 3. Turn ignition switch OFF. Disconnect Intelligent Key unit connector. Check voltage between Intelligent Key unit harness connector and ground. Intelligent Key unit connector Terminal Ignition switch position (+) (–) OFF ACC ON M60 6 Ground 0V 0V Battery voltage OK or NG OK >> Ignition switch signal circuit is OK. NG >> Check the following. ● 10A fuse [No. 5, located in fuse and fusible link box (J/B)] ● Between Intelligent Key unit and fuse. BL-164 PIIB6884E INTELLIGENT KEY SYSTEM Check Key Switch (Intelligent Key Unit Input) BIS00163 1. CHECK KEY SWITCH INPUT SIGNAL A With CONSULT-II Check key switch (“KEY SW”) in “DATA MONITOR” mode with CONSULT-II. B Monitor item Condition Insert mechanical key into ignition switch: ON KEY SW C Remove mechanical key from ignition switch: OFF D E PIIB1359E Without CONSULT-II 1. Turn ignition switch OFF. 2. Disconnect Intelligent Key unit connector. 3. Check voltage between Intelligent Key unit and ground. F G Terminals (+) Intelligent Key unit connector (–) Terminal Insert mechanical key into ignition switch M60 7 Ground H Voltage (V) (Approx.) Condition of key switch BL Battery voltage Remove mechanical key from ignition switch 0 OK or NG OK >> Key switch circuit is OK. NG >> GO TO 2. J PIIB6597E K 2. CHECK KEY SWITCH POWER SUPPLY CIRCUIT 1. 2. 3. L Remove mechanical key from ignition switch. Disconnect key switch and ignition knob switch connector. Check voltage between key switch and ignition knob switch and ground. M Terminals (+) Key switch and ignition knob switch connector Terminal M34 2 (–) Voltage (V) (Approx.) Ground Battery voltage OK or NG OK >> GO TO 3. NG >> Repair or replace key switch and ignition knob switch power supply circuit. BL-165 PIIB6598E INTELLIGENT KEY SYSTEM 3. CHECK KEY SWITCH Check continuity key switch and ignition knob switch. Terminal Condition of key switch Continuity Insert mechanical key into ignition switch Yes Remove mechanical key from ignition switch No Key switch and ignition knob switch 1 2 OK or NG OK >> GO TO 4. NG >> Replace key cylinder assembly (built-in key switch). PIIB6599E 4. CHECK KEY SWITCH CIRCUIT 1. 2. Disconnect Intelligent Key unit connector. Check continuity between Intelligent Key unit and key switch and ignition knob switch. A 3. B Intelligent Key unit connector Terminal Key switch and ignition knob switch connector Terminal M60 7 M34 1 Continuity Yes Check continuity between Intelligent Key unit and ground. A Intelligent Key unit connector Terminal M60 7 Ground Continuity PIIB6600E No OK or NG OK >> Check the condition of harness and harness connector. NG >> Repair or replace harness between Intelligent Key unit and key switch and ignition knob switch. BL-166 INTELLIGENT KEY SYSTEM Check Key Switch (BCM Input) BIS00164 1. CHECK KEY SWITCH POWER SUPPLY CIRCUIT A 1. 2. 3. B Remove mechanical key from ignition switch. Disconnect key switch and ignition knob switch connector. Check voltage between key switch and ignition knob switch and ground. C Terminals (+) Key switch and ignition knob switch connector Terminal M34 2 (–) Voltage (V) (Approx.) Ground Battery voltage OK or NG OK >> GO TO 2. NG >> Check harness between key switch and ignition knob switch and fuse. D E PIIB6598E F 2. CHECK KEY SWITCH OPERATION G Check continuity key switch and ignition knob switch. Terminal Key switch and ignition knob switch 1 2 Condition of key switch Continuity Insert mechanical key into ignition switch Yes Remove mechanical key from ignition switch No H BL OK or NG OK >> GO TO 3. NG >> Replace key cylinder assembly (built-in key switch). J PIIB6599E 3. CHECK KEY SWITCH CIRCUIT K 1. 2. L Disconnect BCM connector. Check continuity between BCM and key switch and ignition knob switch. A 3. B BCM connector Terminal Key switch and ignition knob switch connector Terminal M57 3 M34 1 Continuity M Yes Check continuity between BCM and ground. A Continuity BCM connector Terminal M57 3 Ground MIIB1443E No OK or NG OK >> Key switch (BCM input) circuit is OK. NG >> Repair or replace harness between key switch and ignition knob switch and BCM. BL-167 INTELLIGENT KEY SYSTEM Check Ignition Knob Switch BIS00165 1. CHECK IGNITION KNOB SWITCH INPUT SIGNAL With CONSULT-II Display “PUSH SW” on DATA MONITOR screen, and check if ON/OFF display is linked to ignition switch operation. Monitor item Condition Ignition switch is pressed: ON PUSH SW Ignition switch is released: OFF PIIB1360E Without CONSULT-II 1. Turn ignition switch OFF. 2. Disconnect Intelligent Key unit connector. 3. Check voltage between Intelligent Key unit and ground. Terminals (+) Intelligent Key unit connector M60 Terminal 27 (–) Ground Condition of key switch Voltage (V) (Approx.) Ignition switch is pressed Battery voltage Ignition switch is released 0 OK or NG OK >> Ignition knob switch circuit is OK. NG >> GO TO 2. PIIB6602E 2. CHECK IGNITION KNOB SWITCH POWER SUPPLY CIRCUIT 1. 2. 3. Turn ignition switch OFF. Disconnect key switch and ignition knob switch connector. Check voltage between key switch and ignition knob switch and ground. Terminals (+) Key switch and ignition knob switch connector Terminal M34 4 (–) Voltage (V) (Approx.) Ground Battery voltage OK or NG OK >> GO TO 3. NG >> Repair or replace key switch and ignition knob switch power supply circuit. BL-168 PIIB6603E INTELLIGENT KEY SYSTEM 3. CHECK IGNITION KNOB SWITCH A Check continuity ignition knob switch. Terminal Condition of key switch Continuity Ignition switch is pressed Yes Ignition switch is released No Key switch and ignition knob switch 3 4 B C OK or NG OK >> GO TO 4. NG >> Replace key switch and ignition knob switch. D PIIB6604E E 4. CHECK IGNITION KNOB SWITCH CIRCUIT 1. 2. Disconnect Intelligent Key unit connector. Check continuity between Intelligent Key unit and key switch and ignition knob switch. A 3. F B Intelligent Key unit connector Terminal Key switch and ignition knob switch connector Terminal M60 27 M34 3 Continuity G Yes H Check continuity between Intelligent Key unit and ground. A Intelligent Key unit connector Terminal M60 27 Ground BL Continuity PIIB6605E No OK or NG OK >> Check the condition of harness and harness connector. NG >> Repair or replace harness between Intelligent Key unit and key switch and ignition knob switch. J K L M BL-169 INTELLIGENT KEY SYSTEM Check Door Request Switch BIS00166 1. CHECK DOOR REQUEST SWITCH With CONSULT-II Check door request switch (“DR REQ SW” or “AS REQ SW”) in “DATA MONITOR” mode. Monitor item Condition Door request switch is pressed: ON DR REQ SW AS REQ SW Door request switch is released: OFF PIIB4260E Without CONSULT-II 1. Turn ignition switch OFF. 2. Check voltage between Intelligent Key unit harness connector and ground. Terminals (+) Intelligent Key unit connector M60 Terminal Door request switch (driver side) 5 Door request switch (passenger side) 25 (–) Door request switch Condition Voltage (V) (Approx.) Pressed 0 Released 5 Pressed 0 Released 5 Ground OK or NG OK >> Door request switch circuit is OK. NG >> GO TO 2. BL-170 PIIB6613E INTELLIGENT KEY SYSTEM 2. CHECK DOOR REQUEST SWITCH CIRCUIT 1. 2. A Disconnect Intelligent Key unit and front door request switch connector. Check continuity between Intelligent Key unit connector and front door request switch connector. B A Intelligent Key unit connector B Front door request switch connector Terminal 5 Driver side D12 25 Passenger side D29 M60 3. Continuity Terminal C 1 Yes D Check continuity between Intelligent Key unit connector and ground. PIIB6614E A Intelligent Key unit connector Continuity Terminal Ground F 5 M60 E No 25 OK or NG OK >> GO TO 3. NG >> Repair or replace harness between Intelligent Key unit and front door request switch. G 3. CHECK DOOR REQUEST SWITCH OPERATION H Check front door request switch. Terminal Front outside handle 1 2 BL Door request switch condition Continuity Pressed Yes Released No J OK or NG OK >> GO TO 4. NG >> Replace malfunction front door request switch. K PIIB6615E L 4. CHECK DOOR REQUEST SWITCH GROUND CIRCUIT M Check continuity between front door request switch connector and ground. Front outside handle connector Driver side D12 Passenger side D29 Terminal Continuity Ground 2 Yes OK or NG OK >> GO TO 5. NG >> Repair or replace front door request switch ground circuit. BL-171 PIIB6616E INTELLIGENT KEY SYSTEM 5. CHECK INTELLIGENT KEY UNIT OUTPUT SIGNAL 1. 2. Connect Intelligent Key unit connector. Check voltage between Intelligent Key unit connector and ground. Terminals (+) Intelligent Key unit connector Terminal (–) Voltage (V) (Approx.) Ground 5 5 M60 25 OK or NG OK >> Check the condition of harness and connector. NG >> Replace Intelligent Key unit. PIIB6613E Check Back Door Request Switch BIS00167 1. CHECK BACK DOOR REQUEST SWITCH With CONSULT-II Check back door request switch (“BD/TR REQ SW”) in “DATA MONITOR” mode. Monitor item Condition Back door request switch is pressed: ON BD/TR REQ SW Back door request switch is released: OFF PIIB4266E 1. 2. Without CONSULT-II Turn ignition switch OFF. Check voltage between Intelligent Key unit connector and ground. Terminals (+) Intelligent Key unit connector Terminal M60 29 (–) Ground Back door request switch condition Voltage (V) (Approx.) Pressed 0 Released 5 OK or NG OK >> Trunk lid request switch circuit is OK. NG >> GO TO 2. PIIB6617E BL-172 INTELLIGENT KEY SYSTEM 2. CHECK BACK DOOR REQUEST SWITCH CIRCUIT 1. 2. A Disconnect Intelligent Key unit and back door request switch connector. Check continuity between Intelligent Key unit connector and back door request switch connector. B A B Intelligent Key unit connector Terminal Back door switch connector Terminal M60 29 D102 1 3. Continuity C Yes Check continuity between Intelligent Key unit connector and ground. D A Continuity Intelligent Key unit connector Terminal M60 29 Ground MIIB1444E E No OK or NG OK >> GO TO 3. NG >> Repair or replace harness between Intelligent Key unit and back door request switch. F 3. CHECK BACK DOOR REQUEST SWITCH OPERATION G Check back door request switch. H Terminal Back door request switch 1 2 Back door request switch condition Continuity Pressed Yes Released No BL OK or NG OK >> GO TO 4. NG >> Replace trunk lid request switch. J MIIB1445E K 4. CHECK BACK DOOR REQUEST SWITCH GROUND CIRCUIT L Check continuity between back door request switch connector and ground. Back door request switch connector Terminal D102 2 Continuity M Ground Yes OK or NG OK >> GO TO 5. NG >> Repair or replace back door request switch ground circuit. MIIB1446E BL-173 INTELLIGENT KEY SYSTEM 5. CHECK INTELLIGENT KEY UNIT OUTPUT SIGNAL 1. 2. Connect Intelligent Key unit connector. Check voltage between Intelligent Key unit connector and ground. Terminals (+) Intelligent Key unit connector Terminal M60 29 (–) Voltage (V) (Approx.) Ground 5 OK or NG OK >> Check the condition of harness and connector. NG >> Replace Intelligent Key unit. PIIB6617E Check Door Switch BIS0016J DRIVER SIDE 1. CHECK DOOR SWITCH INPUT SIGNAL With CONSULT- II Check door switch “DOOR SW-DR” in “DATA MONITOR” mode with CONSULT- II. When front door (driver side) is opened: DOOR SW-DR Þ ON When front door (driver side) is close: DOOR SW-DR Þ OFF MIIB1050E Without CONSULT- II Check voltage between BCM connector and ground. Connector M57 Terminals (Wire color) (+) (-) 29 Ground Condition Voltage (V) (Approx.) Open 0 Close Battery voltage OK or NG OK >> Front door switch LH is OK. NG >> GO TO 2. MIIB0342E BL-174 INTELLIGENT KEY SYSTEM 2. CHECK HARNESS CONTINUITY 1. 2. 3. 29 – 1 4. A Turn ignition switch OFF. Disconnect BCM and front door switch LH connector. Check continuity between BCM connector M57 terminal 29 and front door switch LH connector B14 terminal 1. B : Continuity should exist. C Check continuity between BCM connector M57 terminal 29 and ground. 29 – Ground D : Continuity should not exist. OK or NG OK >> GO TO 3. NG >> Repair or replace harness. MKIB0849E 3. CHECK DOOR SWITCH E F Check continuity between door switch terminal 1 and body ground part of door switch. Terminal 1 Body ground part of door switch Condition Continuity Pushed No Released Yes G OK or NG OK >> GO TO 4. NG >> Replace door switch. H BL PIIA3351E J 4. CHECK BCM OUTPUT SIGNAL 1. 2. Connect BCM connector. Check voltage between BCM connector M57 terminal 29 and ground. 29 – Ground K : Battery voltage L OK or NG OK >> Check door switch ground condition. NG >> Replace BCM. M MIIB0342E BL-175 INTELLIGENT KEY SYSTEM PASSENGER SIDE 1. CHECK DOOR SWITCH INPUT SIGNAL With CONSULT- II Check door switch “DOOR SW-AS” in “DATA MONITOR” mode with CONSULT- II. When front door (passenger side) is opened: DOOR SW-AS Þ ON When front door (passenger side) is close: DOOR SW-AS Þ OFF MIIB1051E Without CONSULT- II Check voltage between BCM connector M57 terminal 30 and ground. Terminal (Wire color) Connector M57 (+) (-) 30 Ground Condition Voltage (V) (Approx.) Open 0 Close Battery voltage OK or NG OK >> Front door switch RH is OK. NG >> GO TO 2. MIIB0344E 2. CHECK HARNESS CONTINUITY 1. 2. 3. Turn ignition switch OFF. Disconnect BCM and front door switch RH connector. Check continuity between BCM connector M57 terminal 30 and front door switch RH connector B29 terminal 1. 30 – 1 4. : Continuity should exist. Check continuity between BCM connector M57 terminal 30 and ground. 30 – Ground : Continuity should not exist. OK or NG OK >> GO TO 3. NG >> Repair or replace harness. MKIB0850E BL-176 INTELLIGENT KEY SYSTEM 3. CHECK DOOR SWITCH A Check continuity between door switch terminal 1 and body ground of door switch. Terminal 1 Ground Condition Continuity Pushed No Released Yes B OK or NG OK >> GO TO 4. NG >> Replace door switch. C D PIIA3351E E 4. CHECK BCM OUTPUT SIGNAL 1. 2. Connect BCM connector. Check voltage between BCM connector M57 terminal 30 and ground. 30 – Ground F : Battery voltage G OK or NG OK >> Check door switch ground condition. NG >> Replace BCM. H BL MIIB0344E J K L M BL-177 INTELLIGENT KEY SYSTEM REAR LH SIDE 1. CHECK DOOR SWITCH INPUT SIGNAL With CONSULT- II Check door switch “DOOR SW-RL” in “DATA MONITOR” mode with CONSULT- II. When rear door (LH side) is opened: DOOR SW-RL Þ ON When rear door (LH side) is close: DOOR SW-RL Þ OFF MIIB1052E Without CONSULT- II Check voltage between BCM connector M58 terminal 59 and ground. Terminal (Wire color) Connector M58 Voltage (V) (Approx.) Condition (+) (-) 59 Ground Open 0 Close Battery voltage OK or NG OK >> Rear door switch LH is OK. NG >> GO TO 2. MIIB0346E 2. CHECK HARNESS CONTINUITY 1. 2. 3. Turn ignition switch OFF. Disconnect BCM and rear door switch LH connector. Check continuity between BCM connector and rear door switch LH connector. A 4. B Continuity BCM connector Terminal Rear door switch LH Terminal M58 59 B19 1 Yes Check continuity between BCM connector and ground. A Continuity BCM connector Terminal M58 59 Ground No OK or NG OK >> GO TO 3. NG >> Repair or replace harness. BL-178 MIIB1374E INTELLIGENT KEY SYSTEM 3. CHECK DOOR SWITCH A Check continuity between door switch terminal 1 and body ground of door switch. Terminals 1 Condition Ground Continuity Pushed NO Released YES B C OK or NG OK >> GO TO 4. NG >> Replace door switch. D PIIA3351E E 4. CHECK BCM OUTPUT SIGNAL 1. 2. Connect BCM connector. Check voltage between BCM connector M58 terminal 58 and ground. 59 – Ground F : Battery voltage OK or NG OK >> Check door switch ground condition. NG >> Replace BCM. G H BL MIIB0346E J K L M BL-179 INTELLIGENT KEY SYSTEM REAR RH SIDE 1. CHECK DOOR SWITCH INPUT SIGNAL With CONSULT- II Check door switch “DOOR SW-RR” in “DATA MONITOR” mode with CONSULT- II. When rear door (RH side) is opened: DOOR SW-RR Þ ON When rear door (RH side) is close: DOOR SW-RR Þ OFF MIIB1053E Without CONSULT- II Check voltage between BCM connector and ground. Terminal (Wire color) Connector M58 Voltage (V) (Approx.) Condition (+) (-) 60 (L) Ground Open 0 Close Battery voltage OK or NG OK >> Rear door switch RH is OK. NG >> GO TO 2. MIIB0348E 2. CHECK HARNESS CONTINUITY 1. 2. 3. Turn ignition switch OFF. Disconnect BCM and rear door switch RH connector. Check continuity between BCM connector and rear door switch RH connector. A 4. B Continuity BCM connector Terminal Rear door switch RH Terminal M58 60 B42 1 Yes Check continuity between BCM connector and ground. A Continuity BCM connector Terminal M58 60 Ground No OK or NG OK >> GO TO 3. NG >> Repair or replace harness. BL-180 MIIB1375E INTELLIGENT KEY SYSTEM 3. CHECK DOOR SWITCH A Check continuity between door switch terminal 1 and body ground of door switch. Terminal 1 Ground Condition Continuity Pushed NO Released YES B OK or NG OK >> GO TO 4. NG >> Replace door switch. C D PIIA3351E E 4. CHECK BCM OUTPUT SIGNAL 1. 2. Connect BCM connector. Check voltage between BCM connector M58 terminal 60 and ground. 60 – Ground F : Battery voltage G OK or NG OK >> Check door switch ground condition. NG >> Replace BCM. H BL MIIB0348E BACK DOOR SWITCH 1. CHECK BACK DOOR SWITCH INPUT SIGNAL 1. 2. J Turn ignition switch OFF. Check voltage between BCM connector M57 terminal 10 and ground. Terminal (+) 10 (P) Back door condition Voltage (V) Approx. Closed 5 Open 0 (–) Ground K L M OK or NG OK >> Back door switch circuit is OK. NG >> GO TO 2 MIIB0314E BL-181 INTELLIGENT KEY SYSTEM 2. CHECK BACK DOOR SWITCH HARNESS 1. 2. Disconnect back door switch connector. Check voltage between back door switch connector and ground. (Check harness for open.) Back door switch connector Terminal B46 2 Voltage (V) (Approx.) Ground Battery voltage MIIB1376E 3. 4. Disconnect BCM connector. Check continuity between back door switch connector and ground. (Check harness for short.) Back door switch connector Terminal B46 2 Continuity Ground No OK or NG OK >> GO TO 3. NG >> Repair or replace harness. MIIB1377E 3. CHECK BACK DOOR SWITCH Check continuity between back door switch terminal. Terminal Back door switch 1 2 Rear door condition Continuity Closed No Opened Yes OK or NG OK >> GO TO 4. NG >> Replace back door release actuator (back door switch). MIIB1378E 4. CHECK BACK DOOR SWITCH GROUND HARNESS Check continuity between back door switch connector and ground. Back door switch connector Terminal B46 1 Ground Continuity Yes OK or NG OK >> Check harness connection. NG >> Replace back door switch. MIIB1379E BL-182 INTELLIGENT KEY SYSTEM Check Intelligent Key Warning Buzzer Circuit BIS00168 1. CHECK INTELLIGENT KEY WARNING BUZZER POWER SUPPLY CIRCUIT A 1. 2. 3. B Turn ignition switch OFF. Disconnect Intelligent Key warning buzzer connector. Check voltage between Intelligent Key warning buzzer connector and ground. Terminals C (+) Intelligent Key warning buzzer connector Terminal D10 1 (–) Voltage (V) (Approx.) Ground Battery voltage D OK or NG OK >> GO TO 2. NG >> Check the following. ● 10A fuse [No. 7, located in the fuse block (J/B)] ● Continuity between Intelligent Key warning buzzer and fuse E PIIB6622E F 2. CHECK INTELLIGENT KEY WARNING BUZZER CIRCUIT G 1. 2. H Disconnect Intelligent Key unit connector. Check continuity between Intelligent Key unit connector and Intelligent Key warning buzzer connector. A 3. B Intelligent Key unit connector Terminal Intelligent Key warning buzzer connector M60 4 D10 Terminal 2 Continuity BL Yes J Check continuity between Intelligent Key unit connector and ground. A K Intelligent Key unit connector Terminal M60 4 Ground Continuity PIIB6623E L No OK or NG OK >> GO TO 3. NG >> Repair or replace harness between Intelligent Key unit and Intelligent Key warning buzzer. 3. CHECK INTELLIGENT KEY WARNING BUZZER OPERATION Connect battery power supply to Intelligent Key warning buzzer terminals 1 and 2, and check the operation. 1 (BAT+) - 2 (BAT-) : the buzzer sounds OK or NG OK >> Intelligent Key warning buzzer is OK. NG >> Replace Intelligent Key warning buzzer. PIIB6624E BL-183 M INTELLIGENT KEY SYSTEM Check Outside Key Antenna (Driver Side and Passenger Side) BIS00169 1. CHECK OUTSIDE KEY ANTENNA INPUT SIGNAL 1 1. 2. Turn ignition switch OFF. Check signal between Intelligent Key unit connector and ground with oscilloscope. Terminals (+) Intelligent Key unit connector Driver side Terminal 19 M60 Door request switch is pushed Ground Passenger side Signal (Reference value.) Condition (–) 37 PIIB6626E SIIA1910J OK or NG OK >> Outside key antenna is OK. NG >> GO TO 2. 2. CHECK OUTSIDE KEY ANTENNA CIRCUIT 1. 2. Disconnect Intelligent Key unit and outside key antenna connector. Check continuity between Intelligent Key unit connector and outside key antenna connector. A Intelligent Key unit connector B Terminal 19 Outside key antenna connector D13 37 2 D30 38 Continuity 1 Driver side 20 M60 3. Terminal Yes 1 Passenger side 2 Check continuity between Intelligent Key unit connector and ground. A Intelligent Key unit connector Continuity Terminal 19 Ground 20 M60 No 37 38 OK or NG OK >> GO TO 3. NG >> Repair or replace harness between Intelligent Key unit and outside key antenna. BL-184 PIIB6627E INTELLIGENT KEY SYSTEM 3. CHECK OUTSIDE KEY ANTENNA INPUT SIGNAL 2 1. 2. 3. A Replace outside key antenna. (New antenna or other antenna) Connect Intelligent Key unit and outside key antenna connector. Check signal between Intelligent Key unit connector and ground with oscilloscope. B Terminals (+) Intelligent Key unit connector Condition Driver side M60 (–) Terminal C Signal (Reference value.) D 19 Ground Passenger side 37 Door request switch is pushed E PIIB6626E SIIA1910J F OK or NG OK >> Replace malfunction outside key antenna. NG >> Replace Intelligent Key unit. G Check Outside Key Antenna (Back Door) BIS0016A 1. CHECK OUTSIDE KEY ANTENNA INPUT SIGNAL 1 1. 2. H Turn ignition switch OFF. Check signal between Intelligent Key unit connector and ground with oscilloscope. BL Terminals (+) Intelligent Key unit connector (–) Condition Signal (Reference value.) J Terminal K M60 17 Ground Back door request switch is pushed PIIB6628E SIIA1910J OK or NG OK >> Outside key antenna (back door) is OK. NG >> GO TO 2. BL-185 L M INTELLIGENT KEY SYSTEM 2. CHECK OUTSIDE KEY ANTENNA CIRCUIT 1. 2. Disconnect Intelligent Key unit and outside key antenna (back door) connector. Check continuity between Intelligent Key unit connector and outside key antenna (back door) connector. A Intelligent Key unit connector B Terminal Outside key antenna (back door) connector 17 M60 3. Continuity Terminal 1 B43 18 Yes 2 Check continuity between Intelligent Key unit connector and ground. PIIB6629E A Intelligent Key unit connector Continuity Terminal Ground 17 M60 No 18 OK or NG OK >> GO TO 3. NG >> Repair or replace harness between Intelligent Key unit and outside key antenna (back door). 3. CHECK OUTSIDE KEY ANTENNA INPUT SIGNAL 2 1. 2. 3. Replace outside key antenna. (New antenna or other antenna) Connect Intelligent Key unit and outside key antenna (back door) connector. Check signal between Intelligent Key unit connector and ground with oscilloscope. Terminals (+) Intelligent Key unit connector M60 Condition Terminal 17 (–) Ground Signal (Reference value.) Trunk lid request switch is pushed PIIB6628E SIIA1910J OK or NG OK >> Replace outside key antenna (back door). NG >> Replace Intelligent Key unit. BL-186 INTELLIGENT KEY SYSTEM Check Inside Key Antenna BIS0016B 1. CHECK INSIDE KEY ANTENNA INPUT SIGNAL 1 1. 2. A Turn ignition switch OFF. Check signal between Intelligent Key unit connector and ground with oscilloscope. B Terminals (+) Intelligent Key unit connector M60 Signal (Reference value.) Condition (–) Terminal Dash board 35 Center console 15 Back door 13 C D Any door is open → close Ground E PIIB6630E SIIA1910J F OK or NG OK >> Check the condition of harness and connector. NG >> GO TO 2. G 2. CHECK INSIDE KEY ANTENNA CIRCUIT 1. 2. A Intelligent Key unit connector B Terminal 35 BL Inside key antenna connector M47 Terminal M60 15 J 2 B20 1 Center console 16 13 Continuity 1 Dash board 36 Yes K 2 B32 1 Back door 14 3. H Disconnect Intelligent Key unit and inside key antenna connector. Check continuity between Intelligent Key unit connector and inside key antenna connector. MIIB1447E 2 L Check continuity between Intelligent Key unit connector and ground. A Intelligent Key unit connector Continuity Terminal 35 Dash board 36 Ground 15 M60 Center console No 16 13 Back door 14 OK or NG OK >> GO TO 3. NG >> Repair or replace harness between Intelligent Key unit and inside key antenna. BL-187 M INTELLIGENT KEY SYSTEM 3. CHECK INSIDE KEY ANTENNA INPUT SIGNAL 2 1. 2. 3. Replace inside key antenna. (New antenna or other antenna) Connect Intelligent Key unit and inside key antenna connector. Check signal between Intelligent Key unit connector and ground with oscilloscope. Terminals (+) M60 Signal (Reference value.) Condition Intelligent Key unit connector (–) Terminal Dash board 35 Center console 15 Back door 13 Ground Any door is open → close PIIB6630E SIIA1910J OK or NG OK >> Replace malfunction inside key antenna. NG >> Replace Intelligent Key unit. Check Steering Lock Unit BIS0016C 1. CHECK STEERING LOCK UNIT POWER SUPPLY 1. 2. 3. Turn ignition switch OFF. Disconnect steering lock unit connector. Check voltage between steering lock unit and ground. Terminals (–) Voltage (V) (Approx.) Ground Battery voltage (+) Steering lock unit Terminal M37 1 OK or NG OK >> GO TO 2. NG >> Repair or replace steering lock unit power supply circuit. PIIB6632E 2. CHECK STEERING LOCK UNIT GROUND CIRCUIT Check continuity between steering lock unit and ground. Steering lock unit connector Terminal M37 4 Ground Continuity Yes OK or NG OK >> GO TO 3. NG >> GO TO 6. PIIB6633E BL-188 INTELLIGENT KEY SYSTEM 3. CHECK INTELLIGENT KEY UNIT OUTPUT SIGNAL 1. 2. A Connect steering lock unit connector. Check voltage between Intelligent Key unit and ground. B Terminals (+) Intelligent Key unit connector Terminal M37 1 (–) Voltage (V) (Approx.) Ground 5 C D OK or NG OK >> GO TO 4. NG >> Replace Intelligent Key unit. PIIB6634E E 4. CHECK STEERING LOCK COMMUNICATION SIGNAL F Check signal between Intelligent Key unit and ground with oscilloscope. Terminals (+) Intelligent Key unit connector M37 (–) Condition of key switch G Voltage (V) (Approx.) Terminal H 32 Ground Ignition switch is pressed, when Intelligent Key is into the vehicle. Other than above BL PIIB6635E J SIIA1911J 5 K OK or NG OK >> GO TO 5. NG >> Replace Intelligent Key unit. L M BL-189 INTELLIGENT KEY SYSTEM 5. CHECK STEERING LOCK UNIT COMMUNICATION CIRCUIT 1. 2. Disconnect Intelligent Key unit and steering lock unit connectors. Check continuity between Intelligent Key unit and steering lock unit. A Intelligent Key unit connector B Terminal Steering lock unit connector Terminal 1 M60 2 31 M37 4 32 3. Continuity Yes 3 Check continuity between steering lock unit and ground. A Intelligent Key unit connector Continuity Terminal 1 M60 PIIB6636E Ground 31 No 32 OK or NG OK >> Replace steering lock unit. ● After replacing steering lock unit, perform registration procedure. Refer to “CONSULT-II Operation Manual NATS”. NG >> Repair or replace harness between steering lock unit and Intelligent Key unit. 6. CHECK STEERING LOCK UNIT COMMUNICATION CIRCUIT 1. 2. Disconnect Intelligent Key unit connector. Check continuity between Intelligent Key unit and steering lock unit. A 3. Intelligent Key unit connector M60 B Continuity Terminal Steering lock unit connector Terminal 31 M37 4 Yes Check continuity between steering lock unit and ground. A Continuity Intelligent Key unit connector Terminal M60 31 Ground No OK or NG OK >> Check the following. ● Intelligent Key unit ground circuit. ● Intelligent Key unit. NG >> Repair or replace harness between steering lock unit and Intelligent Key unit. BL-190 PIIB6637E INTELLIGENT KEY SYSTEM Check Warning Lamp BIS0016E 1. CHECK WARNING LAMP OPERATION ● ● A With CONSULT-II Check “INDICATOR” in “ACTIVE TEST” mode with CONSULTII. Select “BLUE ON”, “RED ON” or “KNOB ON” B C Does each warning lamp illuminate? OK or NG OK >> INSPECTION END NG >> GO TO DI-32, "WARNING LAMPS" . D E PIIB4356E Check Warning Buzzer in Combination Meter BIS0016F 1. CHECK WARNING BUZZER OPERATION ● ● F With CONSULT-II Check “INSIDE BUZZER” in “ACTIVE TEST” mode with CONSULT-II. Touch “TAKE OUT”, “KNOB” or “KEY” on “ACTIVE TEST” screen. G H Does each warning buzzer sound? OK or NG OK >> INSPECTION END NG >> GO TO 2. BL PIIB6619E J 2. CHECK OTHER WARNING BUZZER OPERATION K Check other warning buzzer operation using combination meter. Does warning buzzer in combination meter sound? OK or NG OK >> INSPECTION END NG >> GO TO DI-52, "WARNING CHIME" . L Check Hazard Function BIS0016G 1. CHECK HAZARD WARNING LAMP Does hazard warning lamp flash with hazard switch? YES or NO YES >> Hazard warning lamp circuit is OK. NO >> Check hazard circuit. Refer to LT-98, "TURN SIGNAL AND HAZARD WARNING LAMPS" . Check Headlamp Function BIS0016H 1. CHECK HEADLAMP OPERATION Check if headlamp operate by lighting switch. Does headlamp come on when turning lighting switch “ON”? YES >> Headlamp circuit is OK. NO >> Check headlamp system. Refer to LT-7, "HEADLAMP -CONVENTIONAL TYPE-" "HEADLAMP - DAYTIME LIGHT SYSTEM -" . BL-191 or LT-35, M INTELLIGENT KEY SYSTEM Check Stop Lamp Switch BIS0015U 1. CHECK STOP LAMP SWITCH INPUT SIGNAL 1. 2. 3. Turn ignition switch OFF. Disconnect Intelligent Key unit connector. Check voltage between Intelligent Key unit harness connector and ground. Terminal Connector M60 (+) (–) 26 Ground Condition Voltage (V) (Approx.) Brake pedal depressed Battery voltage Brake pedal released 0 OK or NG OK >> Stop lamp switch is OK. NG >> GO TO 2. PIIB4346E 2. CHECK STOP LAMP SWITCH POWER SUPPLY CIRCUIT Check voltage between stop lamp switch harness connector and ground. 1 – Ground : Battery voltage OK or NG OK >> GO TO 3. NG >> Repair or replace harness between stop lamp switch power supply circuit and fuse. MIIB0817E 3. CHECK STOP LAMP SWITCH OPERATION Check continuity between stop lamp switch connector. Connector E38 (LHD with M/T) E60 (LHD with A/T) E203 (RHD with M/T) E204 (RHD with A/T) Terminal 1 2 Condition Continuity Brake pedal depressed Yes Brake pedal not depressed No OK or NG OK >> GO TO 4. NG >> Replace stop lamp switch. MIIB0818E BL-192 INTELLIGENT KEY SYSTEM 4. CHECK STOP LAMP SWITCH CIRCUIT 1. 26 – 2 2. A Check continuity between Intelligent Key unit harness connector and stop lamp switch harness connector. B : Continuity should exist. Check continuity between Intelligent Key unit harness connector and ground. 26 – Ground C : Continuity should not exist. OK or NG OK >> Check condition of harness and connector. NG >> Repair or replace harness. Removal and Installation of Intelligent key unit D MIIB0819E BIS000KU REMOVAL 1. 2. Remove the instrument lower driver panel. Refer to IP-4, "INSTRUMENT PANEL ASSEMBLY" . Disconnect the Intelligent Key unit connector, remove the screw and Intelligent Key unit. E F G H MIIB0305E BL INSTALLATION Install in the reverse order of removal. J Intelligent Key Inspection BIS000KV INTELLIGENT KEY DISASSEMBLY AND ASSEMBLY 1. 2. Remove Intelligent Key cover. Insert a thin screwdriver wrapped with tape into Area A and then separate lower and upper cases while twisting screwdriver. K L M MIIB0303E BL-193 INTELLIGENT KEY SYSTEM 3. 4. When replacing the circuit board or rubber ● Remove the circuit board assembly from the upper case. (Substrate assembly: circuit board + rubber) ● Gently press the rubber and remove the circuit board. CAUTION: Be careful not to touch the printed circuits directly. When replacing the battery ● Remove the battery from the lower case and replace it. Battery replacement 5. : Coin-shaped lithium battery 3V (CR2032) CAUTION: When replacing battery, be sure to keep dirt, grease, and other foreign materials off the electrode contact area. After replacement, assemble the upper and lower cases by engaging the hooks on their circumference while being careful not to pinch the rubber, etc. CAUTION: After replacing the battery, check to make sure all Intelligent Key functions work normally. MIIB0304E REMOTE CONTROLLER BATTERY INSPECTION Check by connecting a resistance (approximately 300Ω) so that the current value becomes about 10 mA. Standard : Approx. 2.5V - 3.0V OCC0607D BL-194 DOOR DOOR Fitting Adjustment PFP:80100 A BIS000KW B C D E F G H BL J K L M PIIB5575J 1. Front fender 2. Front door 3. Rear door 4. Body side outor panel FRONT DOOR Longitudinal Gap and Front End Height Difference Adjustment 1. 2. Remove front fender. Refer to BL-15, "Removal and Installation" . Loosen the hinge bolts on body, then lift the rear end of front door to adjust the clearance and surface difference properly. BL-195 DOOR REAR DOOR Longitudinal Gap and Front End Height Difference Adjustment 1. 2. Remove center pillar upper garnish and center pillar lower garnish. Refer to EI-26, "Removal and Installation" . Working from inside and outside vehicle, loosen bolts and nuts, and then open rear door, and adjust while raising rear door by rear edge. STRIKER ADJUSTMENT Adjust the striker so that it becomes parallel with the lock inserting direction. PIIB2804J Removal and Installation BIS000KZ CAUTION: ● During removal and installation of the door assembly, use a jack to support the door. Place a shop cloth or other suitable material onto the jack plate to protect the door and body from damage. ● After removal and installation of the door assembly, always adjust the fit. ● Check hinge rotating part for poor lubrication. If necessary, apply “Body Grease”. REMOVAL OF FRONT DOOR 1. 2. 3. 4. 5. Remove dash side finisher. Refer to EI-20, "Removal and Installation" . Dissconnect front door harness connectors. Remove harness gromet, and then remove front door harness conectors. Remove connectors and harness clamps in front door, and then pull out harness from front door. Remove check link bolts. PIIB2865J 6. Remove hinge nuts on the door and then the door assembly. PIIB2866J INSTALLATION Install in the reverse order of removal. BL-196 DOOR REMOVAL OF REAR DOOR 1. 2. 3. 4. A Remove rear door finisher. Refer to EI-20, "Removal and Installation" . Remove door window. Refer to GW-93, "Removal and Installation" . Remove connectors and harness clamps from rear door and then pull out harness from rear door. Remove check link bolts. B C D E MIIB0120E 5. Remove hinge nuts on the door and then the door assembly. F G H MIIB0122E BL INSTALLATION Install in the reverse order of removal. J K L M BL-197 DOOR Front Door Weatherstrip BIS000L0 PIIB5586J 1. Front door weatherstrip 2. Front door CAUTION: During removal, if peeling off the double-sided tape is difficult, apply remover (product equivalent to Sumitomo 3M Cleaner 30) and then remove the double-sided tape. When using remover, keep it way from open flame and work in a sufficiently ventilated area. REMOVAL 1. 2. Remove check link bolts. Remove door weatherstrip. INSTALLATION Install in the reverse order of removal. BL-198 DOOR Front Door Weatherstrip BIS000UG A B C D E F G H BL J K L PIIB5587J 1. Rear door weatherstrip 2. Rear door CAUTION: During removal, if peeling off the double-sided tape is difficult, apply remover (product equivalent to Sumitomo 3M Cleaner 30) and then remove the double-sided tape. When using remover, keep it way from open flame and work in a sufficiently ventilated area. REMOVAL 1. 2. Removal check link bolts. Remove door weatherstrip. INSTALLATION Install in the reverse oprder of removal. BL-199 M FRONT DOOR LOCK FRONT DOOR LOCK Component Parts Location PFP:80502 BIS000L1 PIIB5576J 1. Front door panel 2. Inside handle 3. Inside handle cable 4. Door lock assembly 5. Outside handle cable 6. TOLX bolt (T30) 7. Key cylinder connecting rod 8. Grommet 9. TOLX bolt (T30) 10. Rear gasket 11. *Door key cylinder assembly 12. Outside handle 13. Front gasket 14. Lock knob cable 15. Holder 16. Outside handle bracket *: Outside handle escutcheon for vehicles with passenger door key cylinders. Removal and Installation BIS000L2 REMOVAL 1. 2. 3. 4. 5. 6. Remove front door finisher. Refer to EI-20, "Removal and Installation" . Fully close front door glass. Remove sealing screen. Remove front door lower sash (rear). Refer to GW-89, "Removal and Installation" . Remove inside handle cable and lock knob cable from holder. Remove inside handle screws, slide handle toward rear of vehicle, disengage handle from door panel, and remove inside handle. MIIB0126E BL-200 FRONT DOOR LOCK 7. Disconnect inside handle cable and lock knob cable from inside handle. CAUTION: During removal and installation, work so as not to bend the ends of the lock knob cable and inside handle cable. A B C MIIB0127E D 8. Remove door side grommets, and then remove door key cylinder assembly (escutcheon) bolts (Torx T30) from the grommet holes. 9. Remove key cylinder connecting rod (key cylinder side).: If there is no door key cylinder, GO TO 9. 10. Disconnect door antenna and door request switch connector and remove harness clamp. (Vehicle with intelligent key systems only) E F G MIIB0128E 11. Remove door cylinder assembly while pulling outside handle forward. H BL J MIIB0129E K 12. Pull outside door handle forward and then slide it toward vehicle rear to remove. L M MIIB0130E 13. Remove front and rear gaskets. MIIB0131E BL-201 FRONT DOOR LOCK 14. Remove door lock assembly bolts (Torx T30). MIIB0132E 15. Slide outside handle bracket toward rear of vehicle, and then remove outside handle bracket and door lock assembly. 16. Disconnect door lock assembly connector. MIIB0133E 17. Disconnect outside handle cable from outside handle bracket. MIIB0134E Install in the reverse order of removal. CAUTION: ● Before installing door lock assembly, apply “anti-corrosion wax M-97 super” onto mounting seat on the body. ● Install each rod by rotating the rod holder until it engages with a tactile feel. BL-202 FRONT DOOR LOCK Disassembly and Assembly BIS000L3 A DOOR KEY CYLINDER ASSEMBLY B C D MIIB0135E 1. 2. Remove key cylinder escutcheon engagement (3 locations), and then remove door key cylinder. Remove hook (2 locations) engagements, and then remove door request switch from key cylinder escutcheon. (Vehicles with intelligent key systems only) OUTSIDE HANDLE E F G H MIIB0136E 1. 2. Remove handle cover screws. Remove handle cover, and then remove door antenna. (Vehicles with intelligent key systems only) BL J K L M BL-203 REAR DOOR LOCK REAR DOOR LOCK Component Parts Location PFP:82502 BIS000L4 PIIB5577J 1. Rear door panel 2. Inside handle 3. Inside handle cable 4. Door lock assembly 5. TOLX bolt (T30) 6. Outside handle cable 7. Grommet 8. TOLX bolt (T30) 9. Rear gasket 10. Outside handle escutcheon 11. Outside handle 13. Lock knob cable 14. Outside handle bracket 12. Front gasket Removal and Installation BIS000L5 REMOVAL 1. 2. 3. 4. 5. Remove rear door finisher. Refer to EI-20, "Removal and Installation" . Remove sealing screen. Remove partition sash. Refer to GW-93, "Removal and Installation" . Support door glass while lifting it up to the door window completely closed position. Remove inside handle bolts, slide handle toward rear of vehicle, remove engagement with door panel, and remove inside handle. PIIB2870J 6. Disconnect inside handle cable and lock knob cable from inside handle. CAUTION: During removal and installation, work so as not to bend the ends of the lock knob cable and inside handle cable. PIIB2871J BL-204 REAR DOOR LOCK 7. Remove door side grommets, and then remove outside handle escutcheon screws (Torx T30) from grommet holes. A B C PIIB2872J 8. D Pull outside handle forward while removing outside handle escutcheon. E F G PIIB2873J 9. Pull outside door handle forward and then slide it toward vehicle rear to remove. H BL J PIIB2874J K 10. Remove front and rear gaskets. L M PIIB2875J 11. Remove door lock assembly screws (Torx T30). PIIB2876J BL-205 REAR DOOR LOCK 12. Slide outside handle bracket toward rear of vehicle, and then remove outside handle bracket and door lock assembly. 13. Disconnect door lock assembly connector. PIIB2877J 14. Disconnect outside handle cable from outside handle bracket. PIIB2878J Install in the reverse order of removal. CAUTION: ● Before installing door lock assembly, apply “anti-corrosion wax M-97 super” onto mounting seat on the body. ● When installing door lock assembly, be careful when rotating the outside handle cable as shown in the figure. – Place the outside handle bracket cable on the outside of door lock assembly before installing. PIIB2879J BL-206 BACK DOOR BACK DOOR Fitting Adjustment PFP:90100 A BIS000L6 B C D E F G H BL J K L M PIIB5578J 1. Back door hingel 4. Back door panel 2. Back door striker 3. Bamper robber VERTICAL/LATERAL CLEARANCE (SURFACE DIFFERENCE) ADJUSTMENT 1. Remove luggage rear plate. Refer to EI-32, "Removal and Installation" . BL-207 BACK DOOR 2. 3. Loosen back door striker screws. Use a rubber hammer, etc., to strike back door striker to make the gap on the right and left and with the rear bumper even, and then tighten striker screws to specified torque. CAUTION: Adjust gap between back door and other areas to attain the right and left dimensional difference shown below. Back door outer (B) - Body side outer (B) : 2.0 mm or less Back Door Assembly BIS000L7 REMOVAL 1. 2. 3. Remove back door finisher. Refer to EI-22, "Removal and Installation" . Disconnect connectors in back door and unclamp harness. Pull out harness from back door. After supporting the back door lock to keep it from falling, use a screwdriver, etc., to remove the back door stay (glass stay) door side hooks, and then pull out back door stay from stud pole. PIIB2890J 4. Remove back door hinge bolts, and then remove back door assembly. PIIB2886J INSTALLATION Install in the order of removal. INSPECTION 1. 2. Check hinges for the following: - Unusual noise or door closing and opening effort - Component wear or damage Apply body grease to the rotating part of the hinge. PIIB2887J Back Door Striker BIS000L8 REMOVAL 1. Remove luggage rear plate. Refer to EI-32, "Removal and Installation" . BL-208 BACK DOOR 2. Remove screws and back door striker. A B C PIIB5580J D INSTALLATION Install in the reverse order of removal. CAUTION: ● After finishing work, confirm proper operation. ● After finishing work, adjust fitting. Refer to BL-207, "Fitting Adjustment" . Back Door Stay Assembly E BIS000L9 F REMOVAL 1. 2. Support back door lock to prevent it from falling. Remove back door stay assembly (gas stay) vehicle side bracket bolts. G H BL PIIB2889J J 3. Remove back door stud balls, and then remove back door stay assembly from back door. K L M PIIB2890J INSTALLATION Install in the reverse order of removal. CAUTION: ● After finishing work, confirm proper operation. BL-209 BACK DOOR Removal and Installation of Back Door Weatherstrip BIS000LA PIIB5579J 1. Back door panel 2. Back door weatherstrip 3. Roof panel REMOVAL Pull up and remove engagement with body from weatherstrip joint. CAUTION: After removal, do not pull strongly on the weatherstrip. INSTALLATION Install in the reverse order of removal. ● Working from the upper section, align weatherstrip mark with vehicle center position mark and install weatherstrip onto the back door. ● For the lower section, align the weatherstrip seam with center of the striker. ● After finishing work, pull weatherstrip lightly to check for looseness. ● Make sure the weatherstrip is fit tightly at each corner and luggage rear plate. BL-210 BACK DOOR LOCK BACK DOOR LOCK Removal and Installation PFP:90504 A BIS000LB BACK DOOR LOCK ASSEMBLY Removal 1. 2. 3. B Remove back door finisher. Refer to EI-22, "Removal and Installation" . Disconnect back door lock assembly connector. Remove bolts to remove back door lock assembly from inside back door panel. C D E MIIB0149E F Installation Install in the reverse order of removal. ● If greasing condition in each sliding section on back door assembly is poor, apply “BODY GREASE”. ● After finishing work, confirm proper operation. BACK DOOR HANDLE ASSEMBLY Removal 1. 2. 3. G H Remove back door finisher. Refer to EI-22, "Removal and Installation" . Remove back door request switch (vehicles with intelligent key systems) and back door open switch har- BL ness fastening clips and connectors. Remove back door handle assembly nuts, and then remove J back door handle assembly. K L MIIB0150E M Installation Install in the reverse order of removal. CAUTION: After finishing work, confirm proper operation. Disassembly and Assembly Remove screws, and then remove back door request switch (vehicles with intelligent key systems) and back door open switch. MIIB0151E BL-211 FUEL FILLER LID OPENER FUEL FILLER LID OPENER Removal and Installation of Fuel Filler Lid Opener PFP:78820 BIS0014T MIIB1433E 1. Fuel filler lid opener cable (RH) 2. Fuel filler lid opener cable (LH) REMOVAL 1. 2. Remove fuel filler lid. Remove trunk side finisher (RH). Refer to EI-32, "Removal and Installation" . PIIB3776J 3. 4. 5. Remove ruggage rear plat. Remove ruggage side lower finisher. Remove ruggage floor finisher.(LH models) BL-212 FUEL FILLER LID OPENER 6. 7. Remove fuel filler lock. Remove front kicking plate and rear kicking plate. Refer to EI26, "Removal and Installation" . A B C PIIB3831J D 8. Remove fuel filler lid opener cable mounting clip on vehicle. 9. Remove mounting bolts and remove fuel filler lid opener. 10. Remove fuel filler lid opener cable. E F G PIIB2534J H INSTALLATION Install in the reverse order of removal. BL J K L M BL-213 THEFT WARNING SYSTEM THEFT WARNING SYSTEM Wiring Diagram — THEFT — / PRWIRE PFP:25362 BIS000LN MIWA0731E BL-214 NATS (NISSAN ANTI-THEFT SYSTEM) NATS (NISSAN ANTI-THEFT SYSTEM) Component Parts and Harness Connector Location (Hatchback) PFP:28591 A BIS000M0 B C D E F G H BL MIIB1438E 1. BCM M57, M58, M59 (Without Intelligent Key system) 2. Intelligent Key unit M60 (With Intelligent Key system) 4. Steering lock unit M37 (With Intelligent Key system) 5. a: NATS antenna AMP. M35: With Intelligent Key system M36: Without Intelligent Key system b: Key switch and ignition knob switch connector M34 (with Intelligent Key system) 3. Combination meter M27 J K L M BL-215 NATS (NISSAN ANTI-THEFT SYSTEM) MIIB1439E 1. Inside key antenna (dash board) M47 2. Inside key antenna (center console) B20 3. Inside key antenna (luggage room) B32 NOTE: If customer reports a “NO START” condition, request ALL ignition key (without Intelligent Key system) or mechanical key (with Intelligent Key system) to be brought to the dealer to check for a NATS malfunction. BL-216 NATS (NISSAN ANTI-THEFT SYSTEM) System Description BIS000M2 A OPERATING DESCRIPTION NATS (Nissan Anti-Theft System) has the following functions: ● NATS shows a higher anti-theft performance at preventing engine to be initiates by an unregistered key. (Registered key: Ignition key, mechanical key, Intelligent Key) ● Only a key with key ID registered in BCM (without Intelligent Key system) or Intelligent Key unit (with Intelligent Key system) and ECM can start engine, it has a higher protection against auto thefts that duplicates keys. ● If a malfunction has been detected, security indicator will keep illuminates when ignition switch is in ON position. ● Intelligent Key can be registered up to 5 keys (Including the standard key) on request from the owner. ● During trouble diagnosis or when the following parts have been replaced, and if ignition key or mechanical key is added, registration* is required. *: All keys kept by the owner of the vehicle should be registered with ignition key or mechanical key. – ECM – BCM (without Intelligent Key system) – Intelligent Key unit (with Intelligent Key system) – Ignition key (without Intelligent Key system) – Mechanical key (with Intelligent Key system) ● NATS trouble diagnoses, system initialization and additional registration of other ignition key or mechanical key IDs must be carried out using CONSULT-II hardware and CONSULT-II NATS software. When NATS initialization has been completed, the ID of the inserted ignition key or mechanical key is automatically registered. Then, if necessary, additional registration of other ignition key or mechanical key IDs can be carried out. Regarding the procedures of NATS initialization and ignition key or mechanical key ID registration, refer to CONSULT-II operation manual, NATS. ● ● C D E F G H BL SECURITY INDICATOR ● B Fore warns that the vehicle is equipped with NATS (Nissan Anti-Theft System). Vehicles without Intelligent Key system, security indicator will not blink while the ignition knob is in ON or START state. Vehicles with Intelligent Key system, security indicator blinks constantly when the mechanical key is removed from the ignition key cylinder. NOTE: Because security indicator is highly efficient, the battery is barely affected. Condition of Security Indicator (Normal) J K L WITHOUT INTELLIGENT KEY SYSTEM Ignition key state Ignition key ON position ACC position OFF position (Key inserted.) OFF position (Key removed.) Registered key OFF Flashing Flashing Flashing Unregistered key ON Flashing Flashing Flashing Security indicator condition WITH INTELLIGENT KEY SYSTEM Key condition Ignition key Security indicator condition Intelligent key Mechanical key Ignition knob pressed Ignition knob released Key inserted Key removed ON Flashing × × × × OFF Flashing BL-217 M NATS (NISSAN ANTI-THEFT SYSTEM) System Composition BIS000M3 The function of the NATS consists of the following: ● Ignition key (without Intelligent Key system) ● Mechanical key (with Intelligent Key system) ● NATS antenna amp. ● Steering lock unit. (with Intelligent Key system) ● BCM (without Intelligent Key system) ● Intelligent Key unit (with Intelligent Key system) ● Engine control module (ECM) ● Security indicator (built-in combination meter) NOTE: The communication between ECM and BCM/Intelligent Key unit uses the CAN communication system. MIIB0390E ECM Re-communicating Function BIS000M4 Performing following procedure can automatically perform re-communication of ECM and BCM or Intelligent Key unit, but only when the ECM has been replaced with a new one (*1). *1: New one means a virgin ECM which has never been energized on-board. (In this step, initialization procedure by CONSULT-II is not necessary) NOTE: ● When registering new Key IDs or replacing the ECM other than brand new, refer to CONSULT-II Operation Manual NATS. ● If multiple keys are attached to the key holder, separate them before work. ● Distinguish keys with unregistered key ID from those with registered ID. 1. Install ECM. 2. Using a registered key (*2), turn ignition switch to “ON”. *2: To perform this step, use the key that has been used before performing ECM replacement. 3. Maintain ignition switch in “ON” position for at least 5 seconds. 4. Turn ignition switch to “OFF”. 5. Start engine. If engine can be started, procedure is completed. If engine cannot be started, refer to CONSULT-II Operation Manual NATS and initialize control unit. BL-218 NATS (NISSAN ANTI-THEFT SYSTEM) Wiring Diagram —NATS— BIS000M5 A WITHOUT INTELLIGENT KEY SYSTEM B C D E F G H BL J K L M MIWA0732E BL-219 NATS (NISSAN ANTI-THEFT SYSTEM) WITH INTELLIGENT KEY SYSTEM MIWA0733E BL-220 NATS (NISSAN ANTI-THEFT SYSTEM) A B C D E F G H BL J K L M MIWA0734E BL-221 NATS (NISSAN ANTI-THEFT SYSTEM) Terminals and Reference Value for Steering Lock Unit/With Intelligent Key System BIS000M6 Ignition knob position Operation or conditions Voltage (V) (Approx.) Battery power supply Input LOCK — Battery voltage P Steering wheel lock unit power supply Input LOCK — 5 V Steering wheel lock unit communication signal Input/ Output LOCK Press ignition knob with Intelligent Key inside vehicle. Wire color Signal Designation 1 Y 2 3 Measuring condition Signal Input/ Output Terminal SIIA1911J Other than the above 4 G Steering wheel lock unit ground — — — 5 0 Terminals and Reference Value for Intelligent Key Unit/With Intelligent Key System BIS000M7 Measuring condition Signal Input/ Output Ignition knob position Operation or conditions Voltage (V) (Approx.) Steering wheel lock unit power supply Output LOCK — 5 L CAN-H Input/ Output — — — 3 Y CAN-L Input/ Output — — — 6 O Ignition power supply Input ON — Battery voltage 7 GR Ignition knob switch Input — 8 W NATS antenna amp. Input — Ignition knob OFF → ON position Right after turning ignition switch “ON” pointer tester of tester should move 9 O NATS antenna amp. Output — Ignition knob OFF → ON position Right after turning ignition switch to ON position pointer of tester should move Terminal Wire color 1 P 2 Signal designation Press ignition knob. Return ignition knob to LOCK position. Battery voltage 0 10 L ACC power supply Input ACC — Battery voltage 11 Y Battery power supply Input — — Battery voltage 12 B GND — — — 0 13 Y Inside key antenna (+) (Luggage room) LOCK Any door open → all doors shut (Door switch: ON → OFF) 14 BR Inside key antenna (-) (Luggage room) Output Output SIIA1910J BL-222 NATS (NISSAN ANTI-THEFT SYSTEM) Terminal Wire color 15 V Inside key antenna (+) signal (Center console) LG Inside key antenna (-) signal (Center console) 16 Signal designation Signal Input/ Output Measuring condition Ignition knob position Operation or conditions LOCK Any door open → Close (Door switch: ON → OFF) Ignition knob switch: ON (press ignition knob.) Voltage (V) (Approx.) A B Output Output C SIIA1910J 27 O Key switch signal 30 P Security indicator lamp 31 G Steering wheel lock unit ground Input LOCK Insert mechanical key into ignition key cylinder. Battery voltage Remove mechanical key from ignition key cylinder. 0 Goes OFF → illuminates (Every 2.4 seconds) Battery voltage → 0 Output LOCK — — — LOCK Press ignition knob with Intelligent Key inside vehicle. D E F 0 G 32 Y Steering wheel lock unit communication signal Input/ Output H SIIA1911J Other than the above 35 P Inside key antenna (+) signal (Dashboard) Output L Inside key antenna (-) signal (Dashboard) BL Any door open → Close (Door switch: ON → OFF) Ignition knob switch: ON (press ignition knob.) LOCK 36 5 Output J SIIA1910J Terminals and Reference Value for BCM/Without Intelligent Key System Terminal Wire color Signal designation Signal Input/ Output K BIS000M8 L Measuring condition Voltage (V) (Approx.) Ignition switch position Operation or conditions — — — 0 Input/ Output — — — — Battery voltage M 2 B GND 19 L CAN-H 24 O Ignition power supply Input ON 38 V NATS antenna amp. Input/ Output — 39 Y CAN-L Input/ Output — 47 P Security indicator lamp Output OFF 70 B GND — — — 0 74 Y Battery power supply Input — — Battery voltage 79 Y Battery power supply Input — — Battery voltage Ignition knob OFF → ON position — Goes OFF → illuminates (Every 2.4 seconds) BL-223 Right after turning ignition switch to ON position pointer of tester should move — Battery voltage → 0 NATS (NISSAN ANTI-THEFT SYSTEM) CONSULT-II BIS000M9 CONSULT-II INSPECTION PROCEDURE 1. 2. Turn ignition switch OFF. Insert NATS program card into CONSULT-II. Program card 3. : NATS (AEN06A) Connect CONSULT-II and “CONSULT-II CONVERTER” to data link connector. PAIA0070E 4. 5. Turn ignition switch ON position. Touch “START”. PBR455D 6. Select “E11” 7. Perform each diagnostic test mode according to each service procedure. For further information, see the CONSULT-II Operation Manual, NATS. CONSULT-II DIAGNOSTIC TEST MODE FUNCTION CONSULT- II DIAGNOSTIC TEST MODE Description C/U INITIALIZATION When replacing any of the following components, C/U initialization and re-registration of all NATS mechanical keys are necessary. [mechanical key, BCM or Intelligent Key unit] SELF-DIAG RESULTS Detected items (screen terms) are as shown in the chart. NOTE: ● When any initialization is performed, all ID previously registered will be erased and all NATS mechanical keys must be registered again. The engine can not be start be started with an unregistered key. The system will show “DIFFERENCE OF KEY” as IMMU FUNCTION CHECK on the CONSULT-II screen. BL-224 NATS (NISSAN ANTI-THEFT SYSTEM) CHECK RESULT ITEM CHART FOR NATS IMMU FUNCTION Detected items (Screen terms) Description UNREGISTERED BCM* ID is not registered in BCM CHAIN OF IMMU-KEY NATS IMMU cannot receive the key ID signal. DIFFERENCE OF KEY BCM or Intelligent Key unit receive the key ID signal but the result of ID verification between key ID and BCM or Intelligent Key is NG CHAIN OF IPDM-IMMU* The communication with IPDM E/R. ID DISCORD IPDM-IMMU BCM or Intelligent Key unit receive from IPDM E/R signal but the result of ID verification is NG. CHAIN OF METER-IMMU* The communication with combination meter. ID DISCORD METER-IMMU BCM or Intelligent Key unit receive from combination meter ID signal but the result of ID verification is NG. CHAIN OF EPS-IMMU* The communication with EPS is malfunction. ID DISCORD EPS-IMMU BCM or Intelligent Key unit receive from EPS ID signal but the result of ID verification is NG. UNREGISTERED ECM ID is not registered in ECM. ID DISCORD ECM-IMMU The result of ID verification between BCM and ECM is NG. System initialization is required. A B C D E F *: Applied for models without Intelligent Key system. G H BL J K L M BL-225 NATS (NISSAN ANTI-THEFT SYSTEM) Diagnosis Procedure BIS000MA WORK FLOW MIIB0492E BL-226 NATS (NISSAN ANTI-THEFT SYSTEM) Trouble Diagnosis Symptom Chart BIS000MB MODELS WITHOUT INTELLIGENT KEY SYSTEM A NOTE: Perform “Diagnostic Procedure 7”, when “P1610” is displayed by the “SELF-DIAG RESULTS” of the ENGINE. Refer to “CONSULT-II Operation Manual NATS”. B SYMPTOM Displayed “IMMU FUNCTION CHECK” results on CONSULTII screen. UNREGISTERED BCM Diagnoses service procedure DIAGNOSTIC PROCEDURE C Replace BCM Refer to BL-229, "Diagnostic Procedure 1" . 1. Check the following parts CHAIN OF IMMU-KEY ● Open or short circuit between BCM and NATS antenna amp. ● Malfunction of key ID chip ● NATS antenna amp. D Refer to BL-229, "Diagnostic Procedure 2" . 2. If the above system are “OK”, replace BCM Refer to BL-233, "Diagnostic Procedure 3" . 2. If the above system is “OK”, replace BCM Refer to BCS-17, "Removal and Installation of BCM" . 1. Check CAN communication system Refer to BCS-17, "CAN Communication Inspection With CONSULT-II (Self-Diagnosis)" . 2. If CAN communication is “OK”, replace IPDM E/R Refer to PG-37, "Removal and Installation of IPDM E/R" . Replace IPDM E/R Refer to PG-37, "Removal and Installation of IPDM E/R" . 1. Check CAN communication system Refer to BCS-17, "CAN Communication Inspection With CONSULT-II (Self-Diagnosis)" . 2. If CAN communication is “OK”, replace combination meter Refer to DI-20, "Removal and Installation for Combination Meter" . K Refer to DI-20, "Removal and Installation for Combination Meter" . L Replace combination meter 1. Check CAN communication system Refer to BCS-17, "CAN Communication Inspection With CONSULT-II (Self-Diagnosis)" . M 2. If CAN communication is “OK”, replace EPS Refer to BCS-17, "CAN Communication Inspection With CONSULT-II (Self-Diagnosis)" . ID DISCORD EPS-IMMU Replace EPS Refer to PS-7, "STEERING COLUMN" . UNREGISTERED ECM Replace ECM Refer to BL-233, "Diagnostic Procedure 4" . ID DISCORD ECM-IMMU Replace ECM Refer toBL-234, "Diagnostic Procedure 5" . CHAIN OF IPDM-IMMU Security indicator lighting up* ● Engine hard to start F 1. Perform registration key DIFFERENCE OF KEY ● E ID DISCORD IPDM-IMMU CHAIN OF METER-IMMU ID DISCORD METER-IMMU CHAIN OF EPS-IMMU *: When NATS detects trouble, the security indicator lights up while ignition key is in the “ON” position. BL-227 G H BL J NATS (NISSAN ANTI-THEFT SYSTEM) MODELS WITH INTELLIGENT KEY SYSTEM NOTE: Perform “Diagnostic Procedure 7”, when “P1610” is displayed by the “SELF-DIAG RESULTS” of the ENGINE. Refer to “CONSULT-II Operation Manual NATS”. SYMPTOM Displayed “IMMU FUNCTION CHECK” results on CONSULTII screen. Diagnoses service procedure DIAGNOSTIC PROCEDURE 1. Check the following parts ● CHAIN OF IMMU-KEY Open or short circuit between BCM and NATS antenna amp. ● Malfunction of key ID chip ● NATS antenna amp. 2. If the above system are “OK”, replace Intelligent Key unit Refer to BL-193, "Removal and Installation of Intelligent key unit" . 1. Perform key registration Refer to BL-233, "Diagnostic Procedure 3" . 2. If the above system is “OK”, replace Intelligent Key unit Refer to BL-193, "Removal and Installation of Intelligent key unit" . 1. Check CAN communication system Refer to BCS-17, "CAN Communication Inspection With CONSULT-II (Self-Diagnosis)" . 2. If CAN communication system is “OK”, replace IPDM E/R Refer to PG-37, "Removal and Installation of IPDM E/R" . 1. Check CAN communication system Refer to BCS-17, "CAN Communication Inspection With CONSULT-II (Self-Diagnosis)" . 2. If CAN communication system is “OK”, replace combination meter Refer to DI-20, "Removal and Installation for Combination Meter" . 1. Check CAN communication system Refer to BCS-17, "CAN Communication Inspection With CONSULT-II (Self-Diagnosis)" . 2. If CAN communication system is “OK”, replace EPS Refer to PS-7, "STEERING COLUMN" . Replace ECM Refer to BL-234, "Diagnostic Procedure 5" . DIFFERENCE OF KEY ● Security indicator lighting up* ● Engine hard to start ID DISCORD IPDM-IMMU ID DISCORD METER-IMMU ID DISCORD EPS-IMMU ID DISCORD ECM-IMMU Refer to BL-229, "Diagnostic Procedure 2" . *: When NATS detects trouble, the security indicator lights up while mechanical key is inserted. Security Indicator Inspection SYMPTOM BIS000MC SYSTEM (Malfunctioning part or mode) DIAGNOSTIC PROCEDURE Security indicator Open circuit between Fuse and NATS IMMU (BCM or Intelligent Key unit) Security indicator does not operate* Continuation of initialization mode Refer toBL-234, "Diagnostic Procedure 6" . BCM (without Intelligent Key system) Intelligent Key unit (with Intelligent Key system) *: CONSULT-II “IMMU FUNCTION CHECK” results display screen “no malfunction is detected”. BL-228 NATS (NISSAN ANTI-THEFT SYSTEM) Diagnostic Procedure 1 BIS000MD A IMMU FUNCTION CHECK results: “UNREGISTERD BCM” displayed on CONSULT-II screen 1. CONFIRM IMMU FUNCTION CHECK B Confirm “IMMU FUNCTION CHECK” results “UNREGISTERD BCM” displayed on CONSULT-II screen. Is CONSULT-II screen displayed as above? YES >> ● BCM is malfunctioning. ● Replace BCM. ● Perform initialization with CONSULT-II. – For initialization, refer to “CONSULT-II Operation Manual NATS”. NO >> GO TO BL-227, "Trouble Diagnosis Symptom Chart" . Diagnostic Procedure 2 C D BIS000ME E MODELS WITHOUT INTELLIGENT KEY SYSTEM IMMU FUNCTION CHECK results: “CHAIN OF IMMU-KEY” displayed on CONSULT-II screen F 1. CONFIRM IMMU FUNCTION CHECK Confirm “IMMU FUNCTION CHECK” results “CHAIN OF IMMU-KEY” displayed on CONSULT-II screen. Is CONSULT-II screen displayed as above? Yes >> GO TO 2. No >> GO TO BL-227, "Trouble Diagnosis Symptom Chart" . G H 2. CHECK NATS ANTENNA AMP. INSTALLATION Check NATS antenna amp. installation. Refer to BL-237, "Removal and Installation NATS Antenna Amp." . OK or NG OK >> GO TO 3. NG >> Reinstall NATS antenna amp. correctly. 3. CHECK IGNITION KEY ID CHIP L M 4. CHECK POWER SUPPLY FOR NATS ANTENNA AMP. Turn ignition switch “ON”. Check voltage between NATS antenna amp. connector and ground. 3 - Ground: J K Start engine with another registered ignition key. Does the engine start? Yes >> ● Ignition key ID chip is malfunctioning. ● Replace the ignition key. ● Perform initialization with CONSULT-II. For initialization, refer to “CONSULT-II Operation Manual NATS”. No >> GO TO 4. 1. 2. BL Battery voltage OK or NG OK >> GO TO 5. NG >> Check harness for open or short between NATS antenna amp. and fuse. MIIB0401E BL-229 NATS (NISSAN ANTI-THEFT SYSTEM) 5. CHECK NATS ANTENNA AMP. SIGNAL LINE Check voltage between NATS antenna amp. connector and ground with analogue tester. Before turning ignition switch “ON” Voltage: 0V Just after turning ignition switch “ON” : Pointer of tester should move. OK or NG OK >> GO TO 6. NG >> ● Check harness for open or short between NATS MIIB0402E antenna amp. and BCM. NOTE: If harness is OK, replace new* BCM, perform initialization with CONSULT-II. For initialization, refer to “CONSULT-II Operation Manual NATS”. *: New one means virgin control unit that has never been energized on-board. 6. CHECK NATS ANTENNA AMP. GROUND LINE CIRCUIT 1. 2. Turn ignition switch “OFF”. Check continuity between NATS antenna amp. connector and ground. 2 - Ground: Continuity should exist. OK or NG OK >> NATS antenna amp. is malfunctioning. NG >> ● Check harness for open or short between NATS antenna amp. and ground. NOTE: If harness is OK, replace new* BCM, perform initialization with CONSULT-II. For initialization, refer to “CONSULT-II Operation Manual NATS”. *: New one means virgin control unit that has never been energized on-board. BL-230 MIIB0403E NATS (NISSAN ANTI-THEFT SYSTEM) MODELS WITH INTELLIGENT KEY SYSTEM A IMMU FUNCTION CHECK results: “CHAIN OF IMMU-KEY” displayed on CONSULT-II screen 1. CONFIRM IMMU FUNCTION CHECK B Confirm “IMMU FUNCTION CHECK” results “CHAIN OF IMMU-KEY” displayed on CONSULT-II screen. Is CONSULT-II screen displayed as above? Yes >> GO TO 2. No >> GO TO BL-227, "Trouble Diagnosis Symptom Chart" . 2. CHECK NATS ANTENNA AMP. INSTALLATION C D Check NATS antenna amp. installation. Refer to BL-237, "Removal and Installation NATS Antenna Amp." . OK or NG OK >> GO TO 3. NG >> Reinstall NATS antenna amp. correctly. E 3. CHECK MECHANICAL KEY ID CHIP F Start engine with another registered mechanical key. Does the engine start? Yes >> ● Mechanical key ID chip is malfunctioning. ● Replace the mechanical key. ● Perform initialization with CONSULT-II. For initialization, refer to “CONSULT-II Operation Manual NATS”. No >> GO TO 4. G H BL 4. CHECK POWER SUPPLY FOR NATS ANTENNA AMP. 1. 2. Turn ignition switch “ON”. Check voltage between NATS antenna amp. connector and ground. 4 - Ground: J Battery voltage K OK or NG OK >> GO TO 5. NG >> Check harness for open or short between NATS antenna amp. and fuse. L M MIIB0404E BL-231 NATS (NISSAN ANTI-THEFT SYSTEM) 5. CHECK NATS ANTENNA AMP. SIGNAL LINE- 1 Check voltage between NATS antenna amp. connector M35 terminal 2 and ground with analogue tester. Before inserting mechanical key in ignition knob Voltage: 0V Just after inserting mechanical key in ignition knob : Pointer of tester should move. OK or NG OK >> GO TO 6. NG >> ● Check harness for open or short between NATS MIIB0405E antenna amp. and Intelligent Key unit. NOTE: If harness is OK, replace new* Intelligent Key unit, perform initialization with CONSULT-II. For initialization, refer to “CONSULT-II Operation Manual NATS”. *: New one means virgin control unit that has never been energized on-board. 6. CHECK NATS ANTENNA AMP. SIGNAL LINE- 2 Check voltage between NATS antenna amp. connector M35 terminal 3 and ground with analogue tester. Before inserting mechanical key in ignition knob Voltage: 0V Just after inserting mechanical key in ignition knob : Pointer of tester should move. OK or NG OK >> GO TO 7. NG >> ● Check harness for open or short between NATS MIIB0406E antenna amp. and Intelligent Key unit. NOTE: If harness is OK, replace new* Intelligent Key unit, perform initialization with CONSULT-II. For initialization, refer to “CONSULT-II Operation Manual NATS”. *: New one means virgin control unit that has never been energized on-board. 7. CHECK NATS ANTENNA AMP. GROUND LINE CIRCUIT 1. 2. Turn ignition switch “OFF”. Check continuity between NATS antenna amp. connector M35 terminal 1 and ground. 1 - Ground: Continuity should exist. OK or NG OK >> NATS antenna amp. is malfunctioning. NG >> ● Check harness for open or short between NATS antenna amp. and ground. NOTE: If harness is OK, replace new* Intelligent Key unit, perform initialization with CONSULT-II. For initialization, refer to “CONSULT-II Operation Manual NATS”. *: New one means virgin control unit that has never been energized on-board. BL-232 MIIB0407E NATS (NISSAN ANTI-THEFT SYSTEM) Diagnostic Procedure 3 BIS000MF A IMMU FUNCTION CHECK results: “DIFFERENCE OF KEY” displayed on CONSULT-II screen 1. CONFIRM IMMU FUNCTION CHECK B Confirm “IMMU FUNCTION CHECK” results “DIFFERENCE OF KEY” displayed on CONSULT-II screen. Is CONSULT-II screen displayed as above? Yes >> GO TO 2. No >> GO TO BL-227, "Trouble Diagnosis Symptom Chart" . C 2. PERFORM INITIALIZATION WITH CONSULT-II D Perform initialization with CONSULT-II. Re-register all NATS ignition key IDs. For initialization and registration of NATS ignition key IDs, refer to “CONSULT-II Operation Manual NATS”. NOTE: If the initialization is not completed or malfunctions, CONSULT-II shows message on the screen. Can the system be initialized and can the engine be started with reregistered NATS ignition key? Yes >> ● Ignition key ID was unregistered. No >> ● BCM is malfunctioning. (models without Intelligent Key system) ● Replace new* BCM. ● Intelligent Key unit is malfunctioning. (models with Intelligent Key system) SEL297W ● Replace new* Intelligent Key unit. ● Perform initialization with CONSULT-II. ● For initialization, refer to “CONSULT-II Operation Manual NATS”. *: New one means virgin control unit that has never been energized on-board. Diagnostic Procedure 4 E F G H BL J BIS000MG IMMU FUNCTION CHECK results: “UNREGISTERD ECM” displayed on CONSULT-II screen K 1. CONFIRM IMMU FUNCTION CHECK Confirm “IMMU FUNCTION CHECK” results “UNREGISTERD ECM” displayed on CONSULT-II screen. Is CONSULT-II screen displayed as above? YES >> ● ECM is malfunctioning. ● Replace ECM. ● Perform initialization or re-communicating function. – For initialization, refer to BL-218, "ECM Re-communicating Function" . NO >> GO TO BL-227, "Trouble Diagnosis Symptom Chart" . BL-233 L M NATS (NISSAN ANTI-THEFT SYSTEM) Diagnostic Procedure 5 BIS000MH IMMU FUNCTION CHECK results: “ID DISCORD ECM-IMMU” displayed on CONSULT-II screen 1. CONFIRM IMMU FUNCTION CHECK Confirm “IMMU FUNCTION CHECK” results “UNREGISTERD ECM” displayed on CONSULT-II screen. Is CONSULT-II screen displayed as above? YES >> ● ECM is malfunctioning. ● Replace ECM. ● Perform initialization or re-communicating function. – For initialization, refer to “CONSULT-II Operation Manual NATS”. NO >> GO TO BL-227, "Trouble Diagnosis Symptom Chart" . Diagnostic Procedure 6 BIS000MI MODELS WITHOUT INTELLIGENT KEY SYSTEM “Security indicator does not light up” 1. CHECK FUSE Check 10A fuse [No. 7, located in the fuse block (J/B)] OK or NG OK >> GO TO 2. NG >> Replace fuse. 2. CHECK SECURITY INDICATOR LAMP 1. 2. 3. Install 10A fuse. Start engine and turn ignition switch OFF. Check the security indicator lamp lights up. Security indicator lamp should light up. OK or NG OK >> Inspection END. NG >> GO TO 3. 3. CHECK SECURITY INDICATOR LAMP POWER SUPPLY CIRCUIT 1. 2. Disconnect combination meter (security indicator lamp) connector. Check voltage between security indicator lamp connector M27 terminal 27 and ground. 27 - Ground: Battery voltage OK or NG OK >> GO TO 4. NG >> Check harness for open or short between fuse and security indicator lamp. MIIB0393E BL-234 NATS (NISSAN ANTI-THEFT SYSTEM) 4. CHECK BCM FUNCTION 1. 2. 3. A Connect combination meter (security indicator lamp) connector. Disconnect BCM connector. Check voltage between BCM connector M58 terminal 47 and ground. 47 - Ground: B Battery voltage C OK or NG OK >> BCM is malfunctioning. ● Replace BCM. ● Perform initialization with CONSULT-II. ● For initialization, refer to “CONSULT-II Operation Manual NATS”. NG >> Check the following. ● Harness for open or short between security indicator lamp and BCM. ● Indicator lamp condition MODELS WITH INTELLIGENT KEY SYSTEM “Security indicator does not light up” D MIIB0394E F G 1. CHECK FUSE Check 10A fuse [No. 7, located in the fuse block (J/B)] OK or NG OK >> GO TO 2. NG >> Replace fuse. H BL 2. CHECK SECURITY INDICATOR LAMP 1. 2. 3. Install 10A fuse. Start engine and turn ignition knob OFF position. Check the security indicator lamp lights up. J K Security indicator lamp should light up. OK or NG OK >> Inspection END. NG >> GO TO 3. L 3. CHECK SECURITY INDICATOR LAMP POWER SUPPLY CIRCUIT 1. 2. M Disconnect combination meter (security indicator lamp) connector. Check voltage between security indicator lamp connector M27 terminal 27 and ground. 27 - Ground: E Battery voltage OK or NG OK >> GO TO 4. NG >> Check harness for open or short between fuse and security indicator lamp. MIIB0393E BL-235 NATS (NISSAN ANTI-THEFT SYSTEM) 4. CHECK INTELLIGENT KEY UNIT FUNCTION 1. 2. 3. Connect combination meter (security indicator lamp) connector. Disconnect Intelligent Key unit connector. Check voltage between Intelligent Key unit connector M60 terminal 30 and ground. 30 - Ground: Battery voltage OK or NG OK >> Intelligent Key is malfunctioning. ● Replace Intelligent Key unit. ● Perform initialization with CONSULT-II. ● For initialization, refer to “CONSULT-II Operation Manual NATS”. NG >> Check the following. ● Harness for open or short between security indicator lamp and Intelligent Key unit. ● Indicator lamp condition Diagnostic Procedure 7 MIIB1448E BIS000MJ IMMU FUNCTION CHECK results: “P1610” displayed on CONSULT-II screen 1. CONFIRM IMMU FUNCTION CHECK Confirm “IMMU FUNCTION CHECK” results “P1610” (LOCK MODE) is displayed on CONSULT-II screen. Is CONSULT-II screen displayed as above? Yes >> GO TO 2. No >> GO TO BL-226, "WORK FLOW" . 2. ESCAPE FROM LOCK MODE 1. Turn ignition switch OFF. 2. Turn ignition switch ON with registered key. (Do not start engine.) Wait 5 seconds. 3. Return the key to OFF position. Wait 5 seconds. 4. Repeat steps 2 and 3 twice (total of three cycles). 5. Start the engine. Does engine start? Yes >> System is OK (Now system is escaped from “LOCK MODE”). No >> Perform “IMMU FUNCTION CHECK”, and repair the diagnosis result on the display. BL-236 NATS (NISSAN ANTI-THEFT SYSTEM) Removal and Installation NATS Antenna Amp. BIS000MK A REMOVAL CAUTION: Before servicing SRS, turn ignition switch OFF, disconnect both battery cables and wait at least 3 minutes. 1. Remove the spiral cable. Refer to SRS-38, "Removal and Installation" . 2. Disconnect the NATS antenna amp. connect, remove the screw and NATS antenna amp. B C D E PIIB6539E F INSTALLATION Install in the reverse order of removal. G H BL J K L M BL-237 NATS (NISSAN ANTI-THEFT SYSTEM) BL-238 BRAKE SYSTEM F BRAKES SECTION BR BRAKE SYSTEM A B C D CONTENTS PRECAUTIONS .......................................................... 3 Precautions for Supplemental Restraint System (SRS) “AIR BAG” and “SEAT BELT PRE-TENSIONER” .................................................................. 3 PrecautionsforProcedureswithoutCowlTopCover..... 3 Precautions for Brake System .................................. 3 PREPARATION ........................................................... 4 Special Service Tools ............................................... 4 NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING ................................................ 5 NVH Troubleshooting Chart ..................................... 5 BRAKE PEDAL .......................................................... 6 Inspection and Adjustment ....................................... 6 PLAY AND CLEARANCE BETWEEN BRAKE PEDAL AND FLOOR PANEL WITH PEDAL DEPRESSED. ....................................................... 6 Removal and Installation .......................................... 7 COMPONENTS .................................................... 7 REMOVAL ............................................................. 7 INSPECTION AFTER REMOVAL ......................... 8 INSTALLATION ..................................................... 8 BRAKE FLUID ............................................................ 9 Level Inspection ....................................................... 9 Checking Brake Line ................................................ 9 Drain and Refill ......................................................... 9 Bleeding Brake System .......................................... 10 BRAKE PIPING AND HOSE .....................................11 Hydraulic Circuit ......................................................11 Removal and Installation of Front Brake Piping and Brake Hose .............................................................11 REMOVAL ............................................................11 INSTALLATION ................................................... 12 Removal and Installation of Rear Brake Piping and Brake Hose ............................................................ 12 REMOVAL ........................................................... 12 INSTALLATION ................................................... 12 Inspection ............................................................... 13 BRAKE MASTER CYLINDER .................................. 14 Removal and Installation ........................................ 14 REMOVAL ........................................................... 14 INSTALLATION ................................................... 14 Disassembly and Assembly .................................... 14 DISASSEMBLY ................................................... 15 INSPECTION AFTER DISASSEMBLY ............... 15 ASSEMBLY ......................................................... 15 BRAKE BOOSTER ................................................... 17 On-Vehicle Service ................................................. 17 OPERATING CHECK .......................................... 17 AIRTIGHTNESS INSPECTION ........................... 17 Removal and Installation ........................................ 17 COMPONENTS ................................................... 17 REMOVAL ........................................................... 17 INSTALLATION ................................................... 18 VACUUM LINES ....................................................... 19 Components ........................................................... 19 Removal and Installation ........................................ 19 VACUUM HOSE .................................................. 19 VACUUM PUMP .................................................. 19 Inspection ............................................................... 20 VISUAL INSPECTION ......................................... 20 CHECK VALVE INSPECTION ............................. 20 FRONT DISC BRAKE ............................................... 21 On Board Inspection ............................................... 21 PAD WEAR INSPECTION ................................... 21 Components ........................................................... 21 Removal and Installation of Brake Pad .................. 22 REMOVAL ........................................................... 22 INSTALLATION ................................................... 22 RemovalandInstallationofBrakeCaliperAssembly ... 23 REMOVAL ........................................................... 23 INSTALLATION ................................................... 23 Disassembly and Assembly of Brake Caliper Assembly ................................................................ 23 DISASSEMBLY ................................................... 23 BRAKE CALIPER INSPECTION ......................... 24 BR-1 E BR G H I J K L M ASSEMBLY ......................................................... 24 Removal and Installation of Disc Rotor ................... 25 REMOVAL ........................................................... 25 INSTALLATION .................................................... 25 DISC ROTOR INSPECTION ............................... 25 BRAKE BURNISHING PROCEDURE ................. 26 REAR DRUM BRAKE ............................................... 27 Components ........................................................... 27 Removal and Installation of Drum Brake Assembly... 28 REMOVAL ........................................................... 28 INSPECTION AFTER REMOVAL ........................ 28 INSTALLATION .................................................... 29 Removal and Installation of Wheel Cylinder ........... 30 REMOVAL ............................................................30 INSTALLATION ....................................................30 Disassembly and Assembly of Wheel Cylinder .......30 DISASSEMBLY ....................................................30 ASSEMBLY ..........................................................30 Wheel Cylinder Inspection ......................................31 SERVICE DATA AND SPECIFICATIONS (SDS) ......32 General Specifications ............................................32 Brake Pedal ............................................................32 Brake Booster .........................................................32 Check Valve ............................................................32 Front Disc Brake .....................................................33 Rear Drum Brake ....................................................33 BR-2 PRECAUTIONS PRECAUTIONS PFP:00001 Precautions for Supplemental Restraint System (SRS) “AIR BAG” and “SEAT BELT PRE-TENSIONER” A BFS0007Q The Supplemental Restraint System such as “AIR BAG” and “SEAT BELT PRE-TENSIONER”, used along B with a front seat belt, helps to reduce the risk or severity of injury to the driver and front passenger for certain types of collision. This system includes seat belt switch inputs and dual stage front air bag modules. The SRS system uses the seat belt switches to determine the front air bag deployment, and may only deploy one front C air bag, depending on the severity of a collision and whether the front occupants are belted or unbelted. Information necessary to service the system safely is included in the SRS and SB section of this Service Manual. D WARNING: ● To avoid rendering the SRS inoperative, which could increase the risk of personal injury or death in the event of a collision which would result in air bag inflation, all maintenance must be performed by an authorized NISSAN/INFINITI dealer. E ● Improper maintenance, including incorrect removal and installation of the SRS, can lead to personal injury caused by unintentional activation of the system. For removal of Spiral Cable and Air Bag Module, see the SRS section. BR ● Do not use electrical test equipment on any circuit related to the SRS unless instructed to in this Service Manual. SRS wiring harnesses can be identified by yellow and/or orange harnesses or harness connectors. G Precautions for Procedures without Cowl Top Cover BFS0007R When performing the procedure after removing cowl top cover, cover the lower end of windshield with urethane, etc. H I J PIIB3706J Precautions for Brake System ● ● ● ● ● ● ● ● ● ● K BFS0007S Clean dust on front brake and rear brake with a vacuum dust collector. Do not blow with compressed air. Recommended fluid is brake fluid “Nissan Genuine Brake Fluid or DOT 3 or DOT 4 (US FMVSS No.116)”. Never reuse drained brake fluid. Be careful not to splash brake fluid on painted areas; it may cause paint damage. If brake fluid is splashed on painted areas, wash it away with water immediately. To clean or wash all parts of master cylinder, disc brake caliper and wheel cylinder, use new brake fluid. Never use mineral oils such as gasoline or kerosene. They will ruin rubber parts of the hydraulic system. Use a flare nut wrench when removing flare nuts, and use a flare nut torque wrench when tightening flare nuts. Always tighten brake lines to the specified torque when installing. Before working, turn ignition switch OFF and disconnect electrical connector of ABS actuator and electric unit (control unit) or the battery cables. Burnish the brake contact surfaces after refinishing or replacing drums or rotors, after replacing pads or linings, or if a soft pedal occurs at very low mileage. SBR820BA Refer to BR-26, "BRAKE BURNISHING PROCEDURE" . BR-3 L M PREPARATION PREPARATION Special Service Tools PFP:00002 BFS0007T Tool number Tool name Description GG94310000 Flare nut torque wrench a: 10 mm (0.39 in) Removing and installing each brake piping NT406 BR-4 Symptom BRAKE Noise × × × BR-5 Shake × Shimmy, Judder × × × × × × × × × × × × × STEERING × DRIVE SHAFT × × ROAD WHEEL NVH in PS section NVH in FAX section NVH in WT section NVH in WT section NVH in FAX, RAX and FSU, RSU section BR-26 — — — BR-25 BR-25, BR-29 — — BR-21, BR-28 NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING NVH Troubleshooting Chart × × TYRES × AXLE AND SUSPENSION Rotor thickness variation Rotor or drum rust Rotor or drum deflection Rotor or drum deformation Rotor runout Rotor or drum damage Rotor or drum imbalance Return spring damaged Possible cause and SUSPECTED PARTS Pads or linings - uneven wear BR-21, BR-28 Reference page Pads or linings - damaged NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING PFP:00003 BFS0007U A Use the chart below to help you find the cause of the symptom. If necessary, repair or replace these parts. B C × × D E BR G H I J X: Applicable K L M BRAKE PEDAL BRAKE PEDAL Inspection and Adjustment PFP:46501 BFS0007V PLAY AND CLEARANCE BETWEEN BRAKE PEDAL AND FLOOR PANEL WITH PEDAL DEPRESSED. ● ● ● Check the pedal play. Check the brake pedal free height from the dash floor panel. If value is outside the standard, make an adjustment to the following dimension. SFIA1116E LHD H1 Brake pedal height RHD M/T models 161 - 171 mm (6.34 - 6.73 in) A/T models 171 - 181 mm (6.73 - 7.13 in) M/T models 156 - 166 mm (6.14 - 6.54 in) A/T models 166 - 176 mm (6.54 - 6.93 in) M/T models 80 mm (3.15 in) or more A/T models 85 mm (3.35 in) or more H2 Depressed pedal height [under a force of 490 N (50 kg, 110 lb) with the engine running] C Clearance between the stopper rubber and the threaded end of stop lamp switch. A Pedal play 0.74 - 1.96 mm (0.029 - 0.077 in) 3 - 11 mm (0.12 - 0.43 in) BR-6 BRAKE PEDAL Removal and Installation BFS0007W A COMPONENTS B C D E BR SFIA1114E 1. Snap pin 2. Stop lamp switch 4. Brake pedal assembly 5. Clevis pin 3. H CAUTION: ● Be careful not to deform brake tube. ● Do not strike the brake pedal assembly against anything during removal and installation. I REMOVAL 1. 2. 3. 4. 5. 6. G Clip Remove instrument finisher lower. Refer to IP-4, "INSTRUMENT PANEL ASSEMBLY" . Remove accelerator pedal harness clip and connector. Refer to ACC-2, "ACCELERATOR CONTROL SYSTEM" . Disconnect stop lamp switch harness connector and remove stop lamp switch from the pedal assembly. (Remove it by rotating the switch by 45°) Remove snap pin and clevis pin from the brake booster clevis. Remove pedal assembly mounting nut and then remove pedal assembly from the vehicle while moving the master cylinder and brake booster to the engine room side while being careful not to deform the brake tube. Remove accelerator pedal from the brake pedal assembly. J K L M SFIA1115E BR-7 BRAKE PEDAL INSPECTION AFTER REMOVAL Check brake pedal for bend, damage, and cracks on the welded parts. Replace applicable part if any nonstandard condition is detected. CAUTION: Brake pedal is equipped with a crash system. During serious vehicle collision and system activation, brake pedal pivot bolt (1) is displaced rearwards, resulting in brake pedal pad displacement into footwell away from the vehicle occupant. Replace pedal unit complete if Crash System shear rivet (2) has broken following collision (LHD vehicles). ● MFIB9031E During serious vehicle collision and system activation, brake pedal pivot point is displaced rearwards, resulting in brake pedal pad displacement into footwell away from the vehicle occupant. Replace pedal unit complete if Crash System shear rivet (1) has broken or sliding latch plate (2) has de-latched following collision (RHD vehicles). MFIB9032E INSTALLATION ● ● For information regarding the tightening torque, refer to BR-7, "COMPONENTS" . Install in the reverse order of removal. After installing brake pedal assembly to the vehicle, adjust brake pedal. Refer to BR-6, "BRAKE PEDAL" . BR-8 BRAKE FLUID BRAKE FLUID Level Inspection ● ● ● ● PFP:KN100 A BFS0007X Make sure the fluid level in the reservoir tank is within the standard (between MAX and MIN lines). Visually check around the reservoir tank for fluid leaks. If fluid level is excessively low, check brake system for leaks. If warning lamp remains illuminated after parking lever is released, check brake system for fluid leakage and the wear of brake pads or brake linings. B C D SFIA0527J E Checking Brake Line BFS0007Y CAUTION: If leakage occurs around joints, retighten or, if necessary, replace damaged parts. 1. Check brake line (tubes and hoses) for cracks, deterioration or other damage. Replace any damaged parts. 2. Check for oil leakage by fully depressing brake pedal while engine is running. BR G H I SBR389C Drain and Refill BFS0007Z CAUTION: ● Refill with new brake fluid “Nissan Genuine Brake Fluid or DOT 3 or DOT 4 (US FMVSS No.116)”. ● Do not mix different types of brake fluid (DOT 3, DOT 4). ● Never reuse drained brake fluid. ● Be careful not to splash brake fluid on painted areas; it may cause paint damage. If brake fluid is splashed on painted areas, wash it away with water immediately. 1. Turn ignition switch OFF, and remove ABS actuator connector. 2. Connect a vinyl tube to the air bleeder. 3. Drain brake fluid gradually from the air bleeder of each wheel while depressing the brake pedal. BRA0007D BR-9 J K L M BRAKE FLUID 4. 5. Make sure that there is no foreign material in the reservoir tank, and refill with new brake fluid. Rest foot on brake pedal. Loosen air bleeder. Slowly depress pedal until it stops. Tighten air bleeder. Release brake pedal. Repeat this process a few times, then pause to add new brake fluid to master cylinder. Continue until new brake fluid flows out. For information regarding air bleeding work, refer to BR-10, "Bleeding Brake System" . BRA0006D Bleeding Brake System BFS00080 CAUTION: ● While bleeding, pay attention to master cylinder fluid level. ● Fill reservoir with new brake fluid “Nissan Genuine Brake Fluid or DOT 3 or DOT 4 (US FMVSS No.116)” ● Do not mix different types of brake fluid (DOT 3, DOT 4) 1. Turn ignition switch OFF, and remove ABS actuator connector. 2. Connect a vinyl tube to the rear left wheel air bleeder. 3. Fully depress brake pedal 4 to 5 times. 4. With brake pedal depressed, loosen air bleeder and bleed air, and then quickly tighten the air bleeder. 5. Repeat steps 3 - 4 until all of the air is out of the brake line. 6. Tighten the air bleeder to the specified torque. Tightening torque 7. : 10 N·m (1.0 kg-m, 7 ft-lb) Repeat steps 2 to 6. Occasionally refill master cylinder reservoir tank with brake fluid in order to keep it at least half-full. Bleed air in the following order: front RH wheel, RH rear wheel, and front LH wheel. BR-10 BRAKE PIPING AND HOSE BRAKE PIPING AND HOSE Hydraulic Circuit PFP:46210 A BFS00081 B C D E BR MFIB9017E Removal and Installation of Front Brake Piping and Brake Hose G BFS00082 REMOVAL H CAUTION: ● Be careful not to splash brake fluid on painted areas; it may cause paint damage. If brake fluid is splashed on painted areas, wash it away with water immediately. ● All hose must be free from excessive bending, twisting and pulling. ● Cover brake fluid line connections to prevent dust and other foreign material from entering. 1. Drain brake fluid. Refer to BR-9, "Drain and Refill" . 2. Using a flare nut wrench, remove the flare nuts of the brake tube and disconnect the brake tube from the brake hose. 3. Remove brake caliper union bolts and disconnect caliper assembly from brake hose. 4. First remove the lock plate from the mounting positions of brake tubes and struts, and then brake hose. I J K L M SFIA1118E BR-11 BRAKE PIPING AND HOSE INSTALLATION CAUTION: ● Refill with new brake fluid “Nissan Genuine Brake Fluid or DOT 3 or DOT 4 (US FMVSS No.116)”. ● Do not mix different types of brake fluid (DOT3, DOT4). ● Never reuse the drained brake fluid. 1. Install the brake hose to the caliper assembly and tighten union bolts to the specified torque. Tightening torque 2. 3. 4. CAUTION: ● Install brake hose securely by inserting the hose fitting protrusion into the caliper hole. ● Do not reuse the copper washer for union bolts. Connect brake hose to the strut and fix with lock plate. Connect brake hose to brake tube. Temporarily tighten flare nuts by hand as far as they will go. Secure them with the lock plate. Using a flare nut torque wrench, tighten to the specified torque. Tightening torque 5. 6. : 18 N·m (1.8 kg-m, 13 ft-lb) SFIA1119E : 16.2 N·m (1.7 kg-m, 12 ft-lb) Add new brake fluid. Refer to BR-9, "Drain and Refill" . Bleed the air. Refer to BR-10, "Bleeding Brake System" . Removal and Installation of Rear Brake Piping and Brake Hose BFS00083 REMOVAL CAUTION: ● Be careful not to splash brake fluid on painted areas; it may cause paint damage. If brake fluid is splashed on painted areas, wash it away with water immediately. ● All hose must be free from excessive bending, twisting and pulling. ● Cover brake fluid line connections to prevent dust and other foreign material from entering. 1. Drain brake fluid. Refer to BR-9, "Drain and Refill" . 2. Using a flare nut wrench, remove the flare nuts of the brake tube and disconnect the brake tube from the brake hose. 3. Remove the lock plate and remove the brake hose from the vehicle. SFIA1120E INSTALLATION CAUTION: ● Refill with new brake fluid “Nissan Genuine Brake Fluid or DOT 3 or DOT 4 (US FMVSS No.116)”. ● Do not mix different types of brake fluid (DOT3, DOT4). ● Never reuse the drained brake fluid. 1. Connect brake hose to the brake tube. Temporarily tighten flare nut by hand as far as it will go. 2. Secure brake hose with the lock plate, and then use a flare nut wrench to tighten the flare nuts to the specified torque. Tightening torque 3. 4. : 16.2 N·m (1.7 kg-m, 12 ft-lb) Add new brake fluid. Refer to BR-9, "Drain and Refill" . Bleed the air. Refer to BR-10, "Bleeding Brake System" . BR-12 BRAKE PIPING AND HOSE Inspection BFS00084 CAUTION: If leak is detected at the connections, retighten it or replace the damaged part if necessary. 1. Check hose, tube, and connections for fluid leaks, damage, twist, deformation, contact with other parts, and loose connections. 2. While depressing brake pedal with engine running for approximately 5 seconds, check for fluid leak from each part. A B C D E BR G H I J K L M BR-13 BRAKE MASTER CYLINDER BRAKE MASTER CYLINDER Removal and Installation PFP:46010 BFS00085 REMOVAL 1. 2. 3. 4. 5. Drain brake fluid. Refer to BR-9, "Drain and Refill" . Remove harness connector of fluid level sensor. Remove clutch reservoir hose. (M/T models) Using a flare nut wrench, disconnect master cylinder assembly and brake tube. First remove nuts on master cylinder assembly, and then master cylinder assembly from brake booster assembly. SFIA1122E INSTALLATION 1. 2. Install brake tube to the master cylinder assembly and temporarily tighten the flare nuts by hand. Install the master cylinder assembly to the brake booster assembly and tighten mounting nuts to the specified torque. Tightening torque 3. Tighten flare nuts of the brake tube to the specified torque. Tightening torque 4. 5. 6. : 14 N·m (1.4 kg-m, 10 ft-lb) : 16.2 N·m (1.7 kg-m, 12 ft-lb) Install the clutch reservoir hose. (M/T models) Add new brake fluid. Refer to BR-9, "Drain and Refill" . Bleed the air. Refer to BR-10, "Bleeding Brake System" . Disassembly and Assembly BFS00086 MFIB9016E 1. Stopper cap 2. Primary piston assembly 3. Fluid level sensor harness connector 4. Clutch reservoir hose (M/T models) 5. Reservoir tank 6. Secondary piston assembly 7. Grommet 8. Screw 9. Piston stopper 10. Reservoir tank cap BR-14 BRAKE MASTER CYLINDER DISASSEMBLY A CAUTION: Remove master cylinder reservoir tank only when necessary. 1. As shown in the figure, use a screwdriver to lift up the stopper cap hooks and remove the stopper cap from the master cylinder. B C D BRA0031D E 2. 3. 4. 5. Remove reservoir tank mounting screw from cylinder body. Remove reservoir tank and grommet from cylinder body. Using a flat-bladed screwdriver, press and hold piston as shown in the figure. Remove piston stopper from secondary tank boss hole in the cylinder body. CAUTION: Be careful not to damage the inner wall of the cylinder. Carefully pull the primary piston assembly straight out to prevent cylinder inner wall from being damaged. BR G H BRA0519D 6. Tap the flange against a soft block such as wood, and carefully pull the secondary piston assembly straight out to prevent cylinder inner wall from damage. I J K L BRA0033D M INSPECTION AFTER DISASSEMBLY ● Check inner wall of master cylinder for damage, wear, corrosion, and pinholes. Replace cylinder if any non-standard condition is detected. ASSEMBLY CAUTION: ● Never use mineral oils such as kerosene or gasoline during the cleaning and assembly processes. ● Make sure there is no foreign material such as dirt and dust on cylinder inner wall, piston, and cup seal. Be careful not to damage the parts with a service tool when assembling. ● Do not drop the parts. Do not use any dropped parts. BR-15 BRAKE MASTER CYLINDER 1. 2. 3. Apply brake fluid to the cylinder inner wall body and contact surface of the piston assembly. Insert the secondary piston assembly and primary piston assembly into the cylinder body in this order. CAUTION: ● Do not reuse primary and secondary piston assemblies. ● Pay attention to direction of piston cups, and insert straight to prevent the cup from being caught by the inner wall of the cylinder. ● Do not disassemble the new part inner kit. Always replace it as a complete assembly. Visually check secondary piston slit position through cylinder body secondary tank boss hole and install piston stopper. MFIA0009E BRA0519D 4. 5. 6. While holding the piston with the stopper cap, press the stopper cap fully until its tabs are engaged with the groove on the cylinder body to install. CAUTION: Do not reuse the stopper cap. Apply brake fluid to a grommet, and press it into cylinder body. CAUTION: Do not reuse the grommet. Install reservoir tank and reservoir tank mounting screw to cylinder body. BR-16 BRA0535D BRAKE BOOSTER BRAKE BOOSTER On-Vehicle Service PFP:47200 A BFS00087 OPERATING CHECK ● ● Depress brake pedal several times with engine off, and check that there is no change in pedal stroke. Depress brake pedal, then start engine. If pedal goes down slightly, operation is normal. B C D BRA0037D E AIRTIGHTNESS INSPECTION ● ● Start engine, and stop it after one or two minutes. Depress brake pedal several times slowly. If pedal goes further down the first time and gradually rises after second or third time, booster is airtight. Depress brake pedal while engine is running, and stop engine with pedal depressed. If there is no change in pedal stroke after holding pedal down 30 seconds, brake booster is airtight. BR G H SBR365AA I Removal and Installation BFS00088 COMPONENTS J K L M MFIB9018E REMOVAL CAUTION: ● Be careful not to deform or bend brake piping while removing and installing the brake booster. ● Replace clevis pin if it is damaged. ● Be careful not to damage brake booster stud bolt threads. If brake booster is tilted or inclined during installation, the dash panel may damage the threads. ● Be sure to install check valve in the correct orientation. 1. Remove the vacuum hose from the brake booster. BR-17 BRAKE BOOSTER 2. 3. 4. 5. 6. 7. 8. Remove brake master cylinder. Refer to BR-14, "Removal and Installation" . Remove snap pin and clevis pin from the brake pedal mounting area via the vehicle cabin. Remove brake booster and brake pedal assembly nuts. Remove clutch master cylinder from the panel and pull it out through the engine room side and place it where it will not be in the way. Refer to CL-9, "Removal and Installation" (M/T models). Remove the air conditioner lower pressure hose holding bracket. Remove cowl top cover. Refer to EI-12, "Removal and Installation" . Remove booster assembly from engine room. SFIA1127E INSTALLATION 1. Check input rod length so that length B (in the figure) satisfies the specified value. Length B standard LHD models RHD models 2. 3. 4. 5. 6. 7. 8. 9. : 158.25 mm (6.23 in) : 115.35 mm (4.54 in) Install booster assembly in the vehicle. CAUTION: Be sure to install the gasket between the booster assembly and the vehicle. SFIA1128E Connect the brake pedal with the clevis of the input rod. Install nuts to booster assembly and tighten to the specified torque. Install brake master cylinder to the booster assembly. Refer to BR-14, "Removal and Installation" . Install the clutch master cylinder. Refer to CL-9, "Removal and Installation" (M/T models). Install the air conditioner lower pressure hose holding bracket. Install cowl top cover. Refer to EI-12, "Removal and Installation" . Bleed air. Refer to BR-10, "Bleeding Brake System" . BR-18 VACUUM LINES VACUUM LINES Components PFP:41920 A BFS00089 B C D E BR G H I MFIA0010E Removal and Installation BFS0008A J VACUUM HOSE CAUTION: ● Because vacuum hose contains a check valve, it must be installed in the correct orientation. Refer to the stamp or label to confirm correct installation. The brake booster will not operate normally if the hose is installed in the wrong direction. ● Insert the vacuum hose for at least 24 mm (0.94 in). ● Never use lubricating oil during assembly. K L M SBR225B VACUUM PUMP For information regarding vacuum pump removal and installation, refer to EM-261, "VACUUM PUMP" . BR-19 VACUUM LINES Inspection BFS0008B VISUAL INSPECTION Check for improper assembly, damage and aging. CHECK VALVE INSPECTION Airtightness Inspection Use a hand-held vacuum pump to check. When connected to booster side (1): Vacuum decrease should be within 1.3 kPa (10 mmHg, 0.39 inHg) for 15 seconds under a vacuum of -66.7 kPa (-500 mmHg, -19.69 inHg) When connected to engine side (2): Vacuum should not exist. SFIA0210E BR-20 FRONT DISC BRAKE FRONT DISC BRAKE On Board Inspection PFP:41000 A BFS0008C PAD WEAR INSPECTION Inspect the thickness of pad through cylinder body inspection hole. Use a scale for inspection if necessary. ● Standard thickness Wear limit thickness B : 12.4 mm (0.488 in) : 2.0 mm (0.079 in) C D BRA0010D Components E BFS0008D BR G H I J K L M SFIA1129E 1. Torque member 2. Sliding pin 3. Pin boot 4. Pad retainer (upper) 5. Pad retainer (lower) 6. Inner pad 7. Outer pad 8. Cylinder body 9. Piston seal 10. Piston 11. Piston boots 12. Union bolt 13. Copper washer 14. Air bleeder CAUTION: ● Clean dust on the caliper and brake pad with a vacuum dust collector. Do not blow with compressed air. ● While removing the cylinder body, do not depress the brake pedal because the piston will pop out. ● Do not remove brake hose and torque member bolts unless disassembling or replacing caliper assembly. Hang cylinder body with a wire so that brake hose is not under tension. ● Be careful not to damage the piston boot. Do not allow brake fluid to get on the rotor. BR-21 FRONT DISC BRAKE Removal and Installation of Brake Pad BFS0008E REMOVAL CAUTION: Always replace the inner cover and outer shim as a set when replacing the brake pads. 1. Remove tyre from vehicle. 2. Remove brake master cylinder reservoir tank cap. 3. Remove lower sliding pin bolt. SFIA1130E 4. Hang cylinder body with a wire, and remove pads and pad retainers from torque member. SFIA1133E INSTALLATION 1. 2. 3. 4. 5. Apply PBC (Poly Butyl Cuprysil) or silicone-based grease on inner pad (rear surface) and outer pad (rear surface). Apply PBC (Poly Butyl Cuprysil) or silicone-based grease to pad contact surface on pad retainer. Install pad retainers and pads to the torque member. Install cylinder body to torque member. CAUTION: When replacing pads with new ones, press in piston until pads can be installed. In this case, carefully monitor brake fluid level in the reservoir tank because brake fluid will return to the reservoir tank of master cylinder. Insert the lower sliding pin bolt to tighten to the specified torque. Check brake for drag. BR-22 FRONT DISC BRAKE Removal and Installation of Brake Caliper Assembly BFS0008F REMOVAL A 1. 2. 3. B Remove tyre from vehicle. Drain brake fluid. Refer to BR-9, "Drain and Refill" . Remove union bolts and torque member bolts, and remove brake caliper assembly. C D E SFIA1136E INSTALLATION CAUTION: BR ● Refill with new brake fluid “Nissan Genuine Brake Fluid or DOT 3 or DOT 4 (US FMVSS No.116)”. ● Do not mix different types of brake fluid (DOT 3, DOT 4). ● Never reuse the drained brake fluid. G 1. Install brake caliper assembly to the vehicle, and tighten bolts on torque member to the specified torque. CAUTION: Before installing brake caliper assembly, wipe off oil and grease on the nut washer seats and H brake caliper assembly mounting surface. 2. Install brake hose to the brake caliper assembly, and tighten union bolts to the specified torque. I CAUTION: ● Do not reuse the copper washer for union bolts. ● Assemble brake hose securely to the cylinder body J mounting hole. 3. Add new brake fluid. Refer to BR-9, "Drain and Refill" . 4. Bleed air. Refer to BR-10, "Bleeding Brake System" . K SFIA1137E Disassembly and Assembly of Brake Caliper Assembly L BFS0008G DISASSEMBLY WARNING: Be careful not to pinch your fingers in the piston. CAUTION: Be careful not to damage cylinder inner wall. 1. Place a wooden block as shown in the figure, and blow air from the union bolt mounting hole to remove piston and piston boots. M MAA0272D BR-23 FRONT DISC BRAKE 2. Using a flat-bladed screwdriver, remove piston seals. PFIA0269E BRAKE CALIPER INSPECTION Cylinder Body CAUTION: Use new brake fluid to clean. Do not use mineral oils such as gasoline or kerosene. Check the inner wall of the cylinder for wear or damage. If any non-standard condition is detected, replace the cylinder. Torque Member Check for wear, cracks, and damage. If any non-standard condition is detected, replace the applicable part. Piston CAUTION: Piston sliding surface is plated. Do not polish with sandpaper. Check piston surface for corrosion, wear, and damage. If any non-standard condition is detected, replace applicable part. Sliding Pin and Pin Boots Check sliding pin and pin boot for wear, damage, and cracks. If damage or deformation is present, replace the affected part. ASSEMBLY CAUTION: When assembling, use only rubber lubricant specified below. 1. Apply polyglycol ether based lubricant to the piston seals, and install them to the cylinder body. CAUTION: Do not reuse the piston seals. SFIA1060E 2. Apply polyglycol ether based lubricant to the piston boot, cover the end of the piston with the piston boot, evenly insert the piston boot into the cylinder side, and make sure it is in the cylinder body groove. CAUTION: Do not reuse the piston boot. SFIA1061E BR-24 FRONT DISC BRAKE 3. Apply brake fluid to piston. Press piston into cylinder body by hand. Assemble piston side lip on piston boot properly into groove on piston. CAUTION: Press the piston evenly and change the pressing point to prevent the inner wall of the cylinder from being rubbed. A B C SFIA1062E Removal and Installation of Disc Rotor D BFS0008H REMOVAL 1. 2. 3. Remove tyre from vehicle. Remove brake caliper assembly. Refer to BR-23, "REMOVAL" . CAUTION: ● Brake hose need not be disconnected brake caliper. ● Suspend brake caliper with wire so as not to stretch brake hose. ● Be careful not to depress brake pedal, or caliper piston will pop out. ● Make sure brake hose is not twisted. Remove disc rotor mounting screw (torx), then remove disc rotor from front axle. E BR G H I J SFIA1141E INSTALLATION ● K Install in the reverse order of removal. Tighten the mounting screw (torx) to the specified torque. CAUTION: Do not use any disc rotors that have once dropped. L DISC ROTOR INSPECTION Visual Inspection Check surface of the disc rotor for uneven wear, cracks, and serious damage. If any non-standard condition is detected, replace applicable part. Runout Inspection 1. 2. Using wheel bolts, fix disc rotor to the wheel hub. (2 or more positions) Using a dial indicator, check the runout. Measurement position : At a point 10 mm (0.39 in) from outer edge of the disc Runout limit: 0.058 mm (0.0023 in) or less 3. NOTE: Make sure that wheel bearing axial end play is within the specifications before measuring. Refer to FAX-6, "FRONT WHEEL BEARING" . If the runout is outside the limit, find the minimum runout point by shifting the mounting positions of the disc rotor and wheel hub by one hole. BR-25 BRA0013D M FRONT DISC BRAKE 4. If the runout is still out of specification, turn rotor with on-car brake lathe (“MAD DL-8700”, “AMMCO 700 and 705” or equivalent). Thickness Inspection Using a micrometer, check thickness of the disc rotor. If thickness is outside the standard, replace disc rotor. Standard thickness Wear limit Maximum uneven wear (measured at 8 positions) : 22.0 mm (0.87 in) : 20.0 mm (0.79 in) : 0.03 mm (0.0012 in) or less SBR020B BRAKE BURNISHING PROCEDURE Burnish the brake contact surfaces according to the following procedure after refinishing or replacing drums or rotors, after replacing pads or linings, or if a soft pedal occurs at very low mileage. CAUTION: Only perform this procedure under safe road and traffic conditions. Use extreme caution. 1. Drive the vehicle on a straight smooth road at 50 km/h (31MPH). 2. Use medium brake pedal/foot effort to bring the vehicle to a complete stop from 50 km/h (31 MPH). Adjust brake pedal/foot pressure such that vehicle stopping time equals 3 to 5 seconds. 3. To cool the brake system, drive the vehicle at 50 km/h (31 MPH) for 1 minute without stopping. 4. Repeat steps 1 to 3, 10 times or more to complete the burnishing procedure. BR-26 REAR DRUM BRAKE REAR DRUM BRAKE Components PFP:43206 A BFS0008I B C D E BR G H I SFIA1142E 1. Drum 2. Return spring (lower) 3. Return spring (upper) 4. Adjuster 5. Retaining clip 6. Shoe 7. Cylinder body Boots 8. Air bleeder 9. 10. Piston 11. Piston cup 12. Spring 13. Back plate 14. Shoe hold pin WARNING: Clean dust on drum and back plate with a vacuum dust collector. Do not blow with compressed air. J K L CAUTION: ● While removing drum, never depress brake pedal because the piston will pop out. ● Make sure parking brake lever is released completely. BR-27 M REAR DRUM BRAKE Removal and Installation of Drum Brake Assembly BFS0008J REMOVAL 1. 2. Remove tyre from vehicle. With the parking brake lever released, remove the brake drum. Refer to RAX-5, "Removal and Installation" . 3. While pushing and rotating the retainer, pull out shoe hold pin, and remove shoe assembly. CAUTION: Do not damage the wheel cylinder piston boot. SFIA1145E 4. 5. Remove the parking brake cable from the operating lever. CAUTION: Do not bend the parking brake cable. Disassemble the shoe assembly (shoe, springs, spacer, adjuster). SFIA1146E INSPECTION AFTER REMOVAL Lining Thickness Inspection Check lining thickness. Standard thickness Wear limit of thickness (A) : 4.5 mm (0.177 in) : 1.5 mm (0.059 in) SBR021A Drum Inner Diameter Inspection Check the drum inside diameter. BR-28 REAR DRUM BRAKE Measurement area: lining contact surface (center) A Standard inner diameter : 202 mm (7.95 in) dia. Wear limit of inner diameter : 203.2 mm (8.0 in) dia. B C SBR022A D Wheel Cylinder Leakage Inspection Check wheel cylinder for brake fluid leakage. Check for wear, damage, and looseness. If any non-standard condition is found, replace it. ● ● E BR G SFIA1147E H Other Inspections Check inside of the drum for excessive wear, damage, and cracks. Check lining for excessive wear, damage, and peeling. Check shoe sliding surface for excessive wear and damage. Check return spring for sagging. Check back plate for damage, cracks, and deformation. Check bolts on the back plate for looseness. ● ● ● ● ● ● I J INSTALLATION 1. K Apply Nissan brake grease special (KRF0000005) or equivalent to brake shoes sliding surfaces (the shaded areas) and other parts on the back plate as indicated by arrows in the figure. L M SFIA1148E 2. Shorten adjuster by rotating it. Wheel Screw Left Left-hand thread Right Right-hand thread SFIA1149E 3. Assemble the shoe, springs, adjuster and spacer to form the shoe assembly. BR-29 REAR DRUM BRAKE 4. 5. 6. Connect the parking brake cable to the operating lever. Install the shoe assembly. After assembly, be sure that each part is installed properly. CAUTION: Do not damage the wheel cylinder piston boot. Install the brake drum. Refer to RAX-5, "Removal and Installation" . SFIA1217E 7. 8. When installing a new wheel cylinder or overhauling wheel cylinder, bleed air. Refer to BR-10, "Bleeding Brake System" . Adjust the parking brake. Refer to PB-3, "Adjustment" . Removal and Installation of Wheel Cylinder BFS0008K REMOVAL 1. 2. 3. 4. Drain brake fluid. Refer to BR-9, "Drain and Refill" . Remove the rear brake shoe assembly. Remove the brake tube from the wheel cylinder. Remove bolts on the wheel cylinder, and then remove wheel cylinder from the back plate. INSTALLATION ● ● Install in the reverse order of removal. Tighten bolts to the specified torque. Refer to BR-27, "Components" . Refill with new brake fluid and bleed air. Refer to BR-10, "Bleeding Brake System" . Disassembly and Assembly of Wheel Cylinder BFS0008L DISASSEMBLY 1. 2. Remove dust boots at the right and left of the wheel cylinder, and pull out the pistons from cylinder. Remove the piston cups from the pistons. SFIA1151E ASSEMBLY CAUTION: When assembling, use only rubber lubricant specified below. 1. Apply brake fluid to the piston sliding surface on the wheel cylinder. 2. Apply polyglycol ether based lubricant to the cups and boots and assemble as shown in the figure. SFIA1152E BR-30 REAR DRUM BRAKE Wheel Cylinder Inspection BFS0008M Check the pistons, piston cups, and inner wall of the cylinder for wear, corrosion, and damage. If a failure is detected, replace the applicable part. CAUTION: When inserting the piston, be careful not to scratch the cylinder. A B C D E BR G H I J K L M BR-31 SERVICE DATA AND SPECIFICATIONS (SDS) SERVICE DATA AND SPECIFICATIONS (SDS) General Specifications PFP:00030 BFS0008N Unit: mm (in) Brake model Front brake CL22 Rotor outer diameter × thickness 260 × 22.0 (10.24 × 0.87) Pad (thickness) 12.4 (0.488) Piston diameter 53.95 (2.124) Brake model LT20 Drum inner diameter Rear brake 202 (7.95) 195 × 38 × 4.5 (7.68 × 1.50 × 0.177) Lining Length × width × thickness Cylinder bore diameter 19.05 (3/4) Master cylinder Cylinder bore diameter 23.81 (0.94) Control valve Valve model Linkage type load sensing valve Booster model Brake booster T52/ 5/ 255 Diaphragm diameter 254 (10) Nissan Genuine Brake Fluid or DOT 3 or DOT 4 (US FMVSS No.116) Recommended brake fluid Brake Pedal BFS0008O LHD Brake pedal height (from dash panel top surface) RHD Depressed pedal height [under a force of 490 N (50 kg, 110 lb) with the engine running] M/T models 161 - 171 mm (6.34 - 6.73 in) A/T models 171 - 181 mm (6.73 - 7.13 in) M/T models 156 - 166 mm (6.14 - 6.54 in) A/T models 166 - 176 mm (6.54 - 6.93 in) M/T models More than 80 mm (3.15 in) A/T models More than 85 mm (3.35 in) Clearance between the stopper rubber and the threaded end of stop lamp switch. Pedal play 0.74 - 1.96 mm (0.029 - 0.077 in) 3 - 11 mm (0.12 - 0.43 in) Brake Booster BFS0008P Vacuum type Vacuum leakage [at vacuum of – 66.7 kPa (– 500 mmHg, –19.69 inHg)] Input rod installation standard dimension Within 3.3 kPa (25 mmHg, 0.98 inHg) of vacuum for 15 seconds LHD models 158.25 mm (6.23 in) RHD models 115.35 mm (4.54 in) Check Valve Vacuum leakage [at vacuum of – 66.7 kPa(– 500 mmHg, – 19.69 inHg)] BFS0008Q within 1.3 kPa (10 mmHg, 0.39 inHg) of vacuum for 15 seconds BR-32 SERVICE DATA AND SPECIFICATIONS (SDS) Front Disc Brake BFS0008R A Brake model Brake pad CL22 Standard thickness (new) 12.4 mm (0.488 in) Repair limit thickness 2.0 mm (0.079 in) Standard thickness (new) 22.0 mm (0.87 in) Repair limit thickness Disc rotor 20 mm (0.79 in) Maximum uneven wear (measured at 8 positions) 0.03 mm (0.0012 in) or less Runout limit (with it attached to the vehicle) 0.058 mm (0.0023 in) or less BFS0008S Brake model Drum C D Rear Drum Brake Lining B LT20 Standard thickness (new) 4.5 mm (0.177 in) Repair limit thickness 1.5 mm (0.059 in) Standard inner diameter (new) 202 mm (7.95 in) Repair limit inner diameter 203.2 mm (8.0 in) E BR G H I J K L M BR-33 SERVICE DATA AND SPECIFICATIONS (SDS) BR-34 BRAKE CONTROL SYSTEM F BRAKES SECTION BRC BRAKE CONTROL SYSTEM A B C D CONTENTS ABS PRECAUTIONS .......................................................... 3 Precautions for Supplemental Restraint System (SRS) “AIR BAG” and “SEAT BELT PRE-TENSIONER” .................................................................. 3 Precautions for Brake System .................................. 3 Precautions for Brake Control .................................. 3 Precaution for Harness Repair ................................. 4 CAN SYSTEM ....................................................... 4 PREPARATION ........................................................... 5 Special Service Tools ............................................... 5 SYSTEM DESCRIPTION ............................................ 6 System Diagram ....................................................... 6 System Components ................................................ 6 ABS Function ........................................................... 7 EBD Function ........................................................... 7 Fail-Safe Function .................................................... 7 Hydraulic Circuit Diagram ........................................ 7 TROUBLE DIAGNOSIS .............................................. 8 Diagnosis Procedure ................................................ 8 BASIC CONCEPT ................................................. 8 DIAGNOSIS FLOW ............................................... 9 QUESTIONNAIRE .............................................. 10 EXAMPLE OF DIAGNOSIS SHEET ................... 10 Component Parts Location ......................................11 Schematic .............................................................. 12 Wiring Diagram — ABS — ..................................... 13 CONSULT-II Functions (ABS) ................................ 19 CONSULT-II MAIN FUNCTION ........................... 19 CONSULT-IIBASICOPERATIONPROCEDURE ... 19 Self-Diagnosis ........................................................ 19 OPERATION PROCEDURE ............................... 19 ERASE MEMORY ............................................... 19 DISPLAY ITEM LIST ........................................... 20 Data Monitor ........................................................... 21 OPERATION PROCEDURE ............................... 21 DISPLAY ITEM LIST ........................................... 21 Active Test .............................................................. 22 OPERATION PROCEDURE ............................... 22 TEST ITEM —ABS SOLENOID VALVE— ........... 22 TEST ITEM —ABS MOTOR— ............................ 23 CAN Communication .............................................. 24 SYSTEM DESCRIPTION .................................... 24 For Fast and Accurate Diagnosis ........................... 25 PRECAUTIONS FOR TROUBLE DIAGNOSIS ... 25 Basic Inspection ..................................................... 26 BASIC INSPECTION 1: BRAKE FLUID LEVEL, LEAK AND BRAKE PAD INSPECTION .............. 26 BASIC INSPECTION 2: INSPECTION OF POWER SUPPLY SYSTEM TERMINAL LOOSENESS AND BATTERY ......................................... 26 BASIC INSPECTION 3: ABS WARNING LAMP AND BRAKE WARNING LAMP INSPECTION ... 26 Inspection 1 Wheel Sensor System ........................ 27 Inspection 2 Engine System ................................... 29 Inspection 3ABSActuatorandElectricUnit(Control Unit) System ........................................................... 29 Inspection 4 ABS Actuator and Electric Unit Power and Ground System ................................................ 29 Inspection 5 Stop Lamp Switch System ................. 31 Inspection 6 CAN Communication Circuit .............. 33 Symptom 1 ABS Works Frequently. ....................... 33 Symptom 2 Unexpected Pedal Reaction ................ 34 Symptom 3 Longer Stopping Distance ................... 34 Symptom 4 ABS Does Not Work ............................ 35 Symptom 5 Pedal Vibration and ABS Operation Noise ...................................................................... 35 WHEEL SENSORS ................................................... 36 Removal and Installation ........................................ 36 REMOVAL ........................................................... 36 INSTALLATION ................................................... 36 SENSOR ROTOR ..................................................... 37 Removal and Installation ........................................ 37 FRONT ................................................................ 37 REAR .................................................................. 37 ACTUATOR AND ELECTRIC UNIT (ASSEMBLY)... 38 Removal and Installation ........................................ 38 REMOVAL ........................................................... 38 INSTALLATION ................................................... 38 BRC-1 E BRC G H I J K L M ESP/TCS/ABS PRECAUTIONS ......................................................... 39 Precautions for Supplemental Restraint System (SRS) “AIR BAG” and “SEAT BELT PRE-TENSIONER” ................................................................. 39 Precautions for Brake System ................................ 39 Precautions for Brake Control ................................ 39 Diagnosis Precaution .............................................. 40 CAN SYSTEM ..................................................... 40 Precaution for Harness Repair ............................... 40 CAN SYSTEM ..................................................... 40 PREPARATION ......................................................... 41 Special Service Tools ............................................. 41 ON-VEHICLE SERVICE ............................................ 42 Adjustment of Steering Angle Sensor Neutral Position .......................................................................... 42 OPERATION PROCEDURE ................................ 42 SYSTEM DESCRIPTION .......................................... 45 System Diagram ..................................................... 45 ESP Function .......................................................... 45 TCS Function .......................................................... 45 ABS Function .......................................................... 45 EBD Function ......................................................... 46 Fail-Safe Function .................................................. 46 ESP / TCS SYSTEM ........................................... 46 ABS, EBD SYSTEM ............................................ 46 Hydraulic Circuit Diagram ....................................... 47 CAN COMMUNICATION ........................................... 48 System Description ................................................. 48 TROUBLE DIAGNOSIS ............................................ 49 How to Proceed With Diagnosis ............................. 49 BASIC CONCEPT ............................................... 49 DIAGNOSIS FLOWCHART ................................. 50 ASKING COMPLAINTS ....................................... 51 EXAMPLE OF DIAGNOSIS SHEET .................... 51 Component Installation Location ............................ 52 Schematic ............................................................... 53 Wiring Diagram — ESP — ..................................... 54 CONSULT-II Functions (ABS) ................................. 62 CONSULT-II MAIN FUNCTION ........................... 62 CONSULT-IIBASICOPERATIONPROCEDURE ... 62 Self-Diagnosis ........................................................ 62 OPERATION PROCEDURE ................................ 62 ERASE MEMORY ............................................... 62 DISPLAY ITEM LIST ........................................... 63 Data Monitor ........................................................... 64 OPERATION PROCEDURE ................................ 64 DISPLAY ITEM LIST ........................................... 64 Active Test .............................................................. 66 OPERATION PROCEDURE ................................ 66 SOLENOID VALVE OPERATION CHART ........... 67 ABS MONITOR ................................................... 67 For Fast and Accurate Diagnosis ............................68 PRECAUTIONS FOR DIAGNOSIS .....................68 Basic Inspection ......................................................69 BASIC INSPECTION 1: BRAKE FLUID AMOUNT, LEAKS, AND BRAKE PADS INSPECTION ....................................................................69 BASIC INSPECTION 2: POWER SYSTEM TERMINAL LOOSENESS AND BATTERY INSPECTION ....................................................................69 BASIC INSPECTION 3: ABS WARNING LAMP, ESP OFF INDICATOR LAMP AND SLIP INDICATOR LAMP INSPECTION ...............................70 Inspection 1: Wheel Sensor System .......................70 Inspection 2: Engine System ..................................73 Inspection 3: ESP/TCS/ABS Control Unit System...73 Inspection 4: Steering Angle Sensor System ..........73 Inspection 5: Yaw Rate/Side G-Sensor System ......75 Inspection 6: ABS Actuator and Electric Unit (Control Unit) Power Supply and Ground System ..........77 Inspection 7: Stop Lamp Switch System .................79 Inspection 8: Brake Fluid Level Switch System ......81 Inspection 9: CAN Communication System ............81 Component Inspection ............................................82 ESP OFF SWITCH ..............................................82 Symptom 1: Excessive ABS Function Operation Frequency ...............................................................82 Symptom 2: Unexpected Pedal Reaction ...............82 Symptom 3: The Braking Distance Is Long .............83 Symptom 4: The ABS Function Does Not Operate...83 Symptom 5: Pedal Vibration or ABS Operation Sound Occurs .........................................................83 Symptom 6: Vehicle Jerks During ESP/TCS/ABS Control ....................................................................84 WHEEL SENSORS ...................................................86 Removal and Installation .........................................86 REMOVAL ............................................................86 INSTALLATION ....................................................86 SENSOR ROTOR ......................................................87 Removal and Installation .........................................87 FRONT .................................................................87 REAR ...................................................................87 ACTUATOR AND ELECTRIC UNIT (ASSEMBLY) ...88 Removal and Installation .........................................88 REMOVAL ............................................................88 INSTALLATION ....................................................88 YAW RATE/SIDE G SENSOR ...................................89 Removal and Installation .........................................89 REMOVAL ............................................................89 INSTALLATION ....................................................89 STEERING ANGLE SENSOR ...................................90 Removal and Installation .........................................90 REMOVAL ............................................................90 INSTALLATION ....................................................90 BRC-2 PRECAUTIONS [ABS] PRECAUTIONS PFP:00001 Precautions for Supplemental Restraint System (SRS) “AIR BAG” and “SEAT BELT PRE-TENSIONER” [ABS] A BFS0008Z The Supplemental Restraint System such as “AIR BAG” and “SEAT BELT PRE-TENSIONER”, used along B with a front seat belt, helps to reduce the risk or severity of injury to the driver and front passenger for certain types of collision. Information necessary to service the system safely is included in the SRS and SB section of this Service Manual. C WARNING: ● To avoid rendering the SRS inoperative, which could increase the risk of personal injury or death in the event of a collision which would result in air bag inflation, all maintenance must be perD formed by an authorized NISSAN/INFINITI dealer. ● Improper maintenance, including incorrect removal and installation of the SRS, can lead to personal injury caused by unintentional activation of the system. For removal of Spiral Cable and Air E Bag Module, see the SRS section. ● Do not use electrical test equipment on any circuit related to the SRS unless instructed to in this Service Manual. SRS wiring harnesses can be identified by yellow and/or orange harness connecBRC tors. Precautions for Brake System ● ● ● ● ● ● ● ● BFS00090 Recommended fluid is brake fluid “Nissan Genuine Brake Fluid or DOT 3 or DOT 4 (US FMVSS No.116)”. Do not reuse the drained brake fluid. Be careful not to splash brake fluid on painted areas such as body. If brake fluid is splashed, wipe it off and flush area with water immediately. Do not use mineral oils such as gasoline or kerosene to clean. They will ruin rubber parts and cause improper operation. Using a flare nut torque wrench, securely tighten brake tube flare nuts. Brake system is an important safety part. If a brake fluid leak is detected, always disassemble malfunctioning parts. If any malfunctioning part is found, replace the part with a new one. Before working, turn ignition switch OFF and disconnect connectors for ABS actuator and electric unit or battery terminals. When installing brake piping, be sure to check tightening torque. SBR820BA Precautions for Brake Control ● ● ● ● ● ● ● G H I J K L BFS00091 During ABS operation, brake pedal lightly vibrates and a mechanical noise may be heard. This is normal. When starting engine, or just after starting vehicle, brake pedal may vibrate or motor operating noise may be heard from engine compartment. This is a normal status of operation check. Stopping distance may be longer than that of vehicles without ABS when vehicle drives on rough, gravel, or snow-covered (fresh, deep snow) roads. When an error is indicated by ABS or another warning lamp, collect all necessary information from the customer (what symptoms are present under what conditions) and check for simple causes before starting diagnostic servicing. Besides the electrical system inspection, check booster operation, brake fluid level, and oil leaks. If tyre size and type are used in an improper combination, or brake pads are not Genuine Nissan parts, stopping distance or steering stability may deteriorate. If there is a radio, antenna, or antenna lead-in wire (including wiring) near the control unit, ABS system may malfunction or return an error. If aftermarket parts (e.g. car stereo equipment, CD player) have been installed, check electrical harnesses for pinches, open, and improper wiring. BRC-3 M PRECAUTIONS [ABS] Precaution for Harness Repair BFS00092 CAN SYSTEM ● Area to be repaired shall be soldered, and wrapped with a tape (be sure that fraying of twisted wire shall be within 110 mm 4.33 in)). PKIA0306E ● Do not make a bypass connection to repaired area. (If it is done, branch part will be removed and characteristics of twisted wire will be lost.) PKIA0307E BRC-4 PREPARATION [ABS] PREPARATION Special Service Tools PFP:00002 A BFS00093 Tool number Tool name Description GG94310000 Flare nut torque wrench a: 10 mm (0.39 in) Removing and installing each brake piping B C D NT406 E BRC G H I J K L M BRC-5 SYSTEM DESCRIPTION [ABS] SYSTEM DESCRIPTION System Diagram PFP:00000 BFS00094 SFIA1173E System Components BFS00095 SFIA1174E BRC-6 SYSTEM DESCRIPTION [ABS] ABS Function ● ● ● BFS00096 Anti-lock Brake System monitors wheel rotation in braking and electronically controls braking force (brake fluid pressure) to prevent wheel locking. Thus, it improves vehicle stability in abrupt braking and allows driver to clear obstacles more easily. In the event of an electric system malfunction, the fail-safe function will operate, the vehicle will enter the ABS non-operation state, and ABS warning lamp will come on. CONSULT-II can be used to diagnose the electrical system. ● ● BFS00097 The electronically controlled braking force distribution unit detects the minute slips that occur in front and rear wheels during braking and uses electronic control to control rear wheel braking force (brake hydraulic pressure) to suppress rear wheel slipping as much as possible to improve stability during braking. In the event an electrical system malfunction occurs, the fail-safe function will operate and EBD and ABS will enter non-operational states, and ABS warning lamp and brake warning lamp will come on. CONSULT-II can be used to diagnose the electrical system. Fail-Safe Function ● ● B C EBD Function ● A D E BFS00098 BRC If a malfunction occurs in ABS system, “ABS warning lamp” turns ON. If a malfunction occurs in EBD, brake warning lamp and ABS warning lamp turn ON. Hydraulic Circuit Diagram BFS00099 G H I J K L M SBR984D 1. Inlet solenoid valve 2. Outlet solenoid valve 3. Reservoir 4. Pump 5. Motor 6. Inlet valve 7. Outlet valve 8. Bypass check valve 9. Damper BRC-7 TROUBLE DIAGNOSIS [ABS] TROUBLE DIAGNOSIS Diagnosis Procedure PFP:00004 BFS0009A BASIC CONCEPT ● ● The most important point in performing trouble diagnosis is to thoroughly understand the vehicle systems (both control and mechanical). It is also important to clarify customer concerns before starting the inspection. First of all, reproduce the symptom, and understand it fully. Ask the customer about his/her complaints carefully. In some cases, it will be necessary to check the symptoms by driving the vehicle with the customer. CAUTION: Customers are not professional. It is dangerous to make an easy guess like “maybe the customer means that...,” or “maybe the customer mentions this symptom”. EFJ0028D ● ● ● ● It is essential to check symptoms right from the beginning in order to repair a error completely. For an intermittent error, it is important to reproduce the symptom based on an interview with the customer and past examples. Do not perform an inspection on an ad hoc basis. Most intermittent errors are caused by poor contacts. In this case, it will be effective to shake the suspected harness or connector by hand. When repairs are performed without any symptom diagnosis, no one can judge if the error has actually been eliminated. After completing trouble diagnosis, be sure to perform “erase memory”. Refer to BRC-19, "ERASE MEMORY" . SEF233G For an intermittent error, move the harness or harness connector by hand to check for poor contact or false open circuit. Always read the GI section to be aware of the general precautions. Refer to GI-4, "General Precautions" . BRC-8 TROUBLE DIAGNOSIS [ABS] DIAGNOSIS FLOW A B C D E BRC G H I J K L M SFIA0953E BRC-9 TROUBLE DIAGNOSIS [ABS] QUESTIONNAIRE ● ● ● Complaints against a malfunction vary depending on each person. It is important to clarify the customer complaints. Ask the customer about what symptoms are present and under what conditions. Use the information to reproduce the symptom while driving. It is also important to use the diagnosis sheet so as not to miss the information. SBR339B EXAMPLE OF DIAGNOSIS SHEET SFIA0791E BRC-10 TROUBLE DIAGNOSIS [ABS] Component Parts Location BFS0009B A B C D E BRC G H I J K L M MFIB9035E BRC-11 TROUBLE DIAGNOSIS [ABS] Schematic BFS0009C MFWA0034E BRC-12 TROUBLE DIAGNOSIS [ABS] Wiring Diagram — ABS — BFS0009D A B C D E BRC G H I J K L M MFWA0158E BRC-13 TROUBLE DIAGNOSIS [ABS] MFWA0159E BRC-14 TROUBLE DIAGNOSIS [ABS] A B C D E BRC G H I J K L M MFWA0160E BRC-15 TROUBLE DIAGNOSIS [ABS] MFWA0161E BRC-16 TROUBLE DIAGNOSIS [ABS] A B C D E BRC G H I J K L M MFWA0162E BRC-17 TROUBLE DIAGNOSIS [ABS] MFWA0163E BRC-18 TROUBLE DIAGNOSIS [ABS] CONSULT-II Functions (ABS) BFS0009H A CONSULT-II MAIN FUNCTION In a diagnosis function (main function), there are “SELF-DIAG RESULTS”, “DATA MONITOR”, “CAN DIAG SUPPORT MNTR”, “ACTIVE TEST”, “FUNCTION TEST”, “ECU PART NUMBER”. B Diagnostic test mode Function SELF-DIAG RESULTS Self-diagnostic results can be read and erased quickly. DATA MONITOR Input/Output data in the ABS actuator and electric unit (control unit) can be read. CAN DIAG SUPPORT MNTR The results of transmit/receive diagnosis of communication can be read. ACTIVE TEST Diagnostic Test Mode in which CONSULT-II drives some actuators apart from the ABS actuator and electric unit (control unit) and also shifts some parameters in a specified range. FUNCTION TEST Performed by CONSULT-II instead of technician to determine whether each system is “OK” or “NG”. ECU PART NUMBER ABS actuator and electric unit (control unit) part number can be read. Reference BRC-19, "Self-Diagnosis" C BRC-21, "Data Monitor" LAN-15, "CAN Diagnostic Support Monitor" D E BRC-22, "Active Test" Separate volume “CONSULTII OPERATION MANUAL (FUNCTION TEST)” BRC — G CONSULT-II BASIC OPERATION PROCEDURE Refer to GI-36, "CONSULT-II Start Procedure" . H Self-Diagnosis BFS000EV OPERATION PROCEDURE 1. 2. 3. 4. 5. 6. 7. 8. Turn ignition switch OFF. Connect CONSULT-II and CONSULT-II CONVERTER to data link connector. Turn ignition switch ON. Start engine and drive vehicle at 30 km/h (19 MPH) or more for approximately 1 minute. After stopping vehicle, with engine running, touch “START (NISSAN BASED VHCL)”, “ABS”, “SELF-DIAG RESULTS” in order on CONSULT-II screen. CAUTION: If “START (NISSAN BASED VHCL)” is touched immediately after starting engine or turn on the ignition switch, “ABS” might not be displayed in the “SELECT SYSTEM” screen. In this case, repeat the operation from step 1. The self-diagnostic results are displayed. (Touch “PRINT” to print out self-diagnostic results, If necessary.) ● Check ABS warning lamp if “NO FAILURE” is displayed. Perform the appropriate inspection from display item list, and repair or replace the malfunctioning component. Refer to BRC-20, "DISPLAY ITEM LIST" . Start engine and drive vehicle at 30 km/h (19 MPH) or more for approximately 1 minute. CAUTION: When the wheel sensor malfunctions, after inspecting the wheel sensor system, the ABS warning lamp will not turn off even when the system is normal unless the vehicle is driving at 30 km/h (19 MPH) or more for approximately 1 minute. ERASE MEMORY 1. 2. 3. Turn ignition switch OFF. Start engine and touch “START (NISSAN BASED VHCL)”, “ABS”, “SELF-DIAG RESULTS”, “ERASE MEMORY” in order on CONSULT-II screen to erase the error memory. If “ABS” is not indicated, go to GI-38, "CONSULT-II Data Link Connector (DLC) Circuit" . CAUTION: If the error memory is not erased, re-perform the operation from step 4. Perform self-diagnosis again, and make sure that diagnostic memory is erased. BRC-19 I J K L M TROUBLE DIAGNOSIS [ABS] 4. Drive vehicle at 30 km/h (19 MPH) or more for approximately 1 minute as the final inspection, and make sure that the ABS warning lamp turn off. DISPLAY ITEM LIST Code Self-diagnostic item Malfunction detecting condition Check system C100F FR RH SENSOR Circuit of front RH wheel sensor is open, shorted or sensor power voltage is unusual. C101F FR LH SENSOR Circuit of front LH wheel sensor is open, shorted or sensor power voltage is unusual. C102F RR RH SENSOR Circuit of rear RH wheel sensor is open, shorted or sensor power voltage is unusual. C103F RR LH SENSOR Circuit of rear LH wheel sensor is open, shorted or sensor power voltage is unusual. C1041 FR RH SENSOR ROTOR ABS actuator and electric unit (control unit) cannot identify sensor pulses, because of large gap between wheel sensor and sensor rotor. C1042 FR LH SENSOR ROTOR ABS actuator and electric unit (control unit) cannot identify sensor pulses, because of large gap between wheel sensor and sensor rotor. C1043 RR RH SENSOR ROTOR ABS actuator and electric unit (control unit) cannot identify sensor pulses, because of large gap between wheel sensor and sensor rotor. C1044 RR LH SENSOR ROTOR ABS actuator and electric unit (control unit) cannot identify sensor pulses, because of large gap between wheel sensor and sensor rotor. C10C6 STOP LAMP SW CIRC Stop lamp switch is fixed at “ON” position. BRC-31, "Inspection 5 Stop Lamp Switch System" C10C6 STOP LAMP OR CONT Stop lamp switch circuit is open or shorted, or controller failure. BRC-31, "Inspection 5 Stop Lamp Switch System" C1046 ABS SENSOR Wheel sensor input is malfunction or wheel sensor power voltage is too low. BRC-27, "Inspection 1 Wheel Sensor System" (Note 1) C10CC BATTERY VOLTAGE Supply voltage for ABS actuator and electric unit (control unit) is too low or too high, or abnormal. BRC-29, "Inspection 4 ABS Actuator and Electric Unit Power and Ground System" C10C3 CONTROLLER FAILURE Internal malfunction of ABS actuator and electric unit (control unit) BRC-29, "Inspection 3 ABS Actuator and Electric Unit (Control Unit) System" U1000 C1180 CAN COMM CIRCUIT ● CAN communication line is open or shorted. ● ABS actuator and electric unit (control unit) internal malfunction ● Battery voltage for ECM is suddenly interrupted for approximately 0.5 seconds or more. ● CAN communication line is open or shorted. ● CAN communication signal form ECM cannot be received. ECM BRC-27, "Inspection 1 Wheel Sensor System" BRC-33, "Inspection 6 CAN Communication Circuit" (Note 1) BRC-29, "Inspection 2 Engine System" Note 1: If multiple malfunctions are detected including CAN communication line [U1000], perform diagnosis for CAN communication line first. BRC-20 TROUBLE DIAGNOSIS [ABS] Data Monitor BFS000EW A OPERATION PROCEDURE 1. Touch “START (NISSAN BASED VHCL)”, “ABS”, “DATA MONITOR” in order on CONSULT-II screen. CAUTION: When “START (NISSAN BASED VHCL)” is touched immediately after starting engine or turning on ignition switch, “ABS” might not be displayed in “SELECT SYSTEM” screen. In this case, repeat the operation from step 1. At the monitor item selection screen, touch one of the item “ECU INPUT SIGNALS”, “MAIN SIGNALS” or “SELECTION FROM MENU”. Touch “START” to proceed to the data monitor screen. 2. 3. B C D DISPLAY ITEM LIST CAUTION: The display shows the control unit calculation data, so a normal value might be displayed even in the event the output circuit (harness) is open or short-circuited. E E: ECU INPUT SIGNALS M: MAIN SIGNALS S: SELECTION FROM MENU SELECT MONITOR ITEM Data monitor Monitor item Display content E, M, S FR LH SENSOR FR RH SENSOR RR LH SENSOR RR RH SENSOR Vehicle wheel speed S STOP LAMP SWITCH Brake pedal operation M, S FR LH IN SOL FR LH OUT SOL FR RH IN SOL FR RH OUT SOL RR LH IN SOL RR LH OUT SOL RR RH IN SOL RR RH OUT SOL M, S M, S S M, S ACTUATOR RLY MOTOR RELAY EBD WARN LAMP ABS WARN LAMP Condition Reference values for normal operation Vehicle stopped 0 (km/h) While driving (Note 1) Almost in accordance with the speedometer display (within ±10 %) Brake pedal depressed ON BRC G H Brake pedal not depressed OFF ABS solenoid activated or failsafe activated (Note 2) ON I Actuator relay is activated and ABS solenoid is not activated OFF J Vehicle stop (Ignition switch ON) ON K Vehicle stopped (engine running) ON Motor relay and motor activated ON Motor relay and motor not activated OFF Brake warning lamp ON ON Brake warning lamp OFF OFF ABS warning lamp ON ON ABS warning lamp OFF OFF Ignition switch ON Approximately 10 - 16 V EBD is operating ON EBD is not operating OFF ABS activated ON ABS not activated OFF Malfunctions condition (When system is malfunctioning) OFF Solenoid valve operation Actuator relay activated Motor relay and motor activated EBD warning lamp ON ABS warning lamp ON (Note 3) E, M, S BATTERY VOLT Battery voltage supplied to control unit S EBD SIGNAL EBD operation signal S ABS SIGNAL ABS operation signal S EBD FAIL SIG ABS FAIL SIG System error signal status NOTE: 1. Confirm tyre pressure is normal. 2. The solenoid turns off when the actuator relay is not operating. BRC-21 L M TROUBLE DIAGNOSIS [ABS] 3. ON/OFF timing of ABS warning lamp ON: When the switch is turned ON for approximately 1 second or when a malfunction is detected. OFF: Approximately 1 second after ignition switch is turned ON (when the system is in normal operation). Active Test BFS000EX CAUTION: ● Do not perform active test while driving. ● Make sure to completely bleed air from the brake system. ● During active test, ABS and brake warning lamps are on. OPERATION PROCEDURE 1. 2. 3. 4. 5. Touch “ACTIVE TEST”. The “SELECT TEST ITEM” screen is displayed. Touch “TEST ITEM”. Touch “START” with “MAIN SIGNALS” line inverted. The “ACTIVE TEST” screen is displayed, and the following test can be performed. SFIA0840E TEST ITEM —ABS SOLENOID VALVE— ● Touch “UP”, “KEEP” and “DOWN” on the screen to confirm ABS solenoid valves (inlet/outlet) operate as in the following chart. Operation UP KEEP DOWN ABS inlet S/V OFF ON ON ABS outlet S/V OFF OFF ON* *: ON for 1 to 2 seconds after touch, and then OFF SFIA0395E NOTE: ● If active test is performed with brake pedal depressed, pedal stroke may change. This is normal. ● “TEST STOP” is displayed 10 seconds after operation start. ● After “TEST STOP” is displayed, to perform test again, touch “BACK” and repeat step 6. SFIA0396E BRC-22 TROUBLE DIAGNOSIS [ABS] TEST ITEM —ABS MOTOR— ● A Touch “ON” and “OFF” on the screen to confirm the ABS motor relay operates as shown in the following chart. Operation ON OFF ABS actuator relay ON ON ABS motor relay ON OFF NOTE: If active test is performed with brake pedal depressed, pedal stroke may change. This is normal. ● “TEST STOP” is displayed 10 seconds after operation start. B C ● SFIA0397E D E BRC G H I J K L M BRC-23 TROUBLE DIAGNOSIS [ABS] CAN Communication BFS000EY SYSTEM DESCRIPTION CAN (Controller Area Network) is a serial communication line for real time application. It is an on-vehicle multiplex communication line with high data communication speed and excellent error detection ability. Many electronic control units are equipped onto a vehicle, and each control unit shares information and links with other control units during operation (not independent). In CAN communication, control units are connected with 2 communication lines (CAN H line, CAN L line) allowing a high rate of information transmission with less wiring. Each control unit transmits/receives data but selectively reads required data only. Refer to LAN-27, "CAN Communication Unit" . BRC-24 TROUBLE DIAGNOSIS [ABS] For Fast and Accurate Diagnosis BFS000EZ PRECAUTIONS FOR TROUBLE DIAGNOSIS ● ● ● ● ● Always read the “GI General Information” to confirm the general precautions. Refer to GI-4, "General Precautions" . After completing the trouble diagnosis, always erase the fault memory. Refer to BRC-19, "Self-Diagnosis" . When inspection of the continuity or voltage between control units is performed, check connector terminals for disconnection, looseness, bend, or collapse. If any non-standard condition is detected, repair or replace applicable part. Intermittent errors may be caused by a poor connection in the harness, connector, or terminal. If a circuit tester is used for the check, be careful not to forcibly extend any connector terminal. A B C D E BRC G H I J K L M BRC-25 TROUBLE DIAGNOSIS [ABS] Basic Inspection BFS000F0 BASIC INSPECTION 1: BRAKE FLUID LEVEL, LEAK AND BRAKE PAD INSPECTION 1. 2. 3. Check fluid level in brake reservoir tank. If fluid level is low, refill the brake fluid. Check area around the brake piping and ABS actuator for leaks. If a leak or oozing is detected, check as follows: ● If ABS actuator connections are loose, tighten piping to the specified torque. Check again for leaks, and make sure there is no fluid leakage. ● If flare nuts at the connections and the threads of ABS actuator are damaged, replace damaged parts. Then check again for leaks, and make sure that there is no fluid leak. ● If a leak or oozing is detected on other parts than ABS actuator connections, wipe the applicable part with a clean cloth. Then check again for leaks, and if there is still a leak or oozing, replace damaged part. ● If leaks or oozing are detected on ABS actuator body, wipe with a clean cloth and check again. If there is still a leak or oozing, replace ABS actuator. CAUTION: ABS actuator body cannot be disassembled. Check for brake pad wear. Refer to BR-21, "PAD WEAR INSPECTION" . BASIC INSPECTION 2: INSPECTION OF POWER SUPPLY SYSTEM TERMINAL LOOSENESS AND BATTERY Check battery for looseness on battery positive/negative cables and ground connection. Also Make sure battery voltage dose not drop. BASIC INSPECTION 3: ABS WARNING LAMP AND BRAKE WARNING LAMP INSPECTION 1. Make sure ABS warning lamp and brake warning lamp turn on for approximately 1 sec. When ignition switch is turned ON. If they do not turn on, perform CAN communication system diagnosis. Refer to BRC33, "Inspection 6 CAN Communication Circuit" . If CAN communication system is normal, replace combination meter. Refer to DI-20, "Removal and Installation for Combination Meter" . 2. Make sure ABS warning lamp and brake warning lamp turn off after approximately 1 sec. When ignition switch is turned ON. If they do not turn OFF, perform self-diagnosis. 3. Make sure that ABS warning lamp remains off after the vehicle has been driven at approx. 30 km/h (19 MPH) for approx. 1 minute. If it turns on, perform self-diagnosis. 4. After completing self-diagnosis, always erase self-diagnostic results memory. Refer to BRC-19, "ERASE MEMORY" . CAUTION: The brake warning lamp comes on when the parking brake lever is pulled (when switch is on) and when the brake fluid level sensor operates (insufficient brake fluid). BRC-26 TROUBLE DIAGNOSIS [ABS] Inspection 1 Wheel Sensor System BFS000F1 DTC C100F-C103F, C1041-C1043, C1046 After identifying malfunctioning wheel sensor position according to CONSULT-II self-diagnostic results, check the each part and identify the parts to be replaced. CAUTION: ● Do not measure the resistance value and also voltage between sensor terminal with tester etc., because sensor is an active sensor. ● Do not expand terminal of connector with a tester terminal stick, when it does the inspection with tester. INSPECTION PROCEDURE A B C D 1. CHECK TYRE Check air pressure, wear and size. Are air pressure, wear, and size within specifications? YES >> GO TO 2. NO >> Adjust air pressure, or replace tyre. 2. CHECK SENSOR AND SENSOR ROTOR E BRC Inspect the appearance of the sensor and sensor rotor. ● Check sensor rotor rubber bar for damage. ● Check sensor for disconnection or loose. OK or NG OK >> GO TO 3. NG >> Replace sensor rotor. G 3. SELF-DIAGNOSTIC RESULTS I ● Check the self-diagnostic results. H J Self-diagnostic results FR RH SENSOR K FR LH SENSOR RR RH SENSOR RR LH SENSOR L FR RH SENSOR ROTOR FR LH SENSOR ROTOR M RR RH SENSOR ROTOR RR LH SENSOR ROTOR Is any of above displayed on self-diagnosis display? YES >> GO TO 4. NO >> INSPECTION END 4. CHECK CONNECTOR 1. Disconnect control unit connector E32 and malfunctioning wheel sensor connector E42 (FL), E29 (FR), B35 (RL) or B34 (RR) and check for deformation, disconnected and loose. If there is any non-standard condition, repair the connector. 2. Reconnect connectors, drive the vehicle at 30km/h (19 MPH) for approximately 1 minute, and then perform self-diagnosis. OK or NG OK >> The connector terminal contact is loose, damage, open or shorted. NG >> GO TO 5. BRC-27 TROUBLE DIAGNOSIS [ABS] 5. CHECK WHEEL SENSOR HARNESS 1. 2. 3. Disconnect control unit connector E32 and wheel sensor connector E42 (FL), E29 (FR), B35 (RL) and B34 (RR). Check continuity between ABS actuator and electric unit (control unit) and Wheel sensor (Power supply system). A B Connector ABS actuator and electric unit (control unit) Wheel sensor Front LH 5 1 Front RH 10 1 Rear LH 17 1 Rear RH 19 1 Yes MFIB9039E Check continuity between ABS actuator and electric unit (control unit) and wheel sensor (Signal system). A B ABS actuator and electric unit (control unit) Wheel sensor Front LH 16 2 Front RH 9 2 Rear LH 6 2 Rear RH 8 2 Connector 4. Continuity Continuity Yes Check continuity between ABS actuator and electric unit (control unit) terminal (Ground). A Connector Continuity ABS actuator and electric unit (control unit) Front LH 5, 16 4 Front RH 9, 10 4 Rear LH 6, 17 4 Rear RH 8, 19 4 No OK or NG OK >> GO TO 6. NG >> Repair or replace harness connector between ABS actuator and electric unit (control unit) and wheel sensor. 6. CHECK WHEEL SENSOR POWER SUPPLY CIRCUIT 1. 2. 3. Connect control unit connector. Turn ignition switch ON. Check voltage between wheel sensor power supply terminal 1 and ground. Wheel sensor Terminal E42 (FL), E29 (FR), B35 (RL), B34 (RR) 1 Voltage Ground 8V or more OK or NG OK >> Replace wheel sensor. NG >> Replace ABS actuator and electric unit (control unit). BRC-28 MFIB9040E TROUBLE DIAGNOSIS [ABS] Inspection 2 Engine System BFS000F2 A DTC C1180 INSPECTION PROCEDURE 1. CHECK SELF-DIAGNOSTIC RESULTS B Check the self-diagnostic results. C Self-diagnostic results ECM Is the above displayed in the self-diagnosis display items? YES >> GO TO 2. NO >> INSPECTION END D 2. CHECK ENGINE SYSTEM E Perform an ECM self-diagnosis refer to EC-74, "TROUBLE DIAGNOSIS" (CR engine models with EURO-OBD), EC-491, "TROUBLE DIAGNOSIS" (CR engine models without EURO-OBD), EC-863, BRC "TROUBLE DIAGNOSIS" (HR engine models with EURO-OBD), EC-1284, "TROUBLE DIAGNOSIS" (HR engine models without EURO-OBD), EC-1630, "TROUBLE DIAGNOSIS" and repair or replace malfunctioning items. Re-perform ECM self-diagnosis. G 2. Re-perform ABS actuator and electric unit (control unit) self-diagnosis. OK or NG OK >> INSPECTION END H NG >> Repair or replace malfunctioning items. Re-perform the self-diagnosis. 1. Inspection 3 ABS Actuator and Electric Unit (Control Unit) System BFS000F3 I DTC C10C3 INSPECTION PROCEDURE 1. CHECK SELF-DIAGNOSTIC RESULTS J Check the self-diagnostic results. K Self-diagnostic results CONTROLLER FAILURE Is the above displayed in the self-diagnosis display items? YES >> Replace ABS actuator and electric unit (control unit). Re-perform the self-diagnosis. NO >> INSPECTION END Inspection 4 ABS Actuator and Electric Unit Power and Ground System DTC C10CC INSPECTION PROCEDURE 1. CHECK SELF-DIAGNOSTIC RESULTS Check the self-diagnostic results. Self-diagnostic results BATTERY VOLTAGE Does “BATTERY VOLTAGE” appear in self-diagnostic results display? YES >> GO TO 2. NO >> INSPECTION END BRC-29 L BFS000F4 M TROUBLE DIAGNOSIS [ABS] 2. STARTING INSPECTION 1. Disconnect ABS actuator and electric unit (control unit) connector E32. Then reconnect it securely. 2. Perform self-diagnosis. Do any self-diagnosis item appear? YES >> GO TO 3. NO >> Poor connection. Repair or replace connector. 3. CHECK ABS ACTUATOR AND ELECTRIC UNIT (CONTROL UNIT) POWER SUPPLY (1) 1. 2. Disconnect ABS actuator and electric unit (control unit) connector E32. Turn ignition switch ON (not turn on engine). Check voltage between ABS actuator and electric unit (control unit) harness E32 and ground. ABS actuator and electric unit (control unit) Terminal Ground Voltage E32 18 — Approx. 12V MFIB9041E 3. Turn ignition switch OFF. Check voltage between ABS actuator and electric unit (control unit) harness E32 and ground. ABS actuator and electric unit (control unit) Terminal Ground Voltage E32 2, 3 — Approx. 12V OK or NG OK >> GO TO 4. NG >> GO TO 5. MFIB9043E 4. CHECK ABS ACTUATOR AND ELECTRIC UNIT (CONTROL UNIT) GROUND SYSTEM Check ABS actuator and electric unit (control unit) ground system. ABS actuator and electric unit (control unit) Terminal Ground Continuity E32 1, 4 — Yes OK or NG OK >> Perform ABS actuator and electric unit (control unit) selfdiagnosis again. NG >> Repair or replace harness or connectors. MFIB9042E BRC-30 TROUBLE DIAGNOSIS [ABS] 5. CHECK ABS ACTUATOR AND ELECTRIC UNIT (CONTROL UNIT) POWER SUPPLY (2) 1. 2. A Check fusible links 40A (terminal 2) and 30A (terminal 3). Turn ignition switch OFF and check continuity between battery positive terminal and ABS actuator and electric unit (control unit) harness connector E32. A B B ABS actuator and electric unit (control unit) Terminal Battery positive terminal E32 2, 3 — C Continuity Yes D Check fuse 10A (terminal 18) Check continuity between 10A fuse and ABS actuator and elecMFIB9052E tric unit (control unit) harness connector. E OK or NG OK >> Check for non-standard conditions in battery (terminal looseness, low voltage, etc.) and alternator. NG >> ● Replace fusible link 40A or 30A or fuse 10A. BRC ● Open or short in harness. 3. 4. Inspection 5 Stop Lamp Switch System BFS000F5 DTC C10C6 G INSPECTION PROCEDURE 1. CHECK SELF-DIAGNOSTIC RESULTS H Check the self-diagnostic results. I Self-diagnostic results STOP LAMP SW Is the above displayed in the self-diagnosis display item? YES >> GO TO 2. NO >> INSPECTION END J 2. CHECK CONNECTOR K 1. Disconnect stop lamp switch connector E38 (LHD MODELS WITH CR ENGINE AND HR ENGINE WITH M/T), E60 (LHD MODELS WITH HR ENGINE WITH A/T AND K9K ENGINE), M203 (RHD MODELS WITH CR ENGINE AND HR ENGINE WITH M/T), M204 (RHD MODELS WITH HR ENGINE WITH A/T AND K9K ENGINE) and ABS actuator and electric unit (control unit) connector E32 and check terminals for deformation, disconnection, looseness, and so on. If any malfunction is found, repair or replace terminal. 2. Securely reconnect connectors. 3. perform self-diagnosis again. OK or NG OK >> Connector terminal contact is loose, damaged, open or shorted. NG >> GO TO 3. BRC-31 L M TROUBLE DIAGNOSIS [ABS] 3. CHECK STOP LAMP SWITCH CIRCUIT 1. 2. Turn ignition switch OFF and disconnect stop lamp switch connector and ABS actuator and electric unit (control unit) connector. Check continuity between stop lamp switch harness connector and ABS actuator and electric unit (control unit) harness connector. MFIB9044E A B C ABS actuator and electric unit (control unit) Terminal Stop lamp switch (CR engine and HR engine M/T models) Terminal Stop lamp switch (HR engine A/T models and K9K engine models) Terminal E32 20 E38 (LHD models) M203 (RHD models) 2 E60 (LHD models) M204 (RHD models) 2 Continuity Yes OK or NG OK >> GO TO 4. NG >> Open or short in harness between stop lamp switch and ABS actuator and electric unit (control unit). Repair or replace applied harness. 4. CHECK STOP LAMP SWITCH POWER SUPPLY 1. 2. Turn ignition switch OFF and disconnect stop lamp switch harness connector. Check voltage between stop lamp switch harness connector and ground. MFIB9047E A B Stop lamp switch (CR engine and HR engine M/T models) Terminal Stop lamp switch (HR engine A/T models and K9K engine) Terminal E38 (LHD models) M203 (RHD models) 1 E60 (LHD models) M204 (RHD models) 1 OK or NG OK >> GO TO 5. NG >> Repair or replace power supply circuit. BRC-32 Ground Voltage — Approx. 12V TROUBLE DIAGNOSIS [ABS] 5. CHECK STOP LAMP SWITCH 1. 2. A Turn ignition switch OFF and disconnect stop lamp switch. Check continuity between stop lamp switch harness connector terminals 1 and 2. B C D MFIB9048E E A Stop lamp switch (CR engine and HR engine M/T models) B Terminal Stop lamp switch (HR engine A/T models and K9K engine) 1, 2 E60 (LHD models) M204 (RHD models) E38 (LHD models) M203 (RHD models) Terminal 1, 2 Condition Continuity BRC Brake pedal is depressed Yes Brake pedal is released No OK or NG OK >> Connect connectors and conduct an ABS actuator and electric unit (control unit) self-diagnosis. NG >> Replace stop lamp switch. Inspection 6 CAN Communication Circuit BFS000F6 G H I DTC U1000, C1180 INSPECTION PROCEDURE 1. CHECK CONNECTOR J 1. Turn ignition switch OFF and disconnect the ABS actuator and electric unit (control unit) connector, and check the terminal for deformation, disconnection, looseness, and so on. If there is a malfunction, repair or replace the terminal. 2. Reconnect connector to perform self-diagnosis. Is “CAN COMM CIRCUIT” displayed in the self-diagnosis display items? YES >> Print out the self-diagnostic results, and refer to LAN-3, "Precautions When Using CONSULT-II" . NO >> Connector terminal connector is loose, damaged, open, or shorted. Symptom 1 ABS Works Frequently. BFS000F7 1. START INSPECTION Check brake force distribution. OK or NG OK >> GO TO 2. NG >> Check brake system. 2. CHECK FRONT AND REAR AXLE Check front and real axle for significant “looseness”. OK or NG OK >> GO TO 3. NG >> Repair or replace. BRC-33 K L M TROUBLE DIAGNOSIS [ABS] 3. CHECK WHEEL SENSOR AND ROTOR Wheel Sensor Inspection ● Sensor installation and damage inspection ● Sensor rotor installation and damage inspection ● Sensor connector engagement inspection ● Sensor harness inspection OK or NG OK >> GO TO 4. NG >> ● Replace wheel sensor or sensor rotor. ● Repair harness. 4. CHECK INDICATOR DISPLAY OF WARNING LAMP Make sure warning lamp is off approximately 1 second after ignition switch is turned ON or during driving. OK or NG OK >> Normal NG >> Perform self-diagnosis. Refer to BRC-19, "Self-Diagnosis" . Symptom 2 Unexpected Pedal Reaction BFS000F8 1. CHECK BRAKE PEDAL STROKE Check brake pedal stroke. Is brake pedal stroke not excessive? YES >> ● Bleed air from brake piping. ● Check for looseness of brake pedal, master back, and master cylinder. Also check brake system for oil leak. Repair as necessary. NO >> GO TO 2. 2. PERFORMANCE CHECK Disconnect control unit connector E32 to deactivate ABS. In this condition, make sure braking force is normal after inspection, reconnect connector. OK or NG OK >> GO TO 3. Wheel Sensor Inspection in BRC-33, "Symptom 1 ABS Works Frequently." . NG >> Check brake system. Symptom 3 Longer Stopping Distance BFS000F9 CAUTION: On slippery road, stopping distance could be longer when ABS is activated than when it is not. 1. CHECK FUNCTION Disconnect control unit connector E32 to deactivate ABS. In this condition, check braking distance After inspection, reconnect connector. OK or NG OK >> ● Bleed air from brake piping. ● Check brake system. NG >> GO TO 3. Wheel Sensor Inspection in BRC-33, "Symptom 1 ABS Works Frequently." . BRC-34 TROUBLE DIAGNOSIS [ABS] Symptom 4 ABS Does Not Work BFS000FA A CAUTION: ABS does not operate when vehicle speed is 10 km/h (6 MPH) or lower. 1. CHECK INDICATOR DISPLAY OF WARNING LAMP B Make sure warning lamp is off approximately 1 second after ignition switch is turned ON or during driving. OK or NG OK >> GO TO 3. Wheel Sensor Inspection in BRC-33, "Symptom 1 ABS Works Frequently." . NG >> Perform a self-diagnosis. Refer to BRC-19, "Self-Diagnosis" . Symptom 5 Pedal Vibration and ABS Operation Noise C D CAUTION: Under the following conditions, when brake pedal is lightly depressed (just place a foot on it), ABS is activated and vibration is felt. However, this is normal. E ● When shifting gears and operating clutch ● When driving on slippery road BRC ● During cornering at high speed ● When passing over bumps or grooves [50 mm (1.97 in) or more] ● When pulling away just after starting engine [at approximately 10 km/h (6 MPH) or higher] G SYMPTOM CHECK 1 BFS000FB 1. Check brake system for pedal vibration or noise at engine start. OK or NG OK >> GO TO 2. NG >> Perform self-diagnosis. Refer to BRC-19, "Self-Diagnosis" . H I 2. SYMPTOM CHECK 2 Operate electrical equipment (head lamp or equivalents), and confirm symptoms. Does symptom occur when electrical switches (head lamp, etc.) are operated? YES >> Check for radio, antenna, and antenna lead-in wires (including wiring) near the control unit. If they are near ABS actuator and electric unit (control unit), move them. NO >> GO TO 3. Wheel Sensor Inspection in BRC-33, "Symptom 1 ABS Works Frequently." . J K L M BRC-35 WHEEL SENSORS [ABS] WHEEL SENSORS Removal and Installation PFP:47910 BFS0009X MFIB9029E REMOVAL Be careful of the following. CAUTION: ● When removing the sensor, do not rotate it if possible, and not forcibly pull the sensor harness. ● Before removing front or rear wheel hub, remove wheel sensor to avoid sensor wiring damage. INSTALLATION Be certain to tighten bolts to the specified torque. Be careful of the following: ● Check the inside of the sensor mounting hole for foreign material, the rotor surface for iron chips and other foreign material, and if anything is non-standard, clean it before installation, or replace it. ● When installing the front sensor, completely push in the strut bracket and body bracket rubber grommets until they lock so that the sensor harness does not become twisted. In addition, there should be no twists in the harness when installed. Install the harness so that the painted part faces the outside of the vehicle. ● When installing the rear sensor, completely push in the rubber bracket of the suspension arm bracket and lock the marking area of the side member harness mount so that the sensor harness will not be twisted. In addition, there should be no twists in the harness when installed. BRC-36 SENSOR ROTOR [ABS] SENSOR ROTOR Removal and Installation PFP:47970 A BFS0009Y FRONT ● Because the sensor rotor is integrated with the wheel bearing, replace it together with the wheel bearing assembly. Refer to FAX-6, "FRONT WHEEL HUB AND KNUCKLE" . B REAR ● During removal and installation, remove the wheel hub (brake drum). Refer to RAX-5, "WHEEL HUB" . CAUTION: The sensor rotor is a non-reusable part, it must be replaced by an new part when removing it. C D E BRC G H I J K L M BRC-37 ACTUATOR AND ELECTRIC UNIT (ASSEMBLY) [ABS] ACTUATOR AND ELECTRIC UNIT (ASSEMBLY) Removal and Installation PFP:47660 BFS0009Z SFIA1183E REMOVAL Be careful of the following. CAUTION: ● Before servicing, disconnect the battery cables. ● To remove brake tube, use a flare nut wrench to prevent flare nuts and brake tube from being damaged. To install, use a flare nut torque wrench and tighten to the specified torque. ● Do not apply excessive impact to the actuator, such as dropping it. INSTALLATION Be careful of the following. ● When setting the actuator in the bracket, push it in until it locks. ● Tighten the mounting bolts and nuts to the specified torque. ● After the work, breed the air from the brake piping. Refer to BR-10, "Bleeding Brake System" . ● After installing the vehicle harness connector in the actuator, make sure the connector is securely locked. BRC-38 PRECAUTIONS [ESP/TCS/ABS] PRECAUTIONS PFP:00001 Precautions for Supplemental Restraint System (SRS) “AIR BAG” and “SEAT BELT PRE-TENSIONER” [ESP/TCS/ABS] A BFS000A0 The Supplemental Restraint System such as “AIR BAG” and “SEAT BELT PRE-TENSIONER”, used along B with a front seat belt, helps to reduce the risk or severity of injury to the driver and front passenger for certain types of collision. Information necessary to service the system safely is included in the SRS and SB section of this Service Manual. C WARNING: ● To avoid rendering the SRS inoperative, which could increase the risk of personal injury or death in the event of a collision which would result in air bag inflation, all maintenance must be perD formed by an authorized NISSAN/INFINITI dealer. ● Improper maintenance, including incorrect removal and installation of the SRS, can lead to personal injury caused by unintentional activation of the system. For removal of Spiral Cable and Air E Bag Module, see the SRS section. ● Do not use electrical test equipment on any circuit related to the SRS unless instructed to in this Service Manual. SRS wiring harnesses can be identified by yellow and/or orange harnesses or BRC harness connectors. Precautions for Brake System ● ● ● ● ● ● ● ● ● BFS000A1 Recommended fluid is brake fluid “Nissan Genuine Brake Fluid or DOT 3 or DOT 4 (US FMVSS No.116)”. Do not reuse drained brake fluid. Be careful not to splash brake fluid on painted areas such as body. If brake fluid is splashed, wipe it off and flush area with water immediately. Do not use mineral oils such as gasoline or kerosene to clean. They will ruin rubber parts and cause improper operation. Using a flare nut torque wrench, securely tighten brake tube flare nuts. Brake system is an important safety part. If a brake fluid leak is detected, always disassemble the affected part. If a malfunction is detected, replace part with a new one. Before working, turn ignition switch OFF and disconnect electrical connectors of ABS actuator and electric unit (control unit) or battery negative terminals. When installing brake piping, be sure to check torque. After removing/installing any hydraulic parts of the brake or ESP SBR820BA system (such as actuator and piping parts, etc), bleed air from the system. Precautions for Brake Control ● ● ● ● ● ● ● BFS000A2 During ESP/TCS/ABS operation, brake pedal lightly vibrates and a mechanical noise may be heard. This is normal. When starting engine, or just after starting vehicle, brake pedal may vibrate or motor operating noise may be heard from engine room. This is a normal status of operation check. Stopping distance may be longer than that of vehicles without ABS when vehicle drives on rough, gravel, or snow-covered (fresh, deep snow) roads. When an error is indicated by ABS or another warning lamp, collect all necessary information from the customer (what symptoms are present under what conditions) and check for simple causes before starting diagnostic servicing. Besides the electrical system inspection, check booster operation, brake fluid level, and fluid leaks. If tyre size and type are used in an improper combination, or brake pads are not Genuine NISSAN parts, stopping distance or steering stability may deteriorate. If there is a radio, antenna, or antenna lead-in wire (including wiring) near control module, ESP/TCS/ABS function may have a malfunction or error. If aftermarket parts (car stereo, CD player, etc.) have been installed, check for incidents such as harness pinches, open circuits, and improper wiring. BRC-39 G H I J K L M PRECAUTIONS [ESP/TCS/ABS] ● ● ● ● ● If the following components are replaced with non-genuine components or converted, ESP OFF indicator lamp and SLIP indicator lamp may turn on or the ESP system may not operate properly. Components related to suspension (Shock Absorber, Strut, Spring, Bush, etc.), Tyres, wheels (exclude specified size), components related to brake (Pad, Rotor, Caliper, etc.), components related to engine (Muffler, ECM, etc.), components related to body reinforcement (Roll bar, Tower bar, etc.). Driving in the condition of breakage or excessive wear of suspension, tyres or components related to the brakes may cause ESP OFF indicator lamp and SLIP indicator lamp turn on, and the ESP system may not operate properly. When the TCS or ESP is activated by sudden acceleration or sudden turn, some noise may occur. The noise is a result of the normal operation of the TCS and ESP. When driving on roads which have extreme slopes (such as mountainous roads) or high banks (such as sharp carves on a freeway), the ESP may not operate normally, or ESP warning lamp and SLIP indicator lamp may turn on. However, this is not a malfunction, if normal operation can be resumed after restarting engine. Sudden turns (such as spin turns, acceleration turns), drifting, etc. When ESP function is OFF (ESP SW ON) may cause the G -sensor system indicate a malfunction. However, this is not a malfunction, if normal operation can be resumed after restarting engine. Diagnosis Precaution BFS000A3 CAN SYSTEM ● ● ● Do not apply voltage of 7.0 V or higher to terminal to be measured. Maximum open terminal voltage of tester in use shall be 7.0 V or lower. Before checking harnesses, turn ignition switch OFF and disconnect battery negative cable. Precaution for Harness Repair BFS000A4 CAN SYSTEM ● Area to be repaired shall be soldered, and wrapped with a tape [be sure that fraying of twisted wire shall be within 110 mm (4.33 in)]. PKIA0306E ● Do not make a bypass connection to repaired area. (If it is done, branch part will be removed and characteristics of twisted wire will be lost.) PKIA0307E BRC-40 PREPARATION [ESP/TCS/ABS] PREPARATION Special Service Tools PFP:00002 A BFS000A5 Tool number Tool name Description GG94310000 Flare nut torque wrench a: 10 mm (0.39 in) Removing and installing each brake piping B C D NT406 E BRC G H I J K L M BRC-41 ON-VEHICLE SERVICE [ESP/TCS/ABS] ON-VEHICLE SERVICE Adjustment of Steering Angle Sensor Neutral Position PFP:00000 BFS000A6 In case of doing work that applies to the list below, make sure to adjust neutral position of steering angle sensor before running vehicle. Situation Adjustment of Steering Angle Sensor Neutral Position Disconnecting/connecting the battery – Removing/Installing ABS actuator and electric unit (control unit) × Replacing ABS actuator and electric unit (control unit) × Removing/Installing steering angle sensor × Removing/Installing steering components × Removing/Installing suspension components × Removing/Installing the same tyre to the same position – Change 4 tyres to new ones – Change some of 4 tyres to new ones (not 4 tyres) – Tyre rotation – Adjusting wheel alignment × ×: Required –: Not required CAUTION: To adjust neutral position of steering angle sensor, make sure to use CONSULT-II. (Adjustment cannot be done without CONSULT-II.) OPERATION PROCEDURE 1. 2. Stop the vehicle with the front wheels in the straight-ahead position. Connect CONSULT-II and CONSULT-II CONVERTER to data link connector on the vehicle, and turn the ignition switch to ON position (engine not running). MAIA0009E 3. Touch “START (NISSAN BASED VHCL). MBIB0233E BRC-42 ON-VEHICLE SERVICE [ESP/TCS/ABS] 4. Touch “ABS”, “WORK SUPPORT” and “ST ANGLE SENSOR ADJUSTMENT” on the CONSULT-II screen in this order. A B C PBR385C D E BRC G SFIA0365E H I J SFIA0370E 5. 6. 7. 8. Touch “START”. CAUTION: Do not touch the steering wheel while adjusting the steering angle sensor. After approximately 10 seconds, touch “END”. (After approximately 60 seconds, it ends automatically.) Turn the ignition switch OFF, then turn it ON again. CAUTION: Make sure to carry out the above operation. Run the vehicle with the front wheels in the straight-ahead position, then stop. BRC-43 K L M SFIA0371E ON-VEHICLE SERVICE [ESP/TCS/ABS] 9. Select “DATA MONITOR“, “SELECTION FROM MENU” on the CONSULT-II screen. Then check that the “ST ANGLE SIG” is within 0±5deg. If the value is more than the specification, repeat steps 1 to 5. 10. Erase the memory of ESP/TCS/ABS control unit and ECM. 11. Turn the ignition switch OFF. SFIA0365E BRC-44 SYSTEM DESCRIPTION [ESP/TCS/ABS] SYSTEM DESCRIPTION System Diagram PFP:00000 A BFS000A7 B C D E BRC MFIB9036E ESP Function ● ● ● ● BFS000A8 In addition to the TCS/ABS function, the driver steering amount and brake operation amount are detected from steering angle sensor and pressure sensor, and the vehicle's driving status (amount of under steering / over steering) is determined from information from G-sensor, wheel sensor, etc., and this information is used to improve vehicle stability by controlling the braking and engine power to all four wheels. SLIP indicator lamp flashes to inform the driver of ESP operation. During ESP operation, body and brake pedal lightly vibrate and mechanical noises may be heard. This is normal. ABS warning lamp, ESP OFF indicator lamp, and SLIP indicator lamp might turn on when vehicle is subject to strong shaking or large vibration, such as when vehicle is on a turn table, a ship or a steep slope such as bank while engine is running. In this case, restart engine on a normal road, and if ABS warning lamp, ESP OFF indicator lamp, and SLIP indicator lamp turn off, there is no problem. TCS Function ● ● ● ● ● ● ● H I J K BFS000A9 The wheel spin of the drive wheels is detected by ABS actuator and electric unit (control unit) from the wheel speed signals from four wheels, so if wheel spin occurs, drive wheel right and left brake fluid pressure control and engine fuel cut are performed while throttle value is restricted to reduce the engine torque and decrease the amount of wheel spin. In addition, the degree throttle is opened is controlled to achieve the optimum engine torque. Depending on road circumstances, the driver may have a sluggish feel. This is normal, because the optimum traction has the highest priority under TCS operation. TCS may be activated any time vehicle suddenly accelerates, suddenly down/upshifts, or is driven on a road with a varying surface friction coefficient. During TCS operation, it informs a driver of system operation by flashing SLIP indicator lamp. ABS Function ● G BFS000AA The anti-lock brake system is a function that detects wheel revolution while braking, and it improves handling stability during sudden braking by electrically preventing 4 wheel lock. Maneuverability is also improved for avoiding obstacles. If the electrical system breaks down, then the fail-safe function starts, the ABS becomes inoperative, and ABS warning lamp turns on. Electrical system diagnosis by CONSULT-II is available. During ABS operation, brake pedal lightly vibrates and a mechanical noise may be heard. This is normal. BRC-45 L M SYSTEM DESCRIPTION [ESP/TCS/ABS] ● ● When starting engine, or just after starting vehicle, brake pedal may vibrate or motor operating noises may be heard from engine compartment. This is a normal status of operation check. Stopping distance may be longer than that of vehicles without ABS when vehicle drives on rough, gravel, or snow-covered (fresh, deep snow) roads. EBD Function ● ● ● ● ● ● BFS000AB Electronic brake distributor is a function that detects subtle slippages between front and rear wheels during braking, and it improves handling stability by electronically controlling the brake fluid pressure which results in reduced rear wheel slippage. In case of electrical system break down, the fail-safe function is activated, EBD and ABS becomes inoperative, and ABS warning lamp and brake warning lamp are turned on. Electrical system diagnosis by CONSULT-II is available. During EBD operation, brake pedal lightly vibrates and a mechanical noise may be heard. This is normal. When starting engine, or just after starting vehicle, brake pedal may vibrate or motor operating noises may be heard from engine compartment. This is a normal status of operation check. Stopping distance may be longer than that of vehicles without EBD when vehicle drives on rough, gravel, or snow-covered (fresh, deep snow) roads. Fail-Safe Function BFS000AC ESP / TCS SYSTEM In case of malfunction in the ESP/TCS system, ESP OFF indicator lamp and SLIP indicator lamp are turned on, and the condition of vehicle is the same as the condition of vehicles without ESP/TCS system. In case of malfunction in the ESP/TCS system, the ABS control continues to operate normally without ESP/TCS control. CAUTION: If the fail-safe function is activated, then perform the self-diagnosis for ESP/TCS/ABS control system. ABS, EBD SYSTEM In case of electrical malfunctions with the ABS, ABS warning lamp, ESP OFF indicator lamp and SLIP indicator lamp will turn on. In case of electrical malfunctions with the EBD, brake warning lamp, ABS warning lamp, ESP OFF indicator lamp and SLIP indicator lamp will turn on. Simultaneously, the ESP/TCS/ABS become one of the following conditions of the fail-safe function. 1. For malfunction of ABS, only the EBD is activated and the condition of vehicle is the same condition of vehicles without TCS/ABS system. 2. For malfunction of EBD, EBD and ABS become inoperative, and the condition of vehicle is the same as the condition of vehicles without TCS/ABS, EBD system. NOTE: In condition 1 described above, an ABS self-diagnosis sound may be heard. That is a normal condition because a self-diagnosis for “Key Switch ON” and “the First Starting” are being performed. BRC-46 SYSTEM DESCRIPTION [ESP/TCS/ABS] Hydraulic Circuit Diagram BFS000AD A B C D E BRC G H MFIA0013E I J K L M BRC-47 CAN COMMUNICATION [ESP/TCS/ABS] CAN COMMUNICATION System Description PFP:23710 BFS000AE CAN (Controller Area Network) is a serial communication line for real time application. It is an on-vehicle multiplex communication line with high data communication speed and excellent error detection ability. Many electronic control units are equipped onto a vehicle, and each control unit shares information and links with other control units during operation (not independent). In CAN communication, control units are connected with 2 communication lines (CAN H line, CAN L line) allowing a high rate of information transmission with less wiring. Each control unit transmits/receives data but selectively reads required data only. Refer to LAN-27, "CAN Communication Unit" . BRC-48 TROUBLE DIAGNOSIS [ESP/TCS/ABS] TROUBLE DIAGNOSIS How to Proceed With Diagnosis PFP:00004 A BFS000AG BASIC CONCEPT ● Most important point to perform diagnosis is to understand systems (control and mechanism) in vehicle thoroughly. ● It is also important to clarify customer complaints before inspection. First of all, reproduce symptom, and understand it fully. Ask customer about his/her complaints carefully. In some cases, it will be necessary to check symptom by driving vehicle with customer. NOTE: Customers are not professionals. Do not assume “maybe customer means...” or “maybe customer mentioned this symptom”. B C D E SEF234G BRC ● ● ● ● It is essential to check symptoms right from beginning in order to repair a malfunction completely. For an intermittent malfunction, it is important to reproduce symptom based on interview with customer and past examples. Do not perform inspection on ad hoc basis. Most intermittent malfunctions are caused by poor contacts. In this case, it will be effective to shake suspected harness or connector by hand. When repairs are performed without any symptom check, no one can judge if malfunction has actually been eliminated. After diagnosis, make sure to carry out “erase memory”. Refer to BRC-62, "ERASE MEMORY" . SEF233G For an intermittent malfunction, move harness or harness connector by hand to check poor contact or false open circuit. Always read “GI General Information” to confirm general precautions. Refer to GI-4, "General Precautions" . G H I J K L M BRC-49 TROUBLE DIAGNOSIS [ESP/TCS/ABS] DIAGNOSIS FLOWCHART MFIB9004E BRC-50 TROUBLE DIAGNOSIS [ESP/TCS/ABS] ASKING COMPLAINTS ● ● ● A Complaints against malfunction vary depending on each person. It is important to clarify customer complaints. Ask customer about what symptoms are present and under what conditions. Use information to reproduce symptom while driving. It is also important to use diagnosis sheet so as not to miss information. B C SBR339B D EXAMPLE OF DIAGNOSIS SHEET E BRC G H I J K L M SFIA0791E BRC-51 TROUBLE DIAGNOSIS [ESP/TCS/ABS] Component Installation Location BFS000AH MFIB9037E BRC-52 TROUBLE DIAGNOSIS [ESP/TCS/ABS] Schematic BFS000AI A B C D E BRC G H I J K L M MFWA0164E BRC-53 TROUBLE DIAGNOSIS [ESP/TCS/ABS] Wiring Diagram — ESP — BFS000AJ MFWA0165E BRC-54 TROUBLE DIAGNOSIS [ESP/TCS/ABS] A B C D E BRC G H I J K L M MFWA0166E BRC-55 TROUBLE DIAGNOSIS [ESP/TCS/ABS] MFWA0167E BRC-56 TROUBLE DIAGNOSIS [ESP/TCS/ABS] A B C D E BRC G H I J K L M MFWA0168E BRC-57 TROUBLE DIAGNOSIS [ESP/TCS/ABS] MFWA0170E BRC-58 TROUBLE DIAGNOSIS [ESP/TCS/ABS] A B C D E BRC G H I J K L M MFWA0171E BRC-59 TROUBLE DIAGNOSIS [ESP/TCS/ABS] MFWA0172E BRC-60 TROUBLE DIAGNOSIS [ESP/TCS/ABS] A B C D E BRC G H I J K L M MFWA0173E BRC-61 TROUBLE DIAGNOSIS [ESP/TCS/ABS] CONSULT-II Functions (ABS) BFS000FC CONSULT-II MAIN FUNCTION In a diagnosis function (main function), there are “WORK SUPPORT”, “SELF-DIAG RESULTS”, “DATA MONITOR”, “CAN DIAG SUPPORT MNTR”, “ACTIVE TEST”, “FUNCTION TEST”, “ECU PART NUMBER”. Diagnostic test mode Function Reference WORK SUPPORT This mode enables a technician to adjust some devices faster and more accurately by following the indication on CONSULT-II. BRC-42, "Adjustment of Steering Angle Sensor Neutral Position" SELF-DIAG RESULTS Self-diagnostic results can be read and erased quickly. BRC-62, "Self-Diagnosis" DATA MONITOR Input/Output data in the ABS actuator and electric unit (control unit) can be read. BRC-64, "Data Monitor" CAN DIAG SUPPORT MNTR The results of transmit/receive diagnosis of communication can be read. LAN-15, "CAN Diagnostic Support Monitor" ACTIVE TEST Diagnostic Test Mode in which CONSULT-II drives some actuators apart from the ABS actuator and electric unit (control unit) and also shifts some parameters in a specified range. BRC-66, "Active Test" FUNCTION TEST Performed by CONSULT-II instead of a technician to determine whether each system is “OK” or “NG”. Separate volume ″CONSULTII OPERATION MANUAL (FUNCTION TEST)″ ECU PART NUMBER ABS actuator and electric unit (control unit) part number can be read. — CONSULT-II BASIC OPERATION PROCEDURE Refer to GI-36, "CONSULT-II Start Procedure" . Self-Diagnosis BFS000FD OPERATION PROCEDURE 1. 2. 3. 4. 5. 6. 7. 8. Turn ignition switch OFF. Connect CONSULT-II and CONSULT-II CONVERTER to data link connector. CAUTION: If CONSULT-II is used with no connection of CONSULT-II CONVERTER, malfunctions might be detected in self-diagnosis depending on control unit which performs CAN communication. Turn ignition switch ON. Start engine and drive vehicle at 30 km/h (19 MPH) or more for approximately 1 minute. After stopping vehicle, with the engine running, touch “START (NISSAN BASED VHCL)”, “ABS”, “SELFDIAG RESULTS” in order on the CONSULT-II screen. CAUTION: If “START (NISSAN BASED VHCL)” is touched immediately after starting engine or turning on the ignition switch, “ABS” might not be displayed in the “SELECT SYSTEM” screen. In this case, repeat the operation from step 1. The self-diagnostic results are displayed. (Touch “PRINT” to print out self-diagnostic results, if necessary.) ● Check ABS warning lamp, ESP OFF indicator lamp and SLIP indicator lamp if “NO FAILURE” is displayed. Refer to DI-10, "Combination Meter Self-Diagnosis" . Perform the appropriate inspection from display item list, and repair or replace the malfunctioning component. Refer to BRC-63, "DISPLAY ITEM LIST" . Start engine and drive vehicle at 30 km/h (19 MPH) or more for approximately 1 minute. CAUTION: When the wheel sensor malfunctions, after inspecting the wheel sensor system, the ABS warning lamp, ESP OFF indicator lamp, SLIP indicator lamp and brake warning lamp will not turn off even when the system is normal unless the vehicle is driving at approximately 30 km/h (19 MPH) or more for approximately 1 minute. ERASE MEMORY 1. 2. Turn ignition switch OFF. Start engine and touch “START (NISSAN BASED VHCL)”, “ABS”, “SELF-DIAG RESULTS”, “ERASE MEMORY” in order on the CONSULT-II screen to erase the diagnostic memory. If “ABS” is not indicated, go to GI-38, "CONSULT-II Data Link Connector (DLC) Circuit" . BRC-62 TROUBLE DIAGNOSIS [ESP/TCS/ABS] CAUTION: If the diagnostic memory is not erased, re-perform the operation from step 4. 3. Perform self-diagnosis again, and make sure that diagnostic memory is erased. 4. Drive vehicle at 30 km/h (19 MPH) or more for approximately 1 minute as the final inspection, and make sure that the ABS warning lamp, ESP OFF indicator lamp, SLIP indicator lamp and brake warning lamp turn off. NOTE: ● Brake warning lamp will turn on in case of parking brake operation (when switch is ON) or of brake fluid level switch operation (when brake fluid is insufficient). ● ESP OFF switch should not stay “ON” position. Self-diagnostic item Malfunction detecting condition C100F FR RH SENSOR Circuit of front RH wheel sensor is open, shorted or sensor power voltage is unusual. C101F FR LH SENSOR Circuit of front LH wheel sensor is open, shorted or sensor power voltage is unusual. C102F RR RH SENSOR Circuit of rear RH wheel sensor is open, shorted or sensor power voltage is unusual. C103F RR LH SENSOR Circuit of rear LH wheel sensor is open, shorted or sensor power voltage is unusual. C1041 FR RH SENSOR ROTOR ABS actuator and electric unit (control unit) cannot identify sensor pulses, because of large gap between wheel sensor and sensor rotor. C1042 C1043 C1044 B C D DISPLAY ITEM LIST Code A FR LH SENSOR ROTOR ABS actuator and electric unit (control unit) cannot identify sensor pulses, because of large gap between wheel sensor and sensor rotor. RR RH SENSOR ROTOR ABS actuator and electric unit (control unit) cannot identify sensor pulses, because of large gap between wheel sensor and sensor rotor. RR LH SENSOR ROTOR ABS actuator and electric unit (control unit) cannot identify sensor pulses, because of large gap between wheel sensor and sensor rotor. Check system E BRC G BRC-70, "Inspection 1: Wheel Sensor System" H I J K C10C6 STOP LAMP SW CIRC Stop lamp switch is fixed at “ON” position. BRC-79, "Inspection 7: Stop Lamp Switch System" STOP LAMP OR CONT Stop lamp switch circuit is open or shorted, or controller failure. BRC-79, "Inspection 7: Stop Lamp Switch System" L C10C6 BRC-73, "Inspection 4: Steering Angle Sensor System" M ST ANG SEN Neutral position of steering angle sensor is dislocated, or steering angle sensor is malfunctioning initialize of steering angle sensor is not completed. YAW RATE/G-SEN Yaw rate/G-sensor has generated an error, or yaw rate/G-sensor signal line is open or shorted. BRC-75, "Inspection 5: Yaw Rate/ Side G-Sensor System" ABS SENSOR Wheel sensor input is malfunction or wheel sensor power voltage is too low. BRC-70, "Inspection 1: Wheel Sensor System" (Note 1) Supply voltage for ABS actuator and electric unit (control unit) is too low or too high, or abnormal. BRC-77, "Inspection 6: ABS Actuator and Electric Unit (Control Unit) Power Supply and Ground System" C1158 C10F4 C1046 C10CC BATTERY VOLTAGE BRC-63 TROUBLE DIAGNOSIS [ESP/TCS/ABS] Code C10C3 U1000 C1180 C1155 Self-diagnostic item Malfunction detecting condition Internal malfunction of ABS actuator and electric unit (control unit) CONTROLLER FAILURE ● CAN communication line is open or shorted. ● ABS actuator and electric unit (control unit) internal malfunction ● Battery voltage for ECM is suddenly interrupted for approximately 0.5 seconds or more. CAN COMM CIRCUIT ● CAN communication line is open or shorted. ECM ● CAN communication signal form ECM cannot be received. BR FLUID LEVEL LOW Brake fluid level drops or circuit between ABS actuator and electric unit (control unit) and brake fluid level switch is open or shorted. Check system BRC-73, "Inspection 3: ESP/TCS/ ABS Control Unit System" BRC-81, "Inspection 9: CAN Communication System" (Note 1) BRC-73, "Inspection 2: Engine System" BRC-81, "Inspection 8: Brake Fluid Level Switch System" Note 1: If multiple malfunctions are detected including CAN communication line [U1000], perform diagnosis for CAN communication line first. Data Monitor BFS000FE OPERATION PROCEDURE 1. 2. 3. Touch “START (NISSAN BASED VHCL)”, “ABS”, “DATA MONITOR” in order on CONSULT-II screen. CAUTION: When “START (NISSAN BASED VHCL)” is touched immediately after starting engine or turning on the ignition switch, “ABS” might not be displayed in the system selection screen. In this case, repeat the operation from step 1. At the monitor item selection screen, touch one of the items “ECU INPUT SIGNALS”, “MAIN SIGNALS” or “SELECTION FROM MENU”. Touch “START” to proceed to the data monitor screen. DISPLAY ITEM LIST CAUTION: The display shows the control unit calculation data, so a normal value might be displayed even in the event the output circuit (harness) is open or short - circuited. E: ECU INPUT SIGNALS M: MAIN SIGNALS S: SELECTION FROM MENU SELECT MONITOR ITEM E, M, S S Data monitor Monitor item Display content FR RH SENSOR FR LH SENSOR RR RH SENSOR RR LH SENSOR Wheel speed ACCEL POS SIG Open/close condition of throttle valve (linked with accelerator pedal). S ENGINE SPEED With engine running S STR ANGLE SIG Steering angle detected by steering angle sensor Condition Reference value in normal operation Vehicle stopped 0 [km/h (MPH)] Vehicle running (Note 1) Almost in accordance with speedometer display (within ±10 %) Accelerator pedal is not depressed (ignition switch is ON) 0% Accelerator pedal is depressed (ignition switch is ON) 0 to 100 % With engine stopped 0 rpm Engine running Almost in accordance with tachometer display Straight-ahead Approx. 0 deg Steering wheel turned L500 to R500 deg BRC-64 TROUBLE DIAGNOSIS [ESP/TCS/ABS] SELECT MONITOR ITEM S S S Data monitor Monitor item Display content Condition YAW RATE SEN SIDE G-SENSOR PRESS SENSOR Yaw rate detected by yaw rate sensor Vehicle stopped Approx. 0 d/s Vehicle running –200 to 200 d/s Transverse G detected by side G-sensor Vehicle stopped Approx. 0 G Vehicle running –1.8 to 1.8 G With ignition switch turned ON and brake pedal released Approx. 0 bar With ignition switch turned ON and brake pedal depressed 30 to 70 bar Ignition switch ON 10 to 16 V Brake pedal is depressed ON Brake pedal is not depressed OFF ESP OFF switch ON (When ESP OFF indicator lamp is ON) ON ESP OFF switch OFF (When ESP OFF indicator lamp is OFF) OFF ABS warning lamp ON ON ABS warning lamp OFF OFF Ignition switch ON or engine running (ABS not operated) OFF Ignition switch ON or engine running (ABS operated) ON Actuator (solenoid) is active ON When actuator relay is inactive (in fail-safe mode) OFF Brake fluid pressure detected by pressure sensor E, M, S BATTERY VOLT Battery voltage supplied to ABS actuator and electric unit (control unit) S STOP LAMP SW Brake pedal operation OFF SW ESP OFF switch ON/OFF status S M, S M, S M, S S S M, S S S S ABS WARN LAMP MOTOR RELAY Reference value in normal operation ABS warning lamp ON condition (Note 2) Operation status of motor and motor relay Actuator relay operation status OFF LAMP ESP OFF indicator lamp status (Note 3) When ESP OFF indicator lamp is ON ON When ESP OFF indicator lamp is OFF OFF SLIP indicator lamp status (Note 4) When SLIP indicator lamp is ON ON When SLIP indicator lamp is OFF OFF Actuator (solenoid) is active (“ACTIVE TEST” with CONSULT-II) and actuator relay is active (ignition switch ON) ON When actuator (solenoid) is not active or actuator relay is inactive (in fail-safe mode) OFF When actuator (switch-over valve) is active (“ACTIVE TEST” with CONSULTII) and actuator relay is active (ignition switch ON) ON When actuator (switch-over valve) is not active or actuator relay is inactive (in fail-safe mode) OFF FR LH IN SOL FR LH OUT SOL FR RH IN SOL FR RH OUT SOL RR RH IN SOL RR RH OUT SOL RR LH IN SOL RR LH OUT SOL D E BRC G H K L M Solenoid valve operation ESP/TCS switch-over valve status FLUID LEV SW ON/OFF status of brake fluid level switch When brake fluid level switch ON ON When brake fluid level switch OFF OFF Brake warning lamp on condition (Note 5) Brake warning lamp ON ON Brake warning lamp OFF OFF BRC-65 C J HSV [FL-RR] HSV [FR-RL] USV [FL-RR] USV [FR-RL] EBD WARN LAMP B I ACTUATOR RLY SLIP LAMP A TROUBLE DIAGNOSIS [ESP/TCS/ABS] Data monitor SELECT MONITOR ITEM S S Monitor item Display content Condition PARK BRAKE SW CRANKING SIG Condition of parking brake CRANKING status Reference value in normal operation When parking brake is applied ON When parking brake is released OFF Cranking ON Not cranking OFF Note 1: Confirm tire pressure is normal. Note 2: ON/OFF timing of ABS warning lamp ON: Approx. Within 1.5 seconds after ignition switch is turned ON, or when a malfunction is detected. OFF: Approx. 1.5 seconds after ignition switch is turned ON (when system is in normal operation) and ESP/TCS function is not activated. Note 3: ON/OFF timing of ESP OFF indicator lamp ON: Approx. Within 1.5 seconds after ignition switch is turned ON, or when a malfunction is detected and ESP OFF switch is ON. OFF: Approx 1.5 seconds after ignition switch is turned ON (when system is in normal operation.) And when ESP OFF switch is OFF. Note 4: SLIP indicator lamp ON/OFF timing ON: Approx. Within 1.5 seconds after ignition switch is turned ON, or when a malfunction is detected and ESP/TCS function is activated while driving. OFF: Approx. 1.5 seconds after ignition switch is turned ON (when system is in normal operation) and ESP/TCS function is not activated. Blinking: ESP/TCS function is active during driving Note 5: Serves as EBD warning lamp. Active Test BFS000FF CAUTION: ● Do not perform active test while driving. ● Make sure to completely bleed air from the brake system. ● Active test cannot be performed when EBD, ABS, TCS or ESP operation is malfunction. ● ABS and brake warning lamps turn on during the active test. OPERATION PROCEDURE 1. 2. 3. 4. 5. 6. Connect CONSULT-II and CONVERTER to data link connector and start engine. CAUTION: If CONSULT-II is used with no connection of CONSULT-II CONVERTER, malfunctions might be detected in self-diagnosis depending on control unit which carry out CAN communication. Touch “START (NISSAN BASED VHCL) ” on the display screen. Touch “ABS”. If “ABS” is not indicated, go to GI-38, "CONSULT-II Data Link Connector (DLC) Circuit" . Touch “ACTIVE TEST”. The test item selection screen is displayed. Touch necessary test item. PFIA0301E 7. 8. With the “MAIN SIGNALS” display shown in reverse, touch “START”. The “ACTIVE TEST” screen will be displayed, so perform the following test. BRC-66 TROUBLE DIAGNOSIS [ESP/TCS/ABS] SOLENOID VALVE OPERATION CHART ABS solenoid valve A ABS solenoid valve (ACT) Operation UP KEEP DOWN UP ACTUATOR UP ACTUATOR KEEP FR RH SOL OFF ON ON OFF OFF OFF FR LH SOL OFF ON ON OFF OFF OFF RR RH SOL OFF ON ON OFF OFF OFF RR LH SOL OFF ON ON OFF OFF OFF FR RH ABS SOLENOID (ACT) OFF OFF OFF OFF ON* OFF FR LH ABS SOLENOID (ACT) OFF OFF OFF OFF ON ON RR RH ABS SOLENOID (ACT) OFF OFF OFF OFF ON* OFF RR RL ABS SOLENOID (ACT) OFF OFF OFF OFF ON ON B C D E *: ON for 1 to 2 seconds after the touch, and then OFF NOTE: ● If active test is performed with brake pedal depressed, pedal stroke may change. This is normal. ● “TEST IS STOPPED” is displayed approximately 10 seconds after operation starts. ● After “TEST IS STOPPED” is displayed, touch “BACK” and conduct the test from the Step 8. BRC G ABS MONITOR Touch “ON” and “OFF” on the screen. Make sure ABS motor relay operates as shown in table below. Operation ON OFF MOTOR RELAY ON OFF ACTUATOR RELAY ON ON NOTE: ● If active test is performed with brake pedal depressed, pedal stroke may change. This is normal. ● “TEST IS STOPPED” is displayed approximately 10 seconds after operation starts. H I J SFIA0593E K L M BRC-67 TROUBLE DIAGNOSIS [ESP/TCS/ABS] For Fast and Accurate Diagnosis BFS000FG PRECAUTIONS FOR DIAGNOSIS ● ● ● ● ● ● ● ● ● Before performing diagnosis, always read precautions. Refer to BRC-49, "How to Proceed With Diagnosis" . If ABS actuator and electric unit (control unit), steering angle sensor, steering system parts or suspension system parts have been replaced, or if alignment has been adjusted, be sure to adjust neutral position of steering angle sensor before driving. Refer to BRC-42, "Adjustment of Steering Angle Sensor Neutral Position" . After diagnosis is finished, be sure to erase memory. Refer to BRC-62, "ERASE MEMORY" . When checking continuity and voltage between units, be sure to check for disconnection, looseness, bend, or collapse of connector terminals. If any malfunction is found, repair or replace connector terminals. For intermittent symptoms, possible cause is malfunction in harness, harness connector, or terminals. Move harness, harness connector, and terminals to check for poor connections. If a circuit tester is used for the check, be careful not to forcibly extend any connector terminal. To use CONSULT-II to perform self-diagnosis of ABS actuator and electric unit (control unit), active tests, or work support, first stop work, then connect CONSULT-II and select “ABS”. While self-diagnostic results of CONSULT-II shows malfunction, if CONSULT-II active test is performed, an engine system error may be indicated. In this case, start engine to resume the normal screen. ESP/TCS/ABS system electronically controls brake operation and engine output. The following symptoms may be caused by normal operations: Symptom Symptom description Result This is noise of motor inside ABS actuator and electric unit (control unit). Slight noise may occur during ESP, TCS, and ABS operation. Motor operation noise When the vehicle speed goes over 10 km/h (6 MPH), motor and valves operating noise may be heard. It happens only once after IGN (ignition) is ON. This is a normal status of the system operation check. System operation check noise When engine starts, slight “click” noise may be heard from engine room. This is normal and is part of system operation check. Normal Normal TCS may activate momentarily if wheel speed changes when driving over location where friction coefficient varies, when up/downshifting, or when fully depressing accelerator pedal. ESP/TCS operation (SLIP indicator lamp blinking) For inspection of speedometer or other instruments, press ESP OFF SW to turn ESP/TCS function off. When accelerator pedal is depressed on a chassis dynamometer, vehicle speed will not increase. This is not normal. It is result of TCS being activated by stationary front wheels. Warning lamp may also illuminate to indicate “sensor system error”. This is also normal, and is the result of the stationary front wheels being detected. To be certain, restart engine, and drive vehicle at 30 km/h (19 MPH) or above. Make sure warning lamp does not illuminate. Normal Cancel the ESP/TCS function for the inspection on a chassis dynamometer. ABS operation (Longer stopping distance) On roads with low friction coefficients, such as snowy roads or gravel roads, vehicles with ABS may require a longer stopping distance. Therefore, when driving on such roads, avoid overconfidence and keep speed sufficiently low. Normal Insufficient feeling of acceleration Depending on road conditions, driver may feel that feeling of acceleration is insufficient. This is because traction control, which controls engine and brakes to achieve optimal traction, has the highest priority (for safety). As a result, there may be times when acceleration is slightly less than usual for the same accelerator pedal operation. Normal BRC-68 TROUBLE DIAGNOSIS [ESP/TCS/ABS] ON and OFF Timing for ABS Warning Lamp, ESP OFF Indicator Lamp, SLIP Indicator Lamp, Brake Warning Lamp ×: ON ABS warning lamp ESP OFF indicator lamp SLIP indicator lamp Remarks Ignition SW OFF. – – – — Approx. 1.5 seconds after ignition switch is turned ON. × × × — Condition B C Approx. 1.5 seconds later after ignition switch ON. – – – Go out 1.5 seconds after ignition switch is turned ON. ESP OFF SW is turned ON. (ESP/TCS function is OFF.) – × – — D E BRC ESP/TCS/ABS error. × × × There is an ABS actuator and electric unit (control unit) error. (Power, ground or system malfunction) When ESP/TCS is not functioning normally. – × × — NOTE: 1. Brake warning lamp will turn on in case of operating parking brake (switch turned on) or of actuating brake fluid level switch (brake fluid is insufficient). Basic Inspection 3. G BFS000FH BASIC INSPECTION 1: BRAKE FLUID AMOUNT, LEAKS, AND BRAKE PADS INSPECTION 1. 2. A –: OFF Check fluid level in the brake reservoir tank. If fluid level is low, refill brake fluid. Check brake piping and around ABS actuator and electric unit (control unit) for leaks. If there is leaking or oozing fluid, check the following items. ● If ABS actuator and electric unit (control unit) connection is loose, tighten piping to the specified torque and re-perform the leak inspection to make sure there are no leaks. ● If there is damage to the connection flare nut or ABS actuator and electric unit (control unit) screw, replace the damaged part and re-perform the leak inspection to make sure there are no leaks. ● When there is fluid leaking or oozing from a part other than ABS actuator and electric unit (control unit) connection, if fluid is just oozing out, use a clean cloth to wipe off the oozing fluid and re-check for leaks. If fluid is still oozing out, replace the damaged part. ● When there is fluid leaking or oozing at ABS actuator and electric unit (control unit), if fluid is just oozing out, use a clean cloth to wipe off oozing fluid and re-check for leaks. If fluid is still oozing out, replace ABS actuator and electric unit (control unit) body. CAUTION: ABS actuator and electric unit (control unit) body cannot be disassembled. Check brake pad degree of wear. Refer to BR-21, "PAD WEAR INSPECTION" and BR-28, "INSPECTION AFTER REMOVAL" . BASIC INSPECTION 2: POWER SYSTEM TERMINAL LOOSENESS AND BATTERY INSPECTION Make sure battery positive cable, negative cable and ground connection are not loose. If looseness is detected, tighten the cables. In addition, check the battery voltage to make sure it has not dropped and alternator is normal. BRC-69 H I J K L M TROUBLE DIAGNOSIS [ESP/TCS/ABS] BASIC INSPECTION 3: ABS WARNING LAMP, ESP OFF INDICATOR LAMP AND SLIP INDICATOR LAMP INSPECTION 1. 2. 3. 4. 5. Make sure ABS warning lamp and ESP OFF indicator lamp (when ESP OFF switch is OFF) turn ON approximately 1.5 second when ignition switch is turned ON. Make sure SLIP indicator lamp (when ESP OFF switch is OFF) turns ON approximately 3 seconds when ignition switch is turned ON. If they do not, check ESP OFF indicator lamp and then ESP OFF switch. Refer to BRC-82, "ESP OFF SWITCH" . Check CAN communications. Refer to “CAN Communication Inspection”. If there are no errors with ESP OFF switch and CAN communication system, check combination meter. Refer to DI-10, "Combination Meter Self-Diagnosis" . Make sure ABS warning lamp, ESP OFF indicator lamp, SLIP indicator lamp turn off approximately 1.5 second after turn ignition switch ON. If lamps do not turn off, perform self-diagnosis. With engine running, make sure ESP OFF indicator lamp turns on and off when ESP OFF switch is turned ON and OFF. If indicator lamp status does not correspond to switch operation, check the ESP OFF switch system. Refer to BRC-82, "ESP OFF SWITCH" . Make sure ABS warning lamp, ESP OFF indicator lamp, and SLIP indicator lamp turn off 1.5 seconds after engine is started. If ABS warning lamp, ESP OFF indicator lamp, and SLIP indicator lamp have not turned off 10 seconds after engine has been started, perform self-diagnosis of ABS actuator and electric unit (control unit). After performing the self-diagnosis, be sure to erase the error memory. Refer to BRC-62, "ERASE MEMORY" . Inspection 1: Wheel Sensor System BFS000FI DTC C100F-C103F, C1041-C1043, C1046 After using the CONSULT-II SELF-DIAG RESULTS to determine the location of the malfunctioning wheel sensor, check all areas to determine the component to be replaced. CAUTION: ● Do not measure the resistance value and also voltage between sensor terminal with tester etc., because sensor is an active sensor. ● Do not expand terminal of connector with a tester terminal stick, when it does the inspection with tester. INSPECTION PROCEDURE 1. CHECK TIRE Check air pressure, wear and size. Are air pressure, wear, and size within the standard values? YES >> GO TO 2. NO >> Adjust air pressure, or replace tire. 2. CHECK SENSOR AND SENSOR ROTOR Check the condition of the sensor mount (for looseness, etc.). ● Check the surface of front sensor rotor rubber for damage. ● Check rear sensor rotor for damage. OK or NG OK >> GO TO 3. NG >> Repair sensor mount or replace sensor rotor. ● BRC-70 TROUBLE DIAGNOSIS [ESP/TCS/ABS] 3. CHECK SELF-DIAGNOSTIC RESULTS A Check the self-diagnostic results. Self-diagnosis results B FR RH SENSOR FR LH SENSOR C RR RH SENSOR RR LH SENSOR FR RH SENSOR ROTOR D FR LH SENSOR ROTOR RR RH SENSOR ROTOR E RR LH SENSOR ROTOR Is the above displayed in the self-diagnosis display items? YES >> GO TO 4. NO >> INSPECTION END. BRC 4. CHECK CONNECTOR 1. Disconnect ABS actuator and electric unit (control unit) connector E33 and malfunctioning wheel sensor connector E42 (FR-LH), E29 (FR-RH), B35 (RR-LH) or B34 (RR-RH). Check terminal for deformation, open circuit, poor contact, etc., and repair or replace if any malfunctioning condition is found. 2. Reconnect connectors, drive at a speed of approximately 30 km/h (19 MPH) for approximately 1minute, and perform self-diagnosis. OK or NG OK >> Connector terminal contact is loose, damaged, open or shorted. NG >> GO TO 5. G H I J K L M BRC-71 TROUBLE DIAGNOSIS [ESP/TCS/ABS] 5. CHECK WHEEL SENSOR HARNESS 1. 2. Turn ignition switch OFF and disconnect malfunctioning wheel sensor connector E42 (FR-LH), E29 (FR-RH), B35 (RR-RH) or B34 (RR-LH) and ABS actuator and electric unit (control unit) connector E33. Check continuity between ABS actuator and electric unit (control unit) and Wheel sensor (Power supply system). A B ABS actuator and electric unit (control unit) Wheel sensor Front LH 5 1 Front RH 10 1 Rear LH 17 1 Rear RH 19 1 Connector 3. 4. Continuity MFIB9039E Yes Check continuity between ABS actuator and electric unit (control unit) and wheel sensor (Signal system). A B Connector ABS actuator and electric unit (control unit) Wheel sensor Front LH 16 2 Front RH 9 2 Rear LH 6 2 Rear RH 8 2 Continuity Yes Check continuity between ABS actuator and electric unit (control unit) terminal (Ground). A Connector ABS actuator and electric unit (control unit) Front LH 5, 16 Continuity 4 Front RH 9, 10 4 Rear LH 6, 17 4 Rear RH 8, 19 4 No OK or NG OK >> GO TO 6. NG >> Repair harness and connector between ABS actuator and electric unit (control unit) and wheel sensor. 6. CHECK WHEEL SENSOR POWER SUPPLY CIRCUIT 1. 2. 3. Connect ABS actuator and electric unit (control unit) connector. Turn ignition switch ON. Check voltage between wheel sensor power supply terminal 1 and ground. Wheel sensor E42 (FL), E29 (FR), B35 (RL), B34 (RR) Terminal Voltage Ground 1 8V or more OK or NG OK >> Replace wheel sensor. NG >> Replace ABS actuator and electric unit (control unit). BRC-72 MFIB9040E TROUBLE DIAGNOSIS [ESP/TCS/ABS] Inspection 2: Engine System BFS000FJ A DTC C1180 INSPECTION PROCEDURE 1. CHECK SELF-DIAGNOSTIC RESULTS B Check the self-diagnostic results. C Self-diagnostic results ECM Is the above displayed in the self-diagnosis display items? YES >> GO TO 2. NO >> INSPECTION END D 2. CHECK ENGINE SYSTEM E Perform an ECM self-diagnosis refer to EC-74, "TROUBLE DIAGNOSIS" (CR engine models with EURO-OBD), EC-491, "TROUBLE DIAGNOSIS" (CR engine models without EURO-OBD), EC-863, BRC "TROUBLE DIAGNOSIS" (HR engine models with EURO-OBD), EC-1284, "TROUBLE DIAGNOSIS" (HR engine models without EURO-OBD), EC-1630, "TROUBLE DIAGNOSIS" and repair or replace malfunctioning items. Re-perform ECM self-diagnosis. G 2. Re-perform ABS actuator and electric unit (control unit) self-diagnosis. OK or NG OK >> INSPECTION END H NG >> Repair or replace malfunctioning items. Re-perform the self-diagnosis. 1. Inspection 3: ESP/TCS/ABS Control Unit System BFS000FK I DTC C10C3 INSPECTION PROCEDURE 1. CHECK SELF-DIAGNOSTIC RESULTS J Check the self-diagnostic results. K Self-diagnostic results CONTROLLER FAILURE Is the above displayed in the self-diagnosis display items? YES >> Replace ABS actuator and electric unit (control unit). Re-perform the self-diagnosis. NO >> INSPECTION END Inspection 4: Steering Angle Sensor System DTC C1158 INSPECTION PROCEDURE 1. CHECK SELF- DIAGNOSTIC RESULTS Check self-diagnostic results. Self-diagnostic results ST ANGLE SEN CIRCUIT Is above displayed in self-diagnosis item? YES >> GO TO 2. NO >> INSPECTION END BRC-73 L BFS000FL M TROUBLE DIAGNOSIS [ESP/TCS/ABS] 2. CHECK CONNECTOR 1. Turn ignition switch OFF and disconnect steering angle sensor connector M40 and ABS actuator and electric unit (control unit) connector E33 and check terminals for deformation, disconnection, looseness, and so on. If there is an error, repair or replace terminal. 2. Connect the connector securely and perform self-diagnosis again. OK or NG OK >> Connector terminal contact is loose, damaged, open or shorted. NG >> GO TO 3. 3. CHECK STEERING ANGLE SENSOR HARNESS 1. 2. 3. Check CAN communication system. Refer to BRC-81, "Inspection 9: CAN Communication System" . Turn ignition switch ON, OFF and disconnect steering angle sensor connector M40. Check voltage between steering angle sensor harness connector M40 and ground. Steering angle sensor Terminal Ground M40 2 — Condition Voltage Ignition switch ON Approx. 12V Ignition switch OFF Approx. 0V MFIB9049E 4. Turn ignition switch OFF. Check continuity between steering angle sensor harness connector M40 and ground. Steering angle sensor Terminal Ground Continuity M40 1 — Yes OK or NG OK >> GO TO 4. NG >> If the open or short in harness, repair or replace harness. MFIB9050E 4. CHECK DATA MONITOR 1. 2. Connect steering angle sensor and ABS actuator and electric unit (control unit) connectors. Perform “DATA MONITOR” of the “STEERING ANGLE SIGNAL” to check if the status is normal. Steering condition Data monitor Straight-ahead –5° to +5° Turn wheel to the right by 90° Approx. - 90° Turn wheel to the left by 90° Approx.+ 90° OK or NG OK >> Perform ABS actuator and electric unit (control unit) self-diagnosis again. NG >> Replace spiral cable (steering angle sensor) and adjust neutral position of steering angle sensor. Refer to BRC-42, "Adjustment of Steering Angle Sensor Neutral Position" . BRC-74 TROUBLE DIAGNOSIS [ESP/TCS/ABS] Inspection 5: Yaw Rate/Side G-Sensor System BFS000FM DTC C10F4 CAUTION: Sudden turns (such as spin turns, acceleration turns), drifting, etc. May cause the G-sensor system indicate a malfunction. However, this is not a malfunction, if normal operation can be resumed after restarting engine. INSPECTION PROCEDURE A B C 1. CHECK SELF-DIAGNOSTIC RESULTS Check the self-diagnostic results. D Self-diagnostic results YAW RATE/G-SEN E CAUTION: When on a turntable, such as at a parking structure entrance, or when on a moving object with engine running, ESP OFF indicator lamp might turn on and self-diagnosis using CONSULT-II the yaw rate/side G-sensor system might be displayed, but in this case there is no malfunction in yaw rate/side G-sen- BRC sor system. As soon as vehicle leaves turntable or moving object, restart engine to return the system to normal. G Is the above displayed in the self-diagnosis display items? YES >> GO TO 2. NO >> INSPECTION END H CHECK CONNECTOR 2. 1. Disconnect yaw rate/side G-sensor connector B7 and ABS actuator and electric unit (control unit) connector E33 and check terminals for deformation, disconnection, looseness, and so on. If any malfunction is found, repair or replace terminal. 2. Reconnect connectors and re-perform a ABS actuator and electric unit (control unit) self-diagnosis. OK or NG OK >> Connector terminal contact is loose, damaged, open or shorted. NG >> GO TO 3. 3. CHECK YAW RATE/SIDE G-SENSOR POWER SUPPLY 1. 2. 3. Turn ignition switch OFF and disconnect yaw rate/side G-sensor harness connector B7. Turn ignition switch ON. Check voltage between yaw rate/side G-sensor harness connector B7 and ground. Yaw rate/side G sensor Terminal Ground Voltage B7 3 — Approx. 12V OK or NG OK >> GO TO 4. NG >> Repair or replace power supply circuit. BRC-75 I J K L M MFIB9045E TROUBLE DIAGNOSIS [ESP/TCS/ABS] 4. CHECK YAW RATE/SIDE G-SENSOR HARNESS 1. 2. Turn ignition switch OFF and disconnect ABS actuator and electric unit (control unit) connector E33. Check continuity between ABS actuator and electric unit (control unit) harness connector E33 and yaw rate/side G-sensor harness connector B7. A ABS actuator and electric unit (control unit) B Terminal Yaw rate/side G sensor 12 5 13 E33 14 Continuity Terminal MFIB9046E 6 B7 4 24 1 25 2 Yes 3. Check continuity between ABS actuator and electric unit (control unit) harness connector E33 terminals 12, 13, 14, 24 and 25 and ground. Continuity should not exist. OK or NG OK >> GO TO 5. NG >> If the open or short in harness, repair or replace harness. 5. CHECK YAW RATE/SIDE G-SENSOR 1. 2. Connect yaw rate/side G-sensor connector B7 and ABS actuator and electric unit (control unit) connector E33. Use CONSULT-II “DATA MONITOR” to check if yaw rate/side G-sensor are normal. Vehicle status When stopped Right turn Left turn Yaw rate sensor (Data monitor standard) –4 to +4 d/s Negative value Positive value Side G-sensor (Data monitor standard) –0.2 to +0.2 G Negative value Positive value OK or NG OK >> Re-perform ABS actuator and electric unit (control unit) self-diagnosis. NG >> Replace malfunctioning yaw rate/side G-sensor, and then re-perform self-diagnosis for ABS actuator and electric unit (control unit). BRC-76 TROUBLE DIAGNOSIS [ESP/TCS/ABS] Inspection 6: ABS Actuator and Electric Unit (Control Unit) Power Supply and Ground System BFS000FN A DTC C10CC Inspection Procedure B 1. CHECK SELF-DIAGNOSTIC RESULTS Check the self-diagnostic results. C Self-diagnostic results BATTERY VOLTAGE D Does “BATTERY VOLTAGE” appear in self-diagnostic results display? YES >> GO TO 2. NO >> INSPECTION END E 2. STARTING INSPECTION 1. Disconnect ABS actuator and electric unit (control unit) connector E32. Then reconnect it securely. 2. Perform self-diagnosis. Do any self-diagnosis item appear? YES >> GO TO 3. NO >> Poor connection. Repair or replace connector. BRC G 3. CHECK ABS ACTUATOR AND ELECTRIC UNIT (CONTROL UNIT) POWER SUPPLY (1) H 1. 2. I Disconnect ABS actuator and electric unit (control unit) connector E32. Turn ignition switch ON (not turn on engine). Check voltage between ABS actuator and electric unit (control unit) harness E33 and ground. ABS actuator and electric unit (control unit) Terminal Ground Voltage E33 18 — Approx. 12V J K MFIB9041E 3. Turn ignition switch OFF. Check voltage between ABS actuator and electric unit (control unit) harness E33 and ground. ABS actuator and electric unit (control unit) Terminal Ground Voltage E33 2, 3 — Approx. 12V M OK or NG OK >> GO TO 4. NG >> GO TO 5. MFIB9043E BRC-77 L TROUBLE DIAGNOSIS [ESP/TCS/ABS] 4. CHECK ABS ACTUATOR AND ELECTRIC UNIT (CONTROL UNIT) GROUND SYSTEM Check ABS actuator and electric unit (control unit) ground system. ABS actuator and electric unit (control unit) Terminal Ground Continuity E33 1, 4 — Yes OK or NG OK >> Perform ABS actuator and electric unit (control unit) selfdiagnosis again. NG >> Repair or replace harness or connectors. MFIB9042E 5. CHECK ABS ACTUATOR AND ELECTRIC UNIT (CONTROL UNIT) POWER SUPPLY (2) 1. 2. Check fusible links 40A (terminal 2) and 30A (terminal 3). Turn ignition switch OFF and check continuity between battery positive terminal and ABS actuator and electric unit (control unit) harness connector E33. A B ABS actuator and electric unit (control unit) Terminal Battery positive terminal E33 2, 3 — Continuity Yes 3. 4. Check fuse 10A (terminal 18) Check continuity between 10A fuse and ABS actuator and elecMFIB9052E tric unit (control unit) harness connector. OK or NG OK >> Check for non-standard conditions in battery (terminal looseness, low voltage, etc.) and alternator. NG >> ● Replace fusible link 40A or 30A or fuse 10A. ● Open or short in harness. BRC-78 TROUBLE DIAGNOSIS [ESP/TCS/ABS] Inspection 7: Stop Lamp Switch System BFS000FO A DTC C10C6 INSPECTION PROCEDURE 1. CHECK SELF-DIAGNOSTIC RESULTS B Check the self-diagnostic results. C Self-diagnostic results STOP LAMP SW Is the above displayed in the self-diagnosis display item? YES >> GO TO 2. NO >> INSPECTION END D 2. CHECK CONNECTOR E 1. Disconnect stop lamp switch connector E38 (LHD MODELS WITH CR ENGINE AND HR ENGINE WITH M/T), E60 (LHD MODELS WITH HR ENGINE WITH A/T AND K9K ENGINE), M203 (RHD MODELS BRC WITH CR ENGINE AND HR ENGINE WITH M/T), M204 (RHD MODELS WITH HR ENGINE WITH A/T AND K9K ENGINE) and ABS actuator and electric unit (control unit) connector E33 and check terminals for deformation, disconnection, looseness, and so on. If any malfunction is found, repair or replace termiG nal. 2. Securely reconnect connectors. 3. perform self-diagnosis again. H OK or NG OK >> Connector terminal contact is loose, damaged, open or shorted. NG >> GO TO 3. I 3. CHECK STOP LAMP SWITCH CIRCUIT 1. 2. J Turn ignition switch OFF and disconnect stop lamp switch connector and ABS actuator and electric unit (control unit) connector. Check continuity between stop lamp switch harness connector and ABS actuator and electric unit (control unit) harness connector. K L MFIB9044E A B C ABS actuator and electric unit (control unit) Terminal Stop lamp switch (CR engine and HR engine M/T models) Terminal Stop lamp switch (HR engine A/T models and K9K engine models) Terminal E33 20 E38 (LHD models) M203 (RHD models) 2 E60 (LHD models) M204 (RHD models) 2 Continuity Yes OK or NG OK >> GO TO 4. NG >> Open or short in harness between stop lamp switch and ABS actuator and electric unit (control unit). Repair or replace applied harness. BRC-79 M TROUBLE DIAGNOSIS [ESP/TCS/ABS] 4. CHECK STOP LAMP SWITCH POWER SUPPLY 1. 2. Turn ignition switch OFF and disconnect stop lamp switch harness connector. Check voltage between stop lamp switch harness connector and ground. MFIB9047E A B Stop lamp switch (CR engine and HR engine M/T models) Terminal Stop lamp switch (HR engine A/T models and K9K engine) Terminal E38 (LHD models) M203 (RHD models) 1 E60 (LHD models) M204 (RHD models) 1 Ground Voltage — Approx. 12V OK or NG OK >> GO TO 5. NG >> Repair or replace power supply circuit. 5. CHECK STOP LAMP SWITCH 1. 2. Turn ignition switch OFF and disconnect stop lamp switch. Check continuity between stop lamp switch harness connector terminals 1 and 2. MFIB9048E A Stop lamp switch (CR engine and HR engine M/T models) E38 (LHD models) M203 (RHD models) B Terminal Stop lamp switch (HR engine A/T models and K9K engine) 1, 2 E60 (LHD models) M204 (RHD models) Terminal 1, 2 Condition Continuity Brake pedal is depressed Yes Brake pedal is released No OK or NG OK >> Connect connectors and conduct an ABS actuator and electric unit (control unit) self-diagnosis. NG >> Replace stop lamp switch. BRC-80 TROUBLE DIAGNOSIS [ESP/TCS/ABS] Inspection 8: Brake Fluid Level Switch System BFS000FP A DTC C1155 INSPECTION PROCEDURE 1. CHECK SELF-DIAGNOSTIC RESULTS-1 B Check the self-diagnostic results. C Self-diagnosis results CAN COMM CIRCUIT Is the above displayed in the self-diagnosis item? YES >> GO TO Inspection 9, refer to BRC-81, "Inspection 9: CAN Communication System" . NO >> GO TO 2. D 2. CHECK SELF-DIAGNOSTIC RESULTS-2 E 1. 2. Check fluid level in brake fluid reservoir tank. If the level is low, add brake fluid. Clear the stored self-diagnostic results and check self-diagnosis results. BRC Self-diagnostic results G BR FLUID LEVEL LOW Is the above displayed in the self-diagnosis display item? YES >> GO TO 3. NO >> INSPECTION END H 3. CHECK WARNING LAMP SYSTEM Perform an WARNING LAMP self-diagnosis refer to DI-32, "WARNING LAMPS" and repair or replace malfunctioning items. Re-perform WARNING LAMP self-diagnosis. 2. Re-perform ABS actuator and electric unit (control unit) self-diagnosis. OK or NG OK >> INSPECTION END NG >> Repair or replace malfunctioning items. Re-perform the self-diagnosis. 1. Inspection 9: CAN Communication System I J K BFS000FQ DTC U1000, C1180 L INSPECTION PROCEDURE 1. CHECK CONNECTOR M 1. Turn ignition switch OFF and disconnect the ABS actuator and electric unit (control unit) connector, and check the terminal for deformation, disconnection, looseness, and so on. If there is a malfunction, repair or replace the terminal. 2. Reconnect connector to perform self-diagnosis. Is “CAN COMM CIRCUIT” displayed in the self-diagnosis display items? YES >> Print out the self-diagnostic results, and refer to LAN-3, "Precautions When Using CONSULT-II" . NO >> Connector terminal connector is loose, damaged, open, or shorted. BRC-81 TROUBLE DIAGNOSIS [ESP/TCS/ABS] Component Inspection BFS000FR ESP OFF SWITCH ● Turn ignition switch OFF and disconnect ESP OFF switch connector M16, and check continuity between ESP OFF switch connector terminals 1 and 2. ESP OFF switch M16 Terminal 1, 2 Ground Continuity Switch is pressed Yes Switch is released No MFIB9051E Symptom 1: Excessive ABS Function Operation Frequency BFS000FS 1. FRONT AND REAR AXLE INSPECTION Make sure there is no excessive looseness in the front and rear axles. OK or NG OK >> GO TO 2. NG >> Check front or rear axle system. 2. WHEEL SENSOR INSPECTION Perform following inspection for wheel sensor: ● Sensor mount and damage inspection ● Sensor rotor mount and damage inspection ● Sensor connector connection inspection ● Sensor harness inspection OK or NG OK >> GO TO 3. NG >> Sensor or sensor rotor replacement 3. ABS WARNING LAMP DISPLAY CHECK Make sure warning lamp turns off approximately 2 sec. After turn ignition switch ON or when driving. OK or NG OK >> Normal NG >> Perform self-diagnosis. Refer to BRC-62, "Self-Diagnosis" . Symptom 2: Unexpected Pedal Reaction BFS000FT 1. CHECK BRAKE PEDAL STROKE Check brake pedal stroke. Is the stroke too long? YES >> ● Bleed air from brake piping. ● Check brake pedal, brake booster, and master cylinder mount for play, looseness, and brake system for fluid leaks, etc. If any malfunctions are found, make repair. NO >> GO TO 2. BRC-82 TROUBLE DIAGNOSIS [ESP/TCS/ABS] 2. CHECK FUNCTION A Disconnect ABS actuator and electric unit (control unit) connector E33 and make sure that braking force is sufficient when ABS in not operating. After the inspection, reconnect connector. OK or NG OK >> GO TO symptom 1 “Step 2”. Refer to BRC-82, "Symptom 1: Excessive ABS Function Operation Frequency" . NG >> Check brake system. Symptom 3: The Braking Distance Is Long B C BFS000FU CAUTION: On slippery road surfaces, the stopping distance might be longer with the ABS operating than when the ABS is not operating. 1. CHECK FUNCTION D E Disconnect ABS actuator and electric unit (control unit) connector E33 to deactivate ABS. In this condition, check stopping distance. After inspection, connect connector. BRC OK or NG OK >> ● Bleed air from brake piping. ● Check brake system. G NG >> GO TO symptom 1 “Step 2”. Refer to BRC-82, "Symptom 1: Excessive ABS Function Operation Frequency" . Symptom 4: The ABS Function Does Not Operate BFS000FV H CAUTION: The ABS does not operate when the speed is 10 km/h (6 MPH) or less. 1. CHECK ABS WARNING LAMP DISPLAY I Make sure warning lamp turns off approximately 2 second after the ignition switch is turned on or when driving. OK or NG OK >> GO TO symptom 1 “Step 2”. Refer to BRC-82, "Symptom 1: Excessive ABS Function Operation Frequency" . NG >> Perform self-diagnosis. Refer to BRC-62, "Self-Diagnosis" . Symptom 5: Pedal Vibration or ABS Operation Sound Occurs Check if pedal vibration or operation sound occurs when engine is started. OK or NG OK >> Perform self-diagnosis. Refer to BRC-62, "Self-Diagnosis" . NG >> GO TO 2. BRC-83 K BFS000FW CAUTION: Under the following conditions, when brake pedal is lightly depressed (just place a foot on it), ABS is activated and vibration is felt. However, this is normal. ● When shifting gears ● When driving on slippery road ● During cornering at high speed ● When passing over bumps or grooves ● When pulling away just after starting engine [at approximately 10 km/h (6MPH) or higher] 1. SYMPTOM CHECK 1 J L M TROUBLE DIAGNOSIS [ESP/TCS/ABS] 2. SYMPTOM CHECK 2 Check symptom when electrical component (headlamps, etc.) switches are operated. Does the symptom occur when the electrical component (headlamp, etc.) switches are operated? YES >> Check if there is a radio, antenna, antenna lead wire, or wiring close to ABS actuator and electric unit (control unit) (or its wiring), and if there is, move it farther away. NO >> GO TO symptom 1 “Step 2”. Refer to BRC-82, "Symptom 1: Excessive ABS Function Operation Frequency" . Symptom 6: Vehicle Jerks During ESP/TCS/ABS Control BFS000FX 1. CHECK ENGINE SPEED SIGNAL Perform CONSULT-II “DATA MONITOR” to check engine speed. Is engine speed at idle 400 rpm or higher? YES >> GO TO 3. NO >> GO TO 2. 2. ABS WARNING LAMP DISPLAY CHECK Make sure warning lamp turns off approximately 2 sec. After turn ignition switch ON or when driving. OK or NG OK >> System is normal. NG >> GO TO 3. 3. CHECK ECM SELF-DIAGNOSTIC RESULTS Perform ECM self-diagnosis. Are self-diagnosis items displayed? YES >> Check the corresponding items. Refer to EC-74, "TROUBLE DIAGNOSIS" (CR engine models with EURO-OBD), EC-491, "TROUBLE DIAGNOSIS" (CR engine models without EURO-OBD), EC-863, "TROUBLE DIAGNOSIS" (HR engine models with EURO-OBD), EC-1284, "TROUBLE DIAGNOSIS" (HR engine models without EURO-OBD), EC-1630, "TROUBLE DIAGNOSIS" (K9K engine). NO >> GO TO 4. 4. CHECK SELF-DIAGNOSTIC RESULTS 1 Perform self-diagnosis of ABS actuator and electric unit (control unit). Are self-diagnosis items displayed? YES >> Check the corresponding items, make repairs, and re-perform ABS actuator and electric unit (control unit) self-diagnosis. NO >> GO TO 5. 5. CHECK CONNECTOR 1. Disconnect ABS actuator and electric unit (control unit) connector E47 and ECM connector, check terminals for deformation, disconnection, looseness, and so on. If any malfunction is found, repair or replace connector. 2. Securely reconnect connector and perform self-diagnosis. OK or NG OK >> If poor connect, damaged, open or short circuit is found, repair or replace connector terminal. NG >> GO TO 6. BRC-84 TROUBLE DIAGNOSIS [ESP/TCS/ABS] 6. CHECK SELF-DIAGNOSTIC RESULTS 2 A Re-perform ABS actuator and electric unit (control unit) self-diagnosis. Are self-diagnosis items displayed? YES >> Repair or replace malfunctioning items. NO >> GO TO 7. B 7. CHECK CIRCUIT BETWEEN ABS ACTUATOR AND ELECTRIC UNIT (CONTROL UNIT) AND ECM C Check CAN communication system. Refer to BRC-81, "Inspection 9: CAN Communication System" . OK or NG OK >> INSPECTION END NG >> Connect connectors, and re-perform ABS actuator and electric unit (control unit) self-diagnosis. D E BRC G H I J K L M BRC-85 WHEEL SENSORS [ESP/TCS/ABS] WHEEL SENSORS Removal and Installation PFP:47910 BFS000B4 MFIB9030E REMOVAL Be careful of the following. CAUTION: ● When removing the sensor, do not rotate it if possible, and not forcibly pull the sensor harness. ● Before removing front or rear wheel hub, remove wheel sensor to avoid sensor wiring damage. INSTALLATION Be certain to tighten bolts to the specified torque. Be careful of the following: ● Check the inside of the sensor mounting hole for foreign material, the rotor surface for iron chips and other foreign material, and if anything is non-standard, clean it before installation, or replace it. ● When installing the front sensor, completely push in the strut bracket and body bracket rubber grommets until they lock so that the sensor harness does not become twisted. In addition, there should be no twists in the harness when installed. Install the harness so that the painted part faces the outside of the vehicle. ● When installing the rear sensor, completely push in the rubber bracket of the suspension arm bracket and lock the marking area of the side member harness mount so that the sensor harness will not be twisted. In addition, there should be no twists in the harness when installed. BRC-86 SENSOR ROTOR [ESP/TCS/ABS] SENSOR ROTOR Removal and Installation PFP:47970 A BFS000B5 FRONT ● Because the sensor rotor is integrated with the wheel bearing, replace it together with the wheel bearing assembly. Refer to FAX-6, "FRONT WHEEL HUB AND KNUCKLE" . B REAR ● During removal and installation, remove the wheel hub (brake drum). Refer to RAX-5, "WHEEL HUB" . CAUTION: The sensor rotor is a non-reusable part, it must be replaced by an new part when removing it. C D E BRC G H I J K L M BRC-87 ACTUATOR AND ELECTRIC UNIT (ASSEMBLY) [ESP/TCS/ABS] ACTUATOR AND ELECTRIC UNIT (ASSEMBLY) Removal and Installation PFP:47660 BFS000B6 MFIA0015E REMOVAL 1. Disconnect ABS actuator and electric unit (control unit) connector. 2. Loosen brake tube flare nuts, then remove brake tubes from ABS actuator and electric unit (control unit). 3. Remove ABS actuator and electric unit (control unit) mounting nuts. 4. Remove ABS actuator and electric unit (control unit) from vehicle. CAUTION: Be careful of the following when removing ABS actuator and electric unit (control unit). ● If the part number on the part number label (pasted on actuator upper surface) is the same, ABS actuator and electric unit (control unit) cannot be used on another vehicle. If it is used on another vehicle, ABS warning lamp, SLIP indicator lamp and ESP OFF indicator lamp may turn ON or ESP/TCS/ABS may not operate normally. When replacing ABS actuator and electric unit (control unit), must use new service parts. ● Before servicing, disconnect battery cables. ● To remove brake tube, use a flare nut wrench to prevent flare nuts and brake tube from being damaged. To install, use a flare nut torque wrench (commercial service tool) and tighten to the specified torque. ● Do not apply excessive impact to actuator, such as dropping it. ● Do not remove and install ABS actuator and electric unit (control unit) by holding harness. INSTALLATION To install, follow procedure for removal in reverse order. CAUTION: Be careful of the following when installing ABS actuator and electric unit (control unit). ● Tighten the mounting bolts and nuts to the specified torque. ● After the work, bleed air from brake piping. Refer to BR-10, "Bleeding Brake System" . ● After installing vehicle harness connector in the actuator, make sure connector is securely locked. BRC-88 YAW RATE/SIDE G SENSOR [ESP/TCS/ABS] YAW RATE/SIDE G SENSOR Removal and Installation PFP:47931 A BFS000B7 B C D E BRC G H I MFIA0016E J REMOVAL 1. Remove center console. Refer to IP-4, "INSTRUMENT PANEL ASSEMBLY" . 2. Disconnect yaw rate/side G-sensor harness connector. 3. Remove yaw rate/side G-sensor mounting bolts. Then remove yaw rate/side G-sensor from vehicle. CAUTION: ● Do not drop or strike yaw rate/side G-sensor, because it has little endurance to impact. ● Do not use power tool etc., because yaw rate/side G-sensor is weak for the impact. K L INSTALLATION To install, follow procedure for removal in reverse order. CAUTION: ● Do not drop or strike yaw rate/side G-sensor, because it has little endurance to impact. BRC-89 M STEERING ANGLE SENSOR [ESP/TCS/ABS] STEERING ANGLE SENSOR Removal and Installation PFP:25554 BFS000B8 REMOVAL 1. 2. Remove spiral cable assembly. Refer to SRS-38, "SPIRAL CABLE" . Remove steering angle sensor from spiral cable assembly. MFIB9038E INSTALLATION Installation is the reverse order of removal. NOTE: In the case that ABS actuator and electric unit (control unit) are replaced, make sure to adjust neutral position of steering angle sensor. Refer to BRC-42, "Adjustment of Steering Angle Sensor Neutral Position" . BRC-90 CLUTCH C TRANSMISSION/TRANSAXLE SECTION CL CLUTCH A B CL D CONTENTS APPLICATION NOTICE .............................................. 2 How to Check Vehicle Type ..................................... 2 PRECAUTIONS .......................................................... 3 Caution ..................................................................... 3 PREPARATION ........................................................... 4 Special Service Tools ............................................... 4 NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING ................................................ 5 NVH Troubleshooting Chart ..................................... 5 CLUTCH ................................................................ 5 CLUTCH PEDAL ........................................................ 6 On Board Inspection ................................................ 6 HEIGHT INSPECTION .......................................... 6 PLAY INSPECTION .............................................. 6 CLEARANCE CHECK ........................................... 6 Removal and Installation .......................................... 7 REMOVAL ............................................................. 7 INSPECTION AFTER REMOVAL ......................... 7 INSTALLATION ..................................................... 7 CLUTCH FLUID .......................................................... 8 Air Bleeding Procedure ............................................ 8 CLUTCH MASTER CYLINDER .................................. 9 Removal and Installation .......................................... 9 REMOVAL ............................................................. 9 INSTALLATION ..................................................... 9 CSC (CONCENTRIC SLAVE CYLINDER) ................ 10 Removal and Installation ........................................ 10 REMOVAL ........................................................... 10 INSPECTION ...................................................... 10 INSTALLATION ................................................... 10 CLUTCH DISC, CLUTCH COVER AND FLYWHEEL... 11 Removal and Installation ........................................ 11 REMOVAL ........................................................... 12 INSPECTION AND ADJUSTMENT AFTER REMOVAL (CR ENGINE) .................................... 12 INSPECTION AND ADJUSTMENT AFTER REMOVAL (K9K ENGINE) .................................. 13 INSTALLATION ................................................... 13 SERVICE DATA AND SPECIFICATIONS (SDS) ...... 15 Clutch Pedal ........................................................... 15 Clutch Disc ............................................................. 15 Clutch Cover ........................................................... 15 Clutch Control System ............................................ 15 Clutch Master Cylinder ........................................... 15 E F G H I J K L M CL-1 APPLICATION NOTICE APPLICATION NOTICE How to Check Vehicle Type PFP:00000 BCS000KL Confirm K9K engine type with Model written on identification plate (refer to GI-45, "IDENTIFICATION INFORMATION" ),then refer to service information in CL section. Vehicle type Engine type xTKxxxxE11xxE 50kW xTKxxxxE11xxA 63kW CL-2 PRECAUTIONS PRECAUTIONS Caution PFP:00001 A BCS000KM Recommended fluid is brake fluid “Nissan Genuine Brake Fluid or DOT 3 or DOT 4 (US FMVSS No.116)". Refer to MA-24, "Fluids and Lubricants". B ● Never reuse drained brake fluid. ● Be careful not to splash brake fluid on painted areas. CL ● Use new brake fluid to clean or wash all parts of master cylinder and concentric slave cylinder. ● Never use mineral oils such as gasoline or kerosene. It will ruin the rubber parts of the hydraulic system. ● If manual transaxle is removed from the vehicle, always replace CSC (concentric slave cylinder). D CSC insert is returned to original position to remove transaxle. Dust on clutch disc sliding parts may damage CSC seal and may cause fluid leak. E ● Do not disassemble master cylinder and CSC. WARNING: After cleaning clutch disc, wipe it with a dust collector. Do not use compressed air. F ● G H I J K L M CL-3 PREPARATION PREPARATION Special Service Tools PFP:00002 BCS000KN Tool number (Renault tool number) Tool name Description ST20050240 Diaphragm spring adjusting wrench Inspecting diaphragm spring of clutch cover ZZA0508D EM07020000 Clutch aligner Installing clutch cover and disc PCIB0017E KV30101000 Clutch aligner a:15.9mm(0.626in)dia b:19.8mm(0.780in)dia Installing clutch disc ZZA1178D CL-4 Clutch pedal spongy Symptom Clutch slips 1 Clutch does not disengage 1 Clutch grabs/chatters 1 2 Clutch noisy 3 CL-5 1 4 4 4 4 CLUTCH DISC (Hardened) 2 2 2 2 4 2 4 5 3 5 4 6 FLYWHEEL (Distortion) CL-11 CL-12. CL-12. CL-12. CL-11 CL-11 CL-11. CL-11. CL-11. CL-11. CL-11. NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING NVH Troubleshooting Chart PRESSURE PLATE (Distortion) DIAPHRAGM SPRING (Out of tip alignment) DIAPHRAGM SPRING (Damaged) CLUTCH DISC (Lack of spline grease) CLUTCH DISC (Worn out) 2 CLUTCH DISC (Oily) CLUTCH DISC (Dirty or burned) CLUTCH DISC (Lining broken) CLUTCH DISC (Runout is excessive) CL-11. CL-10 RELEASE BEARING (Worn, dirty or damaged) CLUTCH DISC (Out of true) EM-70 . CL-9. MASTER CYLINDER PISTON CUP (Damaged) ENGINE MOUNTING (Loose) CL-8. CL-6. SUSPECTED PARTS (Possible cause) CLUTCH LINE (Air in line) Reference page CLUTCH PEDAL (Free play out of adjustment) NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING PFP:00003 BCS000KO A Use the chart below to help you find the cause of the symptom. The numbers indicate the order of the inspection. If necessary, repair or replace these parts. 2 B CLUTCH CL D E F G H 2 I 1 5 J K L M CLUTCH PEDAL CLUTCH PEDAL On Board Inspection PFP:46540 BCS000KP HEIGHT INSPECTION 1. Make sure clutch pedal height H1 from upper surface of the dash panel is within the specified range. Pedal height H1 : 160 - 169 mm (6.30 - 6.65 in) : 164 - 174 mm (6.46 - 6.85 in) : 170 - 180 mm (6.69 - 7.09 in) : 175 - 185 mm (6.89 - 7.23 in) 2. 3. (LHD with CR engine) (LHD with HR engine) (RHD with CR engine) (LHD K9K 50/63 kW) (RHD K9K 50/63 kW) (RHD with HR engine) If pedal height H1 is outside the specification, replace pedal assembly. Make sure free play A at pedal pad top surface and pedal height H2 when clutch is disengaged are within the ranges specified below. A: Pedal free play at the pedal pad : 0.5 mm (0.02 in) Pedal height H2 when clutch is disengaged : 100 mm (3.94 in) or more (CR engine) 4. SCIA1256E If free play A at pedal pad top surface and pedal height H2 when clutch is disengaged are outside the specification, replace clutch pedal assembly. PLAY INSPECTION ● Press the clutch pedal by hand until certain resistance can be felt. Using a scale, Make sure the free play is within the specified range. Pedal free play : 0.5 mm (0.02 in) MAA0023D CLEARANCE CHECK 1. 2. 3. 4. 5. Start the engine and let it idle. Apply parking brake. Depress the brake pedal. Fully depress clutch pedal and shift to 1st gear. Release clutch pedal gradually. Using a scale, check the clearance between the clutch pedal and floor panel to see if it is within the specified range. Pedal height when the clutch disengages : 100 mm (3.94 in) or more (CR engine) MAA0024D NOTE: Pedal height at clutch disengagement varies slightly from the clutch engagement point. Despite this, pedal height at clutch engagement is commonly used for both cases in order to simplify the inspection. CL-6 CLUTCH PEDAL Removal and Installation BCS000KQ A REMOVAL 1. 2. 3. 4. Remove instrument panel under tray. Refer to IP-4, "INSTRUMENT PANEL ASSEMBLY" . Unlock master cylinder rod end and separate master cylinder from clutch pedal. Remove clutch switch harness clamp from pedal bracket. Disconnect clutch switch connector. B CL D SCIA1284E E 5. Remove nuts (3), and remove clutch pedal assembly. F G H I J K SCIA1260E L INSPECTION AFTER REMOVAL ● Check clutch pedal for bend, damage, and a cracked weld. If bend, damage, or a cracked weld is found, replace clutch pedal assembly. INSTALLATION ● Install in the reverse order of removal. CL-7 M CLUTCH FLUID CLUTCH FLUID Air Bleeding Procedure PFP:00017 BCS000KR CAUTION: ● Monitor fluid level in the reservoir tank to make sure it does not empty. ● Do not spill brake fluid onto painted surfaces. If it spills, wipe up immediately and wash the affected area with water. ● Bleed the bleeding connector. 1. Fill the master cylinder reservoir tank with new brake fluid. 2. Remove rubber cap and connect a transparent vinyl hose to air bleeder of bleeding connector. SCIA1261E 3. 4. Lift tube side lock pin of bleeding connector up one step. CAUTION: Do not remove lock pin. “Depress” and “release” the clutch pedal slowly and fully 15 times at an interval of 2 to 3 seconds and hold it. CAUTION: Hold it to prevent releasing tube from bleeding connector when fluid pressure is applied in the tube. SCIA1262E 5. 6. 7. 8. Slide tube 5 mm (0.20 in) to the direction shown by the arrow and drain clutch fluid. Return tube to its original position. Release clutch pedal and wait for 5 seconds. Repeat steps 4 to 7 until no bubbles can be observed in the brake fluid. SCIA1263E CL-8 CLUTCH MASTER CYLINDER CLUTCH MASTER CYLINDER Removal and Installation PFP:30610 A BCS000KS REMOVAL 1. 2. Drain brake fluid from reservoir tank and remove hose from the nipple. B CAUTION: Do not spill brake fluid onto painted surfaces. If it spills, wipe up immediately and wash the affected area with water. CL Unlock master cylinder rod end in the passenger room and separate master cylinder from clutch pedal. D E F SCIA1284E 3. 4. Remove lock pin from master cylinder and separate clutch tube. Rotate master cylinder clockwise by 45° and remove it from the vehicle. G H I SCIA1285E J INSTALLATION 1. 2. Tilt master cylinder clockwise by 45° and insert to the mounting hole. Rotate counter clockwise and secure it. At this time, nipple is upward of the vehicle. After finishing work, perform clutch pedal height inspection and clutch piping air bleeding. ● Refer to CL-6, "On Board Inspection" ,CL-8, "Air Bleeding Procedure" K L M SCIA1286E CL-9 CSC (CONCENTRIC SLAVE CYLINDER) CSC (CONCENTRIC SLAVE CYLINDER) Removal and Installation PFP:30500 BCS000KT CAUTION: ● Do not spill brake fluid onto painted surfaces. If it spills, wipe up immediately and wash the affected area with water. ● If manual transaxle is removed from the vehicle, always replace CSC (concentric slave cylinder). CSC insert is returned to original position to remove transaxle. Dust on clutch disc sliding parts may damage CSC seal and may cause brake fluid leak. REMOVAL 1. 2. Remove manual transaxle. Refer to MT-7, "REMOVAL AND INSTALLATION" "REMOVAL AND INSTALLATION" (JR5). Remove bolts and CSC from manual transaxle. (JH3) or MT-37, MCIA0172E INSPECTION NOTE: ● Cannot disassemble CSC and release bearing because they are integral parts. Replace them as an assembly. Inspect for the following, and replace parts if necessary. ● CSC: damage, foreign material, wear or pinholes on the cylinder outer surface. ● Release bearing: damage, incorrect rotation direction, or has poor aligning function, and dust seal is deformed or cracked. INSTALLATION 1. Install new CSC to manual transaxle. Tighten to the specified torque. Tightening torque : 21 N·m (2.15 kg-m, 15.5 ft- lb) 2. 3. CAUTION: Do not insert and operate CSC because piston and stopper of CSC components may fall off. Install manual transaxle to the vehicle. Refer to MT-7, "REMOVAL AND INSTALLATION" (JH3) or MT-37, "REMOVAL AND INSTALLATION" (JR5). Bleed air from the clutch piping. Refer to CL-8, "Air Bleeding Procedure" . CL-10 CLUTCH DISC, CLUTCH COVER AND FLYWHEEL CLUTCH DISC, CLUTCH COVER AND FLYWHEEL Removal and Installation PFP:30100 A BCS000KU CAUTION: ● If manual transaxle is removed from the vehicle, always replace CSC (concentric slave cylinder). B CSC insert is returned to original position to remove transaxle. Dust on clutch disc sliding parts may damage CSC seal and may cause brake fluid leak. ● Be careful not to bring any grease into contact with the clutch disc facing, pressure plate surface, CL or flywheel surface. Petrol Engine D E F G H I SCIA1268E Diesel Engine J K L M YCL032 CL-11 CLUTCH DISC, CLUTCH COVER AND FLYWHEEL REMOVAL 1. 2. Remove manual transaxle from the vehicle. Refer to MT-7, "REMOVAL AND INSTALLATION" (JH3) or MT-37, "REMOVAL AND INSTALLATION" (JR5). Loosen clutch cover mounting bolts evenly. Remove clutch cover and clutch disc. INSPECTION AND ADJUSTMENT AFTER REMOVAL (CR ENGINE) Clutch Disc ● Measure circumferential runout relative to the clutch disc center spline. If it is outside the specification, replace the clutch disc. Runout limit/diameter of the area to be measured: CR14 engine :1.0mm (0.039 in) or less/180 (7.08 in) mm dia. HR engine :1.0mm (0.039 in) or less/190 (7.48 in) mm dia. SCIA1270E ● Using calipers, measure the depth to the clutch disc facing rivet heads. If it exceeds the allowable wear limit, replace the clutch disc. Facing wear limit (depth to the rivet head) : 0.3 mm (0.012 in) SCL229 Clutch Cover Check diaphragm spring lever claws for unevenness with the lever still on the vehicle. If they exceed the tolerance, adjust lever height using a diaphragm adjusting wrench (SST). Tolerance for diaphragm spring lever unevenness CR engine : 0.7 mm (0.028 in) HR engine : 0.7 mm (0.028 in) K9K 50/63kW : 0.8 mm (0.031 in) ● ● Check clutch cover thrust ring for wear or breakage. If wear or breakage is found, replace clutch cover assembly. CLA0069D NOTE: ● Worn thrust ring will generate a beating noise when tapped at the rivet with a hammer. ● Broken thrust ring will make a clinking sound when cover is shaken up and down. If a trace of burn or discoloration is found on the clutch cover pressure plate to clutch disc contact surface, repair the surface with sandpaper. If surface is damaged or distorted, replace the assembly. CL-12 CLUTCH DISC, CLUTCH COVER AND FLYWHEEL Flywheel Runout A Using a dial gauge, measure runout at the flywheel clutch contact surface. If runout is outside the specification, replace the flywheel. If a trace of burn or discoloration is found on the surface, repair it with sandpaper. B Flywheel surface runout : EM-93, "FLYWHEEL RUNOUT" . CL CAUTION: Measure it at flywheel outer face (not on knock pin and clutch cover mounting hole). PCIB0016E INSPECTION AND ADJUSTMENT AFTER REMOVAL (K9K ENGINE) Clutch Disc D E The hubs of the clutch discs are nickel plated to improve their sliding performance. ● Clean the splines of the clutch shaft and install the assembly without lubricant. ● Degrease the friction face of the flywheel. ● Install the clutch disc (offset (A) from the hub on the flywheel side). CAUTION: Reworking on the clutch face is not permitted. ● F G H YCL034 Flywheel Runout I Replace the flywheel if it has been damaged. INSTALLATION 1. 2. 3. 4. Clean input shaft spline by removing grease and dust from wear. Apply recommended Grease to clutch disk and input shaft spline. NOTE: Applied amount of grease is 0.4 g. Coating thickness is 1 mm (0.04 in) or less. Insert clutch disc to input shaft. Wipe off any grease oozing from the parts. CAUTION: ● Excessive grease may cause slip or judder. And if it adheres to CSC seal, it cause clutch fluid leak. Wipe off excess grease. ● If grease is not applied, it may cause noise, poor disengagement, or damage to the clutch. Be sure to apply grease. Install clutch disc and clutch cover. Pre-tighten mounting bolts and install a clutch aligner (SST). Tool number 5. A: EM07020000 (CR,K9K engine) A: KV30101000 (HR engine) Tighten clutch cover attaching bolts evenly in two steps in the order shown in the figure. Tightening torque (CR engine) First step : 9.9 - 19 N·m (1.0 - 2.0 kg-m, 8 - 14 ft-lb) Final step : 22 - 29 N·m (2.2 - 3.0 kg-m, 17 - 21 ft-lb) Tightening torque (HR engine) First step : 19 N·m (2.0 kg-m, 14 ft-lb) Final step : 22 - 29 N·m (2.2 - 3.0 kg-m, 17 - 21 ft-lb) Tighten clutch cover attaching bolts according to the order shown in the figure. (K9K engine) CL-13 PCIB1503E J K L M CLUTCH DISC, CLUTCH COVER AND FLYWHEEL 6. Install manual transaxle. Refer to MT-7, "REMOVAL AND INSTALLATION" (JH3) or MT-37, "REMOVAL AND INSTALLATION" (JR5). CL-14 SERVICE DATA AND SPECIFICATIONS (SDS) SERVICE DATA AND SPECIFICATIONS (SDS) Clutch Pedal PFP:00030 A BCS000KV Unit mm (in) Engine type CR K9K B HR 50/63kW Pedal height LHD models 160 - 169 (6.30 - 6.65) 170 - 180 (6.69 - 7.09) 160 - 169 (6.30 - 6.65) RHD models 164 - 174 (6.46 - 6.85) 175 - 185 (6.89 - 7.23) 175 - 185 (6.89 - 7.23) Pedal height at clutch disengagement 100 (3.94) or more Pedal free play — D 0.5 (0.02) Clutch Disc BCS000KW Unit: mm (in) Engine type Size Wear limit (depth to rivet head) CR14 K9K 50/63kW HR 190 (7.48) dia. 216 (8.50) dia. 200 (7.87) dia. 0.3 (0.012) — 0.3 (0.012) — 1 (0.039) — 1.0 (0.039) or less / 180 (7.08) dia. — 1.0 (0.039) or less / 190 (7.48) dia. — 6.8 - 7.2 (0.27 - 0.28) — Wearing thickness of facing Runout limit/diameter of the area to be measured CL Thickness of disc assy with load (new) Clutch Cover E F G H BCS000KX Unit: mm (in) Engine type Size Diaphragm spring lever height Uneven limit diaphragm spring toe height I CR K9K 50/63kW HR 190 (7.48) dia. 216 (8.50) dia. 215 (8.46) dia. 32.0 - 34.0 (1. 26 - 1.34) — 29.0 - 31.0 (1.14 - 1.22) 0.7 (0.028) or less 0.8 (0.031) or less 0.7 (0.028) or less Clutch Control System J BCS000KY Type of clutch control K Hydraulic L Clutch Master Cylinder BCS000KZ Unit: mm (in) Inner diameter 15.87 (5/8) CL-15 M SERVICE DATA AND SPECIFICATIONS (SDS) CL-16 ENGINE COOLING SYSTEM B ENGINE SECTION CO ENGINE COOLING SYSTEM A CO C D E CONTENTS CR PRECAUTIONS .......................................................... 3 Precautions For Liquid Gasket ................................. 3 REMOVAL OF LIQUID GASKET SEALING .......... 3 LIQUID GASKET APPLICATION PROCEDURE..... 3 PREPARATION ........................................................... 4 Special Service Tools ............................................... 4 Commercial Service Tool ......................................... 4 OVERHEATING CAUSE ANALYSIS .......................... 5 Troubleshooting Chart .............................................. 5 COOLING SYSTEM .................................................... 7 Cooling Circuit .......................................................... 7 ENGINE COOLANT .................................................... 8 Inspection ................................................................. 8 LEVEL CHECK ..................................................... 8 LEAK CHECK ....................................................... 8 Changing Engine coolant ......................................... 9 DRAINING ENGINE COOLANT ........................... 9 REFILLING ENGINE COOLANT ........................ 10 FLUSHING COOLING SYSTEM ..........................11 RADIATOR ................................................................ 12 Removal and Installation ........................................ 12 REMOVAL ........................................................... 13 INSTALLATION ................................................... 14 Disassembly and Assembly of Cooling Fan ........... 14 DISASSEMBLY ................................................... 15 ASSEMBLY ......................................................... 15 Checking Radiator Cap (Models without A/C) ........ 15 Checking Reservoir Tank Cap (Models with A/C)... 16 Checking Cooling System Hoses ........................... 16 WATER PUMP .......................................................... 17 Removal and Installation ........................................ 17 REMOVAL ........................................................... 17 INSPECTION AFTER REMOVAL ....................... 18 INSTALLATION ................................................... 18 INSPECTION AFTER INSTALLATION ............... 18 THERMOSTAT .......................................................... 19 Removal and Installation ........................................ 19 REMOVAL ........................................................... 19 INSPECTION AFTER REMOVAL ....................... 19 INSTALLATION ................................................... 20 INSPECTION AFTER INSTALLATION ................ 20 SERVICE DATA AND SPECIFICATIONS (SDS) ...... 21 Standard and Limit .................................................. 21 CAPACITY ........................................................... 21 THERMOSTAT .................................................... 21 RADIATOR .......................................................... 21 Tightening Torque ................................................... 21 HR PRECAUTIONS ........................................................ 22 Precautions For Liquid Gasket ............................... 22 REMOVAL OF LIQUID GASKET SEALING ........ 22 LIQUID GASKET APPLICATION PROCEDURE... 22 PREPARATION ......................................................... 23 Special Service Tools ............................................. 23 Commercial Service Tool ........................................ 23 OVERHEATING CAUSE ANALYSIS ........................ 24 Troubleshooting Chart ............................................ 24 COOLING SYSTEM .................................................. 26 Cooling Circuit ........................................................ 26 ENGINE COOLANT .................................................. 27 Inspection ............................................................... 27 LEVEL CHECK .................................................... 27 LEAK CHECK ...................................................... 27 Changing Engine coolant ....................................... 28 DRAINING ENGINE COOLANT .......................... 28 REFILLING ENGINE COOLANT ......................... 29 FLUSHING COOLING SYSTEM ......................... 30 RADIATOR ................................................................ 31 Removal and Installation ........................................ 31 REMOVAL ........................................................... 32 INSTALLATION ................................................... 33 Disassembly and Assembly of Cooling Fan ........... 33 DISASSEMBLY ................................................... 34 CO-1 F G H I J K L M ASSEMBLY ......................................................... 34 Checking Radiator Cap (All Models Except M/T with A/C) ........................................................................ 34 Checking Reservoir Tank Cap (M/T with A/C Models) .......................................................................... 35 Checking Radiator .................................................. 35 Checking Cooling System Hoses ........................... 35 WATER PUMP ........................................................... 36 Removal and Installation ........................................ 36 REMOVAL ........................................................... 36 INSPECTION AFTER REMOVAL ........................ 37 INSTALLATION .................................................... 37 INSPECTION AFTER INSTALLATION ................ 37 THERMOSTAT .......................................................... 38 Removal and Installation ........................................ 38 REMOVAL ........................................................... 38 INSPECTION AFTER REMOVAL ........................ 38 INSTALLATION .................................................... 39 INSPECTION AFTER INSTALLATION ................ 39 WATER OUTLET ....................................................... 40 Removal and Installation ........................................ 40 REMOVAL ........................................................... 40 INSTALLATION .................................................... 40 INSPECTION AFTER INSTALLATION ................ 41 SERVICE DATA AND SPECIFICATIONS (SDS) ...... 42 Standard and Limit .................................................. 42 CAPACITY ........................................................... 42 THERMOSTAT .................................................... 42 RADIATOR .......................................................... 42 K9K PRECAUTIONS ......................................................... 43 Precautions For Liquid Gasket ............................... 43 REMOVAL OF LIQUID GASKET ......................... 43 LIQUID GASKET APPLICATION PROCEDURE... 43 PREPARATION .........................................................44 Special Service Tools ..............................................44 OVERHEATING CAUSE ANALYSIS ........................45 Troubleshooting Chart .............................................45 COOLING SYSTEM ..................................................47 Cooling Circuit .........................................................47 ENGINE COOLANT ..................................................48 Inspection ................................................................48 LEVEL CHECK ....................................................48 LEAK CHECK ......................................................48 Changing Engine Coolant .......................................49 DRAINING ENGINE COOLANT ..........................49 REFILLING ENGINE COOLANT .........................49 FLUSHING COOLING SYSTEM .........................50 RADIATOR ................................................................51 Removal and Installation .........................................51 REMOVAL ............................................................51 INSTALLATION ....................................................52 Disassembly and Assembly Radiator Fan ..............52 DISASSEMBLY ....................................................53 ASSEMBLY ..........................................................53 Checking Reservoir Tank Cap ................................53 Checking Radiator ..................................................53 WATER PUMP ...........................................................54 Removal and Installation .........................................54 REMOVAL ............................................................54 INSPECTION AFTER REMOVAL ........................54 INSTALLATION ....................................................55 INSPECTION AFTER INSTALLATION ................55 THERMOSTAT ...........................................................56 Inspection ................................................................56 WATER OUTLET .......................................................57 Removal and Installation .........................................57 REMOVAL ............................................................57 INSTALLATION ....................................................57 CO-2 PRECAUTIONS [CR] PRECAUTIONS Precautions For Liquid Gasket [CR] PFP:00001 A BBS002RV REMOVAL OF LIQUID GASKET SEALING After removing the mounting bolts and nuts, separate the mating surface using a seal cutter and remove the liquid gasket. CAUTION: Be careful not to damage the mating surfaces. ● In areas where the seal cutter is difficult to use, use a plastic hammer to lightly tap the gasket area. CAUTION: If for some unavoidable reason a tool such as a flat-bladed screwdriver is used, be careful not to damage the mating surfaces. ● CO C D PBIC0275E E LIQUID GASKET APPLICATION PROCEDURE 1. ● 2. 3. Using a scraper, remove the old liquid gasket adhering to the gasket application surface and the mating surface. Remove the liquid gasket completely from the groove of the gasket application surface, mounting bolts and bolt holes. Wipe the gasket application surface and the mating surface with white gasoline (lighting and heating use) to remove adhering moisture, grease and foreign materials. Attach the liquid gasket to the tube presser. Use Genuine Liquid Gasket or equivalent. F G H PBIC0003E I 4. ● Apply the gasket without breaks to the specified location with the specified dimensions. If there is a groove for the liquid gasket application, apply the gasket to the groove. J K L EMA0622D As for the bolt holes, normally apply the gasket inside the holes. Occasionally, it should be applied outside the holes. Make sure to read the instruction in this manual. ● Within five minutes of gasket application, install the mating component. ● If the liquid gasket protrudes, wipe it off immediately. ● Do not retighten after the installation. ● After 30 minutes or more have passed from the installation, fill the engine oil and coolant. CAUTION: If there are additional instructions in this manual, observe them. M ● CO-3 SEM164F PREPARATION [CR] PREPARATION Special Service Tools PFP:00002 BBS002RW NISSAN Tool number (RENAULT tool number) Tool name Description WS39930000 ( — ) Tube presser Pressing the tube of liquid gasket S-NT052 EG17650301 ( — ) Radiator cap tester adapter Adapting radiator cap tester to radiator filler neck a: 28 (1.10) dia. b: 31.4 (1.236) dia. c: 41.3 (1.626) dia. Unit: mm (in) S-NT564 — (M.S. 554_07) Tester Leak checking Checking reservoir tank and reservoir tank cap MLIA0012E — (M.S. 554_01) Reservoir tank tester adapter Adapting tester to reservoir tank MLIA0013E — (M.S. 554_06) Reservoir tank cap tester adapter Adapting tester to reservoir tank cap MLIA0014E Commercial Service Tool BBS002RX Tool name Description Radiator cap tester Checking radiator and radiator cap PBIC1982E CO-4 OVERHEATING CAUSE ANALYSIS [CR] OVERHEATING CAUSE ANALYSIS Troubleshooting Chart PFP:00012 A BBS002RY Symptom Check items Water pump malfunction Thermostat stuck closed Poor heat transfer CO Worn or loose drive belt — Dust contamination or paper clogging Damaged fins — C Mechanical damage Clogged radiator cooling tube Excess foreign material (rust, dirt, sand, etc.) D Cooling fan does not operate Reduced air flow High resistance to fan rotation E Fan assembly — Damaged fan blades Cooling system parts malfunction F Damaged radiator shroud — — — Improper coolant mixture ratio — — — Poor coolant quality — Coolant viscosity G — Loose clamp Cooling hose Engine coolant leaks Cracked hose Water pump Poor sealing Radiator cap (M/T models without A/C and A/T models Reservoir tank cap (M/T models with A/C) Loose Insufficient engine coolant H I Poor sealing J O-ring for damage, deterioration or improper fitting Radiator Cracked radiator tank K Cracked radiator core Reservoir tank Overflowing reservoir tank CO-5 Exhaust gas leaks into cooling system Cracked reservoir tank Cylinder head deterioration Cylinder head gasket deterioration L M OVERHEATING CAUSE ANALYSIS [CR] Symptom Check items High engine rpm under no load Abusive driving Driving in low gear for extended time Driving at extremely high speed — Overload on engine Powertrain system malfunction Installed improper size wheels and tires Except cooling system parts malfunction — Dragging brakes Improper ignition timing Blocked bumper — Installed car brassiere Blocked radiator grille Blocked or restricted air flow Blocked radiator Mud contamination or paper clogging — Blocked condenser Installed large fog lamp CO-6 Blocked air flow — COOLING SYSTEM [CR] COOLING SYSTEM Cooling Circuit PFP:21020 A BBS002RZ CO C D E F G H I PBIC1475E J K L M CO-7 ENGINE COOLANT [CR] ENGINE COOLANT Inspection PFP:KQ100 BBS002S0 LEVEL CHECK Models without A/C ● ● Check if the reservoir tank engine coolant level is within “MIN” to “MAX” when engine is cool. adjust the engine coolant level as necessary. SMA412B Models with A/C ● ● Check if the reservoir tank coolant level is within MIN to MAX when engine is cool. Adjust coolant if too much or too little. Vehicle front MBIB1360E MBIA0092E LEAK CHECK Model without A/C ● To check for leakage, apply pressure to the cooling system with a radiator cap tester (commercial service tool) and radiator cap tester adapter (SST). Testing pressure: 157 kPa (1.57 bar, 1.6 kg/cm2 , 23 psi) WARNING: Never remove the radiator cap when the engine is hot. Serious burns could occur from high pressure coolant escaping from the radiator. CAUTION: Higher pressure than specified may cause radiator damage. CO-8 SLC134B ENGINE COOLANT [CR] ● NOTE: In a case that engine coolant decreases, replenish radiator with engine coolant. If anything is found, repair or replace damaged parts. A Models with A/C ● CO To check for leakage, fit the adapter to the reservoir tank (1), and then connect it to the tester. C D E MBIB1362E ● ● Warm up the engine and turn it off. Apply pressure to the cooling system and stop pumping. Testing pressure ● ● F : 90 kpa (0.9 bar, 0.92 kg/cm2 , 13.1 psi) If the pressure drops, look for leakage. Unscrew slowly the adapter from the reservoir tank to reduce the pressure in cooling system, and install the reservoir tank cap. WARNING: Never remove the reservoir tank cap when the engine is hot. Serious burns could occur from high pressure engine coolant escaping from the radiator. CAUTION: Higher pressure than specified may cause radiator damage. Changing Engine coolant G H I MBIA0094E J BBS002S1 WARNING: ● To avoid being scalded, never change the coolant when the engine is hot. ● Wrap a thick cloth around radiator cap and carefully remove the cap. First, turn the cap a quarter of a turn to release built-up pressure. Then turn the cap all the way. DRAINING ENGINE COOLANT Models without A/C Disconnect radiator lower hose and radiator cap. CAUTION: Make sure to drain when the engine coolant temperature is cold. 2. Remove reservoir tank and drain the engine coolant in the following procedures. Move relay case in front of the battery. Disconnect the reservoir tank from fan shroud to remove. With force applied in the left direction of vehicle, pull up reservoir tank. Check drain coolant for contaminants such as rust, corrosion or discoloration. If contaminated, flush engine cooling system. Refer to CO-11, "FLUSHING COOLING SYSTEM" . 3. L M 1. a. b. K PBIC1476E CO-9 ENGINE COOLANT [CR] Models with A/C 1. Disconnect radiator lower hose and reservoir tank cap. CAUTION: Make sure to drain when the engine coolant temperature is cold. 2. Remove reservoir tank and drain the engine coolant. : Vehicle front 3. Check drain coolant for contaminants such as rust, corrosion or discoloration. If contaminated, flush engine cooling system. Refer to CO-11, "FLUSHING COOLING SYSTEM" . MBIB1360E REFILLING ENGINE COOLANT 1. 2. 3. Install reservoir tank. Connect radiator lower hose. Disconnect heater hose (at heater hose outlet side: upper side) as shown in figure. Keep hose end at the same height as that of before removal. PBIC1477E 4. Fill radiator and reservoir tank to specified level. ● Pour coolant slowly of less than 2 (1-3/4 lmp qt) a minute to allow air in system to escape. ● When coolant from heater hose starts to drain, connect heater hose and continue to fill. ● Use Nissan Genuine Coolant L250 or equivalent mixed with water (distilled or demineralized). Refer to MA-24, "RECOMMENDED FLUIDS AND LUBRICANTS" . SMA182B Engine coolant capacity Models without A/C With reservoir tank : Approx. 4.9 Reservoir tank : 0.7 (4-3/8 Imp qt) (5/8 lmp qt) SMA412B CO-10 ENGINE COOLANT [CR] Models with A/C With reservoir tank : Approx. 5.3 Reservoir tank : 1.2 A (4-5/8 Imp qt) (1-1/8 lmp qt) CO : Vehicle front C D MBIB1360E E F G H MBIA0092E 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. Warm up engine to normal operating temperature with radiator cap installed. Warm up until thermostat opens. Keep warming at 3,000 rpm for approximately 10 minutes as guide. ● For thermostat opening, touch radiator upper hose by hand to insure that water flow is hot. CAUTION: Be careful not to overheat. Stop the engine. After cooling engine [approximately 50°C (122 °F) or lower], remove radiator cap and check coolant level. If the level is low, fill up to the radiator neck again and repeat from step 5. When the coolant level stabilizes, fill reservoir tank up to the “MAX” line. Check cooling system for leaks with engine running. Allow the engine to cool [approximately 50°C (122°F) or lower]. Start the engine. Perform the following cycle three times. Keep an engine speed of 1,000 rpm for approximately 30 seconds. Then increase it gradually to 3,000 rpm. During the above step 12, make sure water flow sound is not heard from heater core. ● Sound may be noticeable at heater unit. If water flow sound is heard, repeat from step 4 to 13. ● Clean excess coolant from engine. FLUSHING COOLING SYSTEM 1. 2. 3. 4. 5. 6. Fill radiator and reservoir tank with water and reinstall radiator cap. Run engine and warm it up to normal operating temperature. Rev engine two or three times under no-load. Stop engine and wait until it cools down. Drain water. Repeat steps 1 through 5 until clear water begins to drain from radiator. CO-11 I J K L M RADIATOR [CR] RADIATOR Removal and Installation PFP:21400 BBS002S2 Models without A/C MBIB1366E : Vehicle front 1. Cooling fan assembly 2. Hose clamp 3. Radiator hose (upper) 4. Radiator 5. Radiator cap 6. Mounting rubber (upper) 7. Mounting rubber (lower) 8. Radiator hose (lower) 9. Bracket 10. Reservoir tank cap 11. Reservoir tank 12. Reservoir tank hose A. To water outlet B. C. To water suction pipe Refer to GI-9, "Contents" for symbol marks in the figure. CO-12 To a of radiator RADIATOR [CR] Models with A/C A CO C D E F G H PBIC1479E 1. Radiator 2. Mounting rubber 3. 4. Hose clamp 5. Reserve tank cap 6. Hose clamp 7. Reservoir tank hose 8. Reservoir tank 9. Cooling fan assembly 10. Hose clamp 11. Radiator hose (lower) 13. Reservoir tank hose 14. Mounting rubber Radiator hose (upper) 3. 4. 5. 6. J 12. Hose clamp K REMOVAL 1. 2. I Disconnect both battery cables. Drain coolant. Refer to CO-8, "ENGINE COOLANT" . CAUTION: Make sure to drain when the engine coolant temperature is cold. WARNING: Never remove the radiator cap when the engine is hot. Serious burns could occur from high pressure coolant escaping from the radiator. Remove mounting bolts to make relay case movable. Remove the following parts. ● Front grille; Refer to EI-10, "FRONT GRILLE" . ● Reservoir tank (models with A/C) ● Remove radiator core support (upper). Refer to BL-13, "Radiator Core Upper Support" . ● Remove refrigerant lines for A/C models. Refer to ATC-135, "REFRIGERANT LINES" , MTC-81, "REFRIGERANT LINES" . ● Air Duct; Refer to EM-18, "AIR CLEANER AND AIR DUCT" . Remove harness connectors Remove radiator hose (upper) and (lower). CAUTION: ● Install plug to hoses and fluid pipes removed, and be sure to prevent fluid leak. ● Be careful not to damage radiator core and A/C condenser core. CO-13 L M RADIATOR [CR] 7. Remove reservoir tank (models without A/C). ● Disconnect the reservoir tank from fan shroud to remove. With force applied in the left direction of vehicle, pull up reservoir tank. PBIC1476E 8. Remove cooling fan assembly from radiator. INSTALLATION Install in the reverse order of removal which being careful of the following. ● When installing radiator core support (lower), make sure upper and lower mount units of radiator and A/C condenser are fitted in mounting holes of radiator core support (upper/lower). Disassembly and Assembly of Cooling Fan BBS002S3 Models without A/C MBIB1368E 1. Fan shroud 2. Fan motor 3. CO-14 Fan RADIATOR [CR] Models with A/C A CO C D E F MBIB1369E 1. Resistor 4. Fan 2. Fan shroud 3. Fan motor G DISASSEMBLY 1. 2. H Remove fan. CAUTION: Reverse screw are used for the fan attachment screw. When removing or attaching, turn the screw the opposite way as for a normal screw. Remove fan motor from fan shroud. I J PBIC1486E K ASSEMBLY Assemble cooling fan in the reverse order of disassembly. ● Apply thread locking sealant and tighten screw to assemble the fan. Checking Radiator Cap (Models without A/C) 1. L BBS002S4 Pull the negative-pressure valve to open it and check that it closes completely when released. ● Check that there is no dirt or damage on the valve seat of the radiator cap negative-pressure valve. ● Check that there are no unusual conditions in the opening and closing conditions of the negative-pressure valve. SMA967B CO-15 M RADIATOR [CR] 2. Check radiator cap relief pressure. Standard: 78 - 98 kPa (0.78 - 0.98 bar, 0.8 - 1.0 kg/cm2 , 11 - 14 psi) Limit: 59 kPa (0.59 bar, 0.6 kg/cm2 , 9 psi) When connecting the radiator cap to the tester, apply water or engine coolant to the cap seal part. SLC135B ● Replace the radiator cap if there is an unusual conditions in the negative-pressure valve, or if the open-valve pressure is outside of the standard values. CAUTION: When installing radiator cap, thoroughly wipe out the radiator filler neck to remove any waxy residue or foreign material. ● Checking Reservoir Tank Cap (Models with A/C) ● ● ● BBS002S5 Fit the adapter to the tester as shown. When connecting the reservoir tank cap to the tester, apply water or LLC to the cap seal part. Check reservoir tank cap relief pressure. 88 kPa (0.88 bar, 0.90 kg/cm2 , 12.8 psi) ● Replace the reservoir tank cap if the engine coolant passes through it, or if any fur signs is detected. MBIB1079E Checking Cooling System Hoses BBS002S6 Check hoses for improper attachment, leaks, cracks, damage, loose connections, chaffing and deterioration. CO-16 WATER PUMP [CR] WATER PUMP Removal and Installation PFP:21020 A BBS002S8 CO C D E F G H I PBIC1487E 1. Water pump pulley 2. Water pump 3. O-ring 4. Water suction pipe 5. Heater hose 6. Radiator hose (lower) REMOVAL 1. 2. 3. 4. 5. 6. 7. 8. J K Drain engine coolant. Refer to CO-8, "ENGINE COOLANT" . CAUTION: Make sure to drain when the engine coolant temperature is cold. WARNING: Never remove the radiator cap when the engine is hot. Serious burns could occur from high pressure coolant escaping from the radiator. Steer front wheel to the right. Remove front fender protector (RH). Refer to EI-14, "FENDER PROTECTOR" . Loosen mounting bolts of water pump pulley before loosening belt tension of drive belt. Remove drive belt from water pump pulley. Refer to EM-14, "DRIVE BELTS" . Remove the water pump pulley. NOTE: To remove it easily, loosen water pump pulley mounting bolt, then water pump belt. Remove water pump. ● Place a piece of wood or something onto water pump, and tap it with a hammer. Disconnect liquid gasket to remove. ● Engine coolant remaining in the engine is drained. Use tray to collect it. CAUTION: ● Handle the water pump vane so that it does not contact any other parts. ● Water pump cannot be disassembled and should be replaced as a unit. Remove water suction pipe in the following procedures. CO-17 L M WATER PUMP [CR] a. b. c. d. Remove air cleaner case assembly. Refer to EM-18, "AIR CLEANER AND AIR DUCT" . Remove radiator hose (upper and lower), and heater hose. Move harnesses around suction pipe. Remove mounting bolts, and pull water suction pipe toward engine rear side. ● Coolant remaining in the engine is drained. Use tray to collect it. INSPECTION AFTER REMOVAL ● ● ● Visually check that there is no significant dirt or rusting on the water pump body and vane. Check that there is no looseness in the vane shaft, and that it turns smoothly when rotated by hand. If unusualness is found, replace the water pump. PBIC1488E INSTALLATION ● Install in the reverse order of removal which being careful of the following. Water Suction Pipe Installation 1. 2. a. b. Apply neutral detergent on O-ring. Fit O-ring in the groove securely. Tighten mounting bolts with the following procedures. Temporarily tighten bolts in order: A to B. Tighten bolts in order: B to A PBIC1489E Water Pump Installation ● Apply liquid gasket as shown in figure, and install. Use Genuine Liquid Gasket or equivalent. CAUTION: Wait at least 30 minutes after water pump installation. Refill coolant and start the engine. PBIC1490E INSPECTION AFTER INSTALLATION ● ● Check for engine coolant leaks using radiator cap tester adapter (SST: EG17650301) and radiator cap tester (commercial service tool) (M/T models without A/C and A/T models) or reservoir tank cap tester and reservoir cap tester adapter (M/T models with A/C). Refer to CO-8, "LEAK CHECK" . Start and warm up engine. Visually check if there is no leaks of engine coolant. CO-18 THERMOSTAT [CR] THERMOSTAT Removal and Installation PFP:21200 A BBS002S9 CO C D E F MBIB1358E 1. Thermostat 2. Rubber ring 3. Water outlet 4. Radiator hose (upper) 5. Heater hose 6. Heater pipe 7. Copper washer 8. Engine coolant temperature sensor H REMOVAL 1. 2. 3. 4. 5. 6. Drain engine coolant. Refer to CO-8, "ENGINE COOLANT" . CAUTION: Make sure to drain when the engine coolant temperature is cold. WARNING: Never remove the radiator cap when the engine is hot. Serious burns could occur from high pressure coolant escaping from the radiator. Remove air duct and air cleaner body. Refer to EM-18, "AIR CLEANER AND AIR DUCT" . Remove radiator hose (upper). Remove water outlet and thermostat. ● Coolant remaining in the engine is drained. Use tray to collect it. Remove engine coolant temperature sensor if necessary. Remove heater pipe if necessary. INSPECTION AFTER REMOVAL ● ● ● ● ● Place a thread so that it is caught in the valves of the thermostat. Immerse fully in a container filled with water. Heat while stirring. (The example in the figure shows the thermostat.) The valve opening temperature is the temperature at which the valve opens and falls from the thread. Continue heating. Check the full-open lift amount. After checking the full-open lift amount, lower the water temperature and check the valve closing temperature. If the measured value is out of the standard value or unusual valve seating condition is found, replace the thermostat. CO-19 G SLC252B I J K L M THERMOSTAT [CR] Standard values Thermostat Valve opening temperature Full-open lift amount 86.5 - 89.5°C (188 - 193°F) 8 mm or more/ 101°C (0.31 in/ 214 °F) Valve closing temperature 83°C (181°F) INSTALLATION Install in the reverse order of removal which being careful of the following. Installation of Thermostat 1. Install the thermostat with the whole circumference of each flange part fit securely inside the rubber ring. PBIC0157E 2. Install thermostat with jiggle valve facing the direction shown in the figure. NOTE: Care must be taken not to trap the thermostat jiggle valve. PBIC1492E Water Outlet Installation ● ● Install water pipe with it facing upward. Install thermostat in place. PBIC1493E Heater Pipe Installation ● Apply liquid gasket to the threads, and install. Use Genuine Liquid Gasket or equivalent. INSPECTION AFTER INSTALLATION ● ● Check for leaks of engine coolant using radiator cap tester adapter (SST: EG17650301) and a radiator cap tester (commercial service tool) (models without A/C) or reservoir tank cap tester and reservoir tank cap tester adapter (models with A/C). Refer to CO-8, "LEVEL CHECK" . Start and warm up engine. Visually check if there is no leaks of engine coolant. CO-20 SERVICE DATA AND SPECIFICATIONS (SDS) [CR] SERVICE DATA AND SPECIFICATIONS (SDS) Standard and Limit PFP:00030 A BBS002SA CAPACITY Unit: Coolant capacity [With reservoir tank (MAX level)] Models without A/C Approximately 4.9 (4-3/8) Models with A/C Approximately 5.3 (4-5/8) Models without A/C Reservoir tank (Imp qt) 0.7 (5/8) Models with A/C CO C 1.2 (1-1/8) THERMOSTAT D Valve opening temperature 86.5 - 89.5°C (188 - 193°F) Valve lift 8 mm or more/ 101°C (0.31 in/ 214°F) Valve closing temperature E 83°C (181°F) RADIATOR Unit: kPa (bar, kg/cm2 , psi) Radiator cap relief pressure Standard 78 - 98 (0.78 - 0.98, 0.8 - 1.0, 11 - 14) Limit 59 (0.59, 0.6, 9) Reservoir tank cap relief pressure Leakage test pressure F 88 (0.88, 0.90, 12.8) Models without A/C 157 (1.57, 1.6, 23) Models with A/C 90 (0.9, 0.92, 13.1) G H Tightening Torque BBS002SB *1: Parts to be tightened in particular orders Unit: N·m (kg-m, ft-lb) Unit: N·m (kg-m, in-lb)*2 Cooling fan assembly 3.8 - 4.5 (0.39 - 0.45, 34 - 39)*2 Reservoir tank (models without A/C) 3.8 - 4.5 (0.39 - 0.45, 34 - 39)*2 Cooling fan motor 3.0 - 4.0 (0.31 - 0.40, 27 - 35)*2 Cooling fan (reverse screw) 1.7 - 2.3 (0.18 - 0.23, 15 - 20)*2 Water pump *1 I J K 10.0 - 13.7(1.1 - 1.3, 8 - 10) Water pump pulley 6.9 - 9.5 (0.71 - 0.96, 61 - 84)*2 Water suction pipe 16.6 - 23.5 (1.7 - 2.3, 13 - 17) Water outlet 6.3 - 8.3 (0.65 - 0.84, 56 - 73)*2 Heater pipe 29.0 - 39.0 (3.0 - 4.0, 21 - 29) Engine coolant temperature sensor 20 - 27(2.1 - 2.7, 15 - 19) CO-21 L M PRECAUTIONS [HR] PRECAUTIONS Precautions For Liquid Gasket [HR] PFP:00001 BBS002SC REMOVAL OF LIQUID GASKET SEALING After removing the mounting bolts and nuts, separate the mating surface using a seal cutter and remove the liquid gasket. CAUTION: Be careful not to damage the mating surfaces. ● In areas where the seal cutter is difficult to use, use a plastic hammer to lightly tap the gasket area. CAUTION: If for some unavoidable reason a tool such as a flat-bladed screwdriver is used, be careful not to damage the mating surfaces. ● PBIC0275E LIQUID GASKET APPLICATION PROCEDURE 1. ● 2. 3. Using a scraper, remove the old liquid gasket adhering to the gasket application surface and the mating surface. Remove the liquid gasket completely from the groove of the gasket application surface, mounting bolts and bolt holes. Wipe the gasket application surface and the mating surface with white gasoline (lighting and heating use) to remove adhering moisture, grease and foreign materials. Attach the liquid gasket to the tube presser. Use Genuine Liquid Gasket or equivalent. PBIC0003E 4. ● Apply the gasket without breaks to the specified location with the specified dimensions. If there is a groove for the liquid gasket application, apply the gasket to the groove. EMA0622D As for the bolt holes, normally apply the gasket inside the holes. Occasionally, it should be applied outside the holes. Make sure to read the instruction in this manual. ● Within five minutes of gasket application, install the mating component. ● If the liquid gasket protrudes, wipe it off immediately. ● Do not retighten after the installation. ● After 30 minutes or more have passed from the installation, fill the engine oil and coolant. CAUTION: If there are additional instructions in this manual, observe them. ● CO-22 SEM164F PREPARATION [HR] PREPARATION Special Service Tools PFP:00002 A BBS002SD NISSAN Tool number (RENAULT tool number) Tool name CO Description WS39930000 ( — ) Tube presser Pressing the tube of liquid gasket C D S-NT052 EG17650301 ( — ) Radiator cap tester adapter Adapting radiator cap tester to radiator filler neck a: 28 (1.10) dia. b: 31.4 (1.236) dia. c: 41.3 (1.626) dia. Unit: mm (in) E F S-NT564 — (M.S. 554_07) Tester Leak checking Checking reservoir tank and reservoir tank cap G H I MLIA0012E — (M.S. 554_01) Reservoir tank tester adapter Adapting tester to reservoir tank J K MLIA0013E — (M.S. 554_06) Reservoir tank cap tester adapter Adapting tester to reservoir tank cap L M MLIA0014E Commercial Service Tool BBS002SE Tool name Description Radiator cap tester Checking radiator and radiator cap PBIC1982E CO-23 OVERHEATING CAUSE ANALYSIS [HR] OVERHEATING CAUSE ANALYSIS Troubleshooting Chart PFP:00012 BBS002SF Symptom Check items Water pump malfunction Worn or loose drive belt Thermostat stuck closed Poor heat transfer — Dust contamination or paper clogging Damaged fins — Physical damage Clogged radiator cooling tube Excess foreign material (rust, dirt, sand, etc.) Cooling fan does not operate Reduced air flow High resistance to fan rotation Fan assembly — Damaged fan blades Cooling system parts malfunction Damaged radiator shroud — — — Improper engine coolant mixture ratio — — — Poor engine coolant quality — Engine coolant viscosity — Loose clamp Cooling hose Water pump Cracked hose Poor sealing Loose Radiator cap Engine coolant leaks Radiator (without A/C models) Reservoir tank cap (with A/ C models) Insufficient engine coolant Reservoir tank Poor sealing O-ring for damage, deterioration or improper fitting Cracked radiator tank Cracked radiator core Cracked reservoir tank Cylinder head deterioration Overflowing reservoir tank CO-24 Exhaust gas leaks into cooling system Cylinder head gasket deterioration OVERHEATING CAUSE ANALYSIS [HR] Symptom Check items High engine rpm under no load Abusive driving Driving in low gear for extended time A CO Driving at extremely high speed — Overload on engine Installed improper size wheels and tires Except cooling system parts malfunction C Power train system malfunction — D Dragging brakes Improper ignition timing Blocked bumper E — Installed car brassiere Blocked radiator grille Blocked or restricted air flow Blocked radiator Mud contamination or paper clogging — Blocked condenser Installed large fog lamp F — Blocked air flow G H I J K L M CO-25 COOLING SYSTEM [HR] COOLING SYSTEM Cooling Circuit PFP:21020 BBS002SG PBIC3820E CO-26 ENGINE COOLANT [HR] ENGINE COOLANT Inspection PFP:KQ100 A BBS002SH LEVEL CHECK All Models Except M/T with A/C ● ● CO Check if the reservoir tank engine coolant level is within “MIN” to “MAX” when engine is cool. adjust the engine coolant level as necessary. C D E SMA412B M/T with A/C Models ● ● F Check if the reservoir tank coolant level is within MIN to MAX when engine is cool. Adjust coolant if too much or too little. : Vehicle front G H I MBIB1360E J K L M MBIA0092E LEAK CHECK All Models Except M/T with A/C ● To check for leakage, apply pressure to the cooling system with a radiator cap tester (commercial service tool) and radiator cap tester adapter (SST). Testing pressure: 157 kPa (1.57 bar, 1.6 kg/cm2 , 23 psi) WARNING: Never remove the radiator cap when the engine is hot. Serious burns could occur from high pressure coolant escaping from the radiator. CAUTION: Higher pressure than specified may cause radiator damage. CO-27 SLC134B ENGINE COOLANT [HR] ● NOTE: In a case that engine coolant decreases, replenish radiator with engine coolant. If anything is found, repair or replace damaged parts. M/T with A/C Models ● To check for leakage, fit the adapter to the reservoir tank (1), and then connect it to the tester as shown. MBIB1362E ● ● Warm up the engine and turn it off. Apply pressure to the cooling system and stop pumping. Testing pressure ● ● : 90 kpa (0.9 bar, 0.92 kg/cm2 , 13.1 psi) If the pressure drops, look for leakage. Unscrew slowly the adapter from the reservoir tank to reduce the pressure in cooling system, and install the reservoir tank cap. WARNING: Never remove the radiator cap when the engine is hot. Serious burns could occur from high pressure engine coolant escaping from the radiator. CAUTION: Higher pressure than specified may cause radiator damage. Changing Engine coolant MBIA0094E BBS002SI WARNING: ● To avoid being scalded, never change the coolant when the engine is hot. ● Wrap a thick cloth around radiator cap and carefully remove the cap. First, turn the cap a quarter of a turn to release built-up pressure. Then turn the cap all the way. DRAINING ENGINE COOLANT All Models Except M/T with A/C 1. 2. a. b. 3. Disconnect radiator lower hose and radiator cap. CAUTION: Make sure to drain when the engine coolant temperature is cold. Remove reservoir tank and drain the engine coolant in the following procedures. Move relay case in front of the battery. Disconnect the reservoir tank from fan shroud to remove. With force applied in the left direction of vehicle, pull up reservoir tank. Check drain coolant for contaminants such as rust, corrosion or discoloration. If contaminated, flush engine cooling system. Refer to CO-30, "FLUSHING COOLING SYSTEM" . PBIC1476E CO-28 ENGINE COOLANT [HR] M/T with A/C Models 1. 2. A Disconnect radiator lower hose and reservoir tank cap. CAUTION: Make sure to drain when the engine coolant temperature is cold. Remove reservoir tank and drain the engine coolant. CO : Vehicle front 3. Check drain coolant for contaminants such as rust, corrosion or discoloration. If contaminated, flush engine cooling system. Refer to CO-30, "FLUSHING COOLING SYSTEM" . C D E MBIB1360E REFILLING ENGINE COOLANT 1. 2. 3. Install reservoir tank. Connect radiator lower hose. Disconnect heater hose (1) (at heater hose outlet side: upper side) as shown in figure. Keep hose end at the same height as that of before removal. F G : Vehicle front H : Disconnect I J MBIB1361E 4. Fill radiator and reservoir tank to specified level. ● Pour coolant slowly of less than 2 (1-3/4 lmp qt) a minute to allow air in system to escape. ● When coolant from heater hose starts to drain, connect heater hose and continue to fill. ● Use Nissan Genuine Coolant L250 or equivalent mixed with water (distilled or demineralized). Refer to MA-24, "RECOMMENDED FLUIDS AND LUBRICANTS". K L M SMA182B Engine coolant capacity All models except M/T with A/C With reservoir tank : Approx. 5.6 Reservoir tank : 0.7 (4-7/8 Imp qt) (5/8 lmp qt) SMA412B CO-29 ENGINE COOLANT [HR] M/T with A/C models With reservoir tank : Approx. 6.0 (5-1/4 Imp qt) Reservoir tank : 1.2 (1-1/8 lmp qt) : Vehicle front MBIB1360E MBIA0092E 5. 6. 7. 8. 9. 10. 11. 12. 13. ● 14. ● Warm up engine to normal operating temperature with radiator cap installed. Warm up until thermostat opens. Keep warming at 3,000 rpm for approximately 10 minutes as guide. ● For thermostat opening, touch radiator upper hose by hand to insure that water flow is hot. CAUTION: Be careful not to overheat. Stop the engine. After cooling engine [approximately 50°C (122 °F) or lower], remove radiator cap and check coolant level. If the level is low, fill up to the radiator neck again and repeat from step 5. When the coolant level stabilizes, fill reservoir tank up to the “MAX” line. Check cooling system for leaks with engine running. Allow the engine to cool [approximately 50°C (122°F) or lower]. Start the engine. Perform the following cycle three times. Keep an engine speed of 1,000 rpm for approximately 30 seconds. Then increase it gradually to 3,000 rpm. During the above step 12, make sure water flow sound is not heard from heater core. Sound may be noticeable at heater unit. If water flow sound is heard, repeat from step 4 to 13. Clean excess coolant from engine. FLUSHING COOLING SYSTEM 1. 2. 3. 4. 5. 6. Fill radiator and reservoir tank with water and reinstall radiator cap. Run engine and warm it up to normal operating temperature. Rev engine two or three times under no-load. Stop engine and wait until it cools down. Drain water. Repeat steps 1 through 5 until clear water begins to drain from radiator. CO-30 RADIATOR [HR] RADIATOR Removal and Installation PFP:21400 A BBS002SJ All models except M/T with A/C CO C D E F G H I J K MBIB1366E Vehicle front 1. Cooling fan assembly 2. Hose clamp 3. Radiator hose (upper) 4. Radiator 5. Radiator cap 6. Mounting rubber (upper) 7. Mounting rubber (lower) 8. Radiator hose (lower) 9. Bracket 10. Reservoir tank cap 11. Reservoir tank B. C. 12. Reservoir tank hose A. To water outlet L M To water suction pipe Refer to GI-11, "Components" for symbol marks in the figure. CO-31 To a of radiator RADIATOR [HR] M/T with A/C models MBIB1367E Vehicle front 1. Radiator 2. Mounting rubber (upper) 3. Radiator hose (upper) 4. 6. Hose clamp 7. Hose clamp 5. Reserve tank cap Reservoir tank hose 8. 9. Cooling fan assembly Reservoir tank 10. Hose clamp 11 Radiator hose (lower) 12. Hose clamp 13 Reservoir tank hose 14. Mounting rubber (lower) A. B. To water suction pipe To water outlet Refer to GI-9, "Contents" for symbol marks in the figure. REMOVAL 1. 2. 3. 4. 5. 6. Disconnect both battery cables. Drain coolant. Refer to CO-27, "ENGINE COOLANT" . CAUTION: Make sure to drain when the engine coolant temperature is cold. WARNING: Never remove the radiator cap when the engine is hot. Serious burns could occur from high pressure coolant escaping from the radiator. Remove mounting bolts to make relay case movable. Remove the following parts. ● Reservoir tank (M/T with A/C models) ● Front grille; Refer to EI-10, "FRONT GRILLE" . ● Remove radiator core support (upper). Refer to BL-13, "Radiator Core Upper Support" . ● Remove harness connectors ● Air Duct; Refer to EM-118, "AIR CLEANER AND AIR DUCT" . Remove radiator hose (upper) and (lower). Disconnect AT cooler hose. CO-32 RADIATOR [HR] 7. Remove reservoir tank (M/T with A/C models). ● Disconnect the reservoir tank from fan shroud to remove. With force applied in the left direction of vehicle, pull up reservoir tank. A CO C PBIC1476E D 8. Remove cooling fan assembly from radiator. INSTALLATION Install in the reverse order of removal which being careful of the following. ● When installing radiator core support (lower), make sure upper and lower mount units of radiator and A/C condenser are fitted in mounting holes of radiator core support (upper/lower). E F Disassembly and Assembly of Cooling Fan BBS002SK All models except M/T with A/C G H I J K L MBIB1368E 1. Fan shroud 2. Fan motor 3. CO-33 Fan M RADIATOR [HR] M/T with A/C models MBIB1369E 1. Resistor 4. Fan 2. Fan shroud 3. Fan motor DISASSEMBLY 1. 2. Remove fan. CAUTION: Reverse screw are used for the fan attachment screw. When removing or attaching, turn the screw the opposite way as for a normal screw. Remove fan motor from fan shroud. PBIC1486E ASSEMBLY Assemble cooling fan in the reverse order of disassembly. ● Apply thread locking sealant and tighten screw to assemble the fan. Checking Radiator Cap (All Models Except M/T with A/C) 1. BBS002SL Pull the negative-pressure valve to open it and check that it closes completely when released. ● Check that there is no dirt or damage on the valve seat of the radiator cap negative-pressure valve. ● Check that there are no unusual conditions in the opening and closing conditions of the negative-pressure valve. SMA967B CO-34 RADIATOR [HR] 2. Check radiator cap relief pressure. A Standard: 78 - 98 kPa (0.78 - 0.98 bar, 0.8 - 1.0 kg/cm2 , 11 - 14 psi) Limit: CO 59 kPa (0.59 bar, 0.6 kg/cm2 , 9 psi) When connecting the radiator cap to the tester, apply water or engine coolant to the cap seal part. SLC135B ● Replace the radiator cap if there is an unusual conditions in the negative-pressure valve, or if the open-valve pressure is outside of the standard values. CAUTION: When installing radiator cap, thoroughly wipe out the radiator filler neck to remove any waxy residue or foreign material. ● Checking Reservoir Tank Cap (M/T with A/C Models) ● ● ● BBS002SM Fit the adapter to the tester as shown. When connecting the reservoir tank cap to the tester, apply water or LLC to the cap seal part. Check reservoir tank cap relief pressure. D E F G 140 kPa (1.4 bar, 1.43 kg/cm2 , 20.3 psi) ● C H Replace the reservoir tank cap if the engine coolant passes through it, or if any fur signs is detected. I MBIB1079E Checking Radiator BBS002SN Check radiator for mud or clogging. If necessary, clean radiator as follows. ● Be careful not to bend or damage the radiator fins. ● When radiator is cleaned without removal, remove all surrounding parts such as cooling fan, fan shroud and horns. Then tape the harness and connectors to prevent water from entering. 1. Apply water by hose to the back side of the radiator core vertically downwards. 2. Apply water again to all radiator core surface once per minute. 3. Stop washing if any stains no longer flow out from the radiator. 4. Blow air into the back side of radiator core vertically downwards. ● 5. Use compressed air lower than 490 kPa (4.9 bar, 5 kg/cm2 , 71 psi) and keep distance more than 30 cm (11.8 in). Blow air again into all the radiator core surface once per minute until no water sprays out. Checking Cooling System Hoses BBS002SO Check hoses for improper attachment, leaks, cracks, damage, loose connections, chaffing and deterioration. CO-35 J K L M WATER PUMP [HR] WATER PUMP Removal and Installation PFP:21020 BBS002SQ PBIC3807E 1. Gasket 2. Water pump 3. Water pump pulley Refer to GI-11, "Components" for symbol marks in the figure. REMOVAL 1. 2. 3. 4. 5. 6. 7. Drain engine coolant from radiator. Refer to CO-28, "DRAINING ENGINE COOLANT" . WARNING: Never remove the radiator cap when the engine is hot. Serious burns could occur from high pressure coolant escaping from the radiator. CAUTION: Perform this step when engine is cold. Steer front wheel to the right. Remove front fender protector (RH). Refer to EI-14, "FENDER PROTECTOR" . Loosen mounting bolts of water pump pulley before loosening belt tension of drive belt. Remove drive belt. Refer to EM-114, "DRIVE BELTS" . Remove water pump pulley. Remove water pump. ● Loosen mounting bolts in reverse order as shown in the figure. ● Engine coolant will leak from cylinder block, so have a receptacle ready below. CAUTION: ● Handle water pump vane so that it does not contact any other parts. ● Water pump cannot be disassembled and should be replaced as a unit. KBIA3393J CO-36 WATER PUMP [HR] INSPECTION AFTER REMOVAL ● ● ● A Visually check if there is no significant dirt or rusting on water pump body and vane (A). Make sure that there is no looseness in vane shaft, and that it turns smoothly when rotated by hand. Replace water pump, if necessary. CO C PBIC3808E D INSTALLATION Note the following, and install in the reverse order of removal. E Water Pump ● Tighten mounting bolts in numerical order as shown in the figure. F G H KBIA3393J I Water Pump Pulley CAUTION: Do not install mounting bolts (A) to oblong holes (B). 1 J : Water pump pulley K L PBIC3809E INSPECTION AFTER INSTALLATION ● ● Check for engine coolant leaks using radiator cap tester adapter (SST: EG17650301) and radiator cap tester (commercial service tool) (without A/C models) or reservoir tank cap tester and reservoir tank cap tester adapter (with A/C models). Refer to CO-27, "LEAK CHECK" . Start and warm up engine. Visually check if there is no leaks of engine coolant. CO-37 M THERMOSTAT [HR] THERMOSTAT Removal and Installation PFP:21200 BBS002SR PBIC3810E 1. Radiator hose (lower) 4. Thermostat A. To radiator 2. Water inlet 3. Rubber ring Refer to GI-11, "Components" for symbol marks in the figure. REMOVAL 1. 2. 3. 4. Drain engine coolant from radiator. Refer to CO-28, "DRAINING ENGINE COOLANT" . WARNING: Never remove the radiator cap when the engine is hot. Serious burns could occur from high pressure coolant escaping from the radiator. CAUTION: ● Perform this step when engine is cold. ● Do not spill engine coolant on drive belt. Remove reservoir tank. Refer to CO-31, "RADIATOR" . Disconnect radiator hose (lower). Refer to CO-31, "RADIATOR" . Remove water inlet and thermostat. ● Engine coolant will leak from cylinder block, so have a receptacle ready below. INSPECTION AFTER REMOVAL ● ● ● ● Place a thread (A) so that it is caught in the valves of thermostat (1). Immerse fully in a container (B) filled with water. Heat while stirring. The valve opening temperature is the temperature at which the valve opens and falls from the thread. Continue heating. Check the full open valve lift amount. After checking the maximum valve lift amount, lower the water temperature and check the valve closing temperature. PBIC3314J CO-38 THERMOSTAT [HR] Standard: Items Valve opening temperature 80.5 - 83.5°C (177 - 182°F) Maximum valve lift 8 mm/ 95°C (0.315 in/ 203°F) Valve closing temperature ● A Thermostat CO 77°C (171°F) If out of the standard, replace thermostat. C INSTALLATION Note the following, and install in the reverse order of removal. Thermostat ● D Install thermostat with making rubber ring (1) groove fit to thermostat flange (A) with the whole circumference. E F G PBIC3811E ● Install thermostat (2) with jiggle valve (A) facing upwards. 1 H : Cylinder block I J PBIC3812E K Water Inlet After installation, fix water inlet clip (A) on the oil level gauge guide (1) as shown in the figure. B L : Positioning M PBIC3755E INSPECTION AFTER INSTALLATION ● ● Check for leaks of engine coolant using radiator cap tester adapter (SST: EG17650301) and a radiator cap tester (commercial service tool) (without A/C models) or reservoir tank cap tester and reservoir cap tester adapter (with A/C models). Refer to CO-27, "LEAK CHECK" . Start and warm up engine. Visually check if there is no leaks of engine coolant. CO-39 WATER OUTLET [HR] WATER OUTLET Removal and Installation PFP:11060 BBS002SS REMOVAL PBIC3816E 1. Engine coolant temperature sensor 2. Washer 3. Gasket 4. Radiator hose (upper) 5. Water outlet 6. Heater hose 7. Heater hose 8. Water hose 9. Water hose A. To electric throttle control actuator B. To heater C. To radiator Refer to GI-9, "Contents" for symbol marks in the figure. 1. Drain engine coolant from radiator. Refer to CO-28, "DRAINING ENGINE COOLANT" . WARNING: Never remove the radiator cap when the engine is hot. Serious burns could occur from high pressure coolant escaping from the radiator. CAUTION: Perform step when engine is cold. 2. Remove air duct (inlet) and air duct. Refer to EM-118, "AIR CLEANER AND AIR DUCT" . 3. Disconnect radiator hose (upper). Refer to CO-31, "RADIATOR" . 4. Disconnect harness connector from engine coolant temperature sensor. 5. Remove water hose and heater hose. 6. Remove water outlet. 7. Remove engine coolant temperature sensor from water outlet, as necessary. INSTALLATION Installation is the reverse order of removal. CO-40 WATER OUTLET [HR] INSPECTION AFTER INSTALLATION ● ● Check for leaks of engine coolant using radiator cap tester adapter (SST: EG17650301) and a radiator A cap tester (commercial service tool) (without A/C models) or reservoir tank cap tester and reservoir tank cap tester adapter (with A/C models). Refer to CO-27, "LEAK CHECK" . CO Start and warm up engine. Visually check if there is no leaks of engine coolant. C D E F G H I J K L M CO-41 SERVICE DATA AND SPECIFICATIONS (SDS) [HR] SERVICE DATA AND SPECIFICATIONS (SDS) Standard and Limit PFP:00030 BBS002ST CAPACITY Unit: Coolant capacity [With reservoir tank (MAX level)] All models except M/T with A/C Approximately 5.6 (4-7/8) M/T with A/C models Approximately 6.0 (5-1/4) All models except M/T with A/C Reservoir tank M/T with A/C models (Imp qt) 0.7 (5/8) 1.2 (1-1/8) THERMOSTAT Valve opening temperature 80.5 - 83.5°C (177 - 182°F) Maximum valve lift 8 mm/ 95°C (0.315 in/ 203°F) Valve closing temperature More than 77°C (171°F) RADIATOR Unit: kPa (bar, kg/cm2 , psi) Standard Radiator cap relief pressure 78 - 98 (0.78 - 0.98, 0.8 - 1.0, 11 - 14) Limit 59 (0.59, 0.6, 9) Reservoir tank cap relief pressure Leakage test pressure 140 (1.4, 1.43, 20.3) Without A/C models 157 (1.57, 1.6, 23) With A/C models 10 (0.1, 0.10, 1.5) CO-42 PRECAUTIONS [K9K] PRECAUTIONS Precautions For Liquid Gasket [K9K] PFP:00001 A BBS002SV REMOVAL OF LIQUID GASKET ● ● After removing the mounting bolts and nuts, separate the mating surface using a seal cutter and remove the liquid gasket. CAUTION: Be careful not to damage the mating surfaces. In areas where the cutter is difficult to use, use a plastic hammer to lightly tap the gasket applied area. CAUTION: If for some unavoidable reason a tool such as a flat-bladed screwdriver is used, be careful not to damage the mating surfaces. CO C D PBIC0275E E LIQUID GASKET APPLICATION PROCEDURE 1. 2. 3. Using a scraper, remove the old liquid gasket adhering to the gasket application surface and the mating surface. ● Remove the liquid gasket completely from the groove of the gasket application surface, mounting bolts and bolt holes. Wipe the gasket application surface and the mating surface with white gasoline (lighting and heating use) to remove adhering moisture, grease and foreign materials. Attach the liquid gasket to the tube presser. Use Genuine Liquid Gasket or equivalent. F G H PBIC0003E I 4. Apply the gasket without breaks to the specified location with the specified dimensions. ● If there is a groove for the liquid gasket application, apply the gasket to the groove. J K L EMA0622D As for the bolt holes, normally apply the gasket inside the holes. If specified, it should be applied outside the holes. Make sure to read the instruction in this manual. ● Within five minutes of gasket application, install the mating component. ● If the liquid gasket protrudes, wipe it off immediately. ● Do not retighten after the installation. ● After 30 minutes or more have passed from the installation, fill the engine oil and coolant. CAUTION: If there are instructions in this manual, observe them. ● CO-43 M SEM159F PREPARATION [K9K] PREPARATION Special Service Tools PFP:00002 BBS002SW NISSAN tool number (RENAULT too number) Tool name Description WS39930000 ( — ) Tube pressure Pressing the tube of liquid gasket S-NT052 — (M.S. 554_07) Tester Leak checking Checking reservoir tank cap MLIA0012E — (M.S. 554_01) Reservoir tank cap tester adapter A Adapting tester to reservoir tank MLIA0013E — (M.S. 554_06) Reservoir tank cap tester adapter B Adapting tester to reservoir tank cap MLIA0014E CO-44 OVERHEATING CAUSE ANALYSIS [K9K] OVERHEATING CAUSE ANALYSIS Troubleshooting Chart PFP:00012 A BBS002SX Symptom Check items Water pump malfunction Thermostat stuck closed Poor heat transfer CO Worn timing belt — Dust contamination or paper clogging Damaged fins — C Mechanical damage Clogged radiator cooling tube Excess foreign material (rust, dirt, sand, etc.) D Cooling fan does not operate Reduced air flow High resistance to fan rotation E Fan assembly — Damaged fan blades Cooling system parts malfunction F Damaged radiator shroud — — — Improper coolant mixture ratio — — — Poor coolant quality — — — G Loose clamp Cooling hose Water pump Cracked hose Poor sealing Loose Reservoir tank cap Coolant leaks Radiator I Poor sealing O-ring for damage, deterioration or improper fitting Insufficient coolant H J Cracked radiator tank Cracked radiator core Reservoir tank Cracked reservoir tank K Cylinder head deterioration Overflowing reservoir tank Exhaust gas leaks into cooling system Cylinder head gasket deterioration L M CO-45 OVERHEATING CAUSE ANALYSIS [K9K] Symptom Check items High engine rpm under no load Abusive driving Driving in low gear for extended time Driving at extremely high speed — Overload on engine Powertrain system malfunction Installed improper size wheels and tires Except cooling system parts malfunction — Dragging brakes Improper ignition timing Blocked bumper — Installed car brassiere Blocked radiator grille Blocked or restricted air flow Blocked radiator Mud contamination or paper clogging — Blocked condenser Installed large fog lamp CO-46 — — COOLING SYSTEM [K9K] COOLING SYSTEM Cooling Circuit PFP:21020 A BBS002SY CO C D E F G H I J MBIB9046E K 1. Engine 2. Radiator 3. Heater core 4. Reservoir tank 5. Water pump 6. Thermostat 7. Air relief plug 8. Oil cooler 9. EGR cooler L M CO-47 ENGINE COOLANT [K9K] ENGINE COOLANT Inspection PFP:KQ100 BBS002SZ LEVEL CHECK ● ● Check if the reservoir tank coolant level is within MIN to MAX when engine is cool. Adjust coolant if too much or too little. MBIA0092E MBIA0093E LEAK CHECK To check for leakage, fit the adapter to the reservoir tank, and then connect it to the tester as shown. ● Warm up the engine and turn it off. ● Apply pressure to the cooling system and stop pumping at 10 kPa (0.1 bar, 0.10 kg/cm2 , 1.5psi) . ● If the pressure drops, look for leakage. ● Unscrew slowly the adapter from the reservoir tank to reduce the pressure in cooling system, and install the reservoir tank cap. WARNING: Never remove the radiator cap when the engine is hot. Serious burns could occur from high pressure engine coolant escaping from the radiator. CAUTION: Higher pressure than specified may cause radiator damage. ● CO-48 MBIA0094E ENGINE COOLANT [K9K] Changing Engine Coolant BBS002T0 A WARNING: ● To avoid being scalded, never change the coolant when the engine is hot. ● Wrap a thick cloth around cap and carefully remove the cap. First, turn the cap a quarter of a turn CO to release built-up pressure. Then turn the cap all the way. DRAINING ENGINE COOLANT 1. 2. 3. 4. 5. Remove engine undercover. Disconnect lower radiator hose, and remove reservoir tank cap and air relief plug. Remove reservoir tank, drain coolant, then clean reservoir tank. Check drained coolant for contaminants such as rust, corrosion or discoloration. If contaminated, flush engine cooling system. Refer to CO-50, "FLUSHING COOLING SYSTEM" . Remove air relief plug from water outlet. Refer to CO-57, "WATER OUTLET" . C D E F MBIB1056E REFILLING ENGINE COOLANT ● 1. 2. Before start working, turn off the automatic air conditioner and the blower motor. Install reservoir tank, lower radiator hose and air relief plug. Fill reservoir tank slowly with coolant until coolant spills from the air relief hole. Refer to CO-57, "WATER OUTLET" . ● Put a cloth under the air relief plug to prevent engine coolant to dampen the crankshaft position sensor. ● Fill coolant to the MAX level line of the reservoir tank at a rate of 2 litre (1-3/4 lmp qt)/min or lower. G H I J K L SMA412B 3. Close the air relief plug. CAUTION: If the filling rate is too fast, this could lead to air being mixed in the coolant. Be sure to fill the coolant slowly according to the rate indicated above. Use Nissan Genuine Coolant L250 or equivalent mixed with water (distilled or demineralised). Refer to MA-24, "RECOMMENDED FLUIDS AND LUBRICANTS" . Engine coolant capacity (With reservoir tank) Approx. 6.0 Reservoir tank capacity 1.0 4. (5 - 1/4 lmp qt) (7/8 lmp qt) Warm up the engine for approximately five minutes without reservoir tank cap installed, and then turn off the engine and loose air relief plug until coolant spills from air relief hole. ● If coolant overflows reservoir tank hole, install filler cap. ● Watch engine coolant temperature warning light so as not overheat the engine during all of the operation. WARNING: ● Be careful not be scaled with hot engine coolant or vacuum pump when operating. CO-49 M ENGINE COOLANT [K9K] 5. 6. 7. 8. 9. ● Radiator fan blade can start at any time and make personal injuries. Close the air relief plug and run the engine at 2,000 rpm until the upper hose comes hot and radiator fan operates. Let the engine running approximately 5 minutes at idle speed and check for sound of coolant flow while running engine from idle up to 3,000 rpm. ● Sound may be noticeable at heater water cock. If sound is heard, bleed air from cooling system by repeating steps 4 through 5 until coolant lever no longer drops. ● Check the radiator lower hose for any signs of leakage. Turn off the engine and let it cool down. ● Cool down using a fan to reduce the time. After cooling period, loose the air relief plug and check if coolant spills from the air relief hole. In other case, remove the air relief plug until the coolant spills, and then close the relief air plug. Bleed air from cooling system by repeating steps 5 through 8 until the coolant spills immediately. Check the engine coolant level when engine is cool and refill to MAX level line if the level is lower. ● Clean excess coolant from engine. FLUSHING COOLING SYSTEM 1. 2. 3. 4. 5. 6. 7. Fill reservoir tank with water until water spills from the air relief hole, then close air relief plug. Reinstall reservoir tank cap. Run engine and warm it up to normal operating temperature. Rev engine two or three times under no-load. Stop engine and wait until it cools down. Drain water. Repeat steps 1 through 5 until clear water begins to drain from radiator. Blow compressed air into cooling circuit through the reservoir tank valve hole to drain all the water. CO-50 RADIATOR [K9K] RADIATOR Removal and Installation PFP:21400 A BBS002T1 CO C D E F G H I J MBIB9048E 1. Radiator (models with A/C) 2. Mounting rubber 4. Hose clamp 5. Hose clamp 6. Reservoir tank hose 7. Reservoir tank 8. Cooling fan assembly 9. Radiator (models without A/C) 10. Radiator hose (lower) 11. Hose clamp 13. Mounting rubber 14. Hose clip 3. REMOVAL 7. 8. Remove engine room cover. Refer to EM-241, "ENGINE ROOM COVER" . Remove air cleaner case and air duct (inlet). Refer to EM-245, "AIR CLEANER AND AIR DUCT" . Remove reservoir tank hose bracket bolt from radiator upper mounting bracket (RH side). Remove radiator fan motor harnesses. Remove engine undercover. Drain engine coolant. Refer to CO-49, "DRAINING ENGINE COOLANT" . CAUTION: Perform when engine is cold. Disconnect radiator upper hose, reservoir tank hose and mounting bracket. Release charge air cooler from the radiator. Refer to EM-247, "Removal and Installation (For 50kW)" , EM-249, "Removal and Installation (For 65kW)" . CO-51 L 12. Reservoir tank hose WARNING: Never remove the reservoir tank cap when the engine is hot. Serious burns could occur from high pressure coolant escaping from the radiator. Wrap a thick cloth around the cap. Slowly turn it a quarter turn to allow built-up pressure to escape. Carefully remove the cap by turning it all the way. 1. 2. 3. 4. 5. 6. K Radiator hose (upper) M RADIATOR [K9K] 9. Remove radiator and radiator fan assembly. For model with A/C, remove radiator and condenser assembly. Refer to ATC-135, "REFRIGERANT LINES" , MTC-81, "REFRIGERANT LINES" . CAUTION: ● Do not damage or scratch radiator core when removing. ● INSTALLATION ● ● Reinstall any parts removed in reverse order of removal. Check for engine coolant leaks. Refer to CO-48, "LEAK CHECK" . Disassembly and Assembly Radiator Fan BBS002T2 MBIB9047E 1. Radiator fan motors 2. Radiator fan shroud : Moulded clip : Insertion : To radiator core upper : To radiator core lower CO-52 3. Radiator fan RADIATOR [K9K] DISASSEMBLY 1. 2. 3. A Remove radiator fan and shroud assembly. Remove radiator fan reverse screw. Remove fan motor from fan shroud. CO C D PBIC1486E E ASSEMBLY Install in the reverse order of removal. Checking Reservoir Tank Cap ● ● ● BBS002T3 Fit the adapter to the tester as shown. When connecting the reservoir tank cap to the tester, apply water or LLC to the cap seal part. Check reservoir tank cap relief pressure. G 130 - 150 kPa (1.3 - 1.5 bar, 1.33 - 1.53 kg/cm2 , 18.9 21.8 psi) ● F H Replace the reservoir tank cap if the engine coolant passes through it, or if any fur signs is detected. I MBIB1079E Checking Radiator BBS002T4 Check radiator for mud or clogging. If necessary, clean radiator as follows. ● Be careful not to bend or damage the radiator fins. ● When radiator is cleaned without removal, remove all surrounding parts such as radiator fan, radiator shroud and horns. Then tape the harness and connectors to prevent water from entering. 1. Apply water by hose to the back side of the radiator core vertically downwards. 2. Apply water again to all radiator core surface once per minute. 3. Stop washing if any stains no longer flow out from the radiator. 4. Blow air into the back side of radiator core vertically downwards. ● 5. Use compressed air lower than 490 kPa (4.9 bar 5 kg/cm2 , 71psi) and keep distance more than 30 cm (11.8 in). Blow air again into all the radiator core surface once per minute until no water sprays out. CO-53 J K L M WATER PUMP [K9K] WATER PUMP Removal and Installation PFP:21020 BBS002T5 MBIB1232E 1. Water pump 2. Gasket 3. Cylinder block WARNING: Never remove the radiator cap when the engine is hot. Serious burns could occur from high pressure coolant escaping from the radiator. REMOVAL 1. 2. 3. 4. 5. 6. Remove the following parts. ● Battery ground cable ● Undercover ● RH front wheel Remove right side splash cover. Remove drive belt. Refer to EM-242, "DRIVE BELTS" . Drain engine coolant. Refer to CO-49, "DRAINING ENGINE COOLANT" . CAUTION: Perform when engine is cold. Remove timing belt and inner cover. Refer to EM-272, "TIMING BELT" . Remove the water pump. ● Coolant will leak from the cylinder block, so have a receptacle ready below. CAUTION: ● Handle the water pump vane so that it does not contact any other parts. ● Water pump cannot be disassembled and should be replaced as a unit. INSPECTION AFTER REMOVAL ● ● ● Visually make sure there is no significant dirt or rusting on the water pump body and vane. Make sure there is no looseness in the vane shaft, and that it turns smoothly when rotated by hand. If there are any unusualness, replace the water pump assembly. MBIB0546E CO-54 WATER PUMP [K9K] INSTALLATION ● A Install in the reverse order of removal. INSPECTION AFTER INSTALLATION ● Check for engine coolant leaks using reservoir tank cap tester. Refer to CO-48, "LEAK CHECK" . CO C D E F G H I J K L M CO-55 THERMOSTAT [K9K] THERMOSTAT Inspection ● ● ● ● ● PFP:21200 BBS002T6 Place a thread so that it is caught in the valves of the thermostat. Immerse fully in a container filled with water. Heat while stirring. (The example in the figure shows the thermostat.) The valve opening temperature is the temperature at which the valve opens and falls from the thread. Continue heating. Check the full-open lift amount. After checking the full-open lift amount, lower the water temperature and check the valve closing temperature. If the measured value is out of the standard value or unusual valve seating condition is found, replace water inlet and thermostat assembly. SLC949A Temperature °C (°F) Start of opening 89 (192) End of opening 97 - 101 (207 - 214) CO-56 WATER OUTLET [K9K] WATER OUTLET Removal and Installation PFP:11060 A BBS002T7 CO C D E F G H I MBIA0090E 1. Clip 2. Gasket 3. Radiator upper hose 4. Water outlet 5. O-ring 6. Water temperature sensor 7. Heater hose 8. Air relief plug J K REMOVAL 1. 2. 3. 4. 5. 6. Remove engine room cover. Refer to EM-241, "ENGINE ROOM COVER" . Remove air cleaner case and air duct (inlet). Refer to EM-245, "AIR CLEANER AND AIR DUCT" . Remove rear engine slinger. Refer to EM-280, "REMOVAL" . Remove vacuum hose. Remove vacuum pump. Refer to EM-261, "VACUUM PUMP" . Drain engine coolant. Refer to CO-49, "DRAINING ENGINE COOLANT" . CAUTION: Perform when engine is cold. 7. Remove radiator upper hose. Refer to CO-51, "RADIATOR" . 8. Remove heater hose. 9. Disconnect reservoir tank hose. Refer to CO-51, "RADIATOR" . 10. Remove water outlet. INSTALLATION Install in the reverse order of removal. CO-57 L M WATER OUTLET [K9K] CO-58 DRIVER INFORMATION SYSTEM K ELECTRICAL SECTION DI DRIVER INFORMATION SYSTEM A B C D CONTENTS PRECAUTIONS .......................................................... 3 Precautions for Supplemental Restraint System (SRS) “AIR BAG” and “SEAT BELT PRE-TENSIONER” .................................................................. 3 Maintenance Information .......................................... 3 RHD MODELS ...................................................... 3 LHD MODELS ....................................................... 3 COMBINATION METERS ........................................... 4 Component Parts and Harness Connector Location..... 4 System Description .................................................. 4 UNIFIED METER CONTROL UNIT ...................... 4 POWER SUPPLY AND GROUND CIRCUIT ........ 4 SPEEDOMETER ................................................... 4 TACHOMETER ..................................................... 4 LOW WATER TEMPERATURE INDICATOR LAMP, HIGH WATER TEMPERATURE WARNING LAMP ............................................................. 4 FUEL GAUGE ....................................................... 5 ODO/TRIP METER ............................................... 5 CAN Communication ................................................ 5 SYSTEM DESCRIPTION ...................................... 5 CAN Communication Unit ........................................ 5 Arrangement of Combination Meter ......................... 6 Schematic ................................................................ 7 Wiring Diagram — METER — .................................. 8 Terminals and Reference Value for Combination Meter ........................................................................ 9 Combination Meter Self-Diagnosis ......................... 10 PERFORMING SELF-DIAGNOSIS MODE ......... 10 Trouble Diagnoses ................................................. 13 PRELIMINARY CHECK ...................................... 13 SYMPTOM CHART ............................................. 15 Check Power Supply and Ground Circuit ............... 15 Check Vehicle Speed Signal .................................. 16 Check Engine Revolution Signal ............................ 17 Check Fuel Level Sensor Signal ............................ 17 Check Water Temperature Warning/indicator Lamp... 19 Check Fuel Gauge Fluctuation ............................... 19 Fuel Gauge Does Not Move to FULL position ....... 19 Check Electrical Components ................................ 19 CHECK FUEL LEVEL SENSOR UNIT ................ 19 Removal and Installation for Combination Meter ... 20 REMOVAL ........................................................... 20 INSTALLATION ................................................... 20 Disassembly and Assembly for Combination Meter... 20 DISASSEMBLY ................................................... 20 ASSEMBLY ......................................................... 20 DRIVE COMPUTER .................................................. 21 Component Parts and Harness Connector Location... 21 System Description ................................................. 21 DRIVE COMPUTER ............................................ 21 SERVICE REMINDER ......................................... 22 OIL LEVEL WARNING ........................................ 22 OUTSIDE AIR TEMPERATURE .......................... 22 CAN Communication .............................................. 23 SYSTEM DESCRIPTION .................................... 23 CAN Communication Unit ....................................... 23 Wiring Diagram — D/COMP — .............................. 24 Terminals and Reference Value for Combination Meter ...................................................................... 26 Check Ambient Sensor Signal ................................ 26 Check Steering Wheel Switch ................................ 29 Check Oil Level sensor ........................................... 30 WARNING LAMPS .................................................... 32 System Description ................................................. 32 OIL PRESSURE WARNING LAMP ..................... 32 Component Parts and Harness Connector Location... 32 Schematic ............................................................... 33 WiringDiagram —WARN — /WithGasolineEngine Models .................................................................... 34 Wiring Diagram — WARN — / With Diesel Engine Models .................................................................... 40 Oil Pressure Warning Lamp Stays Off (Ignition Switch ON) ............................................................. 45 Oil Pressure Warning Lamp Does Not Turn Off (Oil Pressure Is Normal) ................................................ 46 Electrical Components Inspection .......................... 47 OIL PRESSURE SWITCH CHECK ..................... 47 A/T INDICATOR ........................................................ 48 System Description ................................................. 48 DI-1 E F G H I J DI L M FEATURE DESCRIPTION ................................... 48 Wiring Diagram — AT/IND — ................................. 49 A/T Indicator Does Not Illuminate ........................... 51 WARNING CHIME ..................................................... 52 ComponentParts and Harness Connector Location... 52 System Description ................................................. 53 POWER SUPPLY AND GROUND CIRCUIT ....... 53 IGNITION KEY WARNING CHIME ...................... 53 INTELLIGENTKEYSYSTEMWARNINGCHIME... 53 LIGHT WARNING CHIME ................................... 53 SEAT BELT WARNING CHIME ........................... 54 PARKING BRAKE WARNING CHIME ................. 54 CAN Communication .............................................. 54 SYSTEM DESCRIPTION .................................... 54 DI-2 CAN Communication Unit .......................................54 Schematic ...............................................................55 Wiring Diagram — CHIME — .................................56 Terminals and Reference Value for BCM ................60 Terminals and Reference Value for Combination Meter .......................................................................62 Trouble Diagnosis ...................................................63 HOW TO PERFORM TROUBLE DIAGNOSIS ...63 PRELIMINARY INSPECTION ..............................63 SYMPTOM CHART ..............................................63 Check Front Door Switch (Driver Side) Signal ........63 Check Seat Belt Buckle Switch Signal ....................64 Check Parking Break Switch Signal ........................66 PRECAUTIONS PRECAUTIONS PFP:00011 Precautions for Supplemental Restraint System (SRS) “AIR BAG” and “SEAT BELT PRE-TENSIONER” A BKS000Z9 The Supplemental Restraint System such as “AIR BAG” and “SEAT BELT PRE-TENSIONER”, used along with a front seat belt, helps to reduce the risk or severity of injury to the driver and front passenger for certain types of collision. Information necessary to service the system safely is included in the SRS and SB section of this Service Manual. WARNING: ● To avoid rendering the SRS inoperative, which could increase the risk of personal injury or death in the event of a collision which would result in air bag inflation, all maintenance must be performed by an authorized NISSAN/INFINITI dealer. ● Improper maintenance, including incorrect removal and installation of the SRS, can lead to personal injury caused by unintentional activation of the system. For removal of Spiral Cable and Air Bag Module, see the SRS section. ● Do not use electrical test equipment on any circuit related to the SRS unless instructed to in this Service Manual. SRS wiring harnesses can be identified by yellow and/or orange harnesses or harness connectors. Maintenance Information B C D E F BKS000ZA If any of following part is replaced, always replace with new* one. If it's not (or fail to do so), the electrical system may not be operated properly. *: New one means a virgin control unit that has never been energized on-board. G RHD MODELS H ● ● ● ● ● ● BCM (Models without Intelligent Key system) Intelligent Key unit (Models with Intelligent Key system) ECM IPDM E/R Combination meter EPS control unit I J LHD MODELS ● ● ● BCM (Models without Intelligent Key system) Intelligent Key unit (Models with Intelligent Key system) ECM DI L M DI-3 COMBINATION METERS COMBINATION METERS Component Parts and Harness Connector Location PFP:24814 BKS000ZD MKIB2319E 1. Combination meter M27 2. ABS actuator and electronic unit E32: With ESP E33: Without ESP System Description 3. Fuel level sensor unit and fuel pump B33 BKS0026A UNIFIED METER CONTROL UNIT ● ● ● ● Speedometer, odo/trip meter, tachometer and fuel gauge are controlled by the unified meter control unit, which is built into the combination meter. Warning lamp and indicator lamp are controlled by signals drawn from the CAN communication system, BCM (body control module), and components connected directly to the combination meter. Odo/trip meter and A/T indicator segments can be checked in self-diagnosis mode. Meters/gauges can be checked in self-diagnosis mode. POWER SUPPLY AND GROUND CIRCUIT Power is supplied at all times ● through 10A fuse [No. 7, located in the fuse block (J/B)] ● to combination meter terminal 27. With the ignition switch in the ON or START position, power is supplied ● through 10A fuse [No. 4, located in the fuse block (J/B)] ● to combination meter terminal 28. Ground is supplied ● to combination meter terminals 21, 22 and 23 ● through grounds M21 and M66. SPEEDOMETER The speedometer indicates the vehicle speed. ● ABS actuator and electric unit (control unit) converses a pulse signal from wheel sensor to vehicle speed signal, and transmit vehicle speed signal to combination meter with CAN communication. ● Combination meter converses the vehicle speed signal to angle, and commands to speedometer. TACHOMETER The tachometer indicates engine speed in revolutions per minute (rpm). ● ECM converses a signal from crank position sensor to engine speed signal, and transmits to combination meter with CAN communication. ● Combination meter converses the engine speed signal to angle, and commands to tachometer. LOW WATER TEMPERATURE INDICATOR LAMP, HIGH WATER TEMPERATURE WARNING LAMP The water temperature warning/indicator lamp indicate the engine coolant temperature. ECM provides a engine coolant temperature signal to combination meter for water temperature warning/indicator lamp via CAN communication line. When turn ignition switch ON, water temperature warning/indicator lamp will be ON with red color for 1 second then blue color for1 second. DI-4 COMBINATION METERS After engine started, ● Water temperature warning/indicator lamp will be ON with blue color while engine coolant temperature is less than 55 °C. ● Water temperature warning/indicator lamp will be OFF with blue color, while engine coolant temperature is more than 55 °C. ● Water temperature warning/indicator lamp will be OFF, while engine coolant temperature is between 55 °C and 114 °C. ● Water temperature warning/indicator lamp will be ON with red color, while engine coolant temperature is more than 114 °C. ● Water temperature warning/indicator lamp will be OFF with red color, while engine coolant temperature is less than 108 °C. A B C D FUEL GAUGE The fuel gauge indicates the approximate fuel level in the fuel tank. The fuel gauge is regulated by the combination meter and a variable resistor signal supplied ● to combination meter terminal 6 ● through fuel level sensor unit and fuel pump terminal 2 ● through fuel level sensor unit and fuel pump terminal 4 ● from combination meter terminal 24. E F ODO/TRIP METER G The vehicle speed signal and the memory signals from the meter memory circuit are processed by the combination meter and the mileage is displayed. H How to Change the Display Refer to DI-21, "System Description" . I CAN Communication BKS000ZF SYSTEM DESCRIPTION CAN (Controller Area Network) is a serial communication line for real time application. It is an on-vehicle mul- J tiplex communication line with high data communication speed and excellent error detection ability. Many electronic control units are equipped onto a vehicle, and each control unit shares information and links with other control units during operation (not independent). In CAN communication, control units are connected with 2 communication lines (CAN H line, CAN L line) allowing a high rate of information transmission with less wiring. DI Each control unit transmits/receives data but selectively reads required data only. CAN Communication Unit BKS0026E L Refer to LAN-27, "CAN Communication Unit" M DI-5 COMBINATION METERS Arrangement of Combination Meter BKS0026B MKIB2320E DI-6 COMBINATION METERS Schematic BKS000ZI A B C D E F G H I J DI L M MKWA4297E DI-7 COMBINATION METERS Wiring Diagram — METER — BKS000ZJ MKWA4298E DI-8 COMBINATION METERS Terminals and Reference Value for Combination Meter BKS000ZK A Condition Terminal Wire color 1 L CAN- H 2 Y CAN- L 6 BR Item Fuel level sensor signal Signal Input/ Output Reference value (V) (Approx.) Ignition switch Operation or condition Input/ Output — — — Input/ Output — — — — Refer to (CR engine) FL-4, "FUEL LEVEL SENSOR UNIT, FUEL FILTER AND FUEL PUMP ASSEMBLY" . (HR engine)FL-15, "FUEL LEVEL SENSOR UNIT, FUEL FILTER AND FUEL PUMP ASSEMBLY" . (K9K engine)FL-29, "FUEL LEVEL SENSOR UNIT" . Input B C — 21 B Ground — — — 0 22 B Ground — — — 0 23 B Ground — — — 0 24 G Fuel level sensor ground — ON — 0 27 LG Power source (BAT) Input OFF — Battery voltage 28 W Power source (IGN) Input ON — Battery voltage D E F G H I J DI L M DI-9 COMBINATION METERS Combination Meter Self-Diagnosis BKS000ZL PERFORMING SELF-DIAGNOSIS MODE 1. 2. Turn the ignition switch ON. Turn ignition switch OFF after setting the display to trip A or B with the trip button (1). Turn ON the ignition switch while pressing the trip button. Release the trip button after 1second or more from the ignition switch is turned ON. The sequence (A) is activated. 3. 4. MKIB2321E Check items A Display Remarks Segment test All LCD segments are ON. MKIB2322E 5. After all segments are ON, press the trip button or clock switch within 20seconds the sequence (B to J) is activated. NOTE: If either reset switch is not pressed within 20 seconds, the self-diagnosis mode is exited. Check items B Display Remarks Work instruction code This information is not used for service. Skip this step. MKIB2323E C Software code This information is not used for service. Skip this step. MKIB2324E D EEPROM code This information is not used for service. Skip this step. MKIB2325E DI-10 COMBINATION METERS Check items Display Remarks A E Hardware code This information is not used for service. Skip this step. B C MKIB2326E D F PCB code This information is not used for service. Skip this step. E MKIB2327E G Tachometer, speedometer and fuel level gauge have sweeping movement test. (The meter/gauges operate MIN. → MAX., MAX. → MIN.) Water temperature warning/indicator lamp are ON with blue color during the sweep movement. Meter/gauge test (Sweeping movement) F G MKIB2327E H H Error 1 (Bit 0 - Bit 3) I MKIB2328E I The segment of each bit displays “0” or “5” meaning no malfunction. If the bit(s) displays figures other than “0” or “5” the item of the bit has malfunctioned. For details, refer to DI-12, "Malfunction Chart for “Error 1” and “Error E”" . Error E (Bit 4 - Bit 7) DI MKIB2329E J J L All warning lamp and indicator lamp which is control by meter CPU are ON and odo/trip meter segment “FUEL” flashes. Warning lamp test MKIB2330E DI-11 M COMBINATION METERS Malfunction Chart for “Error 1” and “Error E” MKIB2331E Displayed figure on the bit Bit 0 1 2 3 4 5 Detectable items Speedometer input signal Tachometer input signal Fuel level input signal Description of the malfunction No input signal When no signal is detected for 2seconds minutes continuously with the ignition ON, it should be judged as signal malfunction. Malfunction 1 0 Unusual input signal When invalid value is detected for 2seconds continuously with the ignition switch ON, it should be judged as signal malfunction. 2 No input signal When no signal is detected for 2seconds continuously with the ignition ON, it should be judged as signal malfunction. 1 Short circuit When short circuit of the signal line is detected for 120 seconds or more, it should be judged as short-circuit malfunction. 1 2 Water temperature input signal Short circuit When no signal is detected for 2seconds continuously with the ignition ON, it should be judged as signal malfunction. 1 Odo/trip meter switch has malfunctioned. 1 Reset buttons Short circuit for reset buttons When the short circuit is continuously detected for 5 minutes or more, it should be judged as short-circuit malfunction. Clock switch has malfunctioned. 2 Both switch have malfunctioned. 3 When short circuit of the signal line is detected for 4 seconds or more, it should be judged as short-circuit malfunction. ● When no signal is detected for 2seconds continuously with the ignition ON, it should be judged as signal malfunction. ● When open circuit of the signal line is detected for 4 seconds or more, it should be judged as open-circuit malfunction. ● When unusual signal is detected for 2seconds continuously with the ignition ON, it should be judged as signal malfunction. OAT input signal 0 0 Open circuit When open circuit of the signal line is detected for 120 seconds or more, it should be judged as open-circuit malfunction. ● No malfunction 0 0 1 5 2 6 — — 0 0 7 — — 0 0 DI-12 COMBINATION METERS Trouble Diagnoses BKS000ZM A PRELIMINARY CHECK 1. CHECK POWER SUPPLY 1. Turn ignition switch ON. 2. Warning lamps should illuminate (seat belt warning or door warning etc.). Do warning lamps illuminate? YES >> GO TO 2. NO >> Check power supply and ground circuit check. Refer to DI-15, "Check Power Supply and Ground Circuit" . 2. CHECK OPERATION OF SELF-DIAGNOSIS MODE Perform self-diagnosis mode. Refer to DI-10, "PERFORMING SELF-DIAGNOSIS MODE" . Can self-diagnosis mode be activated? YES >> GO TO 3. NO >> Replace combination meter. Refer to DI-20, "Removal and Installation for Combination Meter" . B C D E F 3. CHECK OPERATION OF METER/GAUGE Check meter/gauge operation in self-diagnosis mode (meter/gauge test). Refer to DI-10, "PERFORMING SELF-DIAGNOSIS MODE" . Is any malfunction indicated in self-diagnosis mode? YES >> GO TO “Symptom Chart 1”. Refer to DI-15, "Symptom Chart 1" . NO >> GO TO 4. 4. CHECK WATER TEMPERATURE WARNING/INDICATOR G H I Check water temperature warning/indicator lamp. 1. Turn ignition switch OFF. J 2. When turn ignition switch ON, water temperature warning/indicator lamp will be ON with red color for 1 second then blue color for 1 second. ● Check water temperature indicator lamp (blue color) DI Check meter/gauge operation in self-diagnosis mode (meter/gauge test). Refer to DI-10, "Combination Meter Self-Diagnosis" . Does water temperature warning/lenticular lamp is ON? L Yes >> GO TO 5. No >> Replace combination meter. ● 5. CHECK SEGMENTS M Check all odo/trip meter segments in self-diagnosis mode (odo/trip meter segment test). Refer to DI-10, "PERFORMING SELF-DIAGNOSIS MODE" . Do all segments indicate? YES >> GO TO 6. NO >> Replace combination meter. 6. CHECK INPUT SIGNALS Check input signals from each sensors in self-diagnosis mode (Error 1 and Error E). Refer to DI-12, "Malfunction Chart for “Error 1” and “Error E”" . OK or NG OK >> GO TO 7. NG >> GO TO “Symptom Chart 2”. Refer to DI-15, "Symptom Chart 2" . DI-13 COMBINATION METERS 7. CHECK WARNING INDICATOR LAMP Check warning lamp in self-diagnosis mode. Refer to DI-10, "PERFORMING SELF-DIAGNOSIS MODE" . All warning/indicator lamp should turn ON. OK or NG OK >> GO TO 8. NG >> Replace combination meter. 8. CHECK OTHER MALFUNCTION Check each malfunction according to the instruction of the “SYMPTOM CHART 3”. Refer to DI-15, "Symptom Chart 3" . OK or NG OK >> Combination meter is OK. NG >> Check the case of malfunction. DI-14 COMBINATION METERS SYMPTOM CHART Symptom Chart 1 A Symptom Possible causes Repair order Reference page B Odo/trip meter indicates malfunction in Diagnosis mode. Multiple meter/gauge indicate malfunction in Diagnosis mode. Unified meter control unit Replace combination meter DI-20 C One of speedometer/tachometer/fuel gauge/Water temperature lamp. indicates malfunction in Diagnosis mode. Symptom Chart 2 D Symptom Possible causes Repair order Reference page Speedometer input signal indicates malfunction in Diagnosis mode. Speedometer input signal Check signal for speedometer DI-16 Tachometer input signal indicates malfunction in Diagnosis mode. Tachometer input signal Check signal for tachometer DI-17 Fuel level input signal indicates malfunction in Diagnosis mode. Fuel level input signal Check fuel level signal DI-17 Water temperature input signal Indicates malfunction in Diagnosis mode. Water temp. warning/indicator lamps input signal Check water temperature signal DI-19 Reset buttons indicates malfunction in Diagnosis mode. Unified meter control unit Combination meter DI-20 CPU indicates malfunction in Diagnosis mode. Unified meter control unit Combination meter DI-20 E F G H Symptom Chart 3 I Symptom Possible causes Fuel gauge pointer fluctuates, Indicator wrong value or varies. — Check the case of malfunction DI-19 Fuel gauge does not move to “F” position. — Check the case of malfunction DI-19 Repair order Check Power Supply and Ground Circuit Reference page BKS0026C 1. CHECK FUSE Check for blown combination meter fuses. J DI L Power source Fuse No. Battery 7 Ignition switch ON or START 4 OK or NG OK >> GO TO 2. NG >> Be sure to eliminate cause of malfunction before installing new fuse. Refer toPG-4, "POWER SUPPLY ROUTING CIRCUIT" . DI-15 M COMBINATION METERS 2. CHECK POWER SUPPLY CIRCUIT Check voltage between combination meter harness connector terminals and ground. Terminals Ignition switch position (+) Combination meter connector Terminal 27 M27 (–) Ground OFF ON Battery voltage Battery voltage 0V Battery voltage 28 OK or NG OK >> GO TO 3. NG >> Repair harness or connector. PKIC0700E 3. CHECK GROUND CIRCUIT 1. 2. 3. Turn ignition switch OFF. Disconnect combination meter connector. Check continuity between combination meter harness connector terminals and ground. Combination meter connector Terminal Continuity 21 M27 22 Ground Yes 23 OK or NG OK >> Replace combination meter. NG >> Repair harness or connector. PKIC0701E Check Vehicle Speed Signal BKS000ZO 1. CHECK ABS ACTUATOR AND ELECTRIC UNIT SYSTEM Perform ABS actuator and electric unit (control unit) self-diagnosis. Refer to BRC-19, "CONSULT-II Functions (ABS)" (With ABS models), BRC-62, "CONSULT-II Functions (ABS)" (With ESP/TCS/ABS models). OK or NG OK >> Replace combination meter. NG >> Perform “Diagnostic procedure” for displayed self-diagnosis result. DI-16 COMBINATION METERS Check Engine Revolution Signal BKS000ZP 1. CHECK ECM SYSTEM A Perform ECM self-diagnosis. Refer to EC-48, "Emission-related Diagnostic Information" (CR engine models with EURO-OBD), EC-476, "Emission-related Diagnostic Information" (CR engine models without EUROOBD), EC-831, "Emission-related Diagnostic Information" (HR engine models with EURO-OBD), EC-1264, "Emission-related Diagnostic Information" (HR engine models without EURO-OBD) or Rfer to EC-1628, "ON BOARD DIAGNOSTIC (OBD) SYSTEM" (K9K engine models). OK or NG OK >> Replace combination meter. NG >> Perform “Diagnostic procedure” for displayed DTC. Check Fuel Level Sensor Signal B C D BKS0026D Symptom: ● Fuel gauge indication is malfunction. ● Low-fuel warning lamp indication is irregular. NOTE: The following symptoms are not malfunction. Fuel level sensor unit ● Depending on vehicle position or driving circumstance, the fuel level in the tank varies, and the pointer may fluctuate. ● If the vehicle is fueled with the ignition switch ON, the pointer will move slowly. Low-fuel warning lamp ● Depending on vehicle position or driving circumstance, the fuel in the tank flows and the warning lamp ON timing may change. 1. CHECK HARNESS CONNECTOR E F G H I 1. 2. Turn ignition switch OFF. Check combination meter and fuel level sensor unit terminals (meter-side and harness-side) for poor con- J nection. OK or NG DI OK >> GO TO 2. NG >> Repair or replace terminals or connectors. L M DI-17 COMBINATION METERS 2. CHECK FUEL LEVEL SENSOR UNIT CIRCUIT 1. 2. Disconnect combination meter connector and fuel level sensor unit connector. Check continuity between combination meter harness connector and fuel level sensor unit and fuel pump harness connector. A Combination meter connector M27 3. B Terminal Fuel level sensor unit and fuel pump connector Terminal 6 B33 2 Continuity Yes Check continuity between combination meter harness connector and ground. PKIC0702E A Combination meter connector Terminal M27 6 Continuity Ground No OK or NG OK >> GO TO 3. NG >> Repair harness or connector. 3. CHECK FUEL LEVEL SENSOR GROUND CIRCUIT 1. Check continuity between combination meter harness connector and fuel level sensor unit and fuel pump harness connector. A Combination meter connector M27 2. B Terminal Fuel level sensor and fuel pump connector Terminal 24 B33 4 Continuity Yes Check continuity between combination meter harness connector (A) and ground. A PKIC0725E Combination meter connector Terminal M27 24 Ground Continuity No OK or NG OK >> GO TO 4. NG >> Repair harness or connector. 4. CHECK FUEL LEVEL SENSOR UNIT Check fuel level sensor unit. Refer to DI-19, "Check Electrical Components" OK or NG OK >> Check fuel level sensor unit installation, and check whether the float arm interferes or binds with any of the internal components in the fuel tank. Repair or replace malfunctioning part, if necessary. NG >> Replace fuel level sensor unit. DI-18 COMBINATION METERS Check Water Temperature Warning/indicator Lamp BKS000ZR 1. CHECK ECM SYSTEM A Perform ECM self-diagnosis. Refer to EC-48, "Emission-related Diagnostic Information" (CR engine models with EURO-OBD), EC-476, "Emission-related Diagnostic Information" (CR engine models without EUROOBD), EC-831, "Emission-related Diagnostic Information" (HR engine models with EURO-OBD), EC-1264, "Emission-related Diagnostic Information" (HR engine models without EURO-OBD) or Rfer to EC-1628, "ON BOARD DIAGNOSTIC (OBD) SYSTEM" (K9K engine models). OK or NG OK >> Replace combination meter. NG >> Perform “Diagnostic procedure” for displayed DTC. Check Fuel Gauge Fluctuation B C D BKS000ZS 1. CHECK FUEL GAUGE FLUCTUATION E Test drive vehicle to see if gauge fluctuates only during driving or at the instant of stopping. Does the indication value vary only during driving or at the instant of stopping? YES >> The pointer fluctuation may be caused by fuel level change in the fuel tank. Condition is normal. NO >> Ask the customer about the situation when the symptom occurs in detail, and perform the trouble diagnosis. F Fuel Gauge Does Not Move to FULL position G BKS000ZT 1. QUESTION 1 H Does it take a long time for the pointer to move to FULL position? YES or NO YES >> GO TO 2. NO >> GO TO 3. I 2. QUESTION 2 J Was the vehicle fueled with the ignition switch ON? YES or NO YES >> Be sure to fuel the vehicle with the ignition switch OFF. Otherwise it will take a long time to move DI to FULL position because of the characteristic of the fuel gauge. NO >> GO TO 3. 3. QUESTION 3 L Is the floor or the vehicle inclined? YES or NO YES >> It may not be filled fully. NO >> GO TO 4. M 4. QUESTION 4 During driving, does the fuel gauge pointer move gradually toward EMPTY position? YES or NO YES >> Check the components. Refer to DI-19, "Check Electrical Components" . NO >> The float arm may interfere or bind with any of the components in the fuel tank. Check Electrical Components BKS000ZV CHECK FUEL LEVEL SENSOR UNIT For removal, refer to [refer to FL-4, "FUEL LEVEL SENSOR UNIT, FUEL FILTER AND FUEL PUMP ASSEMBLY" (CR engine models), FL-15, "FUEL LEVEL SENSOR UNIT, FUEL FILTER AND FUEL PUMP ASSEMBLY" (HR engine models) or FL-29, "FUEL LEVEL SENSOR UNIT" (K9K engine models)]. DI-19 COMBINATION METERS Check the resistance between terminals 2 and 4. Ohmmeter 4 2 Float position Resistance value Full Approx. 46 Empty Approx. 320 [Ω] MKIB0432E Removal and Installation for Combination Meter BKS000ZW CAUTION: Always replace with new* combination meter when the combination meter replacement is required. *: New one means virgin control unit that has never been energized on-board. REMOVAL 1. 2. Remove the cluster lid A. Refer to IP-4, "INSTRUMENT PANEL ASSEMBLY" . Remove the screw (A), and metal clip (B), and remove combination meter (1). PKIB7219J INSTALLATION ● Install in the reverse order of removal. Disassembly and Assembly for Combination Meter BKS000ZX 1. Front cover 2. Upper housing 3. Unified meter control unit assembly PKIB7220J DISASSEMBLY 1. 2. Disengage the tabs (7) to separate upper housing. Disengage the tabs (6) to separate front cover. ASSEMBLY Assembly is the reverse order of disassembly. DI-20 DRIVE COMPUTER DRIVE COMPUTER Component Parts and Harness Connector Location PFP:24859 A BKS000ZY B C D E F G H I MKIB2332E 1. Combination meter M27 2. Steering wheel switch M502 4. Oil level sensor F44: HR engine model F126: K9K engine models 5. Ambient sensor E17 3. Fuel level sensor unit and fuel pump B33 J DI System Description BKS000ZZ Refer to Owner′s Manual for drive computer operating instructions. L DRIVE COMPUTER Drive computer can indicate the following item. ● Odo ● Trip A/B ● Range ● Average fuel consumption ● Average speed ● Journey time ● Outside temp M DI-21 DRIVE COMPUTER Indication can be changed by in the following order by pushing trip button (1). Odo → Trip A → Trip B → Range → Average fuel consumption → Average speed → Journey time → Outside temp → Odo ······ NOTE: ● Holding the switch for more than 1 second in each mode (except odo range and outside temp), the function is reset. ● Holding the switch for more than 3 seconds (the display flash one time) in each mode (except odo, trip A, range and outside temp), all mode are reset at the same time (except odo, trip A, range and outside temp). MKIB2321E Range ● ● The elapsed time indication provides driver with an estimation of the distance that can be driven before refuelling. The range is conducted by fuel tank level sensor unit (fuel remaining), ECM pulse signal (fuel consumption) and vehicle speed signal. The range is conducted by combination meter and sent to CAN communication line. Combination meter calculate the range by fuel level sensor unit (fuel remaining), ECM pulse signal (fuel consumption signal) and vehicle speed signal. Average Fuel Consumption ● ● ● The average fuel economy is conducted by combination meter sent to CAN communication line. Combination meter calculate the average fuel economy by fuel consumption signal and vehicle speed signal. There are two display types, instantaneous and average. At about 0.5 km and for 30 seconds after resetting, the display shows “– – –”. Average Speed ● ● Average vehicle speed indication is conducted by trip distance and trip time. At about 0.5 km and for 30 seconds after resetting, the display shows “– – –”. Journey Time ● ● Trip time is calculated by drive computer as elapsed time since last reset. It only increases with ignition switch ON. SERVICE REMINDER Show the distance to the next maintenance. For the first 5 seconds after ignition switch ON, the odometer displays distance to service and the maintenance symbol. ● The interval can be changed. NOTE: Refer to owner's manual for setting. ● ● OIL LEVEL WARNING The oil amount is shown on the display 5 to 10 seconds after the ignition is turn ON. The display changes depending on the oil level. – Oil level LOW: “o– – – –” – Oil level HI: “ooooo” ● The indicator flashes when the oil level drop below the limit level. Combination meter read oil level sensor signal to measure oil level. The signal is supplied ● to combination meter terminal 36 ● through oil level sensor terminal 1 and 2 ● through combination meter terminal 37. ● ● OUTSIDE AIR TEMPERATURE Outside air temperature is displayed ON when ignition switch ON. DI-22 DRIVE COMPUTER When the outside air temperature is lower than -30°C or higher than 60°C the display shows. only “– –” though it is operating. This is not a malfunction. ● When the outside air temperature drops below freezing point (Approx. 3°C), it indicator as following. (Low temperature warning) – Outside air temperature is 3°C - −30°C: “3°C” is flushed. – Outside air temperature is −30°C - −40°C: “– –°C” is flushed. – Outside air temperature is less than −40°C or more than 60°C: “– –” is flushed. – Outside air temperature is more than 4°C low temperature warning is canceled. Combination meter should read ambient sensor. The ambient sensor is regulated by a variable resistor signal supplied ● to combination meter terminal 25 ● from ambient sensor terminal 2 ● through ambient sensor terminal 1 and ● through combination meter terminal 26. ● CAN Communication A B C D E BKS00100 SYSTEM DESCRIPTION F CAN (Controller Area Network) is a serial communication line for real time application. It is an on-vehicle multiplex communication line with high data communication speed and excellent error detection ability. Many electronic control units are equipped onto a vehicle, and each control unit shares information and links with other control units during operation (not independent). In CAN communication, control units are connected with 2 communication lines (CAN H line, CAN L line) allowing a high rate of information transmission with less wiring. Each control unit transmits/receives data but selectively reads required data only. G CAN Communication Unit H BKS00101 Refer to LAN-27, "CAN Communication Unit" . I J DI L M DI-23 DRIVE COMPUTER Wiring Diagram — D/COMP — BKS00102 MKWA4299E DI-24 DRIVE COMPUTER A B C D E F G H I J DI L M MKWA4300E DI-25 DRIVE COMPUTER Terminals and Reference Value for Combination Meter BKS00103 Condition Terminal No. Wire color 1 L CAN- H 2 Y CAN- L 6 BR 21 B 22 B 23 Signal Input/Output Item Ignition switch Operation or condition Voltage (V) (Approx.) Input/Output — — — Input/Output — — — Fuel level sensor signal Refer to (CR engine)FL-4, "FUEL LEVEL SENSOR UNIT, FUEL FILTER AND FUEL PUMP ASSEMBLY" (HR engine)FL-15, "FUEL LEVEL SENSOR UNIT, FUEL FILTER AND FUEL PUMP ASSEMBLY" (K9K engine) FL-29, "FUEL LEVEL SENSOR UNIT" . Input — — Ground — — — 0 Ground — — — 0 B Ground — — — 0 24 G Fuel level sensor ground — ON — 0 — 2.6 25 V Ambient sensor signal Input ON 26 BR Ambient sensor ground — ON — 0 27 LG Power source (BAT) Input OFF — Battery voltage 28 W Power source (IGN) Input ON — Battery voltage Steering switch release 10 29 G Steering switch signal Input ON Steering switch pushed 0 36 Y Oil level sensor signal Input ON — — 37 G Oil level sensor ground — ON — 0 Disconnect ambient sensor connector Check Ambient Sensor Signal 5 BKS0026M 1. CHECK OUTPUT VOLTAGE OF COMBINATION METER 1. 2. 3. 4. Turn ignition switch OFF. Disconnect ambient sensor harness connector. Turn ignition switch ON. Check voltage between ambient sensor harness connector and ground. Terminals (+) Ambient sensor connector Terminal E17 2 (–) Voltage (V) (Approx.) Ground 5 OK or NG OK >> GO TO 2. NG >> GO TO 4. MKIB2333E DI-26 DRIVE COMPUTER 2. CHECK AMBIENT SENSOR 1. 2. A Turn ignition switch OFF. Check ambient sensor. B Ambient sensor connector Terminals E17 1 Temperature (°C) Resistance (kΩ) −15 12.73 −10 9.92 0 6.19 10 3.99 20 2.65 30 1.81 40 1.27 2 C D MKIB2335E OK or NG OK >> GO TO 3. NG >> Replace ambient sensor. F 3. CHECK AMBIENT SENSOR CIRCUIT (–) 1. 2. H B Combination meter connector Terminal Ambient sensor connector Terminal M27 26 E17 1 3. G Disconnect combination meter connector. Check continuity between combination meter harness connector and ambient sensor harness connector. A E Continuity I Yes J Check continuity between combination meter harness connector and ground. A Combination meter connector Terminal M27 26 Ground Continuity No OK or NG OK >> Replace combination meter. NG >> Repair harness or connector. MKIB2334E DI L M DI-27 DRIVE COMPUTER 4. CHECK AMBIENT SENSOR CIRCUIT (+) 1. 2. 3. Turn ignition switch OFF. Disconnect combination meter connector. Check continuity between combination meter harness connector and ambient sensor harness connector. A B Combination meter connector Terminal ambient sensor connector Terminal M27 25 E17 2 4. Continuity Yes Check continuity between combination meter harness connector and ground. A Combination meter connector Terminal M27 25 Continuity Ground No OK or NG OK >> Replace combination meter. NG >> Repair harness or connector. DI-28 MKIB2336E DRIVE COMPUTER Check Steering Wheel Switch BKS00106 1. CHECK COMBINATION METER INPUT SIGNAL 1. 2. A Turn ignition switch ON. Check voltage between combination meter harness connector and ground. Connector meter connector Terminal (+) Condition (-) B Voltage (V) (Approx.) C Battery voltage D Steering wheel switch is pushed. M27 29 Ground Steering wheel switch is released. OK or NG OK >> Replace combination meter. NG >> GO TO 2. E MKIB2337E 2. CHECK STEERING WHEEL SWITCH F 1. 2. 3. G Turn ignition switch OFF. Disconnect steering wheel switch. Check steering wheel switch (drive computer). Steering wheel switch connector H Terminal M502 16 20 Condition Continuity Steering wheel switch is pushed. No Steering wheel switch is released. Yes OK or NG OK >> GO TO 3. NG >> Replace steering wheel switch. I J MKIB2338E DI 3. CHECK STEERING WHEEL SWITCH CIRCUIT 1. 2. Disconnect combination meter connector. Check continuity between combination meter harness connector and combination switch (spiral cable) harness connector. A 3. B Combination meter connector Terminal Combination switch connector Terminal M27 29 M42 24 Continuity Yes Check continuity between combination meter harness connector and ground. A Combination meter connector Terminal M27 29 Continuity Ground No OK or NG OK >> GO TO 4. NG >> Replace harness or connector. DI-29 MKIB2339E L M DRIVE COMPUTER 4. CHECK STEERING WHEEL SWITCH GROUND CIRCUIT 1. 2. Disconnect audio unit connector. Check continuity between combination switch harness connector and audio unit harness connector. A 3. B Combination meter connector Terminal Audio unit connector Terminal M42 32 M45 12 Continuity Yes Check continuity between combination switch harness connector and ground. A Combination switch connector Terminal M42 32 Continuity MKIB2340E Ground No OK or NG OK >> Check audio unit ground circuit. Refer to PG-4, "POWER SUPPLY ROUTING CIRCUIT" . NG >> Repair harness or connector. Check Oil Level sensor BKS0026N NOTE: For engine oil level inspection, refer to LU-6, "ENGINE OIL" (CR engine models), LU-16, "ENGINE OIL" (HR engine models), LU-23, "ENGINE OIL" (K9K engine models). 1. CHECK OIL LEVEL SENSOR 1. 2. 3. Turn ignition switch OFF. Disconnect oil level sensor connector. Check oil level sensor. Oil level sensor M44: HG engine models F126: K9K engine models Terminal 1 Resistance value (Ω) 2 3 – 20 OK or NG OK >> GO TO 2. NG >> Replace oil level sensor. MKIB2343E DI-30 DRIVE COMPUTER 2. CHECK OIL LEVEL SENSOR POWER SUPPLY CIRCUIT 1. 2. A Disconnect combination meter connector. Check continuity between combination meter harness connector and oil level sensor harness connector. B A Combination meter M27 3. B Terminal Audio unit connector Terminal 36 M44: HG engine models F126: K9K engine models 1 Continuity C Yes Check continuity between combination meter harness connector and ground. D A Combination meter Terminal M27 36 Continuity Ground MKIB2341E No E F OK or NG OK >> GO TO 3. NG >> Repair harness or connector. G 3. CHECK OIL LEVEL SENSOR GROUND CIRCUIT 1. Check continuity between combination meter harness connector and oil level sensor harness connector. A 2. H B Continuity Combination meter Terminal Audio unit connector Terminal M27 37 M44: HG engine models F126: K9K engine models 2 I Yes J Check continuity between combination meter harness connector and ground. A DI MKIB2342E Continuity Combination meter Terminal M27 37 Ground L No OK or NG OK >> Replace combination meter. NG >> Repair harness or connector. M DI-31 WARNING LAMPS WARNING LAMPS System Description PFP:24814 BKS0026Z OIL PRESSURE WARNING LAMP Oil Pressure Warning Oil pressure warning lamp turns ON when engine oil pressure reducing abnormally. ● IPDM E/R reads oil pressure switch signal from oil pressure switch, and transmits the signal to combination meter with CAN communication. ● Combination meter turns oil pressure warning lamp ON with received oil pressure switch signal. SKIB4797E Component Parts and Harness Connector Location BKS00270 MKIB2344E 1. Combination meter M27 2. IPDM E/R E5, E12 DI-32 3. Oil pressure switch F23: CR engine models F45: HR engine models F137 K9K engine models WARNING LAMPS Schematic BKS00271 A B C D E F G H I J DI L M MKWA4301E DI-33 WARNING LAMPS Wiring Diagram — WARN — / With Gasoline Engine Models BKS00272 MKWA4302E DI-34 WARNING LAMPS A B C D E F G H I J DI L M MKWA4303E DI-35 WARNING LAMPS MKWA4304E DI-36 WARNING LAMPS A B C D E F G H I J DI L M MKWA4305E DI-37 WARNING LAMPS MKWA4306E DI-38 WARNING LAMPS A B C D E F G H I J DI L M MKWA4307E DI-39 WARNING LAMPS Wiring Diagram — WARN — / With Diesel Engine Models BKS00273 MKWA4308E DI-40 WARNING LAMPS A B C D E F G H I J DI L M MKWA4309E DI-41 WARNING LAMPS MKWA4310E DI-42 WARNING LAMPS A B C D E F G H I J DI L M MKWA4311E DI-43 WARNING LAMPS MKWA4312E DI-44 WARNING LAMPS Oil Pressure Warning Lamp Stays Off (Ignition Switch ON) BKS00274 1. CHECK IPDM SELF-DIAGNOSIS A 1. Perform IPDM E/R self-diagnosis. Refer to PG-20, "CONSULT-II Function (IPDM E/R)" . self-diagnostic results content NON DTC IS DETECTED >>GO TO 2. DTC IS DETECTED >>Check IPDM E/R. Refer to PG-33, "Inspection With CONSULT-II (Self-Diagnosis)" . C 2. CHECK IPDM E/R INPUT SIGNAL 1. 2. 3. Disconnect oil pressure switch. Turn the ignition switch ON. Check voltage between oil pressure switch harness connector and ground. D E Terminals (+) Oil pressure switch connector F23: CR engine models F45: HR engine models F137: K9K engine models B Voltage (V) (Approx.) (-) Terminal F 1 Ground Battery voltage G OK or NG OK >> Replace combination meter. NG >> GO TO 3. MKIB2345E H 3. CHECK OIL PRESSURE SWITCH I Check oil pressure switch. Refer to DI-47, "Electrical Components Inspection" . OK or NG OK >> GO TO 4. NG >> Replace the oil pressure switch. J 4. CHECK OIL PRESSURE SWITCH CIRCUIT 1. 2. DI Disconnect IPDM E/R connector and oil pressure switch connector. Check continuity between IPDM E/R harness connector and oil pressure switch harness connector. L A IPDM E/R connector E5 B Continuity Terminal Oil pressure switch connector Terminal 66 F23: CR engine models F45: HR engine models F137: K9K engine models 1 M Yes OK or NG OK >> Replace IPDM E/R. NG >> Repair harness or connector. MKIB2346E DI-45 WARNING LAMPS Oil Pressure Warning Lamp Does Not Turn Off (Oil Pressure Is Normal) BKS00275 NOTE: For oil pressure inspection, refer to LU-6, "ENGINE OIL" (CR engine models), LU-16, "ENGINE OIL" (HR engine models) or LU-23, "ENGINE OIL" (K9K engine models). 1. CHECK OIL PRESSURE SWITCH INPUT 1. 2. 3. Disconnect oil pressure switch. Turn the ignition switch ON. Check voltage between oil pressure switch harness connector and ground. Terminals (+) Oil pressure switch connector (-) Voltage (V) (Approx.) Ground Battery voltage Terminal F23: CR engine models F45: HR engine models F137: K9K engine models 1 OK or NG OK >> GO TO 2. NG >> GO TO 3. MKIB2345E 2. CHECK OIL PRESSURE SWITCH Check oil pressure switch. Refer to DI-47, "OIL PRESSURE SWITCH CHECK" . OK or NG OK >> Replace combination meter. NG >> Replace the oil pressure switch. 3. CHECK OIL PRESSURE SWITCH CIRCUIT 1. 2. 3. Turn ignition switch OFF. Disconnect IPDM E/R connector. Check continuity between IPDM E/R harness connector and ground. IPDM E/R connector E5 Terminal 66 Continuity Ground No OK or NG OK >> Replace IPDM E/R. NG >> Repair harness or connector. MKIB2347E DI-46 WARNING LAMPS Electrical Components Inspection BKS00276 A OIL PRESSURE SWITCH CHECK Oil pressure kPa (bar, kg/cm2 , psi) Continuity B Engine running More than 10 - 20 (0.10 0.20, 0.1 - 0.2, 1 - 3) No Engine not running Less than 10 - 20 (0.10 0.20, 0.1 - 0.2, 1 - 3) Yes C Check the continuity between the terminals of oil pressure switch and body ground. D MEL425F E F G H I J DI L M DI-47 A/T INDICATOR A/T INDICATOR System Description PFP:24814 BKS0026J A/T position is displayed in the segment display in the combination meter. FEATURE DESCRIPTION When TCM detects output A/T position indicator signals (R-range, D-range, 2-range, and 1-range) from PNP switch and A/T position indicator signals (P-range and N-range) input from combination meter, TCM sends A/ T position indicator signals to combination meter with the CAN communication. Combination meter indicates received shift position. PKIC0975E DI-48 A/T INDICATOR Wiring Diagram — AT/IND — BKS0026K A B C D E F G H I J DI L M MKWA4380E DI-49 A/T INDICATOR MKWA4381E DI-50 A/T INDICATOR A/T Indicator Does Not Illuminate BKS0026L 1. CHECK SEGMENT OF A/T INDICATOR A Perform self-diagnosis of combination meter. Refer to DI-10, "Combination Meter Self-Diagnosis" . Are all segments displayed? YES >> GO TO 2. NO >> Replace combination meter. B C D SKIB1206J 2. CHECK SELF-DIAGNOSIS RESULTS OF TCM Perform self-diagnosis of TCM. Refer to AT-83, "CONSULT-II Function (A/T)" . OK or NG OK >> Check TCM input/output signal. Repair of replace malfunctioning part, if necessary. Refer to AT80, "TCM Terminals and Reference Value" . NG >> Check applicable part, and repair or replace corresponding parts. E F G H I J DI L M DI-51 WARNING CHIME WARNING CHIME Component Parts and Harness Connector Location PFP:24814 BKS0010E MKIB2348E 1. Combination meter M27 2. BCM M57,M59 3. Intelligent Key unit M60 4. Combination switch M38 5. Key and ignition knob switch M34 (With Intelligent Key system) 6. Key switch M33 (Without Intelligent Key system) 7. Parking break switch M55 8. Front door switch B14: LHD models B29: RHD models DI-52 WARNING CHIME System Description BKS0010F The warning chime is controlled by the BCM. The warning chime is located in the combination meter. POWER SUPPLY AND GROUND CIRCUIT A B Power is supplied at all times ● through 40A fusible link (letter J , located in fuse and fusible link box) ● to BCM terminals 74 and 79 ● through 10A fuse [No. 7, located in fuse block (J/B)] ● to combination meter terminal 27 ● through 10A fuse [No. 9, located in the fuse block (J/B)] ● to key switch terminal 2 (without Intelligent Key system) ● through 10A fuse [No. 13, located in the fuse block (J/B)] ● to key switch and ignition knob terminals 2 and 4 (with Intelligent Key system). With ignition switch in ON or START position, power is supplied ● through 10A fuse [No. 5, located in the fuse block (J/B)] ● to BCM terminal 24. ● through 10 A fuse [No. 4, located in the fuse block (J/B)] ● to combination meter terminals 28 Ground is supplied ● to BCM terminals 2 and 70, and ● to combination meter terminals 21, 22 and 23, ● through body grounds, M19 and M20. IGNITION KEY WARNING CHIME C D E F G H I With the key in the ignition key cylinder, the ignition switch in OFF or ACC position, and the driver's door open, the warning chime will sound. Power is supplied J ● through key switch terminal 2 (without Intelligent Key system) or ● through key switch and ignition knob terminal 2 (with Intelligent Key system) ● to BCM terminal 3. DI Ground is supplied ● from front door switch LH (LHD models) or RH (RHD models) terminal 1 L ● to BCM terminal 29. Ground is supplied through the case of the front door switch LH (LHD models) or RH (RHD models). BCM sends buzzer output signal to combination meter via CAN communication line. M When combination meter receives buzzer output signal, it sounds warning chime. INTELLIGENT KEY SYSTEM WARNING CHIME For information regarding Intelligent Key system, BL-135, "WARNING AND ALARM FUNCTION" . LIGHT WARNING CHIME With ignition switch OFF position, driver's door open, and lighting switch in 1ST or 2ND position, warning chime will sound. [Except when headlamp battery saver control operates (for 5 minutes after ignition switch is turned to OFF or ACC position) and headlamps do not illuminate.] Signal is supplied ● from combination switch (lighting switch) terminals 1, 2, 3, 4, 5, 6, 7, 8, 9 and 10 ● to BCM terminals 7, 8, 9, 13, 14, 15, 27, 28, 33 and 34 NOTE: BCM detection lighting switch in 1st or 2nd position, refer to WW-8, "COMBINATION SWITCH READING FUNCTION" . Ground is supplied ● from front door switch LH (LHD models) or RH (RHD models) terminal 1 ● to BCM terminal 29. DI-53 WARNING CHIME Ground is supplied through the case of the front door switch LH (LHD models) or RH (RHD models). BCM sends buzzer output signal to combination meter via CAN communication line. when combination meter receives buzzer output signal, it sounds warning chime. SEAT BELT WARNING CHIME Seat belt warning chime will sound for approximately 90 seconds, when vehicle speed becomes more than 25 km/h (16 MPH) with driver or passenger seat belt unfastened. When driver side seat belt is unfastened, ground is supplied as signal ● to combination meter terminal 9 ● through seat belt buckle switch (driver side) terminals 1 and 2 ● through grounds B13, B28, B38 and B48. ABS actuator and electric unit (control unit) provides a vehicle speed signal to the combination meter. Combination meter detects that driver or passenger seat belt is unfastened (seat belt buckle switch ON) and vehicle speed more than 25 km/h (16 MPH). And then it sounds seat belt warning chime for 90 seconds. NOTE: Warning chime should be turned off under the following conditions. ● Seat belt is fastened (seat belt buckle switch OFF) ● 90 seconds elapsed since warning chime start PARKING BRAKE WARNING CHIME Parking break warning chime will sound, when vehicle speed becomes more than 7 km/h with parking break applied (parking break: ON) until parking break is released or vehicle speed become less than 3km/h. When parking break is applied, ground is supplied as signal ● to combination meter terminal 10 ● through parking break switch terminals 1 and ground part of parking break switch. CAN Communication BKS0010G SYSTEM DESCRIPTION CAN (Controller Area Network) is a serial communication line for real time application. It is an on-vehicle multiplex communication line with high data communication speed and excellent error detection ability. Many electronic control units are equipped onto a vehicle, and each control unit shares information and links with other control units during operation (not independent). In CAN communication, control units are connected with 2 communication lines (CAN H line, CAN L line) allowing a high rate of information transmission with less wiring. Each control unit transmits/receives data but selectively reads required data only. CAN Communication Unit BKS0010H Refer to LAN-27, "CAN Communication Unit" . DI-54 WARNING CHIME Schematic BKS0010I A B C D E F G H I J DI L M MKWA4313E DI-55 WARNING CHIME Wiring Diagram — CHIME — BKS0010J MKWA4314E DI-56 WARNING CHIME A B C D E F G H I J DI L M MKWA4315E DI-57 WARNING CHIME MKWA4316E DI-58 WARNING CHIME A B C D E F G H I J DI L M MKWA4317E DI-59 WARNING CHIME Terminals and Reference Value for BCM BKS0010K Condition Terminal Wire color 2 B 3 GR (O) Key switch signal 7 BR Combination switch input 5 Output 8 L Combination switch input 3 Output 9 V Combination switch input 1 Output 27 GR Combination switch input 4 Output G Combination switch input 2 Item Ground Signal Input/ Output Ignition switch Measurement method Voltage (V) (Approx.) — ON — 0 Input OFF key is withdrawn. Key is inserted. 0 Battery voltage — SKIA2167J 28 13 SB Combination switch input 1 Output 15 P W Combination switch input 3 Combination switch input 5 19 L CAN H 24 O Power source (IGN) OFF ● Front wiper switch HI (Wiper intermittent dial position 4) ● Rear wiper switch INT (Wiper intermittent dial position 4) ● Wiper intermittent dial position 1 Input ON 14 ● Input ● Wiper intermittent dial position 2 ● Wiper intermittent dial position 3 ● Wiper intermittent dial position 6 ● Wiper intermittent dial position 7 ● OFF ● Lighting switch AUTO ● Rear fog lamp switch ● Front wiper switch MIST ● Front wiper switch INT ● Front wiper switch LO ● OFF ● Lighting switch 1ST ● Lighting switch 2ND ● Lighting switch HIGH beam (Operates only HIGH beam switch) ● Turn signal switch to right Input WW-20, "Reference Values for BCM (Input)" WW-20, "Reference Values for BCM (Input)" WW-20, "Reference Values for BCM (Input)" Input/Output — — — Input ON — Battery voltage DI-60 WARNING CHIME Condition Terminal 29 33 Wire color LG*1 2 BR* R Item Front door switch (driver side) Combination switch input 2 Signal Input/ Output Input Ignition switch OFF 34 Y ON (open) 0 OFF (closed) ● OFF ● Front washer switch (Wiper intermittent dial position 4) ● Rear wiper switch ON (Wiper intermittent dial position 4) ● Rear washer switch ON (Wiper intermittent dial position 4) Input ON Combination switch input 4 Measurement method Input ● Wiper intermittent dial position 1 ● Wiper intermittent dial position 5 ● Wiper intermittent dial position 6 ● OFF ● Front fog lamp switch ON ● Lighting switch 2ND ● Lighting switch PASSING (Operates only PASSING switch) ● Voltage (V) (Approx.) Battery voltage A B C D WW-20, "Reference Values for BCM (Input)" E F G H WW-20, "Reference Values for BCM (Input)" I J Turn signal switch to left 39 Y CAN L Input/Output — — — 70 B Ground — ON — 0 74 Y Power source (BAT) Input OFF — Battery voltage 79 Y Power source (BAT) Input OFF — Battery voltage DI L M (): Without Intelligent Key system *1: LHD models *2: RHD models DI-61 WARNING CHIME Terminals and Reference Value for Combination Meter BKS0010L Condition Measurement method Voltage (V) (Approx.) Input/Output — — — Input/Output — — — Seat belt buckle switch (Driver side) Input ON Unfastened. 0 Fastened. Battery voltage Parking brake switch Input Applied 0 Release Battery voltage Wire color 1 L CAN H 2 Y CAN L 9 10 L*1 O *2 SB Signal Input/ Output Ignition switch Terminal Item ON 21 B Ground — ON — 0 22 B Ground — ON — 0 23 B Ground — ON — 0 27 LG Battery power supply Input OFF — Battery voltage 28 W Ignition switch (ON or START) Input ON — Battery voltage *1 : LHD models *2 : RHD models DI-62 WARNING CHIME Trouble Diagnosis BKS00277 HOW TO PERFORM TROUBLE DIAGNOSIS A 1. 2. 3. 4. B 5. 6. Confirm the symptom and customer complaint. Understand the outline of system. Refer to DI-53, "System Description" . Perform the preliminary inspection. Refer to DI-63, "PRELIMINARY INSPECTION" . Referring to trouble diagnosis chart, repair or replace the cause of the malfunction. Refer to DI-63, "SYMPTOM CHART" . Does warning chime system operate normally? If yes, GO TO 6. If not, GO TO 3. INSPECTION END PRELIMINARY INSPECTION C D 1. CHECK BCM (CONSULT-II) Perform self-diagnosis of BCM. Refer to BCS-9, "CONSULT-II Function (BCM)" . Self-diagnostic results No malfunction detected>>INSPECTION END Malfunction detected>>Check applicable parts, and repair or replace corresponding parts. E F SYMPTOM CHART Symptom Diagnoses/Service procedure Key reminder warning chime does not operate. Check key reminder system trouble diagnosis. Refer to the following: [LHD models] BL-35, "Work Flow". [RHD models] BL-79, "Work Flow". Intelligent Key system warning chime does not operate. (With Intelligent Key) Check Intelligent Key system trouble diagnosis. Refer to BL-153, "Trouble Diagnosis Procedure" . G H I Check the following inspection. Light warning chime does not activate. J ● WW-20, "Reference Values for BCM (Input)". ● DI-63, "Check Front Door Switch (Driver Side) Signal". Replace combination meter, found normal function in the above inspection. DI Check the following inspection. Seat belt warning chime does not activate. ● Confirm speedometer operation ● DI-64, "Check Seat Belt Buckle Switch Signal". Parking brake warning chime does not activate. Check DI-66, "Check Parking Break Switch Signal" . Replace combination meter, found normal function in the above inspection. L Replace combination meter, found normal function in the above inspection. Check Front Door Switch (Driver Side) Signal M BKS00278 1. CHECK BCM INPUT SIGNAL Check voltage between BCM harness connector and ground. Terminal BCM connector (+) (-) M57 29 Ground Condition Voltage (V) (Approx.) Driver side door: CLOSE Battery voltage Driver side door: OPEN 0 OK or NG OK >> Front door switch (driver side) signal is OK. Return to DI-63, "SYMPTOM CHART" . NG >> GO TO 2. MKIB2349E DI-63 WARNING CHIME 2. CHECK FRONT DOOR SWITCH (DRIVER SIDE) CIRCUIT 1. 2. 3. Turn ignition switch OFF. Disconnect BCM connector and front door switch (driver side) connector. Check continuity between BCM harness connector and front door switch (driver side) harness connector. A 4. B BCM connector Terminal Front door switch (driver side) connector Terminal M57 29 B14: LHD B29: RHD 1 Continuity Yes Check continuity between BCM harness connector and ground. A MKIB2350E Continuity BCM connector Terminal M57 29 Ground No OK or NG OK >> GO TO 3. NG >> Repair harness or connector. 3. CHECK FRONT DOOR SWITCH (DRIVER SIDE) Check front door switch (driver side). terminal 1 Door switch case ground Condition Continuity When door switch is released Yes When door switch is pressed No OK or NG OK >> Replace BCM. NG >> Replace front door switch (driver side). MKIB2351E Check Seat Belt Buckle Switch Signal 1. CHECK OPERATION OF SEAT BELT WARNING LAMP 1. 2. Turn ignition switch ON. Check operation of seat belt warning lamp. When driver seat belt is fastened When driver seat belt is unfastened : Seat belt warning lamp OFF : Seat belt warning lamp ON OK or NG OK >> Seat belt buckle switch signal is OK. Return to DI-63, "SYMPTOM CHART" . NG >> GO TO 2. DI-64 BKS00279 WARNING CHIME 2. CHECK COMBINATION METER INPUT SIGNAL A Check voltage between combination meter harness connector and ground. Terminals B (+) Combination meter connector Voltage (V) (Approx.) Condition (–) Terminal M27 9 C Ground Driver seat belt is fastened Battery voltage Driver seat belt is unfastened D 0 OK or NG OK >> Replace combination meter. NG >> GO TO 3. MKIB2352E E 3. CHECK SEAT BELT BUCKLE SWITCH CIRCUIT 1. 2. 3. Turn ignition switch OFF. Disconnect combination meter connector and seat belt buckle switch (driver side) connector. Check continuity between combination meter harness connector and seat belt buckle switch harness connector. A Combination meter connector B Terminal Seat belt buckle switch connector 9 B10 (LHD) B25 (RHD) H Terminal Continuity 1 Yes Check harness continuity between combination meter harness connector and ground. A J MKIB2353E Combination meter connector Terminal M27 9 Ground DI Continuity L No OK or NG OK >> GO TO 4. NG >> Repair harness or connector. M 4. CHECK SEAT BELT BUCKLE SWITCH Check seat belt buckle switch. terminal 1 G I M27 4. F Condition 2 Continuity When seat belt is fastened No When seat belt is unfastened Yes OK or NG OK >> Check seat belt buckle switch (driver side) ground circuit. NG >> Replace seat belt buckle switch (driver side). SKIB4805E DI-65 WARNING CHIME Check Parking Break Switch Signal BKS0027B 1. CHECK OPERATION OF BREAK WARNING LAMP WARNING LAMP 1. 2. Turn ignition switch ON. Check operation of break warning lamp. When parking break is applied When parking break is released : Break warning lamp ON : Break warning lamp OFF OK or NG OK >> Parking break switch signal is OK. Return to DI-63, "SYMPTOM CHART" . NG >> GO TO 2. 2. CHECK COMBINATION METER INPUT SIGNAL Check voltage between combination meter harness connector and ground. Terminals (+) Combination meter connector M27 Voltage (V) (Approx.) Condition (–) Terminal 10 Ground Parking break is applied Battery voltage Parking break is released 0 OK or NG OK >> Replace combination meter. NG >> GO TO 3. MKIB2354E 3. CHECK PARKING BREAK SWITCH CIRCUIT 1. 2. 3. Turn ignition switch OFF. Disconnect combination meter connector and parking break switch connector. Check continuity between combination meter harness connector and parking break switch harness connector. A B Combination meter connector Terminal Parking break switch connector Terminal M27 10 M55 1 4. Continuity Yes Check harness continuity between combination meter harness connector and ground. A Combination meter connector Terminal M27 10 Ground Continuity No OK or NG OK >> GO TO 4. NG >> Repair harness or connector. DI-66 MKIB2355E WARNING CHIME 4. CHECK PARKING BREAK SWITCH (DRIVER SIDE) A Check parking break switch. Terminal 1 Ground part of parking break switch Condition Continuity Parking break is released No Parking break is applied Yes B C OK or NG OK >> Check parking break switch ground condition. NG >> Replace parking break switch. D MKIB2356E E F G H I J DI L M DI-67 WARNING CHIME DI-68 ENGINE CONTROL SYSTEM B ENGINE SECTION EC ENGINE CONTROL SYSTEM A EC C D CONTENTS APPLICATION NOTICE ............................................ 21 How to Check Vehicle Type ................................... 21 CR (WITH EURO-OBD) INDEX FOR DTC ...................................................... 22 DTC No. Index ....................................................... 22 Alphabetical Index .................................................. 24 PRECAUTIONS ........................................................ 26 Precautions for Supplemental Restraint System (SRS) “AIR BAG” and “SEAT BELT PRE-TENSIONER” ................................................................ 26 Maintenance Information ........................................ 26 PrecautionsforProcedureswithoutCowlTopCover... 26 On Board Diagnostic (OBD) System of Engine ...... 26 Precaution .............................................................. 27 PREPARATION ......................................................... 31 Special Service Tools ............................................. 31 Commercial Service Tools ...................................... 32 ENGINE CONTROL SYSTEM .................................. 33 System Diagram ..................................................... 33 Multiport Fuel Injection (MFI) System .................... 34 Electronic Ignition (EI) System ............................... 36 Fuel Cut Control (at No Load and High Engine Speed) .................................................................... 36 AIR CONDITIONING CUT CONTROL ..................... 38 Input/Output Signal Chart ....................................... 38 CAN COMMUNICATION .......................................... 39 System Description ................................................ 39 EVAPORATIVE EMISSION SYSTEM ....................... 40 Description ............................................................. 40 Component Inspection ........................................... 43 NATS (NISSAN ANTI-THEFT SYSTEM) .................. 44 Description ............................................................. 44 POSITIVE CRANKCASE VENTILATION ................. 45 Description ............................................................. 45 Component Inspection ........................................... 45 ON BOARD DIAGNOSTIC (OBD) SYSTEM ............ 47 Introduction ............................................................ 47 Two Trip Detection Logic ........................................ 47 Emission-related Diagnostic Information ................ 48 Malfunction Indicator (MI) ....................................... 58 OBD System Operation Chart ................................ 61 BASIC SERVICE PROCEDURE ............................... 66 Basic Inspection ..................................................... 66 Idle Speed Check ................................................... 69 Accelerator Pedal Released Position Learning ...... 69 Throttle Valve Closed Position Learning ................. 69 Idle Air Volume Learning ........................................ 69 Fuel Pressure Check .............................................. 71 TROUBLE DIAGNOSIS ............................................ 74 Trouble Diagnosis Introduction ............................... 74 DTC Inspection Priority Chart ................................. 80 Fail-Safe Chart ....................................................... 81 Symptom Matrix Chart ............................................ 82 Engine Control Component Parts Location ............ 86 Vacuum Hose Drawing ........................................... 92 Circuit Diagram ....................................................... 93 ECM Harness Connector Terminal Layout ............. 95 ECM Terminals and Reference Value ..................... 95 CONSULT-II Function (ENGINE) .......................... 102 Generic Scan Tool (GST) Function ........................111 CONSULT-IIReferenceValueinDataMonitorMode . 112 Major Sensor Reference Graph in Data Monitor Mode ..................................................................... 115 TROUBLE DIAGNOSIS - SPECIFICATION VALUE. 117 Description ............................................................ 117 Testing Condition .................................................. 117 Inspection Procedure ............................................ 117 Diagnostic Procedure ........................................... 118 TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT ....................................................................... 127 Description ............................................................ 127 Diagnostic Procedure ........................................... 127 POWER SUPPLY AND GROUND CIRCUIT ........... 128 Wiring Diagram ..................................................... 128 Diagnostic Procedure ........................................... 129 Ground Inspection ................................................ 133 EC-1 E F G H I J K L M DTC U1001 CAN COMMUNICATION LINE ............ 134 Description ............................................................ 134 On Board Diagnosis Logic .................................... 134 DTC Confirmation Procedure ............................... 134 Wiring Diagram ..................................................... 135 Diagnostic Procedure ........................................... 136 DTC U1010 CAN COMMUNICATION ..................... 137 Description ............................................................ 137 On Board Diagnosis Logic .................................... 137 DTC Confirmation Procedure ............................... 137 Diagnostic Procedure ........................................... 138 DTC P0011 IVT CONTROL ..................................... 139 Description ............................................................ 139 CONSULT-IIReferenceValueinDataMonitorMode . 139 On Board Diagnosis Logic .................................... 140 DTC Confirmation Procedure ............................... 140 Diagnostic Procedure ........................................... 141 Component Inspection .......................................... 142 Removal and Installation ...................................... 142 DTC P0031, P0032 HO2S1 HEATER ..................... 143 Description ............................................................ 143 CONSULT-IIReferenceValueinDataMonitorMode . 143 On Board Diagnosis Logic .................................... 143 DTC Confirmation Procedure ............................... 144 Wiring Diagram ..................................................... 145 Diagnostic Procedure ........................................... 146 Component Inspection .......................................... 148 Removal and Installation ...................................... 148 DTC P0037, P0038 HO2S2 HEATER ..................... 149 Description ............................................................ 149 CONSULT-IIReferenceValueinDataMonitorMode . 149 On Board Diagnosis Logic .................................... 149 DTC Confirmation Procedure ............................... 149 Wiring Diagram ..................................................... 151 Diagnostic Procedure ........................................... 152 Component Inspection .......................................... 154 Removal and Installation ...................................... 154 DTC P0107, P0108 MANIFOLD ABSOLUTE PRESSURE SENSOR ....................................................... 155 Component Description ........................................ 155 On Board Diagnosis Logic .................................... 155 DTC Confirmation Procedure ............................... 155 Wiring Diagram ..................................................... 156 Diagnostic Procedure ........................................... 157 Component Inspection .......................................... 159 Removal and Installation ...................................... 160 DTC P0112, P0113 IAT SENSOR ........................... 161 Component Description ........................................ 161 On Board Diagnosis Logic .................................... 161 DTC Confirmation Procedure ............................... 162 Wiring Diagram ..................................................... 163 Diagnostic Procedure ........................................... 164 Component Inspection .......................................... 165 Removal and Installation ...................................... 165 DTC P0117, P0118 ECT SENSOR .......................... 166 Component Description ........................................ 166 On Board Diagnosis Logic .................................... 166 DTC Confirmation Procedure ................................ 167 Wiring Diagram ..................................................... 168 Diagnostic Procedure ............................................ 169 Component Inspection ..........................................170 Removal and Installation ....................................... 170 DTC P0122, P0123 TP SENSOR ............................ 171 Component Description ........................................ 171 CONSULT-IIReferenceValueinDataMonitorMode .171 On Board Diagnosis Logic .................................... 171 DTC Confirmation Procedure ................................ 172 Wiring Diagram ..................................................... 173 Diagnostic Procedure ............................................ 174 Component Inspection ..........................................177 Removal and Installation ....................................... 177 DTC P0132 HO2S1 ................................................. 178 Component Description ........................................ 178 CONSULT-IIReferenceValueinDataMonitorMode .178 On Board Diagnosis Logic .................................... 178 DTC Confirmation Procedure ................................ 179 Wiring Diagram ..................................................... 180 Diagnostic Procedure ............................................ 181 Component Inspection ..........................................183 Removal and Installation ....................................... 184 DTC P0133 HO2S1 ................................................. 185 Component Description ........................................ 185 CONSULT-IIReferenceValueinDataMonitorMode .185 On Board Diagnosis Logic .................................... 185 DTC Confirmation Procedure ................................ 186 Overall Function Check ......................................... 187 Wiring Diagram ..................................................... 188 Diagnostic Procedure ............................................ 189 Component Inspection ..........................................193 Removal and Installation ....................................... 194 DTC P0134 HO2S1 ................................................. 195 Component Description ........................................ 195 CONSULT-IIReferenceValueinDataMonitorMode .195 On Board Diagnosis Logic .................................... 195 DTC Confirmation Procedure ................................ 196 Overall Function Check ......................................... 197 Wiring Diagram ..................................................... 198 Diagnostic Procedure ............................................ 199 Component Inspection ..........................................201 Removal and Installation ....................................... 202 DTC P0138 HO2S2 ................................................. 203 Component Description ........................................ 203 CONSULT-IIReferenceValueinDataMonitorMode .203 On Board Diagnosis Logic .................................... 203 DTC Confirmation Procedure ................................ 204 Wiring Diagram ..................................................... 205 Diagnostic Procedure ............................................ 206 Component Inspection ..........................................208 Removal and Installation ....................................... 209 EC-2 DTC P0139 HO2S2 ................................................. 210 Component Description ........................................ 210 CONSULT-IIReferenceValueinDataMonitorMode . 210 On Board Diagnosis Logic ................................... 210 DTC Confirmation Procedure ................................211 Overall Function Check ........................................ 212 Wiring Diagram .................................................... 213 Diagnostic Procedure ........................................... 214 Component Inspection ......................................... 216 Removal and Installation ...................................... 217 DTCP0171FUELINJECTIONSYSTEMFUNCTION. 218 On Board Diagnosis Logic ................................... 218 DTC Confirmation Procedure ............................... 218 Wiring Diagram .................................................... 220 Diagnostic Procedure ........................................... 222 DTCP0172FUELINJECTIONSYSTEMFUNCTION. 226 On Board Diagnosis Logic ................................... 226 DTC Confirmation Procedure ............................... 226 Wiring Diagram .................................................... 228 Diagnostic Procedure ........................................... 230 DTC P0222, P0223 TP SENSOR ........................... 233 Component Description ........................................ 233 CONSULT-IIReferenceValueinDataMonitorMode . 233 On Board Diagnosis Logic ................................... 233 DTC Confirmation Procedure ............................... 234 Wiring Diagram .................................................... 235 Diagnostic Procedure ........................................... 236 Component Inspection ......................................... 239 Removal and Installation ...................................... 239 DTC P0300 - P0304 MULTIPLE CYLINDER MISFIRE, NO. 1 - 4 CYLINDER MISFIRE ..................... 240 On Board Diagnosis Logic ................................... 240 DTC Confirmation Procedure ............................... 240 Diagnostic Procedure ........................................... 241 DTC P0327, P0328 KS ........................................... 246 Component Description ........................................ 246 On Board Diagnosis Logic ................................... 246 DTC Confirmation Procedure ............................... 246 Wiring Diagram .................................................... 247 Diagnostic Procedure ........................................... 248 Component Inspection ......................................... 249 Removal and Installation ...................................... 249 DTC P0335 CKP SENSOR (POS) .......................... 250 Component Description ........................................ 250 CONSULT-IIReferenceValueinDataMonitorMode . 250 On Board Diagnosis Logic ................................... 250 DTC Confirmation Procedure ............................... 250 Wiring Diagram .................................................... 252 Diagnostic Procedure ........................................... 254 Component Inspection ......................................... 256 Removal and Installation ...................................... 256 DTC P0340 CMP SENSOR (PHASE) ..................... 257 Component Description ........................................ 257 On Board Diagnosis Logic ................................... 257 DTC Confirmation Procedure ............................... 257 Wiring Diagram .................................................... 259 Diagnostic Procedure ........................................... 260 Component Inspection .......................................... 263 Removal and Installation ...................................... 263 DTC P0420 THREE WAY CATALYST FUNCTION. 264 On Board Diagnosis Logic .................................... 264 DTC Confirmation Procedure ............................... 264 Overall Function Check ........................................ 265 Diagnostic Procedure ........................................... 266 DTC P0444 EVAP CANISTER PURGE VOLUME CONTROL SOLENOID VALVE ............................... 270 Description ............................................................ 270 CONSULT-IIReferenceValueinDataMonitorMode . 270 On Board Diagnosis Logic .................................... 270 DTC Confirmation Procedure ............................... 271 Wiring Diagram ..................................................... 272 Diagnostic Procedure ........................................... 274 Component Inspection .......................................... 275 Removal and Installation ...................................... 276 DTC P0500 VSS ...................................................... 277 Description ............................................................ 277 On Board Diagnosis Logic .................................... 277 DTC Confirmation Procedure ............................... 277 Overall Function Check ........................................ 278 Diagnostic Procedure ........................................... 278 DTC P0605 ECM ..................................................... 279 Component Description ........................................ 279 On Board Diagnosis Logic .................................... 279 DTC Confirmation Procedure ............................... 279 Diagnostic Procedure ........................................... 280 DTC P1065 ECM POWER SUPPLY ....................... 282 Component Description ........................................ 282 On Board Diagnosis Logic .................................... 282 DTC Confirmation Procedure ............................... 282 Wiring Diagram ..................................................... 283 Diagnostic Procedure ........................................... 284 DTC P1111 IVT CONTROL SOLENOID VALVE ..... 286 Component Description ........................................ 286 CONSULT-IIReferenceValueinDataMonitorMode . 286 On Board Diagnosis Logic .................................... 286 DTC Confirmation Procedure ............................... 286 Wiring Diagram ..................................................... 287 Diagnostic Procedure ........................................... 289 Component Inspection .......................................... 290 Removal and Installation ...................................... 290 DTC P1121 ELECTRIC THROTTLE CONTROL ACTUATOR ............................................................. 291 Component Description ........................................ 291 On Board Diagnosis Logic .................................... 291 DTC Confirmation Procedure ............................... 291 Diagnostic Procedure ........................................... 292 DTC P1122 ELECTRIC THROTTLE CONTROL FUNCTION .............................................................. 293 Description ............................................................ 293 On Board Diagnosis Logic .................................... 293 DTC Confirmation Procedure ............................... 293 Wiring Diagram ..................................................... 294 Diagnostic Procedure ........................................... 295 EC-3 A EC C D E F G H I J K L M Component Inspection .......................................... 298 Removal and Installation ...................................... 298 DTC P1124, P1126 THROTTLE CONTROL MOTOR RELAY ..................................................................... 299 Component Description ........................................ 299 CONSULT-IIReferenceValueinDataMonitorMode . 299 On Board Diagnosis Logic .................................... 299 DTC Confirmation Procedure ............................... 299 Wiring Diagram ..................................................... 301 Diagnostic Procedure ........................................... 302 DTC P1128 THROTTLE CONTROL MOTOR ......... 305 Component Description ........................................ 305 On Board Diagnosis Logic .................................... 305 DTC Confirmation Procedure ............................... 305 Wiring Diagram ..................................................... 306 Diagnostic Procedure ........................................... 307 Component Inspection .......................................... 308 Removal and Installation ...................................... 309 DTC P1143 HO2S1 ................................................. 310 Component Description ........................................ 310 CONSULT-IIReferenceValueinDataMonitorMode . 310 On Board Diagnosis Logic .................................... 310 DTC Confirmation Procedure ............................... 311 Overall Function Check ........................................ 312 Diagnostic Procedure ........................................... 312 Component Inspection .......................................... 314 Removal and Installation ...................................... 315 DTC P1144 HO2S1 ................................................. 316 Component Description ........................................ 316 CONSULT-IIReferenceValueinDataMonitorMode . 316 On Board Diagnosis Logic .................................... 316 DTC Confirmation Procedure ............................... 317 Overall Function Check ........................................ 318 Diagnostic Procedure ........................................... 318 Component Inspection .......................................... 320 Removal and Installation ...................................... 321 DTC P1146 HO2S2 ................................................. 322 Component Description ........................................ 322 CONSULT-IIReferenceValueinDataMonitorMode . 322 On Board Diagnosis Logic .................................... 322 DTC Confirmation Procedure ............................... 322 Overall Function Check ........................................ 324 Wiring Diagram ..................................................... 325 Diagnostic Procedure ........................................... 326 Component Inspection .......................................... 328 Removal and Installation ...................................... 329 DTC P1147 HO2S2 ................................................. 330 Component Description ........................................ 330 CONSULT-IIReferenceValueinDataMonitorMode . 330 On Board Diagnosis Logic .................................... 330 DTC Confirmation Procedure ............................... 331 Overall Function Check ........................................ 332 Wiring Diagram ..................................................... 333 Diagnostic Procedure ........................................... 334 Component Inspection ..........................................336 Removal and Installation ....................................... 337 DTC P1171 INTAKE ERROR .................................. 338 On Board Diagnosis Logic .................................... 338 DTC Confirmation Procedure ................................ 338 Wiring Diagram ..................................................... 339 Diagnostic Procedure ............................................ 340 DTC P1211 TCS CONTROL UNIT .......................... 343 Description ............................................................ 343 On Board Diagnosis Logic .................................... 343 DTC Confirmation Procedure ................................ 343 Diagnostic Procedure ............................................ 343 DTC P1212 TCS COMMUNICATION LINE ............. 344 Description ............................................................ 344 On Board Diagnosis Logic .................................... 344 DTC Confirmation Procedure ................................ 344 Diagnostic Procedure ............................................ 344 DTC P1217 ENGINE OVER TEMPERATURE ........ 345 System Description ............................................... 345 CONSULT-IIReferenceValueinDataMonitorMode .346 On Board Diagnosis Logic .................................... 346 Overall Function Check ......................................... 347 Wiring Diagram ..................................................... 349 Diagnostic Procedure ............................................ 351 Main 12 Causes of Overheating ........................... 357 Component Inspection ..........................................358 DTC P1225 TP SENSOR ........................................ 359 Component Description ........................................ 359 On Board Diagnosis Logic .................................... 359 DTC Confirmation Procedure ................................ 359 Diagnostic Procedure ............................................ 360 Removal and Installation ....................................... 360 DTC P1226 TP SENSOR ........................................ 361 Component Description ........................................ 361 On Board Diagnosis Logic .................................... 361 DTC Confirmation Procedure ................................ 361 Diagnostic Procedure ............................................ 362 Removal and Installation ....................................... 362 DTC P1229 SENSOR POWER SUPPLY ................ 363 On Board Diagnosis Logic .................................... 363 DTC Confirmation Procedure ................................ 363 Wiring Diagram ..................................................... 364 Diagnostic Procedure ............................................ 368 DTC P1706 PNP SWITCH ....................................... 371 Component Description ........................................ 371 CONSULT-IIReferenceValueinDataMonitorMode .371 On Board Diagnosis Logic .................................... 371 DTC Confirmation Procedure ................................ 371 Overall Function Check ......................................... 372 Wiring Diagram ..................................................... 373 Diagnostic Procedure ............................................ 374 DTC P1805 BRAKE SWITCH ................................. 377 Description ............................................................ 377 CONSULT-IIReferenceValueinDataMonitorMode .377 On Board Diagnosis Logic .................................... 377 DTC Confirmation Procedure ................................ 377 EC-4 Wiring Diagram .................................................... 379 Diagnostic Procedure ........................................... 380 Component Inspection ......................................... 382 DTC P2122, P2123 APP SENSOR ........................ 383 Component Description ........................................ 383 CONSULT-IIReferenceValueinDataMonitorMode . 383 On Board Diagnosis Logic ................................... 383 DTC Confirmation Procedure ............................... 384 Wiring Diagram .................................................... 385 Diagnostic Procedure ........................................... 388 Component Inspection ......................................... 390 Removal and Installation ...................................... 391 DTC P2127, P2128 APP SENSOR ........................ 392 Component Description ........................................ 392 CONSULT-IIReferenceValueinDataMonitorMode . 392 On Board Diagnosis Logic ................................... 392 DTC Confirmation Procedure ............................... 393 Wiring Diagram .................................................... 394 Diagnostic Procedure ........................................... 397 Component Inspection ......................................... 400 Removal and Installation ...................................... 401 DTC P2135 TP SENSOR ........................................ 402 Component Description ........................................ 402 CONSULT-IIReferenceValueinDataMonitorMode . 402 On Board Diagnosis Logic ................................... 402 DTC Confirmation Procedure ............................... 403 Wiring Diagram .................................................... 404 Diagnostic Procedure ........................................... 405 Component Inspection ......................................... 408 Removal and Installation ...................................... 408 DTC P2138 APP SENSOR ..................................... 409 Component Description ........................................ 409 CONSULT-IIReferenceValueinDataMonitorMode . 409 On Board Diagnosis Logic ................................... 409 DTC Confirmation Procedure ............................... 410 Wiring Diagram .....................................................411 Diagnostic Procedure ........................................... 414 Component Inspection ......................................... 418 Removal and Installation ...................................... 418 ELECTRICAL LOAD SIGNAL ................................ 419 Description ........................................................... 419 CONSULT-IIReferenceValueinDataMonitorMode . 419 Diagnostic Procedure ........................................... 419 FUEL INJECTOR .................................................... 421 Component Description ........................................ 421 CONSULT-IIReferenceValueinDataMonitorMode . 421 Wiring Diagram .................................................... 422 Diagnostic Procedure ........................................... 423 Component Inspection ......................................... 426 Removal and Installation ...................................... 426 FUEL PUMP ........................................................... 427 Description ........................................................... 427 CONSULT-IIReferenceValueinDataMonitorMode . 427 Wiring Diagram ..................................................... 428 Diagnostic Procedure ........................................... 429 Component Inspection .......................................... 431 Removal and Installation ...................................... 432 IGNITION SIGNAL .................................................. 433 Component Description ........................................ 433 Wiring Diagram ..................................................... 434 Diagnostic Procedure ........................................... 437 Component Inspection .......................................... 441 Removal and Installation ...................................... 442 REFRIGERANT PRESSURE SENSOR .................. 443 Component Description ........................................ 443 Wiring Diagram ..................................................... 444 Diagnostic Procedure ........................................... 445 Removal and Installation ...................................... 447 MI & DATA LINK CONNECTORS ........................... 448 Wiring Diagram ..................................................... 448 SERVICE DATA AND SPECIFICATIONS (SDS) .... 449 Fuel Pressure ....................................................... 449 Idle Speed ............................................................ 449 Calculated Load Value .......................................... 449 Manifold Absolute Pressure Sensor ..................... 449 Intake Air Temperature Sensor ............................. 449 Engine Coolant Temperature Sensor ................... 449 Knock Sensor ....................................................... 449 Crankshaft Position Sensor (POS) ....................... 449 Camshaft Position Sensor (PHASE) .................... 449 Heated Oxygen Sensor 1 Heater ......................... 449 Heated Oxygen Sensor 2 Heater ......................... 449 Intake Valve Timing Control Solenoid Valve ......... 449 Throttle Control Motor ........................................... 450 Fuel Injector .......................................................... 450 Fuel Pump ............................................................ 450 A EC C D E F G H I J K CR (WITHOUT EURO-OBD) INDEX FOR DTC ..................................................... 451 DTC No. Index ...................................................... 451 Alphabetical Index ................................................ 453 PRECAUTIONS ...................................................... 455 Precautions for Supplemental Restraint System (SRS) “AIR BAG” and “SEAT BELT PRE-TENSIONER” ............................................................... 455 Maintenance Information ...................................... 455 Precautions forProcedureswithoutCowlTopCover. 455 On Board Diagnostic (OBD) System of Engine .... 455 Precaution ............................................................ 456 PREPARATION ....................................................... 460 Special Service Tools ........................................... 460 Commercial Service Tools .................................... 461 ENGINE CONTROL SYSTEM ................................ 462 System Diagram ................................................... 462 Multiport Fuel Injection (MFI) System ................... 463 Electronic Ignition (EI) System ............................. 465 Fuel Cut Control (at No Load and High Engine Speed) .................................................................. 465 AIR CONDITIONING CUT CONTROL .................... 467 Input/Output Signal Chart ..................................... 467 EC-5 L M CAN COMMUNICATION ......................................... 468 System Description ............................................... 468 EVAPORATIVE EMISSION SYSTEM ..................... 469 Description ............................................................ 469 Component Inspection .......................................... 472 NATS (NISSAN ANTI-THEFT SYSTEM) ................ 473 Description ............................................................ 473 POSITIVE CRANKCASE VENTILATION ............... 474 Description ............................................................ 474 Component Inspection .......................................... 474 ON BOARD DIAGNOSTIC (OBD) SYSTEM .......... 476 Introduction ........................................................... 476 Two Trip Detection Logic ...................................... 476 Emission-related Diagnostic Information .............. 476 Malfunction Indicator (MI) ..................................... 479 BASIC SERVICE PROCEDURE ............................. 483 Basic Inspection ................................................... 483 Idle Speed Check ................................................. 486 Accelerator Pedal Released Position Learning .... 486 Throttle Valve Closed Position Learning ............... 486 Idle Air Volume Learning ...................................... 486 Fuel Pressure Check ............................................ 488 TROUBLE DIAGNOSIS .......................................... 491 Trouble Diagnosis Introduction ............................. 491 DTC Inspection Priority Chart ............................... 497 Fail-Safe Chart ..................................................... 498 Symptom Matrix Chart .......................................... 499 Engine Control Component Parts Location .......... 503 Vacuum Hose Drawing ......................................... 509 Circuit Diagram ..................................................... 510 ECM Harness Connector Terminal Layout ........... 512 ECM Terminals and Reference Value ................... 512 CONSULT-II Function (ENGINE) .......................... 519 CONSULT-IIReferenceValueinDataMonitorMode . 527 Major Sensor Reference Graph in Data Monitor Mode ..................................................................... 530 TROUBLE DIAGNOSIS - SPECIFICATION VALUE. 532 Description ............................................................ 532 Testing Condition .................................................. 532 Inspection Procedure ............................................ 532 Diagnostic Procedure ........................................... 533 TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT ....................................................................... 542 Description ............................................................ 542 Diagnostic Procedure ........................................... 542 POWER SUPPLY AND GROUND CIRCUIT ........... 543 Wiring Diagram ..................................................... 543 Diagnostic Procedure ........................................... 544 Ground Inspection ................................................ 548 DTC U1001 CAN COMMUNICATION LINE ............ 549 Description ............................................................ 549 On Board Diagnosis Logic .................................... 549 DTC Confirmation Procedure ............................... 549 Wiring Diagram ..................................................... 550 Diagnostic Procedure ........................................... 551 DTC U1010 CAN COMMUNICATION ..................... 552 Description ............................................................ 552 On Board Diagnosis Logic .................................... 552 DTC Confirmation Procedure ................................ 552 Diagnostic Procedure ............................................ 553 DTC P0011 IVT CONTROL ..................................... 554 Description ............................................................ 554 CONSULT-IIReferenceValueinDataMonitorMode .554 On Board Diagnosis Logic .................................... 555 DTC Confirmation Procedure ................................ 555 Overall Function Check ......................................... 556 Diagnostic Procedure ............................................ 556 Component Inspection ..........................................557 Removal and Installation ....................................... 558 DTC P0107, P0108 MANIFOLD ABSOLUTE PRESSURE SENSOR ....................................................... 559 Component Description ........................................ 559 On Board Diagnosis Logic .................................... 559 DTC Confirmation Procedure ................................ 559 Wiring Diagram ..................................................... 560 Diagnostic Procedure ............................................ 561 Component Inspection ..........................................563 Removal and Installation ....................................... 564 DTC P0117, P0118 ECT SENSOR .......................... 565 Component Description ........................................ 565 On Board Diagnosis Logic .................................... 565 DTC Confirmation Procedure ................................ 566 Wiring Diagram ..................................................... 567 Diagnostic Procedure ............................................ 568 Component Inspection ..........................................569 Removal and Installation ....................................... 569 DTC P0122, P0123 TP SENSOR ............................ 570 Component Description ........................................ 570 CONSULT-IIReferenceValueinDataMonitorMode .570 On Board Diagnosis Logic .................................... 570 DTC Confirmation Procedure ................................ 571 Wiring Diagram ..................................................... 572 Diagnostic Procedure ............................................ 573 Component Inspection ..........................................576 Removal and Installation ....................................... 576 DTC P0132 HO2S1 ................................................. 577 Component Description ........................................ 577 CONSULT-IIReferenceValueinDataMonitorMode .577 On Board Diagnosis Logic .................................... 577 DTC Confirmation Procedure ................................ 578 Wiring Diagram ..................................................... 579 Diagnostic Procedure ............................................ 580 Component Inspection ..........................................582 Removal and Installation ....................................... 583 DTC P0134 HO2S1 ................................................. 584 Component Description ........................................ 584 CONSULT-IIReferenceValueinDataMonitorMode .584 On Board Diagnosis Logic .................................... 584 Overall Function Check ......................................... 585 Wiring Diagram ..................................................... 586 Diagnostic Procedure ............................................ 587 Component Inspection ..........................................589 Removal and Installation ....................................... 590 EC-6 DTC P0138 HO2S2 ................................................. 591 Component Description ........................................ 591 CONSULT-IIReferenceValueinDataMonitorMode . 591 On Board Diagnosis Logic ................................... 591 DTC Confirmation Procedure ............................... 591 Wiring Diagram .................................................... 593 Diagnostic Procedure ........................................... 594 Component Inspection ......................................... 596 Removal and Installation ...................................... 597 DTC P0222, P0223 TP SENSOR ........................... 598 Component Description ........................................ 598 CONSULT-IIReferenceValueinDataMonitorMode . 598 On Board Diagnosis Logic ................................... 598 DTC Confirmation Procedure ............................... 598 Wiring Diagram .................................................... 600 Diagnostic Procedure ........................................... 601 Component Inspection ......................................... 604 Removal and Installation ...................................... 604 DTC P0327, P0328 KS ........................................... 605 Component Description ........................................ 605 On Board Diagnosis Logic ................................... 605 DTC Confirmation Procedure ............................... 605 Wiring Diagram .................................................... 606 Diagnostic Procedure ........................................... 607 Component Inspection ......................................... 608 Removal and Installation ...................................... 608 DTC P0335 CKP SENSOR (POS) .......................... 609 Component Description ........................................ 609 CONSULT-IIReferenceValueinDataMonitorMode . 609 On Board Diagnosis Logic ................................... 609 DTC Confirmation Procedure ............................... 609 Wiring Diagram .....................................................611 Diagnostic Procedure ........................................... 613 Component Inspection ......................................... 615 Removal and Installation ...................................... 615 DTC P0340 CMP SENSOR (PHASE) ..................... 616 Component Description ........................................ 616 On Board Diagnosis Logic ................................... 616 DTC Confirmation Procedure ............................... 616 Wiring Diagram .................................................... 618 Diagnostic Procedure ........................................... 619 Component Inspection ......................................... 622 Removal and Installation ...................................... 622 DTC P0605 ECM .................................................... 623 Component Description ........................................ 623 On Board Diagnosis Logic ................................... 623 DTC Confirmation Procedure ............................... 623 Diagnostic Procedure ........................................... 625 DTC P1065 ECM POWER SUPPLY ....................... 626 Component Description ........................................ 626 On Board Diagnosis Logic ................................... 626 DTC Confirmation Procedure ............................... 626 Wiring Diagram .................................................... 627 Diagnostic Procedure ........................................... 628 DTC P1111 IVT CONTROL SOLENOID VALVE .... 630 Component Description ........................................ 630 CONSULT-IIReferenceValueinDataMonitorMode . 630 On Board Diagnosis Logic .................................... 630 DTC Confirmation Procedure ............................... 630 Wiring Diagram ..................................................... 631 Diagnostic Procedure ........................................... 633 Component Inspection .......................................... 634 Removal and Installation ...................................... 634 DTC P1121 ELECTRIC THROTTLE CONTROL ACTUATOR ............................................................. 635 Component Description ........................................ 635 On Board Diagnosis Logic .................................... 635 DTC Confirmation Procedure ............................... 635 Diagnostic Procedure ........................................... 636 DTC P1122 ELECTRIC THROTTLE CONTROL FUNCTION .............................................................. 637 Description ............................................................ 637 On Board Diagnosis Logic .................................... 637 DTC Confirmation Procedure ............................... 637 Wiring Diagram ..................................................... 638 Diagnostic Procedure ........................................... 639 Component Inspection .......................................... 642 Removal and Installation ...................................... 642 DTC P1124, P1126 THROTTLE CONTROL MOTOR RELAY ..................................................................... 643 Component Description ........................................ 643 CONSULT-IIReferenceValueinDataMonitorMode . 643 On Board Diagnosis Logic .................................... 643 DTC Confirmation Procedure ............................... 643 Wiring Diagram ..................................................... 645 Diagnostic Procedure ........................................... 646 DTC P1128 THROTTLE CONTROL MOTOR ......... 649 Component Description ........................................ 649 On Board Diagnosis Logic .................................... 649 DTC Confirmation Procedure ............................... 649 Wiring Diagram ..................................................... 650 Diagnostic Procedure ........................................... 651 Component Inspection .......................................... 652 Removal and Installation ...................................... 653 DTC P1171 INTAKE ERROR .................................. 654 On Board Diagnosis Logic .................................... 654 DTC Confirmation Procedure ............................... 654 Wiring Diagram ..................................................... 656 Diagnostic Procedure ........................................... 657 DTC P1211 TCS CONTROL UNIT .......................... 660 Description ............................................................ 660 On Board Diagnosis Logic .................................... 660 DTC Confirmation Procedure ............................... 660 Diagnostic Procedure ........................................... 660 DTC P1212 TCS COMMUNICATION LINE ............ 661 Description ............................................................ 661 On Board Diagnosis Logic .................................... 661 DTC Confirmation Procedure ............................... 661 Diagnostic Procedure ........................................... 661 DTC P1217 ENGINE OVER TEMPERATURE ........ 662 System Description ............................................... 662 CONSULT-IIReferenceValueinDataMonitorMode . 663 EC-7 A EC C D E F G H I J K L M On Board Diagnosis Logic .................................... 663 Overall Function Check ........................................ 664 Wiring Diagram ..................................................... 666 Diagnostic Procedure ........................................... 668 Main 12 Causes of Overheating ........................... 674 Component Inspection .......................................... 675 DTC P1225 TP SENSOR ........................................ 676 Component Description ........................................ 676 On Board Diagnosis Logic .................................... 676 DTC Confirmation Procedure ............................... 676 Diagnostic Procedure ........................................... 677 Removal and Installation ...................................... 677 DTC P1226 TP SENSOR ........................................ 678 Component Description ........................................ 678 On Board Diagnosis Logic .................................... 678 DTC Confirmation Procedure ............................... 678 Diagnostic Procedure ........................................... 679 Removal and Installation ...................................... 679 DTC P1229 SENSOR POWER SUPPLY ................ 680 On Board Diagnosis Logic .................................... 680 DTC Confirmation Procedure ............................... 680 Wiring Diagram ..................................................... 681 Diagnostic Procedure ........................................... 685 DTC P1706 PNP SWITCH ...................................... 688 Component Description ........................................ 688 CONSULT-IIReferenceValueinDataMonitorMode . 688 On Board Diagnosis Logic .................................... 688 Overall Function Check ........................................ 688 Wiring Diagram ..................................................... 689 Diagnostic Procedure ........................................... 690 DTC P1805 BRAKE SWITCH ................................. 693 Description ............................................................ 693 CONSULT-IIReferenceValueinDataMonitorMode . 693 On Board Diagnosis Logic .................................... 693 DTC Confirmation Procedure ............................... 693 Wiring Diagram ..................................................... 695 Diagnostic Procedure ........................................... 696 Component Inspection .......................................... 698 DTC P2122, P2123 APP SENSOR ......................... 699 Component Description ........................................ 699 CONSULT-IIReferenceValueinDataMonitorMode . 699 On Board Diagnosis Logic .................................... 699 DTC Confirmation Procedure ............................... 699 Wiring Diagram ..................................................... 701 Diagnostic Procedure ........................................... 704 Component Inspection .......................................... 706 Removal and Installation ...................................... 707 DTC P2127, P2128 APP SENSOR ......................... 708 Component Description ........................................ 708 CONSULT-IIReferenceValueinDataMonitorMode . 708 On Board Diagnosis Logic .................................... 708 DTC Confirmation Procedure ............................... 708 Wiring Diagram ..................................................... 710 Diagnostic Procedure ........................................... 713 Component Inspection ..........................................716 Removal and Installation ....................................... 717 DTC P2135 TP SENSOR ........................................ 718 Component Description ........................................ 718 CONSULT-IIReferenceValueinDataMonitorMode .718 On Board Diagnosis Logic .................................... 718 DTC Confirmation Procedure ................................ 718 Wiring Diagram ..................................................... 720 Diagnostic Procedure ............................................ 721 Component Inspection ..........................................724 Removal and Installation ....................................... 724 DTC P2138 APP SENSOR ...................................... 725 Component Description ........................................ 725 CONSULT-IIReferenceValueinDataMonitorMode .725 On Board Diagnosis Logic .................................... 725 DTC Confirmation Procedure ................................ 726 Wiring Diagram ..................................................... 727 Diagnostic Procedure ............................................ 730 Component Inspection ..........................................734 Removal and Installation ....................................... 734 ELECTRICAL LOAD SIGNAL ................................ 735 Description ............................................................ 735 CONSULT-IIReferenceValueinDataMonitorMode .735 Diagnostic Procedure ............................................ 735 EVAP CANISTER PURGE VOLUME CONTROL SOLENOID VALVE .................................................. 737 Description ............................................................ 737 CONSULT-IIReferenceValueinDataMonitorMode .737 Wiring Diagram ..................................................... 738 Diagnostic Procedure ............................................ 740 Component Inspection ..........................................743 Removal and Installation ....................................... 743 FUEL INJECTOR ..................................................... 744 Component Description ........................................ 744 CONSULT-IIReferenceValueinDataMonitorMode .744 Wiring Diagram ..................................................... 745 Diagnostic Procedure ............................................ 746 Component Inspection ..........................................749 Removal and Installation ....................................... 749 FUEL PUMP ............................................................ 750 Description ............................................................ 750 CONSULT-IIReferenceValueinDataMonitorMode .750 Wiring Diagram ..................................................... 751 Diagnostic Procedure ............................................ 752 Component Inspection ..........................................754 Removal and Installation ....................................... 755 HO2S1 ..................................................................... 756 Component Description ........................................ 756 CONSULT-IIReferenceValueinDataMonitorMode .756 Wiring Diagram ..................................................... 757 Diagnostic Procedure ............................................ 759 EC-8 Component Inspection ......................................... 760 Removal and Installation ...................................... 762 HO2S1 HEATER ..................................................... 763 Description ........................................................... 763 CONSULT-IIReferenceValueinDataMonitorMode . 763 Wiring Diagram .................................................... 764 Diagnostic Procedure ........................................... 765 Component Inspection ......................................... 767 Removal and Installation ...................................... 767 HO2S2 .................................................................... 768 Component Description ........................................ 768 CONSULT-IIReferenceValueinDataMonitorMode . 768 Wiring Diagram .................................................... 769 Diagnostic Procedure ........................................... 770 Component Inspection ......................................... 772 Removal and Installation ...................................... 773 HO2S2 HEATER ..................................................... 774 Description ........................................................... 774 CONSULT-IIReferenceValueinDataMonitorMode . 774 Wiring Diagram .................................................... 775 Diagnostic Procedure ........................................... 776 Component Inspection ......................................... 778 Removal and Installation ...................................... 778 IAT SENSOR ........................................................... 779 Component Description ........................................ 779 Wiring Diagram .................................................... 780 Diagnostic Procedure ........................................... 781 Component Inspection ......................................... 783 Removal and Installation ...................................... 783 IGNITION SIGNAL .................................................. 784 Component Description ........................................ 784 Wiring Diagram .................................................... 785 Diagnostic Procedure ........................................... 788 Component Inspection ......................................... 792 Removal and Installation ...................................... 793 REFRIGERANT PRESSURE SENSOR ................. 794 Component Description ........................................ 794 Wiring Diagram .................................................... 795 Diagnostic Procedure ........................................... 796 Removal and Installation ...................................... 798 VSS ......................................................................... 799 Description ........................................................... 799 Diagnostic Procedure ........................................... 799 MI & DATA LINK CONNECTORS .......................... 800 Wiring Diagram .................................................... 800 SERVICE DATA AND SPECIFICATIONS (SDS) .... 801 Fuel Pressure ....................................................... 801 Idle Speed ............................................................ 801 Manifold Absolute Pressure Sensor ..................... 801 Intake Air Temperature Sensor ............................ 801 Engine Coolant Temperature Sensor ................... 801 Knock Sensor ....................................................... 801 Crankshaft Position Sensor (POS) ....................... 801 Camshaft Position Sensor (PHASE) .................... 801 Heated Oxygen Sensor 1 Heater ......................... 801 Heated Oxygen Sensor 2 Heater ......................... 801 Intake Valve Timing Control Solenoid Valve ......... 801 Throttle Control Motor ........................................... 801 Fuel Injector .......................................................... 801 Fuel Pump ............................................................ 802 A EC HR (WITH EURO-OBD) INDEX FOR DTC ..................................................... 803 DTC No. Index ...................................................... 803 Alphabetical Index ................................................ 806 PRECAUTIONS ...................................................... 809 Precautions for Supplemental Restraint System (SRS) “AIR BAG” and “SEAT BELT PRE-TENSIONER” ............................................................... 809 Maintenance Information ...................................... 809 Precautions forProcedureswithoutCowlTopCover. 809 On Board Diagnostic (OBD) System of Engine and A/T ........................................................................ 809 Precaution ............................................................ 810 PREPARATION ....................................................... 814 Special Service Tools ........................................... 814 Commercial Service Tools .................................... 815 ENGINE CONTROL SYSTEM ................................ 816 System Diagram ................................................... 816 Multiport Fuel Injection (MFI) System ................... 817 Electronic Ignition (EI) System ............................. 819 Fuel Cut Control (at No Load and High Engine Speed) .................................................................. 820 AIR CONDITIONING CUT CONTROL .................... 821 Input/Output Signal Chart ..................................... 821 System Description ............................................... 821 CAN COMMUNICATION ......................................... 822 System Description ............................................... 822 EVAPORATIVE EMISSION SYSTEM ..................... 823 Description ............................................................ 823 Component Inspection .......................................... 826 NATS (NISSAN ANTI-THEFT SYSTEM) ................ 827 Description ............................................................ 827 POSITIVE CRANKCASE VENTILATION ............... 828 Description ............................................................ 828 Component Inspection .......................................... 828 ON BOARD DIAGNOSTIC (OBD) SYSTEM .......... 830 Introduction ........................................................... 830 Two Trip Detection Logic ...................................... 830 Emission-related Diagnostic Information .............. 831 Malfunction Indicator (MI) ..................................... 843 OBD System Operation Chart .............................. 846 BASIC SERVICE PROCEDURE ............................. 851 Basic Inspection ................................................... 851 Idle Speed and Ignition Timing Check .................. 856 Accelerator Pedal Released Position Learning .... 857 Throttle Valve Closed Position Learning ............... 857 Idle Air Volume Learning ...................................... 858 Fuel Pressure Check ............................................ 860 TROUBLE DIAGNOSIS .......................................... 863 Trouble Diagnosis Introduction ............................. 863 DTC Inspection Priority Chart ............................... 869 Fail-Safe Chart ..................................................... 870 Symptom Matrix Chart .......................................... 871 EC-9 C D E F G H I J K L M Engine Control Component Parts Location .......... 875 Vacuum Hose Drawing ......................................... 880 Circuit Diagram ..................................................... 881 ECM Harness Connector Terminal Layout ........... 883 ECM Terminals and Reference Value ................... 883 CONSULT-II Function (ENGINE) .......................... 891 Generic Scan Tool (GST) Function ....................... 900 CONSULT-II Reference Value in Data Monitor ..... 902 Major Sensor Reference Graph in Data Monitor Mode ..................................................................... 905 TROUBLE DIAGNOSIS - SPECIFICATION VALUE. 907 Description ............................................................ 907 Testing Condition .................................................. 907 Inspection Procedure ............................................ 907 Diagnostic Procedure ........................................... 908 TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT ....................................................................... 917 Description ............................................................ 917 Diagnostic Procedure ........................................... 917 POWER SUPPLY AND GROUND CIRCUIT ........... 918 Wiring Diagram ..................................................... 918 Diagnostic Procedure ........................................... 919 Ground Inspection ................................................ 924 DTC U1000, U1001 CAN COMMUNICATION LINE. 925 Description ............................................................ 925 On Board Diagnosis Logic .................................... 925 DTC Confirmation Procedure ............................... 925 Wiring Diagram ..................................................... 926 Diagnostic Procedure ........................................... 927 DTC U1010 CAN COMMUNICATION ..................... 928 Description ............................................................ 928 On Board Diagnosis Logic .................................... 928 DTC Confirmation Procedure ............................... 928 Diagnostic Procedure ........................................... 929 DTC P0011 IVT CONTROL ..................................... 930 Description ............................................................ 930 CONSULT-IIReferenceValueinDataMonitorMode . 930 On Board Diagnosis Logic .................................... 931 DTC Confirmation Procedure ............................... 931 Diagnostic Procedure ........................................... 932 Component Inspection .......................................... 933 Removal and Installation ...................................... 934 DTC P0102, P0103 MAF SENSOR ......................... 935 Component Description ........................................ 935 CONSULT-IIReferenceValueinDataMonitorMode . 935 On Board Diagnosis Logic .................................... 935 DTC Confirmation Procedure ............................... 936 Wiring Diagram ..................................................... 937 Diagnostic Procedure ........................................... 938 Component Inspection .......................................... 940 Removal and Installation ...................................... 941 DTC P0112, P0113 IAT SENSOR ........................... 942 Component Description ........................................ 942 On Board Diagnosis Logic .................................... 942 DTC Confirmation Procedure ............................... 942 Wiring Diagram ..................................................... 944 Diagnostic Procedure ........................................... 945 Component Inspection ..........................................946 Removal and Installation ....................................... 946 DTC P0117, P0118 ECT SENSOR .......................... 947 Component Description ........................................ 947 On Board Diagnosis Logic .................................... 947 DTC Confirmation Procedure ................................ 948 Wiring Diagram ..................................................... 949 Diagnostic Procedure ............................................ 950 Component Inspection ..........................................951 Removal and Installation ....................................... 952 DTC P0122, P0123 TP SENSOR ............................ 953 Component Description ........................................ 953 CONSULT-IIReferenceValueinDataMonitorMode .953 On Board Diagnosis Logic .................................... 953 DTC Confirmation Procedure ................................ 954 Wiring Diagram ..................................................... 955 Diagnostic Procedure ............................................ 956 Component Inspection ..........................................958 Removal and Installation ....................................... 958 DTC P0132 HO2S1 ................................................. 959 Component Description ........................................ 959 CONSULT-IIReferenceValueinDataMonitorMode .959 On Board Diagnosis Logic .................................... 959 DTC Confirmation Procedure ................................ 960 Wiring Diagram ..................................................... 961 Diagnostic Procedure ............................................ 962 Component Inspection ..........................................965 Removal and Installation ....................................... 966 DTC P0133 HO2S1 ................................................. 967 Component Description ........................................ 967 CONSULT-IIReferenceValueinDataMonitorMode .967 On Board Diagnosis Logic .................................... 967 DTC Confirmation Procedure ................................ 968 Overall Function Check ......................................... 969 Wiring Diagram ..................................................... 970 Diagnostic Procedure ............................................ 971 Component Inspection ..........................................975 Removal and Installation ....................................... 976 DTC P0134 HO2S1 ................................................. 977 Component Description ........................................ 977 CONSULT-IIReferenceValueinDataMonitorMode .977 On Board Diagnosis Logic .................................... 977 DTC Confirmation Procedure ................................ 978 Overall Function Check ......................................... 979 Wiring Diagram ..................................................... 980 Diagnostic Procedure ............................................ 981 Component Inspection ..........................................983 Removal and Installation ....................................... 984 DTC P0135 HO2S1 HEATER .................................. 985 Description ............................................................ 985 CONSULT-IIReferenceValueinDataMonitorMode .985 On Board Diagnosis Logic .................................... 985 DTC Confirmation Procedure ................................ 986 Wiring Diagram ..................................................... 987 EC-10 Diagnostic Procedure ........................................... 988 Component Inspection ......................................... 990 Removal and Installation ...................................... 990 DTC P0138 HO2S2 ................................................. 991 Component Description ........................................ 991 CONSULT-IIReferenceValueinDataMonitorMode . 991 On Board Diagnosis Logic ................................... 991 DTC Confirmation Procedure ............................... 992 Wiring Diagram .................................................... 993 Diagnostic Procedure ........................................... 994 Component Inspection ......................................... 995 Removal and Installation ...................................... 997 DTC P0139 HO2S2 ................................................. 998 Component Description ........................................ 998 CONSULT-IIReferenceValueinDataMonitorMode . 998 On Board Diagnosis Logic ................................... 998 DTC Confirmation Procedure ............................... 999 Overall Function Check .......................................1000 Wiring Diagram ...................................................1001 Diagnostic Procedure ..........................................1002 Component Inspection ........................................1004 Removal and Installation .....................................1005 DTC P0141 HO2S2 HEATER ................................1006 Description ..........................................................1006 CONSULT-IIReferenceValueinDataMonitorMode 1006 On Board Diagnosis Logic ..................................1006 DTC Confirmation Procedure ..............................1007 Wiring Diagram ...................................................1008 Diagnostic Procedure ..........................................1009 Component Inspection ........................................1011 Removal and Installation .....................................1011 DTCP0171FUELINJECTIONSYSTEMFUNCTION1012 On Board Diagnosis Logic ..................................1012 DTC Confirmation Procedure ..............................1012 Wiring Diagram ...................................................1014 Diagnostic Procedure ..........................................1016 DTCP0172FUELINJECTIONSYSTEMFUNCTION1019 On Board Diagnosis Logic ..................................1019 DTC Confirmation Procedure ..............................1019 Wiring Diagram ...................................................1021 Diagnostic Procedure ..........................................1023 DTC P0222, P0223 TP SENSOR ..........................1026 Component Description .......................................1026 CONSULT-IIReferenceValueinDataMonitorMode 1026 On Board Diagnosis Logic ..................................1026 DTC Confirmation Procedure ..............................1027 Wiring Diagram ...................................................1028 Diagnostic Procedure ..........................................1029 Component Inspection ........................................1031 Removal and Installation .....................................1031 DTC P0300 - P0304 MULTIPLE CYLINDER MISFIRE, NO. 1 - 4 CYLINDER MISFIRE ....................1032 On Board Diagnosis Logic ..................................1032 DTC Confirmation Procedure ..............................1033 Diagnostic Procedure ..........................................1033 DTC P0327, P0328 KS ..........................................1038 Component Description .......................................1038 On Board Diagnosis Logic ...................................1038 DTC Confirmation Procedure ..............................1038 Wiring Diagram ....................................................1039 Diagnostic Procedure ..........................................1040 Component Inspection .........................................1041 Removal and Installation .....................................1041 DTC P0335 CKP SENSOR (POS) .........................1042 Component Description .......................................1042 CONSULT-IIReferenceValueinDataMonitorMode 1042 On Board Diagnosis Logic ...................................1042 DTC Confirmation Procedure ..............................1043 Wiring Diagram ....................................................1044 Diagnostic Procedure ..........................................1046 Component Inspection .........................................1048 Removal and Installation .....................................1048 DTC P0340 CMP SENSOR (PHASE) ....................1049 Component Description .......................................1049 On Board Diagnosis Logic ...................................1049 DTC Confirmation Procedure ..............................1050 Wiring Diagram ....................................................1051 Diagnostic Procedure ..........................................1052 Component Inspection .........................................1054 Removal and Installation .....................................1055 DTC P0420 THREE WAY CATALYST FUNCTION1056 On Board Diagnosis Logic ...................................1056 DTC Confirmation Procedure ..............................1056 Overall Function Check .......................................1057 Diagnostic Procedure ..........................................1059 DTC P0444 EVAP CANISTER PURGE VOLUME CONTROL SOLENOID VALVE ..............................1063 Description ...........................................................1063 CONSULT-IIReferenceValueinDataMonitorMode 1063 On Board Diagnosis Logic ...................................1063 DTC Confirmation Procedure ..............................1064 Wiring Diagram ....................................................1065 Diagnostic Procedure ..........................................1067 Component Inspection .........................................1068 Removal and Installation .....................................1069 DTC P0500 VSS .....................................................1070 Description ...........................................................1070 On Board Diagnosis Logic ...................................1070 DTC Confirmation Procedure ..............................1070 Overall Function Check .......................................1071 Diagnostic Procedure ..........................................1071 DTC P0605 ECM ....................................................1072 Component Description .......................................1072 On Board Diagnosis Logic ...................................1072 DTC Confirmation Procedure ..............................1072 Diagnostic Procedure ..........................................1073 DTC P1065 ECM ....................................................1075 Component Description .......................................1075 On Board Diagnosis Logic ...................................1075 DTC Confirmation Procedure ..............................1075 Diagnostic Procedure ..........................................1076 EC-11 A EC C D E F G H I J K L M DTC P1111 IVT CONTROL SOLENOID VALVE ....1077 Component Description .......................................1077 CONSULT-IIReferenceValueinDataMonitorMode 1077 On Board Diagnosis Logic ...................................1077 DTC Confirmation Procedure ..............................1077 Wiring Diagram ....................................................1078 Diagnostic Procedure ..........................................1080 Component Inspection .........................................1081 Removal and Installation .....................................1081 DTC P1121 ELECTRIC THROTTLE CONTROL ACTUATOR ............................................................1082 Component Description .......................................1082 On Board Diagnosis Logic ...................................1082 DTC Confirmation Procedure ..............................1082 Diagnostic Procedure ..........................................1083 Removal and Installation .....................................1083 DTC P1122 ELECTRIC THROTTLE CONTROL FUNCTION .............................................................1084 Description ...........................................................1084 On Board Diagnosis Logic ...................................1084 DTC Confirmation Procedure ..............................1084 Wiring Diagram ....................................................1085 Diagnostic Procedure ..........................................1086 Component Inspection .........................................1089 Removal and Installation .....................................1089 DTC P1124, P1126 THROTTLE CONTROL MOTOR RELAY ....................................................................1090 Component Description .......................................1090 CONSULT-IIReferenceValueinDataMonitorMode 1090 On Board Diagnosis Logic ...................................1090 DTC Confirmation Procedure ..............................1090 Wiring Diagram ....................................................1092 Diagnostic Procedure ..........................................1093 DTC P1128 THROTTLE CONTROL MOTOR ........1096 Component Description .......................................1096 On Board Diagnosis Logic ...................................1096 DTC Confirmation Procedure ..............................1096 Wiring Diagram ....................................................1097 Diagnostic Procedure ..........................................1098 Component Inspection .........................................1100 Removal and Installation .....................................1100 DTC P1143 HO2S1 ................................................1101 Component Description .......................................1101 CONSULT-IIReferenceValueinDataMonitorMode 1101 On Board Diagnosis Logic ...................................1101 DTC Confirmation Procedure ..............................1102 Overall Function Check .......................................1103 Diagnostic Procedure ..........................................1103 Component Inspection .........................................1105 Removal and Installation .....................................1106 DTC P1144 HO2S1 ................................................1107 Component Description .......................................1107 CONSULT-IIReferenceValueinDataMonitorMode 1107 On Board Diagnosis Logic ...................................1107 DTC Confirmation Procedure ..............................1108 Overall Function Check ........................................1109 Diagnostic Procedure ...........................................1109 Component Inspection .........................................1111 Removal and Installation ......................................1112 DTC P1146 HO2S2 .................................................1113 Component Description .......................................1113 CONSULT-IIReferenceValueinDataMonitorMode 1113 On Board Diagnosis Logic ...................................1113 DTC Confirmation Procedure ...............................1114 Overall Function Check ........................................1115 Wiring Diagram ....................................................1116 Diagnostic Procedure ...........................................1117 Component Inspection .........................................1119 Removal and Installation ......................................1120 DTC P1147 HO2S2 .................................................1121 Component Description .......................................1121 CONSULT-IIReferenceValueinDataMonitorMode 1121 On Board Diagnosis Logic ...................................1121 DTC Confirmation Procedure ...............................1122 Overall Function Check ........................................1123 Wiring Diagram ....................................................1124 Diagnostic Procedure ...........................................1125 Component Inspection .........................................1127 Removal and Installation ......................................1128 DTC P1212 TCS COMMUNICATION LINE ............1129 Description ...........................................................1129 On Board Diagnosis Logic ...................................1129 DTC Confirmation Procedure ...............................1129 Diagnostic Procedure ...........................................1129 DTC P1217 ENGINE OVER TEMPERATURE .......1130 System Description ..............................................1130 CONSULT-IIReferenceValueinDataMonitorMode 1131 On Board Diagnosis Logic ...................................1131 Overall Function Check ........................................1132 Wiring Diagram ....................................................1135 Diagnostic Procedure ...........................................1137 Main 12 Causes of Overheating ..........................1144 Component Inspection .........................................1145 DTC P1225 TP SENSOR .......................................1146 Component Description .......................................1146 On Board Diagnosis Logic ...................................1146 DTC Confirmation Procedure ...............................1146 Diagnostic Procedure ...........................................1147 Removal and Installation ......................................1147 DTC P1226 TP SENSOR .......................................1148 Component Description .......................................1148 On Board Diagnosis Logic ...................................1148 DTC Confirmation Procedure ...............................1148 Diagnostic Procedure ...........................................1149 Removal and Installation ......................................1149 DTC P1229 SENSOR POWER SUPPLY ...............1150 On Board Diagnosis Logic ...................................1150 DTC Confirmation Procedure ...............................1150 Wiring Diagram ....................................................1151 Diagnostic Procedure ...........................................1155 EC-12 DTC P1706 PNP SWITCH .....................................1158 Component Description .......................................1158 CONSULT-IIReferenceValueinDataMonitorMode 1158 On Board Diagnosis Logic ..................................1158 DTC Confirmation Procedure ..............................1158 Overall Function Check .......................................1159 Wiring Diagram ...................................................1160 Diagnostic Procedure ..........................................1163 DTC P1805 BRAKE SWITCH ...............................1167 Description ..........................................................1167 CONSULT-IIReferenceValueinDataMonitorMode 1167 On Board Diagnosis Logic ..................................1167 FAIL-SAFE MODE ..............................................1167 DTC Confirmation Procedure ..............................1167 Wiring Diagram ...................................................1168 Diagnostic Procedure ..........................................1169 Component Inspection ........................................1171 DTC P2122, P2123 APP SENSOR .......................1172 Component Description .......................................1172 CONSULT-IIReferenceValueinDataMonitorMode 1172 On Board Diagnosis Logic ..................................1172 DTC Confirmation Procedure ..............................1173 Wiring Diagram ...................................................1174 Diagnostic Procedure ..........................................1177 Component Inspection ........................................1180 Removal and Installation .....................................1180 DTC P2127, P2128 APP SENSOR .......................1181 Component Description .......................................1181 CONSULT-IIReferenceValueinDataMonitorMode 1181 On Board Diagnosis Logic ..................................1181 DTC Confirmation Procedure ..............................1182 Wiring Diagram ...................................................1183 Diagnostic Procedure ..........................................1187 Component Inspection ........................................1190 Removal and Installation .....................................1190 DTC P2135 TP SENSOR .......................................1191 Component Description .......................................1191 CONSULT-IIReferenceValueinDataMonitorMode 1191 On Board Diagnosis Logic ..................................1191 DTC Confirmation Procedure ..............................1192 Wiring Diagram ...................................................1193 Diagnostic Procedure ..........................................1194 Component Inspection ........................................1196 Removal and Installation .....................................1196 DTC P2138 APP SENSOR ....................................1197 Component Description .......................................1197 CONSULT-IIReferenceValueinDataMonitorMode 1197 On Board Diagnosis Logic ..................................1197 DTC Confirmation Procedure ..............................1198 Wiring Diagram ...................................................1199 Diagnostic Procedure ..........................................1203 Component Inspection ........................................1206 Removal and Installation .....................................1206 ELECTRICAL LOAD SIGNAL ...............................1207 CONSULT-IIReferenceValueinDataMonitorMode 1207 Diagnostic Procedure ..........................................1207 FUEL INJECTOR ...................................................1209 Component Description .......................................1209 CONSULT-IIReferenceValueinDataMonitorMode 1209 Wiring Diagram ....................................................1210 Diagnostic Procedure ..........................................1211 Component Inspection .........................................1214 Removal and Installation .....................................1214 FUEL PUMP ...........................................................1215 Description ...........................................................1215 CONSULT-IIReferenceValueinDataMonitorMode 1215 Wiring Diagram ....................................................1216 Diagnostic Procedure ..........................................1217 Component Inspection .........................................1220 Removal and Installation .....................................1220 IGNITION SIGNAL .................................................1221 Component Description .......................................1221 Wiring Diagram ....................................................1222 Diagnostic Procedure ..........................................1225 Component Inspection .........................................1229 Removal and Installation .....................................1230 REFRIGERANT PRESSURE SENSOR .................1231 Component Description .......................................1231 Wiring Diagram ....................................................1232 Diagnostic Procedure ..........................................1233 Removal and Installation .....................................1235 MI & DATA LINK CONNECTORS ..........................1236 Wiring Diagram ....................................................1236 SERVICE DATA AND SPECIFICATIONS (SDS) ...1237 Fuel Pressure ......................................................1237 Idle Speed and Ignition Timing ............................1237 Calculated Load Value .........................................1237 Mass Air Flow Sensor ..........................................1237 Intake Air Temperature Sensor ............................1237 Engine Coolant Temperature Sensor ..................1237 Knock Sensor ......................................................1237 Heated Oxygen Sensor 1 Heater ........................1237 Heated Oxygen sensor 2 Heater .........................1237 Crankshaft Position Sensor (POS) ......................1238 Camshaft Position Sensor (PHASE) ...................1238 Intake Valve Timing Control Solenoid Valve ........1238 Throttle Control Motor ..........................................1238 Fuel Injector .........................................................1238 Fuel Pump ...........................................................1238 HR (WITHOUT EURO-OBD) INDEX FOR DTC ....................................................1239 DTC No. Index .....................................................1239 Alphabetical Index ...............................................1241 PRECAUTIONS .....................................................1243 Precautions for Supplemental Restraint System (SRS) “AIR BAG” and “SEAT BELT PRE-TENSIONER” ..............................................................1243 EC-13 A EC C D E F G H I J K L M Maintenance Information .....................................1243 Precautions for ProcedureswithoutCowlTopCover1243 On Board Diagnostic (OBD) System of Engine ...1243 Precaution ...........................................................1244 PREPARATION ......................................................1248 Special Service Tools ..........................................1248 Commercial Service Tools ...................................1249 ENGINE CONTROL SYSTEM ...............................1250 System Diagram ..................................................1250 Multiport Fuel Injection (MFI) System ..................1251 Electronic Ignition (EI) System ............................1253 Fuel Cut Control (at No Load and High Engine Speed) .................................................................1254 AIR CONDITIONING CUT CONTROL ...................1255 Input/Output Signal Chart ....................................1255 System Description ..............................................1255 CAN COMMUNICATION ........................................1256 System Description ..............................................1256 EVAPORATIVE EMISSION SYSTEM ....................1257 Description ...........................................................1257 Component Inspection .........................................1260 NATS (NISSAN ANTI-THEFT SYSTEM) ...............1261 Description ...........................................................1261 POSITIVE CRANKCASE VENTILATION ..............1262 Description ...........................................................1262 Component Inspection .........................................1262 ON BOARD DIAGNOSTIC (OBD) SYSTEM .........1264 Introduction ..........................................................1264 Two Trip Detection Logic .....................................1264 Emission-related Diagnostic Information .............1264 Malfunction Indicator (MI) ....................................1268 BASIC SERVICE PROCEDURE ............................1272 Basic Inspection ..................................................1272 Idle Speed and Ignition Timing Check .................1277 Accelerator Pedal Released Position Learning ...1278 Throttle Valve Closed Position Learning ..............1279 Idle Air Volume Learning .....................................1279 Fuel Pressure Check ...........................................1281 TROUBLE DIAGNOSIS .........................................1284 Trouble Diagnosis Introduction ............................1284 DTC Inspection Priority Chart ..............................1290 Fail-Safe Chart ....................................................1291 Symptom Matrix Chart .........................................1292 Engine Control Component Parts Location .........1296 Vacuum Hose Drawing ........................................1301 Circuit Diagram ....................................................1302 ECM Harness Connector Terminal Layout ..........1304 ECM Terminals and Reference Value ..................1304 CONSULT-II Function (ENGINE) .........................1312 CONSULT-II Reference Value in Data Monitor ....1321 Major Sensor Reference Graph in Data Monitor Mode ....................................................................1324 TROUBLE DIAGNOSIS - SPECIFICATION VALUE1326 Description ...........................................................1326 Testing Condition .................................................1326 Inspection Procedure ...........................................1326 Diagnostic Procedure ..........................................1327 TROUBLE DIAGNOSIS FOR INTERMITTENT INCI- DENT ......................................................................1336 Description ........................................................... 1336 Diagnostic Procedure ........................................... 1336 POWER SUPPLY AND GROUND CIRCUIT ..........1337 Wiring Diagram ....................................................1337 Diagnostic Procedure ........................................... 1338 Ground Inspection ................................................ 1342 DTC U1000, U1001 CAN COMMUNICATION LINE1344 Description ........................................................... 1344 On Board Diagnosis Logic ...................................1344 DTC Confirmation Procedure ............................... 1344 Wiring Diagram ....................................................1345 Diagnostic Procedure ........................................... 1346 DTC U1010 CAN COMMUNICATION ....................1347 Description ........................................................... 1347 On Board Diagnosis Logic ...................................1347 DTC Confirmation Procedure ............................... 1347 Diagnostic Procedure ........................................... 1348 DTC P0011 IVT CONTROL ....................................1349 Description ........................................................... 1349 CONSULT-IIReferenceValueinDataMonitorMode 1349 On Board Diagnosis Logic ...................................1350 DTC Confirmation Procedure ............................... 1350 Overall Function Check ........................................ 1351 Diagnostic Procedure ........................................... 1352 Component Inspection ......................................... 1353 Removal and Installation ......................................1353 DTC P0102, P0103 MAF SENSOR ........................ 1354 Component Description ....................................... 1354 CONSULT-IIReferenceValueinDataMonitorMode 1354 On Board Diagnosis Logic ...................................1354 DTC Confirmation Procedure ............................... 1355 Wiring Diagram ....................................................1356 Diagnostic Procedure ........................................... 1357 Component Inspection ......................................... 1359 Removal and Installation ......................................1360 DTC P0117, P0118 ECT SENSOR ......................... 1361 Component Description ....................................... 1361 On Board Diagnosis Logic ...................................1361 DTC Confirmation Procedure ............................... 1362 Wiring Diagram ....................................................1363 Diagnostic Procedure ........................................... 1364 Component Inspection ......................................... 1365 Removal and Installation ......................................1366 DTC P0122, P0123 TP SENSOR ........................... 1367 Component Description ....................................... 1367 CONSULT-IIReferenceValueinDataMonitorMode 1367 On Board Diagnosis Logic ...................................1367 DTC Confirmation Procedure ............................... 1368 Wiring Diagram ....................................................1369 Diagnostic Procedure ........................................... 1370 Component Inspection ......................................... 1372 Removal and Installation ......................................1372 DTC P0132 HO2S1 ................................................ 1373 Component Description ....................................... 1373 CONSULT-IIReferenceValueinDataMonitorMode EC-14 1373 On Board Diagnosis Logic ..................................1373 DTC Confirmation Procedure ..............................1374 Wiring Diagram ...................................................1375 Diagnostic Procedure ..........................................1376 Component Inspection ........................................1379 Removal and Installation .....................................1380 DTC P0134 HO2S1 ................................................1381 Component Description .......................................1381 CONSULT-IIReferenceValueinDataMonitorMode 1381 On Board Diagnosis Logic ..................................1381 Overall Function Check .......................................1382 Wiring Diagram ...................................................1383 Diagnostic Procedure ..........................................1384 Component Inspection ........................................1385 Removal and Installation .....................................1387 DTC P0138 HO2S2 ................................................1388 Component Description .......................................1388 CONSULT-IIReferenceValueinDataMonitorMode 1388 On Board Diagnosis Logic ..................................1388 DTC Confirmation Procedure ..............................1389 Wiring Diagram ...................................................1390 Diagnostic Procedure ..........................................1391 Component Inspection ........................................1392 Removal and Installation .....................................1394 DTC P0222, P0223 TP SENSOR ..........................1395 Component Description .......................................1395 CONSULT-IIReferenceValueinDataMonitorMode 1395 On Board Diagnosis Logic ..................................1395 DTC Confirmation Procedure ..............................1396 Wiring Diagram ...................................................1397 Diagnostic Procedure ..........................................1398 Component Inspection ........................................1400 Removal and Installation .....................................1400 DTC P0327, P0328 KS ..........................................1401 Component Description .......................................1401 On Board Diagnosis Logic ..................................1401 DTC Confirmation Procedure ..............................1401 Wiring Diagram ...................................................1402 Diagnostic Procedure ..........................................1403 Component Inspection ........................................1404 Removal and Installation .....................................1404 DTC P0335 CKP SENSOR (POS) .........................1405 Component Description .......................................1405 CONSULT-IIReferenceValueinDataMonitorMode 1405 On Board Diagnosis Logic ..................................1405 DTC Confirmation Procedure ..............................1406 Wiring Diagram ...................................................1407 Diagnostic Procedure ..........................................1409 Component Inspection ........................................1412 Removal and Installation .....................................1412 DTC P0340 CMP SENSOR (PHASE) ....................1413 Component Description .......................................1413 On Board Diagnosis Logic ..................................1413 DTC Confirmation Procedure ..............................1414 Wiring Diagram ....................................................1415 Diagnostic Procedure ..........................................1416 Component Inspection .........................................1418 Removal and Installation .....................................1419 DTC P0605 ECM ....................................................1420 Component Description .......................................1420 On Board Diagnosis Logic ...................................1420 DTC Confirmation Procedure ..............................1420 Diagnostic Procedure ..........................................1422 DTC P1065 ECM ....................................................1423 Component Description .......................................1423 On Board Diagnosis Logic ...................................1423 DTC Confirmation Procedure ..............................1423 Diagnostic Procedure ..........................................1424 DTC P1111 IVT CONTROL SOLENOID VALVE ....1425 Component Description .......................................1425 CONSULT-IIReferenceValueinDataMonitorMode 1425 On Board Diagnosis Logic ...................................1425 DTC Confirmation Procedure ..............................1425 Wiring Diagram ....................................................1426 Diagnostic Procedure ..........................................1428 Component Inspection .........................................1429 Removal and Installation .....................................1429 DTC P1121 ELECTRIC THROTTLE CONTROL ACTUATOR ............................................................1430 Component Description .......................................1430 On Board Diagnosis Logic ...................................1430 DTC Confirmation Procedure ..............................1430 Diagnostic Procedure ..........................................1431 Removal and Installation .....................................1432 DTC P1122 ELECTRIC THROTTLE CONTROL FUNCTION .............................................................1433 Description ...........................................................1433 On Board Diagnosis Logic ...................................1433 DTC Confirmation Procedure ..............................1433 Wiring Diagram ....................................................1434 Diagnostic Procedure ..........................................1435 Component Inspection .........................................1438 Removal and Installation .....................................1438 DTC P1124, P1126 THROTTLE CONTROL MOTOR RELAY ....................................................................1439 Component Description .......................................1439 CONSULT-IIReferenceValueinDataMonitorMode 1439 On Board Diagnosis Logic ...................................1439 DTC Confirmation Procedure ..............................1439 Wiring Diagram ....................................................1441 Diagnostic Procedure ..........................................1442 DTC P1128 THROTTLE CONTROL MOTOR ........1445 Component Description .......................................1445 On Board Diagnosis Logic ...................................1445 DTC Confirmation Procedure ..............................1445 Wiring Diagram ....................................................1446 Diagnostic Procedure ..........................................1447 Component Inspection .........................................1449 Removal and Installation .....................................1449 DTC P1212 TCS COMMUNICATION LINE ...........1450 Description ...........................................................1450 EC-15 A EC C D E F G H I J K L M On Board Diagnosis Logic ...................................1450 DTC Confirmation Procedure ..............................1450 Diagnostic Procedure ..........................................1450 DTC P1217 ENGINE OVER TEMPERATURE .......1451 System Description ..............................................1451 CONSULT-IIReferenceValueinDataMonitorMode 1452 On Board Diagnosis Logic ...................................1452 Overall Function Check .......................................1453 Wiring Diagram ....................................................1456 Diagnostic Procedure ..........................................1458 Main 12 Causes of Overheating ..........................1465 Component Inspection .........................................1466 DTC P1225 TP SENSOR .......................................1467 Component Description .......................................1467 On Board Diagnosis Logic ...................................1467 DTC Confirmation Procedure ..............................1467 Diagnostic Procedure ..........................................1468 Removal and Installation .....................................1468 DTC P1226 TP SENSOR .......................................1469 Component Description .......................................1469 On Board Diagnosis Logic ...................................1469 DTC Confirmation Procedure ..............................1469 Diagnostic Procedure ..........................................1470 Removal and Installation .....................................1470 DTC P1229 SENSOR POWER SUPPLY ...............1471 On Board Diagnosis Logic ...................................1471 DTC Confirmation Procedure ..............................1471 Wiring Diagram ....................................................1472 Diagnostic Procedure ..........................................1476 DTC P1706 PNP SWITCH .....................................1479 Component Description .......................................1479 CONSULT-IIReferenceValueinDataMonitorMode 1479 On Board Diagnosis Logic ...................................1479 Overall Function Check .......................................1479 Wiring Diagram ....................................................1480 Diagnostic Procedure ..........................................1483 DTC P1805 BRAKE SWITCH ................................1487 Description ...........................................................1487 CONSULT-IIReferenceValueinDataMonitorMode 1487 On Board Diagnosis Logic ...................................1487 FAIL-SAFE MODE ...............................................1487 DTC Confirmation Procedure ..............................1487 Wiring Diagram ....................................................1488 Diagnostic Procedure ..........................................1489 Component Inspection .........................................1491 DTC P2122, P2123 APP SENSOR ........................1492 Component Description .......................................1492 CONSULT-IIReferenceValueinDataMonitorMode 1492 On Board Diagnosis Logic ...................................1492 DTC Confirmation Procedure ..............................1493 Wiring Diagram ....................................................1494 Diagnostic Procedure ..........................................1497 Component Inspection .........................................1499 Removal and Installation .....................................1500 DTC P2127, P2128 APP SENSOR ........................ 1501 Component Description ....................................... 1501 CONSULT-IIReferenceValueinDataMonitorMode 1501 On Board Diagnosis Logic ...................................1501 DTC Confirmation Procedure ............................... 1502 Wiring Diagram ....................................................1503 Diagnostic Procedure ........................................... 1507 Component Inspection ......................................... 1509 Removal and Installation ......................................1510 DTC P2135 TP SENSOR .......................................1511 Component Description .......................................1511 CONSULT-IIReferenceValueinDataMonitorMode 1511 On Board Diagnosis Logic ...................................1511 DTC Confirmation Procedure ............................... 1512 Wiring Diagram ....................................................1513 Diagnostic Procedure ........................................... 1514 Component Inspection ......................................... 1516 Removal and Installation ......................................1516 DTC P2138 APP SENSOR .....................................1517 Component Description ....................................... 1517 CONSULT-IIReferenceValueinDataMonitorMode 1517 On Board Diagnosis Logic ...................................1517 DTC Confirmation Procedure ............................... 1518 Wiring Diagram ....................................................1519 Diagnostic Procedure ........................................... 1523 Component Inspection ......................................... 1527 Removal and Installation ......................................1527 ELECTRICAL LOAD SIGNAL ............................... 1528 CONSULT-IIReferenceValueinDataMonitorMode 1528 Diagnostic Procedure ........................................... 1528 EVAP CANISTER PURGE VOLUME CONTROL SOLENOID VALVE ................................................. 1530 Description ........................................................... 1530 CONSULT-IIReferenceValueinDataMonitorMode 1530 Wiring Diagram ....................................................1531 Diagnostic Procedure ........................................... 1533 Component Inspection ......................................... 1536 Removal and Installation ......................................1536 FUEL INJECTOR ....................................................1537 Component Description ....................................... 1537 CONSULT-IIReferenceValueinDataMonitorMode 1537 Wiring Diagram ....................................................1538 Diagnostic Procedure ........................................... 1539 Component Inspection ......................................... 1542 Removal and Installation ......................................1542 FUEL PUMP ........................................................... 1543 Description ........................................................... 1543 CONSULT-IIReferenceValueinDataMonitorMode 1543 Wiring Diagram ....................................................1544 Diagnostic Procedure ........................................... 1545 Component Inspection ......................................... 1548 Removal and Installation ......................................1548 EC-16 HO2S1 ...................................................................1549 Component Description .......................................1549 CONSULT-IIReferenceValueinDataMonitorMode 1549 Wiring Diagram ...................................................1550 Diagnostic Procedure ..........................................1552 Component Inspection ........................................1555 Removal and Installation .....................................1556 HO2S1 HEATER ....................................................1557 Description ..........................................................1557 CONSULT-IIReferenceValueinDataMonitorMode 1557 Wiring Diagram ...................................................1558 Diagnostic Procedure ..........................................1560 Component Inspection ........................................1562 Removal and Installation .....................................1562 HO2S2 ...................................................................1563 Component Description .......................................1563 CONSULT-IIReferenceValueinDataMonitorMode 1563 Wiring Diagram ...................................................1564 Diagnostic Procedure ..........................................1565 Component Inspection ........................................1567 Removal and Installation .....................................1568 HO2S2 HEATER ....................................................1569 Description ..........................................................1569 CONSULT-IIReferenceValueinDataMonitorMode 1569 Wiring Diagram ...................................................1570 Diagnostic Procedure ..........................................1572 Component Inspection ........................................1574 Removal and Installation .....................................1574 IAT SENSOR ..........................................................1575 Component Description .......................................1575 Wiring Diagram ...................................................1576 Diagnostic Procedure ..........................................1577 Component Inspection ........................................1579 Removal and Installation .....................................1579 IGNITION SIGNAL .................................................1580 Component Description .......................................1580 Wiring Diagram ...................................................1581 Diagnostic Procedure ..........................................1584 Component Inspection ........................................1588 Removal and Installation .....................................1589 REFRIGERANT PRESSURE SENSOR ................1590 Component Description .......................................1590 Wiring Diagram ...................................................1591 Diagnostic Procedure ..........................................1592 Removal and Installation .....................................1594 VSS ........................................................................1595 Description ..........................................................1595 Diagnostic Procedure ..........................................1595 MI & DATA LINK CONNECTORS .........................1596 Wiring Diagram ...................................................1596 SERVICE DATA AND SPECIFICATIONS (SDS) ...1597 Fuel Pressure ......................................................1597 Idle Speed and Ignition Timing ............................1597 Mass Air Flow Sensor .........................................1597 Intake Air Temperature Sensor ...........................1597 Engine Coolant Temperature Sensor ..................1597 Knock Sensor ......................................................1597 Heated Oxygen Sensor 1 Heater ........................1597 Heated Oxygen sensor 2 Heater .........................1597 Crankshaft Position Sensor (POS) ......................1597 Camshaft Position Sensor (PHASE) ...................1597 Intake Valve Timing Control Solenoid Valve ........1597 Throttle Control Motor ..........................................1598 Fuel Injector .........................................................1598 Fuel Pump ...........................................................1598 K9K INDEX FOR DTC ....................................................1599 DTC No. Index .....................................................1599 Alphabetical Index ...............................................1601 PRECAUTIONS .....................................................1603 Precautions for Supplemental Restraint System (SRS) “AIR BAG” and “SEAT BELT PRE-TENSIONER” ..............................................................1603 Maintenance Information .....................................1603 Precautions forProcedureswithoutCowlTopCover1603 On Board Diagnostic (OBD) System of Engine ...1603 Precautions ..........................................................1604 Cleanliness ..........................................................1606 ENGINE CONTROL SYSTEM ...............................1609 System Diagram ..................................................1609 Vacuum Hose Drawing ........................................1611 System Overview .................................................1612 Fuel Injection Control ...........................................1612 Functions Performed ...........................................1613 Idle Speed Control ...............................................1616 Air Conditioning Control .......................................1618 Pre/Postheating (Glow Plug) Control ...................1619 Glow Plugs ..........................................................1620 Cooling Fan Control .............................................1620 Oil Vapour Rebreathing .......................................1622 Exhaust Gas Recirculation (EGR) .......................1622 CAN Communication ...........................................1624 BASIC SERVICE PROCEDURE ............................1625 Fuel Filter .............................................................1625 Injector Adjustment Value Registration ................1625 Tightening The High Pressure Pipes ...................1626 Checking Sealing After Repair ............................1626 Replacing ECM ....................................................1626 Replacing Fuel Injectors ......................................1627 ON BOARD DIAGNOSTIC (OBD) SYSTEM .........1628 Introduction ..........................................................1628 How to Erase DTC ...............................................1628 NATS (Nissan Anti-Theft System) .......................1629 TROUBLE DIAGNOSIS .........................................1630 Trouble Diagnosis Introduction ............................1630 Trouble Diagnosis - Symptom .............................1634 Trouble Diagnosis - Basic Test Procedure ..........1660 Engine Control Component Parts Location .........1668 Wiring Diagram — ECM — ..................................1671 ECM Harness Connector Terminal Layout ..........1673 ECM Terminals And Reference Value .................1673 EC-17 A EC C D E F G H I J K L M Conformity Check ................................................1680 CONSULT-IIReferenceValueinDataMonitorMode 1694 TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT ......................................................................1697 Description ...........................................................1697 Diagnostic Procedure ..........................................1697 POWER SUPPLY AND GROUND CIRCUIT ..........1698 Wiring Diagram ....................................................1698 Diagnostic Procedure ..........................................1699 Ground Inspection ...............................................1703 DTC PC001 CAN COMMUNICATION LINE ..........1705 Description ...........................................................1705 On Board Diagnosis Logic ...................................1705 Wiring Diagram ....................................................1706 Diagnostic Procedure ..........................................1707 DTC P0016 CKP - CMP CORRELATION ..............1708 On Board Diagnosis Logic ...................................1708 Diagnostic Procedure ..........................................1708 DTC P0045 TC BOOST CONTROL SORENOID VALVE ....................................................................1710 Description ...........................................................1710 On Board Diagnosis Logic ...................................1710 Wiring Diagram ....................................................1711 Diagnostic Procedure ..........................................1713 Component Inspection .........................................1714 DTC P0070 IAT SENSOR ......................................1715 Component Description .......................................1715 On Board Diagnosis Logic ...................................1715 Wiring Diagram ....................................................1716 Diagnostic Procedure ..........................................1717 Component Inspection .........................................1718 Removal and Installation .....................................1718 DTC P0087 FUEL SYSTEM ...................................1719 On Board Diagnosis Logic ...................................1719 Diagnostic Procedure ..........................................1719 Removal and Installation .....................................1720 DTC P0089 FUEL PUMP .......................................1721 On Board Diagnosis Logic ...................................1721 Diagnostic Procedure ..........................................1721 Removal and Installation .....................................1721 DTC P0100 MAF SENSOR ....................................1722 Component Description .......................................1722 CONSULT-IIReferenceValueinDataMonitorMode 1722 On Board Diagnosis Logic ...................................1722 Wiring Diagram ....................................................1723 Diagnostic Procedure ..........................................1724 Component Inspection .........................................1726 Removal and Installation .....................................1726 DTC P0115 ECT SENSOR .....................................1727 Description ...........................................................1727 On Board Diagnosis Logic ...................................1727 Wiring Diagram ....................................................1728 Diagnostic Procedure ..........................................1729 Component Inspection .........................................1730 Removal and Installation .....................................1730 DTC P0170 FUEL INJECTOR ADJUSTMENT VALUE ....................................................................1731 On Board Diagnosis Logic ...................................1731 Diagnostic Procedure ........................................... 1731 DTCP0180FUELPUMPTEMPERATURESENSOR 1732 Description ........................................................... 1732 CONSULT-IIReferenceValueinDataMonitorMode 1732 On Board Diagnosis Logic ...................................1732 Wiring Diagram ....................................................1733 Diagnostic Procedure ........................................... 1734 Component Inspection ......................................... 1735 Removal and Installation ......................................1735 DTC P0190 FRP SENSOR .....................................1736 CONSULT-IIReferenceValueinDataMonitorMode 1736 On Board Diagnosis Logic ...................................1736 Wiring Diagram ....................................................1737 Diagnostic Procedure ........................................... 1738 Component Inspection ......................................... 1739 Removal and Installation ......................................1739 DTC P0200 FUEL INJECTOR ................................1740 Component Description ....................................... 1740 CONSULT-IIReferenceValueinDataMonitorMode 1740 On Board Diagnosis Logic ...................................1740 Wiring Diagram ....................................................1741 Diagnostic Procedure ........................................... 1743 Removal and Installation ......................................1744 DTC P0201 - P0204 FUEL INJECTOR .................. 1745 Component Description ....................................... 1745 CONSULT-IIReferenceValueinDataMonitorMode 1745 On Board Diagnosis Logic ...................................1745 Wiring Diagram ....................................................1746 Diagnostic Procedure ........................................... 1747 Component Inspection ......................................... 1750 Removal and Installation ......................................1750 DTC P0225 APP SENSOR .....................................1751 Description ........................................................... 1751 CONSULT-IIReferenceValueinDataMonitorMode 1751 On Board Diagnosis Logic ...................................1751 Wiring Diagram ....................................................1752 Diagnostic Procedure ........................................... 1755 Component Inspection ......................................... 1757 Removal and Installation ......................................1758 DTC P0231 FUEL PUMP .......................................1759 Description ........................................................... 1759 CONSULT-IIReferenceValueinDataMonitorMode 1759 On Board Diagnosis Logic ...................................1759 Wiring Diagram ....................................................1760 Diagnostic Procedure ........................................... 1761 Component Inspection ......................................... 1762 Removal and Installation ......................................1762 DTC P0235 TC BOOST SENSOR .........................1763 Component Description ....................................... 1763 CONSULT-IIReferenceValueinDataMonitorMode EC-18 1763 On Board Diagnosis Logic ..................................1763 Wiring Diagram ...................................................1764 Diagnostic Procedure ..........................................1765 Removal and Installation .....................................1767 DTC P0263, P0266, P0269, P0272 NO.1 - 4 CYLINDER MISFIRE ....................................................1768 On Board Diagnosis Logic ..................................1768 Diagnostic Procedure ..........................................1769 DTC P0325 KNOCK SENSOR (KS) ......................1770 Component Description .......................................1770 On Board Diagnosis Logic ..................................1770 Wiring Diagram ...................................................1771 Diagnostic Procedure ..........................................1772 Removal and Installation .....................................1773 DTC P0335 CKP SENSOR ....................................1774 Description ..........................................................1774 CONSULT-IIReferenceValueinDataMonitorMode 1774 On Board Diagnosis Logic ..................................1774 Wiring Diagram ...................................................1775 Diagnostic Procedure ..........................................1776 Component Inspection ........................................1777 Removal and Installation .....................................1777 DTC P0340 CMP SENSOR ...................................1778 Description ..........................................................1778 On Board Diagnosis Logic ..................................1778 Wiring Diagram ...................................................1779 Diagnostic Procedure ..........................................1780 Component Inspection ........................................1783 Removal and Installation .....................................1783 DTC P0380 GLOW CONTROL UNIT ....................1784 On Board Diagnosis Logic ..................................1784 Wiring Diagram ...................................................1785 Diagnostic Procedure ..........................................1786 DTC P0382 GLOW CONTROL UNIT ....................1788 On Board Diagnosis Logic ..................................1788 Wiring Diagram ...................................................1789 Diagnostic Procedure ..........................................1790 DTC P0400 EGR FUNCTION ................................1791 CONSULT-IIReferenceValueinDataMonitorMode 1791 On Board Diagnosis Logic ..................................1791 Wiring Diagram ...................................................1792 Diagnostic Procedure ..........................................1794 DTC P0403 EGR VOLUME CONTROL VALVE ....1795 CONSULT-IIReferenceValueinDataMonitorMode 1795 On Board Diagnosis Logic ..................................1795 Wiring Diagram ...................................................1796 Diagnostic Procedure ..........................................1798 Component Inspection ........................................1799 Removal and Installation .....................................1799 DTC P0409 EGRVOLUME CONTROL VALVE CONTROL POSITION SENSOR ...................................1800 CONSULT-IIReferenceValueinDataMonitorMode 1800 On Board Diagnosis Logic ..................................1800 Wiring Diagram ...................................................1801 Diagnostic Procedure ..........................................1803 Component Inspection .........................................1804 Removal and Installation .....................................1804 DTC P0487EGR VOLUME CONTROL VALVE CONTROL POSITION SENSOR ...................................1805 CONSULT-IIReferenceValueinDataMonitorMode 1805 On Board Diagnosis Logic ...................................1805 Wiring Diagram ....................................................1806 Diagnostic Procedure ..........................................1808 Component Inspection .........................................1809 Removal and Installation .....................................1809 DTC P0500 VSS .....................................................1810 Description ...........................................................1810 On Board Diagnosis Logic ...................................1810 Diagnostic Procedure ..........................................1810 DTC P0530 REFRIGERANT PRESSURE SENSOR1811 Component Description .......................................1811 CONSULT-IIReferenceValueinDataMonitorMode 1811 On Board Diagnosis Logic ...................................1811 Wiring Diagram ....................................................1812 Diagnostic Procedure ..........................................1813 Removal and Installation .....................................1815 DTC P0560 BATTERY VOLTAGE .........................1816 On Board Diagnosis Logic ...................................1816 Wiring Diagram ....................................................1817 Diagnostic Procedure ..........................................1818 DTC P0571 BRAKE SWITCH ................................1820 Description ...........................................................1820 On Board Diagnosis Logic ...................................1820 Wiring Diagram ....................................................1821 Diagnostic Procedure ..........................................1822 Component Inspection .........................................1824 DTC P0604 ECM ....................................................1825 Description ...........................................................1825 On Board Diagnosis Logic ...................................1825 Diagnostic Procedure ..........................................1825 DTC P0606 ECM ....................................................1826 Description ...........................................................1826 On Board Diagnosis Logic ...................................1826 Diagnostic Procedure ..........................................1826 DTC P062F ECM ....................................................1828 Description ...........................................................1828 On Board Diagnosis Logic ...................................1828 Diagnostic Procedure ..........................................1828 DTC P0641 SENSOR POWER SUPPLY ...............1830 On Board Diagnosis Logic ...................................1830 Wiring Diagram ....................................................1831 Diagnostic Procedure ..........................................1835 DTC P0651 APP SENSOR ....................................1837 Description ...........................................................1837 CONSULT-IIReferenceValueinDataMonitorMode 1837 On Board Diagnosis Logic ...................................1837 Wiring Diagram ....................................................1838 Diagnostic Procedure ..........................................1841 Component Inspection .........................................1843 Removal and Installation .....................................1844 EC-19 A EC C D E F G H I J K L M DTC P0685 ECM RELAY .......................................1845 On Board Diagnosis Logic ...................................1845 Wiring Diagram ....................................................1846 Diagnostic Procedure ..........................................1847 DTC P0703 BRAKE SWITCH ................................1850 Description ...........................................................1850 On Board Diagnosis Logic ...................................1850 Wiring Diagram ....................................................1851 Diagnostic Procedure ..........................................1852 Component Inspection .........................................1854 DTC P2120 APP SENSOR ....................................1855 Description ...........................................................1855 CONSULT-IIReferenceValueinDataMonitorMode 1855 On Board Diagnosis Logic ...................................1855 Wiring Diagram ....................................................1856 Diagnostic Procedure ........................................... 1859 Component Inspection ......................................... 1861 Removal and Installation ......................................1862 DTC P2226 BARO SENSOR ................................. 1863 Description ........................................................... 1863 On Board Diagnosis Logic ...................................1863 Diagnostic Procedure ........................................... 1863 COOLING FAN .......................................................1864 System Description .............................................. 1864 Wiring Diagram ....................................................1866 Diagnostic Procedure ........................................... 1867 Component Inspection ......................................... 1868 MI & DATA LINK CONNECTORS ..........................1869 Wiring Diagram ....................................................1869 SERVICE DATA AND SPECIFICATIONS (SDS) ... 1870 .............................................................................1870 EC-20 APPLICATION NOTICE APPLICATION NOTICE How to Check Vehicle Type PFP:00000 A BBS002T8 CR ENGINE AND HR ENGINE Check the Euro-OBD (E-OBD) discrimination of the vehicle (refer to GI-45, "IDENTIFICATION INFORMA- EC TION" ) to confirm the service information in EC section. K9K ENGINE Confirm K9K engine type with “Model” written on the “IDENTIFICATION PLATE” (Refe to GI-45, "IDENTIFICATION INFORMATION" ), then refer to service information in EC section. Vehicle type C Engine type xTKxxxxE11xxE 50kw xTKxxxxE11xxA 63kw D E F G H I J K L M EC-21 INDEX FOR DTC [CR (WITH EURO-OBD)] INDEX FOR DTC DTC No. Index [CR (WITH EURO-OBD)] PFP:00024 BBS002TA NOTE: ● If DTC U1001 is displayed with other DTC, first perform the trouble diagnosis for DTC U1001. Refer to EC-134, "DTC U1001 CAN COMMUNICATION LINE" . ● If DTC U1010 is displayed with other DTC, first perform the trouble diagnosis for DTC U1010. Refer to EC-137, "DTC U1010 CAN COMMUNICATION" . DTC*1 CONSULT-II 2 GST* ECM*3 Items (CONSULT-II screen terms) Reference page NO DTC IS DETECTED. FURTHER TESTING MAY BE REQUIRED. EC-59 1001*5 CAN COMM CIRCUIT EC-134 U1010 1010 CONTROL UNIT(CAN) EC-137 P0000 0000 NO DTC IS DETECTED. FURTHER TESTING MAY BE REQUIRED. P0011 0011 INT/V TIM CONT-B1 EC-139 P0031 0031 HO2S1 HTR (B1) EC-143 P0032 0032 HO2S1 HTR (B1) EC-143 P0037 0037 HO2S2 HTR (B1) EC-149 P0038 0038 HO2S2 HTR (B1) EC-149 P0107 0107 ABSL PRES SEN/CIRC EC-155 P0108 0108 ABSL PRES SEN/CIRC EC-155 P0112 0112 IAT SEN/CIRCUIT EC-161 P0113 0113 IAT SEN/CIRCUIT EC-161 P0117 0117 ECT SEN/CIRC EC-166 P0118 0118 ECT SEN/CIRC EC-166 P0122 0122 TP SEN 2/CIRC EC-171 P0123 0123 TP SEN 2/CIRC EC-171 P0132 0132 HO2S1 (B1) EC-178 P0133 0133 HO2S1 (B1) EC-185 P0134 0134 HO2S1 (B1) EC-195 P0138 0138 HO2S2 (B1) EC-203 P0139 0139 HO2S2 (B1) EC-210 P0171 0171 FUEL SYS-LEAN-B1 EC-218 P0172 0172 FUEL SYS-RICH-B1 EC-226 P0222 0222 TP SEN 1/CIRC EC-233 No DTC Flashing*4 U1001 — P0223 0223 TP SEN 1/CIRC EC-233 P0300 0300 MULTI CYL MISFIRE EC-240 P0301 0301 CYL 1 MISFIRE EC-240 P0302 0302 CYL 2 MISFIRE EC-240 P0303 0303 CYL 3 MISFIRE EC-240 P0304 0304 CYL 4 MISFIRE EC-240 P0327 0327 KNOCK SEN/CIRC-B1 EC-246 P0328 0328 KNOCK SEN/CIRC-B1 EC-246 EC-22 INDEX FOR DTC [CR (WITH EURO-OBD)] DTC*1 CONSULT-II Items (CONSULT-II screen terms) 3 Reference page GST*2 ECM* P0335 0335 CKP SEN/CIRCUIT EC-250 P0340 0340 CMP SEN/CIRC-B1 EC-257 P0420 0420 TW CATALYST SYS-B1 EC-264 P0444 0444 PURG VOLUME CONT/V EC-270 P0500 0500 VEH SPEED SEN/CIRC EC-277 P0605 0605 ECM EC-279 P1065 1065 ECM BACK UP/CIRCUIT EC-282 P1111 1111 INT/V TIM V/CIR-B1 EC-286 P1121 1121 ETC ACTR EC-291 P1122 1122 ETC FUNCTION/CIRC EC-293 P1124 1124 ETC MOT PWR EC-299 P1126 1126 ETC MOT PWR EC-299 P1128 1128 ETC MOT EC-305 P1143 1143 HO2S1 (B1) EC-310 P1144 1144 HO2S1 (B1) EC-316 P1146 1146 HO2S2 (B1) EC-322 P1147 1147 HO2S2 (B1) EC-330 P1171 1171 INTAKE ERROR EC-338 P1211 1211 TCS C/U FUNCTN EC-343 P1212 1212 TCS/CIRC EC-344 P1217 1217 ENG OVER TEMP EC-345 P1225 1225 CTP LEARNING EC-359 P1226 1226 CTP LEARNING EC-361 P1229 1229 SENSOR POWER/CIRC EC-363 P1610 - P1615 1610 - 1615 NATS MALFUNCTION EC-44 P1706 1706 P-N POS SW/CIRCUIT EC-371 P1805 1805 BRAKE SW/CIRCUIT EC-377 P2122 2122 APP SEN 1/CIRC EC-383 P2123 2123 APP SEN 1/CIRC EC-383 P2127 2127 APP SEN 2/CIRC EC-392 P2128 2128 APP SEN 2/CIRC EC-392 P2135 2135 TP SENSOR EC-402 P2138 2138 APP SENSOR EC-409 *1: 1st trip DTC No. is the same as DTC No. *2: This number is prescribed by ISO 15031-5. *3: In Diagnostic Test Mode II (Self-diagnostic results), this number is controlled by NISSAN. *4: When engine is running. *5: The troubleshooting for this DTC needs CONSULT-II. EC-23 A EC C D E F G H I J K L M INDEX FOR DTC [CR (WITH EURO-OBD)] Alphabetical Index BBS002T9 NOTE: ● If DTC U1001 is displayed with other DTC, first perform the trouble diagnosis for DTC U1001. Refer to EC-134, "DTC U1001 CAN COMMUNICATION LINE" . ● If DTC U1010 is displayed with other DTC, first perform the trouble diagnosis for DTC U1010. Refer to EC-137, "DTC U1010 CAN COMMUNICATION" . Items (CONSULT-II screen terms) DTC*1 CONSULT-II GST* 2 Reference page ECM*3 ABSL PRES SEN/CIRC P0107 0107 EC-155 ABSL PRES SEN/CIRC P0108 0108 EC-155 APP SEN 1/CIRC P2122 2122 EC-383 APP SEN 1/CIRC P2123 2123 EC-383 APP SEN 2/CIRC P2127 2127 EC-392 APP SEN 2/CIRC P2128 2128 EC-392 APP SENSOR P2138 2138 EC-409 BRAKE SW/CIRCUIT P1805 1805 EC-377 CAN COMM CIRCUIT U1001 1001*5 EC-134 CKP SEN/CIRCUIT P0335 0335 EC-250 CMP SEN/CIRC-B1 P0340 0340 EC-257 CONTROL UNIT(CAN) U1010 1010 EC-137 CTP LEARNING P1225 1225 EC-359 CTP LEARNING P1226 1226 EC-361 CYL 1 MISFIRE P0301 0301 EC-240 CYL 2 MISFIRE P0302 0302 EC-240 CYL 3 MISFIRE P0303 0303 EC-240 CYL 4 MISFIRE P0304 0304 EC-240 ECM P0605 0605 EC-279 ECM BACK UP/CIRCUIT P1065 1065 EC-282 ECT SEN/CIRC P0117 0117 EC-166 ECT SEN/CIRC P0118 0118 EC-166 ENG OVER TEMP P1217 1217 EC-345 ETC ACTR P1121 1121 EC-291 ETC FUNCTION/CIRC P1122 1122 EC-293 ETC MOT P1128 1128 EC-305 ETC MOT PWR P1124 1124 EC-299 ETC MOT PWR P1126 1126 EC-299 FUEL SYS-LEAN-B1 P0171 0171 EC-218 FUEL SYS-RICH-B1 P0172 0172 EC-226 HO2S1 (B1) P0132 0132 EC-178 HO2S1 (B1) P0133 0133 EC-185 HO2S1 (B1) P0134 0134 EC-195 HO2S1 (B1) P1143 1143 EC-310 HO2S1 (B1) P1144 1144 EC-316 HO2S1 HTR (B1) P0031 0031 EC-143 HO2S1 HTR (B1) P0032 0032 EC-143 EC-24 INDEX FOR DTC [CR (WITH EURO-OBD)] DTC*1 Items (CONSULT-II screen terms) CONSULT-II Reference page A 3 GST*2 ECM* HO2S2 (B1) P0138 0138 EC-203 HO2S2 (B1) P0139 0139 EC-210 HO2S2 (B1) P1146 1146 EC-322 HO2S2 (B1) P1147 1147 EC-330 HO2S2 HTR (B1) P0037 0037 EC-149 HO2S2 HTR (B1) P0038 0038 EC-149 IAT SEN/CIRCUIT P0112 0112 EC-161 IAT SEN/CIRCUIT P0113 0113 EC-161 INTAKE ERROR P1171 1171 EC-338 INT/V TIM CONT-B1 P0011 0011 EC-139 EC C D E INT/V TIM V/CIR-B1 P1111 1111 EC-286 KNOCK SEN/CIRC-B1 P0327 0327 EC-246 KNOCK SEN/CIRC-B1 P0328 0328 EC-246 MULTI CYL MISFIRE P0300 0300 EC-240 NATS MALFUNCTION P1610 - P1615 1610 - 1615 EC-44 NO DTC IS DETECTED. FURTHER TESTING MAY BE REQUIRED. No DTC Flashing*4 EC-59 H NO DTC IS DETECTED. FURTHER TESTING MAY BE REQUIRED. P0000 0000 — I P-N POS SW/CIRCUIT P1706 1706 EC-371 PURG VOLUME CONT/V P0444 0444 EC-270 SENSOR POWER/CIRC P1229 1229 EC-363 TCS C/U FUNCTN P1211 1211 EC-343 TCS/CIRC P1212 1212 EC-344 TP SEN 1/CIRC P0222 0222 EC-233 TP SEN 1/CIRC P0223 0223 EC-233 TP SEN 2/CIRC P0122 0122 EC-171 TP SEN 2/CIRC P0123 0123 EC-171 TP SENSOR P2135 2135 EC-402 TW CATALYST SYS-B1 P0420 0420 EC-264 VEH SPEED SEN/CIRC P0500 0500 EC-277 *1: 1st trip DTC No. is the same as DTC No. *2: This number is prescribed by ISO 15031-5. *3: In Diagnostic Test Mode II (Self-diagnostic results), this number is controlled by NISSAN. *4: When engine is running. *5: The troubleshooting for this DTC needs CONSULT-II. EC-25 F G J K L M PRECAUTIONS [CR (WITH EURO-OBD)] PFP:00001 PRECAUTIONS Precautions for Supplemental Restraint System (SRS) “AIR BAG” and “SEAT BELT PRE-TENSIONER” BBS003ZU The Supplemental Restraint System such as “AIR BAG” and “SEAT BELT PRE-TENSIONER”, used along with a front seat belt, helps to reduce the risk or severity of injury to the driver and front passenger for certain types of collision. Information necessary to service the system safely is included in the SRS and SB section of this Service Manual. WARNING: ● To avoid rendering the SRS inoperative, which could increase the risk of personal injury or death in the event of a collision which would result in air bag inflation, all maintenance must be performed by an authorized NISSAN/INFINITI dealer. ● Improper maintenance, including incorrect removal and installation of the SRS, can lead to personal injury caused by unintentional activation of the system. For removal of Spiral Cable and Air Bag Module, see the SRS section. ● Do not use electrical test equipment on any circuit related to the SRS unless instructed to in this Service Manual. SRS wiring harnesses can be identified by yellow and/or orange harnesses or harness connectors. Maintenance Information BBS005AP If any of following part is replaced, always replace with new* one. If it's not (or fail to do so), the electrical system may not be operated properly. *: New one means a virgin control unit that has never been energized on-board. RHD MODELS ● ● ● ● ● ● BCM (Models without Intelligent Key system) Intelligent Key unit (Models with Intelligent Key system) ECM IPDM E/R Combination meter EPS control unit LHD MODELS ● ● ● BCM (Models without Intelligent Key system) Intelligent Key unit (Models with Intelligent Key system) ECM Precautions for Procedures without Cowl Top Cover BBS003ZV When performing the procedure after removing cowl top cover, cover the lower end of windshield with urethane, etc. PIIB3706J On Board Diagnostic (OBD) System of Engine BBS002TD The ECM has an on board diagnostic system. It will light up the malfunction indicator (MI) to warn the driver of a malfunction causing emission deterioration. CAUTION: ● Be sure to turn the ignition switch OFF and disconnect the battery ground cable before any repair or inspection work. The open/short circuit of related switches, sensors, solenoid valves, etc. will cause the MI to light up. EC-26 PRECAUTIONS [CR (WITH EURO-OBD)] ● ● ● ● ● Be sure to connect and lock the connectors securely after work. A loose (unlocked) connector will cause the MI to light up due to the open circuit. (Be sure the connector is free from water, grease, A dirt, bent terminals, etc.) Certain systems and components, especially those related to OBD, may use a new style slidelocking type harness connector. For description and how to disconnect, refer to PG-88, "HAR- EC NESS CONNECTOR" . Be sure to route and secure the harnesses properly after work. The interference of the harness with a bracket, etc. may cause the MI to light up due to the short circuit. C Be sure to connect rubber tubes properly after work. A misconnected or disconnected rubber tube may cause the MI to light up due to the malfunction of the fuel injection system, etc. Be sure to erase the unnecessary malfunction information (repairs completed) from the ECM D before returning the vehicle to the customer. Precaution ● ● ● ● BBS002TE E Always use a 12 volt battery as power source. Do not attempt to disconnect battery cables while engine is running. Before connecting or disconnecting the ECM harness connector, turn ignition switch OFF and disconnect negative battery cable. Failure to do so may damage the ECM because battery voltage is applied to ECM even if ignition switch is turned off. Before removing parts, turn ignition switch OFF and then disconnect negative battery cable. F G H SEF289H ● ● ● – – – – – – ● Do not disassemble ECM. If battery cable is disconnected, the memory will return to the initial ECM values. The ECM will now start to self-control at its initial values. Engine operation can vary slightly when the cable is disconnected. However, this is not an indication of a malfunction. Do not replace parts because of a slight variation. If the battery is disconnected, the following emission related diagnostic information will be lost within 24 hours. Diagnostic trouble codes 1st trip diagnostic trouble codes Freeze frame data 1st freeze frame data System readiness test (SRT) codes Test values I J K PBIB1164E M When connecting ECM harness connector, fasten it securely with levers as far as they will go as shown in the figure. PBIB1512E EC-27 L PRECAUTIONS [CR (WITH EURO-OBD)] ● ● ● ● ● ● ● ● ● ● ● When connecting or disconnecting pin connectors into or from ECM, take care not to damage pin terminals (bend or break). Make sure that there are not any bends or breaks on ECM pin terminal, when connecting pin connectors. Securely connect ECM harness connectors. A poor connection can cause an extremely high (surge) voltage to develop in coil and condenser, thus resulting in damage to ICs. Keep engine control system harness at least 10 cm (4 in) away from adjacent harness, to prevent engine control system malfunctions due to receiving external noise, degraded operation of ICs, etc. Keep engine control system parts and harness dry. Before replacing ECM, perform ECM Terminals and Reference Value inspection and make sure ECM functions properly. Refer to EC-95, "ECM Terminals and Reference Value" . Handle manifold absolute pressure sensor carefully to avoid damage. Do not clean air clear element with any type of detergent. Do not disassemble electric throttle control actuator. Even a slight leak in the air intake system can cause serious incidents. Do not shock or jar the camshaft position sensor (PHASE), crankshaft position sensor (POS). After performing each TROUBLE DIAGNOSIS, perform DTC Confirmation Procedure or Overall Function Check. The DTC should not be displayed in the DTC Confirmation Procedure if the repair is completed. The Overall Function Check should be a good result if the repair is completed. PBIB0090E MEF040D SAT652J EC-28 PRECAUTIONS [CR (WITH EURO-OBD)] ● ● ● When measuring ECM signals with a circuit tester, connect a break-out box (SST) and Y-cable adapter (SST) between the ECM and ECM harness connector. When measuring ECM signals with a circuit tester, never allow the two tester probes to contact. Accidental contact of probes will cause a short circuit and damage the ECM power transistor. Do not use ECM ground terminals when measuring input/ output voltage. Doing so may result in damage to the ECM's transistor. Use a ground other than ECM terminals, such as the ground. A EC C D E F G SEF348N ● ● Do not operate fuel pump when there is no fuel in lines. Tighten fuel hose clamps to the specified torque. H I J MBIB0291E ● ● ● Do not depress accelerator pedal when starting. Immediately after starting, do not rev up engine unnecessarily. Do not rev up engine just prior to shutdown. K L M SEF709Y EC-29 PRECAUTIONS [CR (WITH EURO-OBD)] ● – – – – When installing C.B. ham radio or a mobile phone, be sure to observe the following as it may adversely affect electronic control systems depending on installation location. Keep the antenna as far as possible from the electronic control units. Keep the antenna feeder line more than 20 cm (8 in) away from the harness of electronic controls. Do not let them run parallel for a long distance. Adjust the antenna and feeder line so that the standingwave radio can be kept smaller. Be sure to ground the radio to vehicle body. EC-30 SEF708Y PREPARATION [CR (WITH EURO-OBD)] PREPARATION Special Service Tools PFP:00002 A BBS002TG Tool number Tool name Description EG17650301 Radiator cap tester adapter Adapting radiator cap tester to radiator cap and radiator filler neck a: 28 (1.10) dia. b: 31.4 (1.236) dia. c: 41.3 (1.626) dia. Unit: mm (in) EC C D S-NT564 KV10117100 Heated oxygen sensor wrench Loosening or tightening heated oxygen sensors with 22 mm (0.87 in) hexagon nut E F S-NT379 KV10114400 Heated oxygen sensor wrench Loosening or tightening heated oxygen sensors a: 22 mm (0.87 in) G H S-NT636 KV109E0010 Break-out box Measuring ECM signals with a circuit tester I J K NT825 KV109E0080 Y-cable adapter Measuring ECM signals with a circuit tester L M NT826 EC-31 PREPARATION [CR (WITH EURO-OBD)] Commercial Service Tools BBS002TH Tool name Description Quick connector release Removing fuel tube quick connectors in engine room (Available in SEC. 164 of PARTS CATALOG: Part No. 16441 6N210) PBIC0198E Fuel filler cap adapter Checking fuel tank vacuum relief valve opening pressure S-NT653 Socket wrench Removing and installing engine coolant temperature sensor S-NT705 Oxygen sensor thread cleaner Reconditioning the exhaust system threads before installing a new oxygen sensor. Use with anti-seize lubricant shown below. a: 18 mm diameter with pitch 1.5 mm for Zirconia Oxygen Sensor b: 12 mm diameter with pitch 1.25 mm for Titania Oxygen Sensor AEM488 Lubricating oxygen sensor thread cleaning tool when reconditioning exhaust system threads. Anti-seize lubricant i.e.: (PermatexTM 133AR or equivalent meeting MIL specification MIL-A907) S-NT779 EC-32 ENGINE CONTROL SYSTEM [CR (WITH EURO-OBD)] ENGINE CONTROL SYSTEM System Diagram PFP:23710 A BBS002TI EC C D E F G H I J K L M MBIB1551E EC-33 ENGINE CONTROL SYSTEM [CR (WITH EURO-OBD)] Multiport Fuel Injection (MFI) System BBS002TL INPUT/OUTPUT SIGNAL CHART Sensor Input Signal to ECM Crankshaft position sensor (POS) Camshaft position sensor (PHASE) Engine speed*3 Piston position Manifold absolute pressure sensor Amount of intake air Engine coolant temperature sensor Engine coolant temperature Heated oxygen sensor 1 Density of oxygen in exhaust gas Throttle position sensor Throttle position Accelerator pedal position sensor Accelerator pedal position Park/neutral position (PNP) switch Gear position Knock sensor Engine knocking condition Battery Battery voltage*3 EPS control unit Power steering operation*2 Heated oxygen sensor 2*1 Density of oxygen in exhaust gas Wheel sensor Vehicle speed*2 Air conditioner switch Air conditioner operation*2 ECM Function Fuel injection & mixture ratio control Actuator Fuel injector *1: This sensor is not used to control the engine system under normal conditions. *2: This signal is sent to the ECM through CAN communication line. *3: ECM determines the start signal status by the signals of engine speed and battery voltage. SYSTEM DESCRIPTION The amount of fuel injected from the fuel injector is determined by the ECM. The ECM controls the length of time the valve remains open (injection pulse duration). The amount of fuel injected is a program value in the ECM memory. The program value is preset by engine operating conditions. These conditions are determined by input signals (for engine speed and intake air volume) from the crankshaft position sensor (POS), camshaft position sensor (PHASE) and the manifold absolute pressure sensor. VARIOUS FUEL INJECTION INCREASE/DECREASE COMPENSATION In addition, the amount of fuel injected is compensated to improve engine performance under various operating conditions as listed below. ● During warm-up ● When starting the engine ● During acceleration ● Hot-engine operation ● High-load, high-speed operation ● During deceleration ● During high engine speed operation MIXTURE RATIO FEEDBACK CONTROL (CLOSED LOOP CONTROL) PBIB2938E EC-34 ENGINE CONTROL SYSTEM [CR (WITH EURO-OBD)] The mixture ratio feedback system provides the best air-fuel mixture ratio for driveability and emission control. The three way catalyst (manifold) can then better reduce CO, HC and NOx emissions. This system uses A heated oxygen sensor 1 in the exhaust manifold to monitor whether the engine operation is rich or lean. The ECM adjusts the injection pulse width according to the sensor voltage signal. For more information about heated oxygen sensor 1, refer to EC-178 . This maintains the mixture ratio within the range of stoichiometric EC (ideal air-fuel mixture). This stage is referred to as the closed loop control condition. Heated oxygen sensor 2 is located downstream of the three way catalyst (manifold). Even if the switching characteristics of heated oxygen sensor 1 shift, the air-fuel ratio is controlled to stoichiometric by the signal C from heated oxygen sensor 2. Open Loop Control D The open loop system condition refers to when the ECM detects any of the following conditions. Feedback control stops in order to maintain stabilized fuel combustion. ● Deceleration and acceleration ● High-load, high-speed operation ● Malfunction of heated oxygen sensor 1 or its circuit ● Insufficient activation of heated oxygen sensor 1 at low engine coolant temperature ● High engine coolant temperature ● During warm-up ● When starting the engine E F G MIXTURE RATIO SELF-LEARNING CONTROL The mixture ratio feedback control system monitors the mixture ratio signal transmitted from heated oxygen sensor 1. This feedback signal is then sent to the ECM. The ECM controls the basic mixture ratio as close to the theoretical mixture ratio as possible. However, the basic mixture ratio is not necessarily controlled as originally designed. Both manufacturing differences (i.e., manifold absolute pressure sensor silicon diaphragm) and characteristic changes during operation (i.e., fuel injector clogging) directly affect mixture ratio. Accordingly, the difference between the basic and theoretical mixture ratios is monitored in this system. This is then computed in terms of “injection pulse duration” to automatically compensate for the difference between the two ratios. “Fuel trim” refers to the feedback compensation value compared against the basic injection duration. Fuel trim includes short term fuel trim and long term fuel trim. “Short term fuel trim” is the short-term fuel compensation used to maintain the mixture ratio at its theoretical value. The signal from heated oxygen sensor 1 indicates whether the mixture ratio is RICH or LEAN compared to the theoretical value. The signal then triggers a reduction in fuel volume if the mixture ratio is rich, and an increase in fuel volume if it is lean. “Long term fuel trim” is overall fuel compensation carried out long-term to compensate for continual deviation of the short term fuel trim from the central value. Such deviation will occur due to individual engine differences, wear over time and changes in the usage environment. FUEL INJECTION TIMING H I J K L M SEF337W Two types of systems are used. Sequential Multiport Fuel Injection System Fuel is injected into each cylinder during each engine cycle according to the firing order. This system is used when the engine is running. EC-35 ENGINE CONTROL SYSTEM [CR (WITH EURO-OBD)] Simultaneous Multiport Fuel Injection System Fuel is injected simultaneously into all four cylinders twice each engine cycle. In other words, pulse signals of the same width are simultaneously transmitted from the ECM. The four fuel injectors will then receive the signals two times for each engine cycle. This system is used when the engine is being started and/or if the fail-safe system (CPU) is operating. FUEL SHUT-OFF Fuel to each cylinder is cut off during deceleration or operation of the engine at excessively high speeds or operation of the vehicle at excessively high speeds. Electronic Ignition (EI) System BBS002TM INPUT/OUTPUT SIGNAL CHART Sensor Input Signal to ECM Crankshaft position sensor (POS) Camshaft position sensor (PHASE) Engine speed*2 Piston position Manifold absolute pressure sensor Amount of intake air Engine coolant temperature sensor Engine coolant temperature Throttle position sensor Throttle position Accelerator pedal position sensor Accelerator pedal position Knock sensor Engine knocking Park/neutral position (PNP) switch Gear position Battery Battery voltage*2 Wheel sensor Vehicle speed*1 ECM Function Ignition timing control Actuator Power transistor *1: This signal is sent to the ECM through CAN communication line. *2: ECM determines the start signal status by the signals of engine speed and battery voltage. SYSTEM DESCRIPTION Firing order: 1 - 3 - 4 - 2 The ignition timing is controlled by the ECM to maintain the best air-fuel ratio for every running condition of the engine. The ignition timing data is stored in the ECM. The ECM receives information such as the injection pulse width and camshaft position sensor signal. Computing this information, ignition signals are transmitted to the power transistor. During the following conditions, the ignition timing is revised by the ECM according to the other data stored in the ECM. ● At starting ● During warm-up ● At idle ● At low battery voltage ● During acceleration The knock sensor retard system is designed only for emergencies. The basic ignition timing is programmed within the anti-knocking zone, if recommended fuel is used under dry conditions. The retard system does not operate under normal driving conditions. If engine knocking occurs, the knock sensor monitors the condition. The signal is transmitted to the ECM. The ECM retards the ignition timing to eliminate the knocking condition. Fuel Cut Control (at No Load and High Engine Speed) BBS002TO INPUT/OUTPUT SIGNAL CHART Sensor Park/neutral position (PNP) switch Input Signal to ECM ECM Function Actuator Neutral position Accelerator pedal position sensor Accelerator pedal position Engine coolant temperature sensor Engine coolant temperature Crankshaft position sensor (POS) Camshaft position sensor (PHASE) Engine speed Wheel sensor Vehicle speed* EC-36 Fuel cut control Fuel injector ENGINE CONTROL SYSTEM [CR (WITH EURO-OBD)] *: This signal is sent to the ECM through CAN communication line. A SYSTEM DESCRIPTION If the engine speed is above 2,500 rpm with no load (for example, the shift position is neutral and engine speed is over 2,500 rpm) fuel will be cut off after some time. The exact time when the fuel is cut off varies EC based on engine speed. Fuel cut will operate until the engine speed reaches 2,000 rpm, then fuel cut is cancelled. NOTE: This function is different from deceleration control listed under EC-34, "Multiport Fuel Injection (MFI) System" . C D E F G H I J K L M EC-37 AIR CONDITIONING CUT CONTROL [CR (WITH EURO-OBD)] AIR CONDITIONING CUT CONTROL Input/Output Signal Chart Sensor PFP:23710 BBS003ZD Input Signal to ECM ECM Function Actuator 1 Air conditioner switch Air conditioner ON signal* Accelerator pedal position sensor Accelerator pedal position Crankshaft position sensor (POS) Camshaft position sensor (PHASE) Engine speed*2 Engine coolant temperature sensor Engine coolant temperature Refrigerant pressure sensor Refrigerant pressure EPS control unit Power steering operation*1 Wheel sensor Vehicle speed*1 Battery Battery voltage*2 Air conditioner cut control *1: This signal is sent to the ECM through CAN communication line. *2: ECM determines the start signal status by the signals of engine speed and battery voltage. SYSTEM DESCRIPTION This system improves engine operation when the air conditioner is used. Under the following conditions, the air conditioner is turned OFF. ● When the accelerator pedal is fully depressed. ● When cranking the engine. ● At high engine speeds. ● When the engine coolant temperature becomes excessively high. ● When operating power steering during low engine speed or low vehicle speed. ● When engine speed is excessively low. ● When refrigerant pressure is excessively low or high. EC-38 Air conditioner relay CAN COMMUNICATION [CR (WITH EURO-OBD)] CAN COMMUNICATION System Description PFP:23710 A BBS003ZE CAN (Controller Area Network) is a serial communication line for real time application. It is an on-vehicle multiplex communication line with high data communication speed and excellent error detection ability. Many elec- EC tronic control units are equipped onto a vehicle, and each control unit shares information and links with other control units during operation (not independent). In CAN communication, control units are connected with 2 communication lines (CAN H line, CAN L line) allowing a high rate of information transmission with less wiring. C Each control unit transmits/receives data but selectively reads required data only. Refer to LAN-21, "CAN COMMUNICATION" , about CAN communication for detail. D E F G H I J K L M EC-39 EVAPORATIVE EMISSION SYSTEM [CR (WITH EURO-OBD)] EVAPORATIVE EMISSION SYSTEM Description PFP:14950 BBS00343 SYSTEM DESCRIPTION PBIB0491E The evaporative emission system is used to reduce hydrocarbons emitted into the atmosphere from the fuel system. This reduction of hydrocarbons is accomplished by activated charcoals in the EVAP canister. The fuel vapor in the sealed fuel tank is led into the EVAP canister which contains activated carbon and the vapor is stored there when the engine is not operating or when refueling to the fuel tank. The vapor in the EVAP canister is purged by the air through the purge line to the intake manifold when the engine is operating. EVAP canister purge volume control solenoid valve is controlled by ECM. When the engine operates, the flow rate of vapor controlled by EVAP canister purge volume control solenoid valve is proportionally regulated as the air flow increases. EVAP canister purge volume control solenoid valve also shuts off the vapor purge line during decelerating and idling. EC-40 EVAPORATIVE EMISSION SYSTEM [CR (WITH EURO-OBD)] EVAPORATIVE EMISSION LINE DRAWING A EC C D E F G H I J K L M MBIB0544E EC-41 EVAPORATIVE EMISSION SYSTEM [CR (WITH EURO-OBD)] MBIB1450E : Vehicle front 1. : To previous page EVAP canister EC-42 EVAPORATIVE EMISSION SYSTEM [CR (WITH EURO-OBD)] Component Inspection BBS00344 A EVAP CANISTER Check EVAP canister as follows: 1. Block port (B). 2. Blow air into port (A) and check that it flows freely out of port (C). 3. Release blocked port (B). 4. Apply vacuum pressure to port (B) and check that vacuum pressure exists at the ports (A) and (C). 5. Block port (A) and (B). 6. Apply pressure to port (C) and check that there is no leakage. EC C D PBIB2961E FUEL CHECK VALVE 1. 2. 3. E Blow air through connector on fuel tank side. A considerable resistance should be felt and a portion of air flow should be directed toward the EVAP canister side. Blow air through connector on EVAP canister side. Air flow should be smoothly directed toward fuel tank side. If fuel check valve is suspected of not properly functioning in steps 1 and 2 above, replace it. F G H SEF552Y FUEL TANK VACUUM RELIEF VALVE (BUILT INTO FUEL FILLER CAP) 1. I Wipe clean valve housing. J K SEF989X 2. Check valve opening pressure and vacuum. Pressure: Vacuum: 3. L M 15.3 - 20.0 kPa (0.153 - 0.200 bar, 0.156 - 0.204 kg/cm2 , 2.22 - 2.90 psi) −6.0 to −3.4 kPa (−0.060 to −0.034 bar, −0.061 to −0.035 kg/cm2 , −0.87 to −0.49 psi) If out of specification, replace fuel filler cap as an assembly. SEF943S EVAP CANISTER PURGE VOLUME CONTROL SOLENOID VALVE Refer to EC-275, "Component Inspection" . EC-43 NATS (NISSAN ANTI-THEFT SYSTEM) [CR (WITH EURO-OBD)] NATS (NISSAN ANTI-THEFT SYSTEM) Description ● ● ● PFP:25386 BBS003ZF If the security indicator lights up with the ignition switch in the ON position or “NATS MALFUNCTION” is displayed on “SELF-DIAG RESULTS” screen, perform self-diagnostic results mode with CONSULT-II using NATS program card. Refer to BL-215, "NATS (Nissan Anti-Theft System)" . Confirm no self-diagnostic results of NATS is displayed before touching “ERASE” in “SELF-DIAG RESULTS” mode with CONSULT-II. When replacing ECM, initialization of NATS system and registration of all NATS ignition key IDs must be carried out SEF515Y with CONSULT-II using NATS program card. Therefore, be sure to receive all keys from vehicle owner. Regarding the procedures of NATS initialization and all NATS ignition key ID registration, refer to CONSULT-II Operation Manual, NATS. EC-44 POSITIVE CRANKCASE VENTILATION [CR (WITH EURO-OBD)] POSITIVE CRANKCASE VENTILATION Description PFP:11810 A BBS00345 SYSTEM DESCRIPTION EC C D E F G PBIB0492E This system returns blow-by gas to the intake manifold. The positive crankcase ventilation (PCV) valve is provided to conduct crankcase blow-by gas to the intake manifold. During partial throttle operation of the engine, the intake manifold sucks the blow-by gas through the PCV valve. Normally, the capacity of the valve is sufficient to handle any blow-by and a small amount of ventilating air. The ventilating air is then drawn from the air inlet tubes into the crankcase. In this process the air passes through the hose connecting air inlet tubes to rocker cover. Under full-throttle condition, the manifold vacuum is insufficient to draw the blow-by flow through the valve. The flow goes through the hose connection in the reverse direction. On vehicles with an excessively high blow-by, the valve does not meet the requirement. This is because some of the flow will go through the hose connection to the air inlet tubes under all conditions. H I J K L PBIB1588E Component Inspection BBS00346 PCV (POSITIVE CRANKCASE VENTILATION) VALVE With engine running at idle, remove PCV valve from rocker cover. A properly working valve makes a hissing noise as air passes through it. A strong vacuum should be felt immediately when a finger is placed over valve inlet. PBIB1589E EC-45 M POSITIVE CRANKCASE VENTILATION [CR (WITH EURO-OBD)] PCV VALVE VENTILATION HOSE 1. 2. Check hoses and hose connections for leaks. Disconnect all hoses and clean with compressed air. If any hose cannot be freed of obstructions, replace. S-ET277 EC-46 ON BOARD DIAGNOSTIC (OBD) SYSTEM [CR (WITH EURO-OBD)] ON BOARD DIAGNOSTIC (OBD) SYSTEM Introduction PFP:00028 A BBS002TV The ECM has an on board diagnostic system, which detects malfunctions related to engine sensors or actuators. The ECM also records various emission-related diagnostic information including: EC Emission-related diagnostic information ISO Standard Diagnostic Trouble Code (DTC) Service $03 of ISO 15031-5 Freeze Frame data Service $02 of ISO 15031-5 System Readiness Test (SRT) code Service $01 of ISO 15031-5 1st Trip Diagnostic Trouble Code (1st Trip DTC) Service $07 of ISO 15031-5 C D 1st Trip Freeze Frame data Test values and Test limits Service $06 of ISO 15031-5 Calibration ID Service $09 of ISO 15031-5 The above information can be checked using procedures listed in the table below. E ×: Applicable —: Not applicable DTC 1st trip DTC Freeze Frame data 1st trip Freeze Frame data SRT code Test value CONSULT-II × × × × × — GST × × × — × × ECM × ×* — — — — G H *: When DTC and 1st trip DTC simultaneously appear on the display, they cannot be clearly distinguished from each other. The malfunction indicator (MI) on the instrument panel lights up when the same malfunction is detected in two consecutive trips (Two trip detection logic), or when the ECM enters fail-safe mode. (Refer to EC-81 .) Two Trip Detection Logic F I BBS002TW When a malfunction is detected for the first time, 1st trip DTC and 1st trip Freeze Frame data are stored in the ECM memory. The MI will not light up at this stage. <1st trip> If the same malfunction is detected again during the next drive, the DTC and Freeze Frame data are stored in the ECM memory, and the MI lights up. The MI lights up at the same time when the DTC is stored. <2nd trip> The “trip” in the “Two Trip Detection Logic” means a driving mode in which self-diagnosis is performed during vehicle operation. Specific on board diagnostic items will cause the ECM to light up or blink the MI, and store DTC and Freeze Frame data, even in the 1st trip, as shown below. ×: Applicable MI DTC 1st trip Items 2nd trip 1st trip DTC 2nd trip displaying 1st trip displaying 2nd trip displaying — — — × — × — — × — — × — — × — — — — — × — × × — Blinking Blinking Lighting up Misfire (Possible three way catalyst damage) — DTC: P0300 - P0304 is being detected × — — Misfire (Possible three way catalyst damage) — DTC: P0300 - P0304 is being detected — — One trip detection diagnoses (Refer to EC-48 ) — Except above — When there is an open circuit on MI circuit, the ECM can not warn the driver by lighting up MI when there is a malfunction on engine control system. Therefore, when electrical controlled throttle and part of ECM related diagnoses are continuously detected as NG for 5 trips, ECM warns the driver that engine control system has malfunction and MI circuit is open by means of operating fail-safe function. EC-47 K —: Not applicable 1st trip displaying Lighting up J L M ON BOARD DIAGNOSTIC (OBD) SYSTEM [CR (WITH EURO-OBD)] The fail-safe function also operate when above diagnoses except MI circuit are detected and demands the driver to repair the malfunction. Engine operating condition in fail-safe mode Engine speed will not rise more than 2,500 rpm due to the fuel cut Emission-related Diagnostic Information BBS002TX EMISSION-RELATED DIAGNOSTIC INFORMATION ITEMS 1 DTC* Items (CONSULT-II screen terms) CONSULT-II GST*2 ×: Applicable —: Not applicable SRT code Test Valve/ Test Limit (GST only) Trip MI lighting up Reference page ECM*3 CAN COMM CIRCUIT U1001 1001*4 — — 2 — EC-134 CONTROL UNIT(CAN) U1010 1010 — — 2 — EC-137 NO DTC IS DETECTED. FURTHER TESTING MAY BE REQUIRED. P0000 0000 — — — — — INT/V TIM CONT-B1 P0011 0011 — — 2 — EC-139 HO2S1 HTR (B1) P0031 0031 × × 2 × EC-143 HO2S1 HTR (B1) P0032 0032 × × 2 × EC-143 HO2S2 HTR (B1) P0037 0037 × × 2 × EC-149 HO2S2 HTR (B1) P0038 0038 × × 2 × EC-149 ABSL PRES SEN/CIRC P0107 0107 — — 2 × EC-155 ABSL PRES SEN/CIRC P0108 0108 — — 2 × EC-155 IAT SEN/CIRCUIT P0112 0112 — — 2 × EC-161 IAT SEN/CIRCUIT P0113 0113 — — 2 × EC-161 ECT SEN/CIRC P0117 0117 — — 1 × EC-166 ECT SEN/CIRC P0118 0118 — — 1 × EC-166 TP SEN 2/CIRC P0122 0122 — — 1 × EC-171 TP SEN 2/CIRC P0123 0123 — — 1 × EC-171 HO2S1 (B1) P0132 0132 × × 2 × EC-178 HO2S1 (B1) P0133 0133 × × 2 × EC-185 HO2S1 (B1) P0134 0134 × × 2 × EC-195 HO2S2 (B1) P0138 0138 × × 2 × EC-203 HO2S2 (B1) P0139 0139 × × 2 × EC-210 FUEL SYS-LEAN-B1 P0171 0171 — — 2 × EC-218 FUEL SYS-RICH-B1 P0172 0172 — — 2 × EC-226 TP SEN 1/CIRC P0222 0222 — — 1 × EC-233 TP SEN 1/CIRC P0223 0223 — — 1 × EC-233 MULTI CYL MISFIRE P0300 0300 — — 2 × EC-240 CYL 1 MISFIRE P0301 0301 — — 2 × EC-240 CYL 2 MISFIRE P0302 0302 — — 2 × EC-240 CYL 3 MISFIRE P0303 0303 — — 2 × EC-240 CYL 4 MISFIRE P0304 0304 — — 2 × EC-240 KNOCK SEN/CIRC-B1 P0327 0327 — — 2 — EC-246 KNOCK SEN/CIRC-B1 P0328 0328 — — 2 — EC-246 CKP SEN/CIRCUIT P0335 0335 — — 2 × EC-250 CMP SEN/CIRC-B1 P0340 0340 — — 2 × EC-257 TW CATALYST SYS-B1 P0420 0420 × × 2 × EC-264 PURG VOLUME CONT/V P0444 0444 — — 2 × EC-270 EC-48 ON BOARD DIAGNOSTIC (OBD) SYSTEM [CR (WITH EURO-OBD)] DTC*1 Items (CONSULT-II screen terms) CONSULT-II SRT code Test Valve/ Test Limit (GST only) Trip MI lighting up Reference page A EC 3 GST*2 ECM* VEH SPEED SEN/CIRC P0500 0500 — — 2 × EC-277 ECM P0605 0605 — — 1 or 2 × or — EC-279 ECM BACK UP/CIRCUIT P1065 1065 — — 2 × EC-282 INT/V TIM V/CIR-B1 P1111 1111 — — 2 × EC-286 ETC ACTR P1121 1121 — — 1 × EC-291 ETC FUNCTION/CIRC P1122 1122 — — 1 × EC-293 ETC MOT PWR P1124 1124 — — 1 × EC-299 ETC MOT PWR P1126 1126 — — 1 × EC-299 ETC MOT P1128 1128 — — 1 × EC-305 HO2S1 (B1) P1143 1143 × × 2 × EC-310 HO2S1 (B1) P1144 1144 × × 2 × EC-316 HO2S2 (B1) P1146 1146 × × 2 × EC-322 HO2S2 (B1) P1147 1147 × × 2 × EC-330 INTAKE ERROR P1171 1171 — — 1 × EC-338 TCS C/U FUNCTN P1211 1211 — — 2 — EC-343 TCS/CIRC P1212 1212 — — 2 — EC-344 ENG OVER TEMP P1217 1217 — — 1 × EC-345 CTP LEARNING P1225 1225 — — 2 — EC-359 CTP LEARNING P1226 1226 — — 2 — EC-361 SENSOR POWER/CIRC P1229 1229 — — 1 × EC-363 NATS MALFUNCTION P1610 P1615 1610 - 1615 — — 2 — EC-44 P-N POS SW/CIRCUIT P1706 1706 — — 2 × EC-371 BRAKE SW/CIRCUIT P1805 1805 — — 2 — EC-377 APP SEN 1/CIRC P2122 2122 — — 1 × EC-383 APP SEN 1/CIRC P2123 2123 — — 1 × EC-383 APP SEN 2/CIRC P2127 2127 — — 1 × EC-392 APP SEN 2/CIRC P2128 2128 — — 1 × EC-392 TP SENSOR P2135 2135 — — 1 × EC-402 APP SENSOR P2138 2138 — — 1 × EC-409 *1: 1st trip DTC No. is the same as DTC No. *2: This number is prescribed by ISO 15031-5. *3: In Diagnostic Test Mode II (Self-diagnostic results), this number is controlled by NISSAN. *4: The troubleshooting for this DTC needs CONSULT-II. DTC AND 1ST TRIP DTC The 1st trip DTC (whose number is the same as the DTC number) is displayed for the latest self-diagnostic result obtained. If the ECM memory was cleared previously, and the 1st trip DTC did not reoccur, the 1st trip DTC will not be displayed. If a malfunction is detected during the 1st trip, the 1st trip DTC is stored in the ECM memory. The MI will not light up (two trip detection logic). If the same malfunction is not detected in the 2nd trip (meeting the required driving pattern), the 1st trip DTC is cleared from the ECM memory. If the same malfunction is detected in the 2nd trip, both the 1st trip DTC and DTC are stored in the ECM memory and the MI lights up. In other words, the DTC is stored in the ECM memory and the MI lights up when the same malfunction occurs in two consecutive trips. If a 1st trip DTC is stored and a non-diagnostic operation is performed between the 1st and 2nd trips, only the 1st trip DTC will continue to be stored. For malfunctions that blink or light up the MI during the 1st trip, the DTC and 1st trip DTC are stored in the ECM memory. EC-49 C D E F G H I J K L M ON BOARD DIAGNOSTIC (OBD) SYSTEM [CR (WITH EURO-OBD)] Procedures for clearing the DTC and the 1st trip DTC from the ECM memory are described in EC-57, "HOW TO ERASE EMISSION-RELATED DIAGNOSTIC INFORMATION" . For malfunctions in which 1st trip DTCs are displayed, refer to EC-48, "EMISSION-RELATED DIAGNOSTIC INFORMATION ITEMS" . These items are required by legal regulations to continuously monitor the system/ component. In addition, the items monitored non-continuously are also displayed on CONSULT-II. 1st trip DTC is specified in Service $07 of ISO 15031-5. 1st trip DTC detection occurs without lighting up the MI and therefore does not warn the driver of a malfunction. However, 1st trip DTC detection will not prevent the vehicle from being tested, for example during Inspection/Maintenance (I/M) tests. When a 1st trip DTC is detected, check, print out or write down and erase (1st trip) DTC and Freeze Frame data as specified in Work Flow procedure Step 2, refer to EC-75, "WORK FLOW" . Then perform DTC Confirmation Procedure or Overall Function Check to try to duplicate the malfunction. If the malfunction is duplicated, the item requires repair. How to Read DTC and 1st Trip DTC DTC and 1st trip DTC can be read by the following methods. With CONSULT-II With GST CONSULT-II or GST (Generic Scan Tool) Examples: P0112, P1217, P1805, etc. These DTCs are prescribed by ISO 15031-5. (CONSULT-II also displays the malfunctioning component or system.) No Tools The number of blinks of the MI in the Diagnostic Test Mode II (Self-Diagnostic Results) indicates the DTC. Example: 0112, 1217, 1805 etc. These DTCs are controlled by NISSAN. ● 1st trip DTC No. is the same as DTC No. ● Output of a DTC indicates a malfunction. However, GST or the Diagnostic Test Mode II do not indicate whether the malfunction is still occurring or has occurred in the past and has returned to normal. CONSULT-II can identify malfunction status as shown below. Therefore, using CONSULT-II (if available) is recommended. A sample of CONSULT-II display for DTC and 1st trip DTC is shown below. DTC or 1st trip DTC of a malfunction is displayed in SELF-DIAGNOSTIC RESULTS mode of CONSULT-II. Time data indicates how many times the vehicle was driven after the last detection of a DTC. If the DTC is being detected currently, the time data will be [0]. If a 1st trip DTC is stored in the ECM, the time data will be [1t]. PBIB0911E FREEZE FRAME DATA AND 1ST TRIP FREEZE FRAME DATA The ECM records the driving conditions such as fuel system status, calculated load value, engine coolant temperature, short term fuel trim, long term fuel trim, engine speed, vehicle speed, base fuel schedule and intake air temperature at the moment a malfunction is detected. Data which are stored in the ECM memory, along with the 1st trip DTC, are called 1st trip freeze frame data. The data, stored together with the DTC data, are called freeze frame data and displayed on CONSULT-II or GST. The 1st trip freeze frame data can only be displayed on the CONSULT-II screen, not on the GST. For details, see EC-104, "Freeze Frame Data and 1st Trip Freeze Frame Data" . Only one set of freeze frame data (either 1st trip freeze frame data or freeze frame data) can be stored in the ECM. 1st trip freeze frame data is stored in the ECM memory along with the 1st trip DTC. There is no priority for 1st trip freeze frame data and it is updated each time a different 1st trip DTC is detected. However, once freeze frame data (2nd trip detection/MI on) is stored in the ECM memory, 1st trip freeze frame data is no longer stored. Remember, only one set of freeze frame data can be stored in the ECM. The ECM has the following priorities to update the data. EC-50 ON BOARD DIAGNOSTIC (OBD) SYSTEM [CR (WITH EURO-OBD)] Priority 1 Items Freeze frame data 2 3 A Misfire — DTC: P0300 - P0304 Fuel Injection System Function — DTC: P0171, P0172 Except the above items EC 1st trip freeze frame data For example, the EGR malfunction (Priority: 2) was detected and the freeze frame data was stored in the 2nd trip. After that when the misfire (Priority: 1) is detected in another trip, the freeze frame data will be updated from the EGR malfunction to the misfire. The 1st trip freeze frame data is updated each time a different malfunction is detected. There is no priority for 1st trip freeze frame data. However, once freeze frame data is stored in the ECM memory, 1st trip freeze data is no longer stored (because only one freeze frame data or 1st trip freeze frame data can be stored in the ECM). If freeze frame data is stored in the ECM memory and freeze frame data with the same priority occurs later, the first (original) freeze frame data remains unchanged in the ECM memory. Both 1st trip freeze frame data and freeze frame data (along with the DTCs) are cleared when the ECM memory is erased. Procedures for clearing the ECM memory are described in EC-57, "HOW TO ERASE EMISSION-RELATED DIAGNOSTIC INFORMATION" . System Readiness Test (SRT) code is specified in Service $01 of ISO 15031-5. As part of an enhanced emissions test for Inspection & Maintenance (I/M), certain states require the status of SRT be used to indicate whether the ECM has completed self-diagnosis of major emission systems and components. Completion must be verified in order for the emissions inspection to proceed. If a vehicle is rejected for a State emissions inspection due to one or more SRT items indicating “INCMP”, use the information in this Service Manual to set the SRT to “CMPLT”. In most cases the ECM will automatically complete its self-diagnosis cycle during normal usage, and the SRT status will indicate “CMPLT” for each application system. Once set as “CMPLT”, the SRT status remains “CMPLT” until the self-diagnosis memory is erased. Occasionally, certain portions of the self-diagnostic test may not be completed as a result of the customer's normal driving pattern; the SRT will indicate “INCMP” for these items. NOTE: The SRT will also indicate “INCMP” if the self-diagnosis memory is erased for any reason or if the ECM memory power supply is interrupted for several hours. If, during the state emissions inspection, the SRT indicates “CMPLT” for all test items, the inspector will continue with the emissions test. However, if the SRT indicates “INCMP” for one or more of the SRT items the vehicle is returned to the customer untested. NOTE: If MI is ON during the state emissions inspection, the vehicle is also returned to the customer untested even though the SRT indicates “CMPLT” for all test items. Therefore, it is important to check SRT (“CMPLT”) and DTC (No DTCs) before the inspection. SRT Item E Required self-diagnostic items to set the SRT to “CMPLT” Corresponding DTC No. CATALYST 2 Three way catalyst function P0420 HO2S 1 Heated oxygen sensor 1 P0132 Heated oxygen sensor 1 P0133 Heated oxygen sensor 1 P0134 Heated oxygen sensor 1 P1143 Heated oxygen sensor 1 P1144 Heated oxygen sensor 2 P0138 Heated oxygen sensor 2 P0139 Heated oxygen sensor 2 P1146 Heated oxygen sensor 2 P1147 EC-51 G H I J K L M The table below shows required self-diagnostic items to set the SRT to “CMPLT”. Performance Priority* D F SYSTEM READINESS TEST (SRT) CODE SRT item (CONSULT-II indication) C ON BOARD DIAGNOSTIC (OBD) SYSTEM [CR (WITH EURO-OBD)] SRT item (CONSULT-II indication) Performance Priority* HO2S HTR 1 Required self-diagnostic items to set the SRT to “CMPLT” Corresponding DTC No. Heated oxygen sensor 1 heater P0031, P0032 Heated oxygen sensor 2 heater P0037, P0038 *: If completion of several SRTs is required, perform driving patterns (DTC confirmation procedure), one by one based on the priority for models with CONSULT-II. SRT Set Timing SRT is set as “CMPLT” after self-diagnosis has been performed one or more times. Completion of SRT is done regardless of whether the result is OK or NG. The set timing is different between OK and NG results and is shown in the table below. Example Self-diagnosis result All OK Case 1 Case 2 NG exists Case 3 Ignition cycle ← ON → OFF ← ON → Diagnosis ← ON → P0400 OK (1) — (1) OK (2) — (2) P0402 OK (1) — (1) — (1) OK (2) P1402 OK (1) OK (2) — (2) — (2) SRT of EGR “CMPLT” “CMPLT” “CMPLT” “CMPLT” P0400 OK (1) — (1) — (1) — (1) P0402 — (0) — (0) OK (1) — (1) P1402 OK (1) OK (2) — (2) — (2) SRT of EGR “INCMP” “INCMP” “CMPLT” “CMPLT” P0400 OK OK — — P0402 — — — — P1402 NG — NG NG (Consecutive NG) (1st trip) DTC 1st trip DTC — 1st trip DTC DTC (= MI “ON”) SRT of EGR “INCMP” “INCMP” “INCMP” “CMPLT” OFF OFF ← ON → OK: Self-diagnosis is carried out and the result is OK. NG: Self-diagnosis is carried out and the result is NG. —: Self-diagnosis is not carried out. When all SRT related self-diagnoses showed OK results in a single cycle (Ignition OFF-ON-OFF), the SRT will indicate “CMPLT”. → Case 1 above When all SRT related self-diagnoses showed OK results through several different cycles, the SRT will indicate “CMPLT” at the time the respective self-diagnoses have at least one OK result. → Case 2 above If one or more SRT related self-diagnoses showed NG results in 2 consecutive cycles, the SRT will also indicate “CMPLT”. → Case 3 above The table above shows that the minimum number of cycles for setting SRT as “INCMP” is one (1) for each self-diagnosis (Case 1 & 2) or two (2) for one of self-diagnoses (Case 3). However, in preparation for the state emissions inspection, it is unnecessary for each self-diagnosis to be executed twice (Case 3) for the following reasons: ● The SRT will indicate “CMPLT” at the time the respective self-diagnoses have one (1) OK result. ● The emissions inspection requires “CMPLT” of the SRT only with OK self-diagnosis results. ● When, during SRT driving pattern, 1st trip DTC (NG) is detected prior to “CMPLT” of SRT, the self-diagnosis memory must be erased from ECM after repair. ● If the 1st trip DTC is erased, all the SRT will indicate “INCMP”. NOTE: SRT can be set as “CMPLT” together with the DTC (s). Therefore, DTC check must always be carried out prior to the state emission inspection even though the SRT indicates “CMPLT”. EC-52 ON BOARD DIAGNOSTIC (OBD) SYSTEM [CR (WITH EURO-OBD)] SRT Service Procedure If a vehicle has failed the state emissions inspection due to one or more SRT items indicating “INCMP”, review the flowchart diagnostic sequence on the next page. A EC C D E F G H I J K L M SEF573XB *1 EC-50 *2 EC-54 *3 EC-53 EC-54 ON BOARD DIAGNOSTIC (OBD) SYSTEM [CR (WITH EURO-OBD)] How to Display SRT Code WITH CONSULT-II Selecting “SRT STATUS” in “DTC & SRT CONFIRMATION” mode with CONSULT-II. For items whose SRT codes are set, a “CMPLT” is displayed on the CONSULT-II screen; for items whose SRT codes are not set, “INCMP” is displayed. A sample of CONSULT-II display for SRT code is shown at right. “INCMP” means the self-diagnosis is incomplete and SRT is not set. “CMPLT” means the self-diagnosis is complete and SRT is set. WITH GST Selecting Service $01 with GST (Generic Scan Tool) PBIB0666E How to Set SRT Code To set all SRT codes, self-diagnosis for the items indicated above must be performed one or more times. Each diagnosis may require a long period of actual driving under various conditions. WITH CONSULT-II Perform corresponding DTC Confirmation Procedure one by one based on Performance Priority in the table on EC-51 . WITHOUT CONSULT-II The most efficient driving pattern in which SRT codes can be properly set is explained on the next page. The driving pattern should be performed one or more times to set all SRT codes. EC-54 ON BOARD DIAGNOSTIC (OBD) SYSTEM [CR (WITH EURO-OBD)] Driving Pattern A EC C D E F G H I J K L M PBIB2451E EC-55 ON BOARD DIAGNOSTIC (OBD) SYSTEM [CR (WITH EURO-OBD)] The time required for each diagnosis varies with road surface conditions, weather, altitude, individual driving habits, etc. Zone A refers to the range where the time, required for the diagnosis under normal conditions*, is the shortest. Zone B refers to the range where the diagnosis can still be performed if the diagnosis is not completed within zone A. *: Normal conditions refer to the following: ● Sea level ● Flat road ● Ambient air temperature: 20 - 30°C (68 - 86°F) ● Diagnosis is performed as quickly as possible under normal conditions. Under different conditions [For example: ambient air temperature other than 20 - 30°C (68 - 86°F)], diagnosis may also be performed. Pattern 1: ● The engine is started at the engine coolant temperature of −10 to 35°C (14 to 95°F) (where the voltage between the ECM terminal 72 and ground is 3.0 - 4.3V). ● The engine must be operated at idle speed until the engine coolant temperature is greater than 70°C (158°F) (where the voltage between the ECM terminal 72 and ground is lower than 1.4V). Pattern 2: ● When steady-state driving is performed again even after it is interrupted, each diagnosis can be conducted. In this case, the time required for diagnosis may be extended. *1: Depress the accelerator pedal until vehicle speed is 90 km/h (56 MPH), then release the accelerator pedal and keep it released for more than 10 seconds. Depress the accelerator pedal until vehicle speed is 90 km/h (56 MPH) again. *2: Checking the vehicle speed with GST is advised. ● TEST VALUE AND TEST LIMIT (GST ONLY — NOT APPLICABLE TO CONSULT-II) The following is the information specified in Service $06 of ISO 15031-5. The test value is a parameter used to determine whether a system/circuit diagnostic test is OK or NG while being monitored by the ECM during self-diagnosis. The test limit is a reference value which is specified as the maximum or minimum value and is compared with the test value being monitored. These data (test value and test limit) are specified by Test ID (TID) and Component ID (CID) and can be displayed on the GST screen. SRT item CATALYST Self-diagnostic test item Three way catalyst function Heated oxygen sensor 1 HO2S Heated oxygen sensor 2 Heated oxygen sensor 1 heater HO2S HTR Heated oxygen sensor 2 heater Test value (GST display) DTC Test limit TID CID P0420 01H 01H Max. P0420 02H 81H Min. P0133 09H 04H Max. P1143 0AH 84H Min. P1144 0BH 04H Max. P0132 0CH 04H Max. P0134 0DH 04H Max. P0139 19H 86H Min. P1147 1AH 86H Min. P1146 1BH 06H Max. P0138 1CH 06H Max. P0032 29H 08H Max. P0031 2AH 88H Min. P0038 2DH 0AH Max. P0037 2EH 8AH Min. EC-56 ON BOARD DIAGNOSTIC (OBD) SYSTEM [CR (WITH EURO-OBD)] HOW TO ERASE EMISSION-RELATED DIAGNOSTIC INFORMATION How to Erase DTC A With CONSULT-II The emission related diagnostic information in the ECM can be erased by selecting “ERASE” in the “SELFEC DIAG RESULTS” mode with CONSULT-II. 1. If the ignition switch stays ON after repair work, be sure to turn ignition switch OFF once. Wait at least 10 seconds and then turn it ON (engine stopped) again. C 2. Touch “ENGINE”. 3. Touch “SELF-DIAG RESULTS”. 4. Touch “ERASE”. (The DTC in the ECM will be erased.) D E F G H I MBIB1303E With GST The emission related diagnostic information in the ECM can be erased by selecting Service $04 with GST. 1. If the ignition switch stays ON after repair work, be sure to turn ignition switch OFF once. Wait at least 10 seconds and then turn it ON (engine stopped) again. 2. Select Service $04 with GST (Generic Scan Tool). No Tools If the ignition switch stays ON after repair work, be sure to turn ignition switch OFF once. Wait at least 10 seconds and then turn it ON (engine stopped) again. Change the diagnostic test mode from Mode II to Mode I by depressing the accelerator pedal. Refer to EC-59, "HOW TO SWITCH DIAGNOSTIC TEST MODE" . ● If the battery is disconnected, the emission-related diagnostic information will be lost within 24 hours. ● The following data are cleared when the ECM memory is erased. – Diagnostic trouble codes – 1st trip diagnostic trouble codes – Freeze frame data – 1st trip freeze frame data – System readiness test (SRT) codes – Test values Actual work procedures are explained using a DTC as an example. Be careful so that not only the DTC, but all of the data listed above, are cleared from the ECM memory during work procedures. 1. 2. 3. EC-57 J K L M ON BOARD DIAGNOSTIC (OBD) SYSTEM [CR (WITH EURO-OBD)] Malfunction Indicator (MI) BBS002TZ DESCRIPTION The MI is located on the instrument panel. 1. The MI will light up when the ignition switch is turned ON without the engine running. This is a bulb check. If the MI does not light up, refer to DI-32, "WARNING LAMPS" or see EC-448 . 2. When the engine is started, the MI should go off. If the MI remains on, the on board diagnostic system has detected an engine system malfunction. SAT652J ON BOARD DIAGNOSTIC SYSTEM FUNCTION The on board diagnostic system has the following four functions. Diagnostic Test Mode KEY and ENG. Status Function Explanation of Function Mode I Ignition switch in ON position BULB CHECK This function checks the MI bulb for damage (blown, open circuit, etc.). If the MI does not come on, check MI circuit. MALFUNCTION WARNING This is a usual driving condition. When a malfunction is detected twice in two consecutive driving cycles (two trip detection logic), the MI will light up to inform the driver that a malfunction has been detected. The following malfunctions will light up or blink the MI in the 1st trip. Engine stopped Engine running Mode II Ignition switch in ON position ● Misfire (Possible three way catalyst damage) ● One trip detection diagnoses SELF-DIAGNOSTIC RESULTS This function allows DTCs and 1st trip DTCs to be read. HEATED OXYGEN SENSOR 1 MONITOR This function allows the fuel mixture condition (lean or rich), monitored by heated oxygen sensor 1, to be read. Engine stopped Engine running When there is an open circuit on MI circuit, the ECM can not warn the driver by lighting up MI when there is malfunction on engine control system. Therefore, when electrical controlled throttle and part of ECM related diagnoses are continuously detected as NG for 5 trips, ECM warns the driver that engine control system has a malfunction and MI circuit is open by means of operating fail-safe function. The fail-safe function also operate when above diagnoses except MI circuit are detected and demands the driver to repair the a malfunction. Engine operating condition in fail-safe mode Engine speed will not rise more than 2,500 rpm due to the fuel cut EC-58 ON BOARD DIAGNOSTIC (OBD) SYSTEM [CR (WITH EURO-OBD)] MI Flashing without DTC If the ECM is in Diagnostic Test Mode II, MI may flash when engine is running. In this case, check ECM diag- A nostic test mode. EC-59, "HOW TO SWITCH DIAGNOSTIC TEST MODE" . How to switch the diagnostic test (function) modes, and details of the above functions are described later, EC59, "HOW TO SWITCH DIAGNOSTIC TEST MODE" . EC The following emission-related diagnostic information is cleared when the ECM memory is erased. ● Diagnostic trouble codes ● 1st trip diagnostic trouble codes C ● Freeze frame data ● 1st trip freeze frame data D ● System readiness test (SRT) codes ● Test values HOW TO SWITCH DIAGNOSTIC TEST MODE E NOTE: ● It is better to count the time accurately with a clock. ● It is impossible to switch the diagnostic mode when an accelerator pedal position sensor circuit has a malfunction. ● Always ECM returns to Diagnostic Test Mode I after ignition switch is turned OFF. F How to Set Diagnostic Test Mode II (Self-diagnostic Results) G 1. 2. a. b. 3. H 4. Confirm that accelerator pedal is fully released, turn ignition switch ON and wait 3 seconds. Repeat the following procedure quickly five times within 5 seconds. Fully depress the accelerator pedal. Fully release the accelerator pedal. Wait 7 seconds, fully depress the accelerator pedal and keep it for approx. 10 seconds until the MI starts blinking. Fully release the accelerator pedal. ECM has entered to Diagnostic Test Mode II (Self-diagnostic results). I J K L PBIB0092E How to Set Diagnostic Test Mode II (Heated Oxygen Sensor 1 Monitor) 1. 2. Set the ECM in Diagnostic Test Mode II (Self-diagnostic results). Refer to EC-59, "How to Set Diagnostic Test Mode II (Self-diagnostic Results)" . Start Engine. ECM has entered to Diagnostic Test Mode II (Heated oxygen sensor 1 monitor). How to Erase Diagnostic Test Mode II (Self-diagnostic Results) 1. 2. 3. Set ECM in Diagnostic Test Mode II (Self-diagnostic results). Refer to EC-59, "How to Erase Diagnostic Test Mode II (Self-diagnostic Results)" . Fully depress the accelerator pedal and keep it for more than 10 seconds. The emission-related diagnostic information has been erased from the backup memory in the ECM. Fully release the accelerator pedal, and confirm the DTC 0000 is displayed. DIAGNOSTIC TEST MODE I — BULB CHECK In this mode, the MI on the instrument panel should stay ON. If it remains OFF, check the bulb. Refer to DI-32, "WARNING LAMPS" or see EC-448 . EC-59 M ON BOARD DIAGNOSTIC (OBD) SYSTEM [CR (WITH EURO-OBD)] DIAGNOSTIC TEST MODE I — MALFUNCTION WARNING MI ● Condition ON When the malfunction is detected. OFF No malfunction. These DTC numbers are clarified in Diagnostic Test Mode II (SELF-DIAGNOSTIC RESULTS) DIAGNOSTIC TEST MODE II — SELF-DIAGNOSTIC RESULTS In this mode, the DTC and 1st trip DTC are indicated by the number of blinks of the MI as shown below. The DTC and 1st trip DTC are displayed at the same time. If the MI does not illuminate in diagnostic test mode I (Malfunction warning), all displayed items are 1st trip DTCs. If only one code is displayed when the MI illuminates in diagnostic test mode II (SELF-DIAGNOSTIC RESULTS), it is a DTC; if two or more codes are displayed, they may be either DTCs or 1st trip DTCs. DTC No. is same as that of 1st trip DTC. These unidentified codes can be identified by using the CONSULT-II or GST. A DTC will be used as an example for how to read a code. PBIA3905E A particular trouble code can be identified by the number of four-digit numeral flashes. The “zero” is indicated by the number of ten flashes. The length of time the 1,000th-digit numeral flashes on and off is 1.2 seconds consisting of an ON (0.6-second) - OFF (0.6-second) cycle. The 100th-digit numeral and lower digit numerals consist of a 0.3-second ON and 0.3-second OFF cycle. A change from one digit numeral to another occurs at an interval of 1.0-second OFF. In other words, the later numeral appears on the display 1.3 seconds after the former numeral has disappeared. A change from one trouble code to another occurs at an interval of 1.8-second OFF. In this way, all the detected malfunctions are classified by their DTC numbers. The DTC 0000 refers to no malfunction. (See EC-22, "INDEX FOR DTC" ) How to Erase Diagnostic Test Mode II (Self-diagnostic Results) The DTC can be erased from the back up memory in the ECM by depressing accelerator pedal. Refer to EC59, "HOW TO SWITCH DIAGNOSTIC TEST MODE" . ● If the battery is disconnected, the DTC will be lost from the backup memory within 24 hours. ● Be careful not to erase the stored memory before starting trouble diagnoses. DIAGNOSTIC TEST MODE II — HEATED OXYGEN SENSOR 1 MONITOR In this mode, the MI displays the condition of the fuel mixture (lean or rich) which is monitored by the heated oxygen sensor 1. MI Fuel mixture condition in the exhaust gas ON Lean OFF Rich *Remains ON or OFF Any condition EC-60 Air-fuel ratio feedback control condition Closed loop system Open loop system ON BOARD DIAGNOSTIC (OBD) SYSTEM [CR (WITH EURO-OBD)] *: Maintains conditions just before switching to open loop. A To check the heated oxygen sensor 1 function, start engine in the Diagnostic Test Mode II and warm it up until engine coolant temperature indicator points to the middle of the gauge. Next run engine at about 2,000 rpm for about 2 minutes under no load conditions. Then make sure that the MI EC comes ON more than 5 times within 10 seconds with engine running at 2,000 rpm under no load. OBD System Operation Chart BBS002U0 RELATIONSHIP BETWEEN MI, 1ST TRIP DTC, DTC, AND DETECTABLE ITEMS ● ● ● ● ● When a malfunction is detected for the first time, the 1st trip DTC and the 1st trip freeze frame data are stored in the ECM memory. When the same malfunction is detected in two consecutive trips, the DTC and the freeze frame data are stored in the ECM memory, and the MI will come on. For details, refer to EC-47, "Two Trip Detection Logic" . The MI will go off after the vehicle is driven 3 times (driving pattern B) with no malfunction. The drive is counted only when the recorded driving pattern is met (as stored in the ECM). If another malfunction occurs while counting, the counter will reset. The DTC and the freeze frame data will be stored until the vehicle is driven 40 times (driving pattern A) without the same malfunction recurring (except for Misfire and Fuel Injection System). For Misfire and Fuel Injection System, the DTC and freeze frame data will be stored until the vehicle is driven 80 times (driving pattern C) without the same malfunction recurring. The “TIME” in “SELF-DIAGNOSTIC RESULTS” mode of CONSULT-II will count the number of times the vehicle is driven. The 1st trip DTC is not displayed when the self-diagnosis results in OK for the 2nd trip. C D E F G SUMMARY CHART Items MI (goes off) DTC, Freeze Frame Data (no display) 1st Trip DTC (clear) 1st Trip Freeze Frame Data (clear) Fuel Injection System Misfire Other 3 (pattern B) 3 (pattern B) 3 (pattern B) 80 (pattern C) 80 (pattern C) 40 (pattern A) 1 (pattern C), *1 1 (pattern C), *1 1 (pattern B) *1 , *2 *1 , *2 1 (pattern B) For details about patterns “B” and “C” under “Fuel Injection System” and “Misfire”, see EC-63 . For details about patterns “A” and “B” under “Other”, see EC-65 . *1: Clear timing is at the moment OK is detected. *2: Clear timing is when the same malfunction is detected in the 2nd trip. H I J K L M EC-61 ON BOARD DIAGNOSTIC (OBD) SYSTEM [CR (WITH EURO-OBD)] RELATIONSHIP BETWEEN MI, DTC, 1ST TRIP DTC AND DRIVING PATTERNS FOR “MISFIRE” , “FUEL INJECTION SYSTEM” SEF392SA *1: When the same malfunction is detected in two consecutive trips, MI will light up. *2: MI will go off after vehicle is driven 3 times (pattern B) without any malfunctions. *4: The DTC and the freeze frame data *5: When a malfunction is detected for will not be displayed any longer after the first time, the 1st trip DTC and vehicle is driven 80 times (pattern C) the 1st trip freeze frame data will be without the same malfunction. (The stored in ECM. DTC and the freeze frame data still remain in ECM.) *7: When the same malfunction is detected in the 2nd trip, the 1st trip freeze frame data will be cleared. *8: 1st trip DTC will be cleared when vehicle is driven once (pattern C) without the same malfunction after DTC is stored in ECM. EC-62 *3: When the same malfunction is detected in two consecutive trips, the DTC and the freeze frame data will be stored in ECM. *6: The 1st trip DTC and the 1st trip freeze frame data will be cleared at the moment OK is detected. ON BOARD DIAGNOSTIC (OBD) SYSTEM [CR (WITH EURO-OBD)] EXPLANATION FOR DRIVING PATTERNS FOR “MISFIRE ”, “FUEL INJECTION SYSTEM” Driving pattern B means the vehicle operation as follows: All components and systems should be monitored at least once by the OBD system. ● The B counter will be cleared when the malfunction is detected once regardless of the driving pattern. ● The B counter will be counted up when driving pattern B is satisfied without any malfunction. ● The MI will go off when the B counter reaches 3. (*2 in OBD SYSTEM OPERATION CHART) A EC C Driving pattern C means the vehicle operation as follows: 1. The following conditions should be satisfied at the same time: Engine speed: (Engine speed in the freeze frame data) ±375 rpm Calculated load value: (Calculated load value in the freeze frame data) x (1±0.1) [%] Engine coolant temperature (T) condition: ● When the freeze frame data shows lower than 70°C (158°F), T should be lower than 70°C (158°F). ● When the freeze frame data shows higher than or equal to 70°C (158°F), T should be higher than or equal to 70°C (158°F). Example: If the stored freeze frame data is as follows: Engine speed: 850 rpm, Calculated load value: 30%, Engine coolant temperature: 80°C (176°F) To be satisfied with driving pattern C, the vehicle should run under the following conditions: Engine speed: 475 - 1,225 rpm, Calculated load value: 27 - 33%, Engine coolant temperature: more than 70°C (158°F) ● The C counter will be cleared when the malfunction is detected regardless of vehicle conditions above. ● The C counter will be counted up when vehicle conditions above is satisfied without the same malfunction. ● The DTC will not be displayed after C counter reaches 80. ● The 1st trip DTC will be cleared when C counter is counted once without the same malfunction after DTC is stored in ECM. D E F G H I J K L M EC-63 ON BOARD DIAGNOSTIC (OBD) SYSTEM [CR (WITH EURO-OBD)] RELATIONSHIP BETWEEN MI, DTC, 1ST TRIP DTC AND DRIVING PATTERNS EXCEPT FOR “MISFIRE ”, “FUEL INJECTION SYSTEM” PBIB2551E *1: When the same malfunction is detected in two consecutive trips, MI will light up. *2: MI will go off after vehicle is driven 3 times (pattern B) without any malfunctions. *3: When the same malfunction is detected in two consecutive trips, the DTC and the freeze frame data will be stored in ECM. *4: The DTC and the freeze frame data will not be displayed any longer after vehicle is driven 40 times (pattern A) without the same malfunction. (The DTC and the freeze frame data still remain in ECM.) *5: When a malfunction is detected for the first time, the 1st trip DTC and the 1st trip freeze frame data will be stored in ECM. *6: 1st trip DTC will be cleared after vehicle is driven once (pattern B) without the same malfunction. *7: When the same malfunction is detected in the 2nd trip, the 1st trip freeze frame data will be cleared. EC-64 ON BOARD DIAGNOSTIC (OBD) SYSTEM [CR (WITH EURO-OBD)] EXPLANATION FOR DRIVING PATTERNS EXCEPT FOR “MISFIRE ”, “FUEL INJECTION SYSTEM” A EC C D E F G AEC574 ● ● ● The A counter will be cleared when the malfunction is detected regardless of (1) - (4). The A counter will be counted up when (1) - (4) are satisfied without the same malfunction. The DTC will not be displayed after the A counter reaches 40. Driving pattern B means the vehicle operation as follows: All components and systems should be monitored at least once by the OBD system. ● The B counter will be cleared when the malfunction is detected once regardless of the driving pattern. ● The B counter will be counted up when driving pattern B is satisfied without any malfunctions. ● The MI will go off when the B counter reaches 3 (*2 in OBD SYSTEM OPERATION CHART). H I J K L M EC-65 BASIC SERVICE PROCEDURE [CR (WITH EURO-OBD)] BASIC SERVICE PROCEDURE Basic Inspection PFP:00018 BBS002U4 1. INSPECTION START 1. 2. – – – – – – 3. – – – – 4. Check service records for any recent repairs that may indicate a related malfunction, or a current need for scheduled maintenance. Open engine hood and check the following: Harness connectors for improper connections Wiring harness for improper connections, pinches and cut Vacuum hoses for splits, kinks and improper connections Hoses and ducts for leaks Air cleaner clogging Gasket Confirm that electrical or mechanical loads are not applied. Headlamp switch is OFF. SEF983U Air conditioner switch is OFF. Rear window defogger switch is OFF. Steering wheel is in the straight-ahead position, etc. Start engine and warm it up until engine coolant temperature indicator points the middle of gauge. Ensure engine stays below 1,000 rpm. SEF976U 5. Run engine at about 2,000 rpm for about 2 minutes under no load. 6. Make sure that no DTC is displayed with CONSULT-II or GST. OK or NG OK >> GO TO 3. NG >> GO TO 2. SEF977U 2. REPAIR OR REPLACE Repair or replace components as necessary according to corresponding Diagnostic Procedure. >> GO TO 3 EC-66 BASIC SERVICE PROCEDURE [CR (WITH EURO-OBD)] 3. CHECK TARGET IDLE SPEED 1. 2. A With CONSULT-II Run engine at about 2,000 rpm for about 2 minutes under no load. Rev engine (2,000 to 3,000 rpm) two or three times under no load, then run engine at idle speed for about 1 minute. EC C D E PBIA8513J 3. Read idle speed in “DATA MONITOR” mode with CONSULT-II. Refer to EC-69, "IDLE SPEED" . F 650 ± 50 rpm (in Neutral position) G H SEF058Y I Without CONSULT-II 1. Run engine at about 2,000 rpm for about 2 minutes under no load. 2. Rev engine (2,000 to 3,000 rpm) two or three times under no load, then run engine at idle speed for about 1 minute. 3. Check idle speed. Refer to EC-69, "IDLE SPEED" . K 650 ± 50 rpm (in Neutral position) OK or NG OK >> INSPECTION END NG >> GO TO 4. L 4. PERFORM ACCELERATOR PEDAL RELEASED POSITION LEARNING 1. 2. J Stop engine. Perform EC-69, "Accelerator Pedal Released Position Learning" . >> GO TO 5. 5. PERFORM THROTTLE VALVE CLOSED POSITION LEARNING Perform EC-69, "Throttle Valve Closed Position Learning" . >> GO TO 6. EC-67 M BASIC SERVICE PROCEDURE [CR (WITH EURO-OBD)] 6. PERFORM IDLE AIR VOLUME LEARNING Refer to EC-69, "Idle Air Volume Learning" . Is Idle Air Volume Learning carried out successfully? Yes or No Yes >> GO TO 7. No >> 1. Follow the instruction of Idle Air Volume Learning. 2. GO TO 4. 7. CHECK TARGET IDLE SPEED AGAIN 1. 2. With CONSULT-II Start engine and warm it up to normal operating temperature. Read idle speed in “DATA MONITOR” mode with CONSULT-II. Refer to EC-69, "IDLE SPEED" . 650 ± 50 rpm (in Neutral position) Without CONSULT-II 1. Start engine and warm it up to normal operating temperature. 2. Check idle speed. Refer to EC-69, "IDLE SPEED" . 650 ± 50 rpm (in Neutral position) OK or NG OK >> INSPECTION END NG >> GO TO 8. 8. DETECT MALFUNCTIONING PART Check the following. ● Check camshaft position sensor (PHASE) and circuit. Refer to EC-257 . ● Check crankshaft position sensor (POS) and circuit. Refer to EC-250 . OK or NG OK >> GO TO 9. NG >> 1. Repair or replace. 2. GO TO 4. 9. CHECK ECM FUNCTION 1. 2. Substitute another known-good ECM to check ECM function. (ECM may be the cause of an incident, but this is a rare case.) Perform initialization of NATS system and registration of all NATS ignition key IDs. Refer to BL-218, "ECM Re-communicating Function" . >> GO TO 4. EC-68 BASIC SERVICE PROCEDURE [CR (WITH EURO-OBD)] Idle Speed Check BBS002TQ A IDLE SPEED With CONSULT-II Check idle speed in “DATA MONITOR” mode with CONSULT-II. EC C D SEF058Y E With GST Check idle speed with GST. Accelerator Pedal Released Position Learning BBS002TR F DESCRIPTION Accelerator Pedal Released Position Learning is an operation to learn the fully released position of the accelerator pedal by monitoring the accelerator pedal position sensor output signal. It must be performed each time harness connector of accelerator pedal position sensor or ECM is disconnected. OPERATION PROCEDURE 1. 2. 3. 4. 5. H Make sure that accelerator pedal is fully released. Turn ignition switch ON and wait at least 2 seconds. Turn ignition switch OFF and wait at least 10 seconds. Turn ignition switch ON and wait at least 2 seconds. Turn ignition switch OFF and wait at least 10 seconds. Throttle Valve Closed Position Learning G I BBS002TS J DESCRIPTION Throttle Valve Closed Position Learning is an operation to learn the fully closed position of the throttle valve by monitoring the throttle position sensor output signal. It must be performed each time harness connector of electric throttle control actuator or ECM is disconnected. OPERATION PROCEDURE 1. 2. 3. L Make sure that accelerator pedal is fully released. Turn ignition switch ON. Turn ignition switch OFF and wait at least 10 seconds. Make sure that throttle valve moves during above 10 seconds by confirming the operating sound. Idle Air Volume Learning M BBS002TT DESCRIPTION Idle Air Volume Learning is an operation to learn the idle air volume that keeps each engine within the specific range. It must be performed under any of the following conditions: ● Each time electric throttle control actuator or ECM is replaced. ● Idle speed is out of specification. PREPARATION Before performing Idle Air Volume Learning, make sure that all of the following conditions are satisfied. Learning will be cancelled if any of the following conditions are missed for even a moment. ● Battery voltage: More than 12.9V (At idle) ● Engine coolant temperature: 70 - 100°C (158 - 212°F) ● PNP switch: ON ● Electric load switch: OFF (Air conditioner, headlamp, rear window defogger) EC-69 K BASIC SERVICE PROCEDURE [CR (WITH EURO-OBD)] On vehicles equipped with daytime light systems, set lighting switch to the 1st position to light only small lamps. Steering wheel: Neutral (Straight-ahead position) Vehicle speed: Stopped Transmission: Warmed-up Drive vehicle for 10 minutes. ● ● ● – OPERATION PROCEDURE With CONSULT-II 1. 2. 3. 4. 5. Perform EC-69, "Accelerator Pedal Released Position Learning" . Perform EC-69, "Throttle Valve Closed Position Learning" . Start engine and warm it up to normal operating temperature. Check that all items listed under the topic PREPARATION (previously mentioned) are in good order. Select “IDLE AIR VOL LEARN” in “WORK SUPPORT” mode. SEF217Z 6. Touch “START” and wait 20 seconds. SEF454Y 7. 8. Make sure that “CMPLT” is displayed on CONSULT-II screen. If “CMPLT” is not displayed, Idle Air Volume Learning will not be carried out successfully. In this case, find the cause of the incident by referring to the Diagnostic Procedure below. Rev up the engine two or three times and make sure that idle speed is within the specification. ITEM SPECIFICATION Idle speed 650 ± 50 rpm (in Neutral position) MBIB0238E Without CONSULT-II NOTE: ● It is better to count the time accurately with a clock. ● It is impossible to switch the diagnostic mode when an accelerator pedal position sensor circuit has a malfunction. 1. Perform EC-69, "Accelerator Pedal Released Position Learning" . 2. Perform EC-69, "Throttle Valve Closed Position Learning" . EC-70 BASIC SERVICE PROCEDURE [CR (WITH EURO-OBD)] 3. 4. 5. 6. 7. a. b. 8. Start engine and warm it up to normal operating temperature. A Check that all items listed under the topic PREPARATION (previously mentioned) are in good order. Turn ignition switch OFF and wait at least 10 seconds. Confirm that accelerator pedal is fully released, turn ignition switch ON and wait 3 seconds. EC Repeat the following procedure quickly five times within 5 seconds. Fully depress the accelerator pedal. Fully release the accelerator pedal. C Wait 7 seconds, fully depress the accelerator pedal and keep it for approx. 20 seconds until the MI stops blinking and turned ON. 9. Fully release the accelerator pedal within 3 seconds after the MI turned ON. D 10. Start engine and let it idle. 11. Wait 20 seconds. E F G PBIB0665E H 12. Rev up the engine two or three times and make sure that idle speed is within the specification. ITEM SPECIFICATION Idle speed 650 ± 50 rpm (in Neutral position) I 13. If idle speed is not within the specification, Idle Air Volume Learning will not be carried out successfully. In this case, find the cause of the incident by referring to the Diagnostic Procedure below. J DIAGNOSTIC PROCEDURE If idle air volume learning cannot be performed successfully, proceed as follows: 1. Check that throttle valve is fully closed. 2. Check PCV valve operation. 3. Check that downstream of throttle valve is free from air leakage. 4. When the above three items check out OK, engine component parts and their installation condition are questionable. Check and eliminate the cause of the incident. It is useful to perform EC-117, "TROUBLE DIAGNOSIS - SPECIFICATION VALUE" . 5. If any of the following conditions occur after the engine has started, eliminate the cause of the incident and perform Idle Air Volume Learning all over again: ● Engine stalls. ● Erroneous idle. Fuel Pressure Check BBS002TU FUEL PRESSURE RELEASE With CONSULT-II 1. Turn ignition switch ON. EC-71 K L M BASIC SERVICE PROCEDURE [CR (WITH EURO-OBD)] 2. 3. 4. 5. Perform “FUEL PRESSURE RELEASE” in “WORK SUPPORT” mode with CONSULT-II. Start engine. After engine stalls, crank it 2 or 3 times to release all fuel pressure. Turn ignition switch OFF. SEF214Y Without CONSULT-II 1. 2. 3. 4. 5. Remove fuel pump fuse located in IPDM E/R. Start engine. After engine stalls, crank it 2 or 3 times to release all fuel pressure. Turn ignition switch OFF. Reinstall fuel pump fuse after servicing fuel system. MBIB0277E FUEL PRESSURE CHECK CAUTION: ● Before disconnecting fuel line, release fuel pressure from fuel line to eliminate danger. ● The fuel hose connection method used when taking fuel pressure check must not be used for other purposes. ● Be careful not to scratch or put debris around connection area when servicing, so that the quick connector maintains sealability with O-rings inside. ● When installing fuel hose quick connector, refer to EM-18, "AIR CLEANER AND AIR DUCT" . NOTE: Prepare pans or saucers under the disconnected fuel line because the fuel may spill out. The fuel pressure cannot be completely released because E11 models do not have fuel return system. 1. Release fuel pressure to zero. Refer to EC-71, "FUEL PRESSURE RELEASE" . 2. Prepare fuel hose and fuel hose clamp for fuel pressure check, and connect fuel pressure gauge. ● Use suitable fuel hose for fuel pressure check (genuine NISSAN fuel hose without quick connector). ● To avoid unnecessary force or tension to hose, use moderately long fuel hose for fuel pressure check. ● Do not use the fuel hose for checking fuel pressure with damage or cracks on it. ● Use Pressure Gauge to check fuel pressure. 3. Remove fuel hose. Refer to EM-18, "AIR CLEANER AND AIR DUCT" . ● Do not twist or kink fuel hose because it is plastic hose. ● Do not remove fuel hose from quick connector. ● Keep the original fuel hose to be free from intrusion of dust or foreign substances with a suitable cover. EC-72 BASIC SERVICE PROCEDURE [CR (WITH EURO-OBD)] 4. Install the fuel pressure gauge as shown in the figure. ● Wipe off oil or dirt from hose insertion part using cloth moistened with gasoline. ● Apply proper amount of gasoline between top of the fuel tube and No.1 spool. ● Insert fuel hose for fuel pressure check until it touches the No.1 spool on fuel tube. ● Use NISSAN genuine hose clamp (part number: 16439 N4710 or 16439 40U00). ● When reconnecting fuel line, always use new clamps. ● When reconnecting fuel hose, check the original fuel hose for damage and abnormality. ● Use a torque driver to tighten clamps. ● Install hose clamp to the position within 1 - 2 mm (0.04 - 0.08 in). – A: Fuel pressure gauge Tightening torque: 6. 7. 8. EC C PBIB0669E 1 - 1.5 N·m (0.1 - 0.15 kg-m, 9 - 13 in-lb) Make sure that clamp screw does not contact adjacent parts. After connecting fuel hose for fuel pressure check, pull the hose with a force of approximately 98 N (10 kg, 22 lb) to confirm fuel tube does not come off. MBIB1495E Turn ignition switch ON, and check for fuel leakage. Start engine and check for fuel leakage. Read the indication of fuel pressure gauge. ● Do not perform fuel pressure check with system operating. Fuel pressure gauge may indicate false readings. ● During fuel pressure check, confirm for fuel leakage from fuel connection every 3 minutes. ● 5. A At idling: D E F G H I J Approximately 350 kPa (3.5 bar, 3.57 kg/cm2 , 51 psi) K 9. If result is unsatisfactory, go to next step. 10. Check the following. ● Fuel hoses and fuel tubes for clogging ● Fuel filter for clogging ● Fuel pump ● Fuel pressure regulator for clogging If OK, replace fuel pressure regulator. If NG, repair or replace. L M EC-73 TROUBLE DIAGNOSIS [CR (WITH EURO-OBD)] TROUBLE DIAGNOSIS Trouble Diagnosis Introduction PFP:00004 BBS002U1 INTRODUCTION The engine has an ECM to control major systems such as fuel control, ignition control, idle air control system, etc. The ECM accepts input signals from sensors and instantly drives actuators. It is essential that both input and output signals are proper and stable. At the same time, it is important that there are no malfunctions such as vacuum leaks, fouled spark plugs, or other malfunctions with the engine. MEF036D It is much more difficult to diagnose an incident that occurs intermittently rather than continuously. Most intermittent incidents are caused by poor electric connections or improper wiring. In this case, careful checking of suspected circuits may help prevent the replacement of good parts. SEF233G A visual check only may not find the cause of the incidents. A road test with CONSULT-II (or GST) or a circuit tester connected should be performed. Follow the Work Flow on EC-75 . Before undertaking actual checks, take a few minutes to talk with a customer who approaches with a driveability complaint. The customer can supply good information about such incidents, especially intermittent ones. Find out what symptoms are present and under what conditions they occur. A Diagnostic Worksheet like the example on EC-79 should be used. Start your diagnosis by looking for conventional malfunctions first. This will help troubleshoot driveability malfunctions on an electronically controlled engine vehicle. EC-74 SEF234G TROUBLE DIAGNOSIS [CR (WITH EURO-OBD)] WORK FLOW Overall Sequence A EC C D E F G H I J K L M PBIB2267E EC-75 TROUBLE DIAGNOSIS [CR (WITH EURO-OBD)] Detailed Flow 1. GET INFORMATION FOR SYMPTOM Get the detailed information from the customer about the symptom (the condition and the environment when the incident/malfunction occurred) using the EC-78, "DIAGNOSTIC WORKSHEET" . >> GO TO 2. 2. CHECK DTC*1 1. Check DTC*1 . 2. Perform the following procedure if DTC*1 is displayed. – Record DTC*1 and freeze frame data*2 . (Print them out with CONSULT-II or GST.) – Erase DTC*1 . (Refer to EC-57, "HOW TO ERASE EMISSION-RELATED DIAGNOSTIC INFORMATION" .) Study the relationship between the cause detected by DTC*1 and the symptom described by the customer. (Symptom Matrix Chart is useful. Refer to EC-82, "Symptom Matrix Chart" .) 3. Check related service bulletins for information. Is any symptom described and any DTC detected? – Symptom is described, DTC*1 is displayed>>GO TO 3. Symptom is described, DTC*1 is not displayed>>GO TO 4. Symptom is not described, DTC*1 is displayed>>GO TO 5. 3. CONFIRM THE SYMPTOM Try to confirm the symptom described by the customer (except MI ON). DIAGNOSIS WORK SHEET is useful to verify the incident. Connect CONSULT-II to the vehicle in “DATA MONITOR (AUTO TRIG)” mode and check real time diagnosis results. Verify relation between the symptom and the condition when the symptom is detected. >> GO TO 5. 4. CONFIRM THE SYMPTOM Try to confirm the symptom described by the customer. DIAGNOSIS WORK SHEET is useful to verify the incident. Connect CONSULT-II to the vehicle in “DATA MONITOR (AUTO TRIG)” mode and check real time diagnosis results. Verify relation between the symptom and the condition when the symptom is detected. >> GO TO 6. EC-76 TROUBLE DIAGNOSIS [CR (WITH EURO-OBD)] 5. PERFORM DTC CONFIRMATION PROCEDURE A 1 1 Perform DTC Confirmation Procedure for the displayed DTC* , and then make sure that DTC* is detected again. At this time, always connect CONSULT-II to the vehicle, and check diagnostic results in real time on “DATA EC MONITOR (AUTO TRIG)”. If two or more DTCs*1 are detected, refer to EC-80, "DTC Inspection Priority Chart" and determine trouble diagnosis order. C NOTE: ● Freeze frame data*2 is useful if the DTC*1 is not detected. ● Perform Overall Function Check if DTC Confirmation Procedure is not included on Service Manual. This D simplified check procedure is an effective alternative though DTC*1 cannot be detected during this check. If the result of Overall Function Check is NG, it is the same as the detection of DTC*1 by DTC ConfirmaE tion Procedure. Is DTC*1 detected? Yes >> GO TO 10. No >> Check according to EC-127, "TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT" . F 6. PERFORM BASIC INSPECTION G Perform EC-66, "Basic Inspection" . With CONSULT-II>>GO TO 7. Without CONSULT-II>>GO TO 9. H 7. PERFORM DATA MONITOR (SPEC) MODE I With CONSULT-II Make sure that “B/FUEL SCHDL”, and “A/F ALPHA-B1” are within the SP value using CONSULT-II “DATA MONITOR (SPEC)” mode. Refer to EC-118, "Diagnostic Procedure" . Are they within the SP value? Yes >> GO TO 9. No >> GO TO 8. J K L SEF601Z 8. DETECT MALFUNCTIONING PART BY TROUBLE DIAGNOSIS - SPECIFICATION VALUE Detect malfunctioning part according to EC-117, "TROUBLE DIAGNOSIS - SPECIFICATION VALUE" . Is malfunctioning part detected? Yes >> GO TO 11. No >> GO TO 9. 9. DETECT MALFUNCTIONING SYSTEM BY SYMPTOM MATRIX CHART Detect malfunctioning system according to EC-82, "Symptom Matrix Chart" based on the confirmed symptom in step 4, and determine the trouble diagnosis order based on possible causes and symptom. >> GO TO 10. EC-77 M TROUBLE DIAGNOSIS [CR (WITH EURO-OBD)] 10. DETECT MALFUNCTIONING PART BY DIAGNOSTIC PROCEDURE Inspect according to Diagnostic Procedure of the system. NOTE: The Diagnostic Procedure in EC section described based on open circuit inspection. A short circuit inspection is also required for the circuit check in the Diagnostic Procedure. For details, refer to Circuit Inspection in GI25, "How to Perform Efficient Diagnosis for an Electrical Incident" . Is malfunctioning part detected? Yes >> GO TO 11. No >> Monitor input data from related sensors or check voltage of related ECM terminals using CONSULT-II. Refer to EC-95, "ECM Terminals and Reference Value" , EC-112, "CONSULT-II Reference Value in Data Monitor Mode" . 11. REPAIR OR REPLACE THE MALFUNCTIONING PART 1. 2. 3. Repair or replace the malfunctioning part. Reconnect parts or connectors disconnected during Diagnostic Procedure again after repair and replacement. Check DTC. If DTC is displayed, erase it, refer to EC-57, "HOW TO ERASE EMISSION-RELATED DIAGNOSTIC INFORMATION" . >> GO TO 12. 12. FINAL CHECK When DTC was detected in step 2, perform DTC Confirmation Procedure or Overall Function Check again, and then make sure that the malfunction have been repaired securely. When symptom was described from the customer, refer to confirmed symptom in step 3 or 4, and make sure that the symptom is not detected. OK or NG NG (DTC*1 is detected)>>GO TO 10. NG (Symptom remains)>>GO TO 6. OK >> 1. Before returning the vehicle to the customer, make sure to erase unnecessary DTC*1 in ECM. (Refer to EC-57, "HOW TO ERASE EMISSION-RELATED DIAGNOSTIC INFORMATION" .) 2. If the completion of SRT is needed, drive vehicle under the specific driving pattern. Refer to EC55, "Driving Pattern" . 3. INSPECTION END *1: Include 1st trip DTC. *2: Include 1st trip freeze frame data. DIAGNOSTIC WORKSHEET Description There are many operating conditions that lead to the malfunction of engine components. A good grasp of such conditions can make troubleshooting faster and more accurate. In general, each customer feels differently about a incident. It is important to fully understand the symptoms or conditions for a customer complaint. Utilize a diagnostic worksheet like the one on the next page in order to organize all the information for troubleshooting. Some conditions may cause the MI to come on steady or blink and DTC to be detected. Examples: ● Vehicle ran out of fuel, which caused the engine to misfire. EC-78 SEF907L TROUBLE DIAGNOSIS [CR (WITH EURO-OBD)] Worksheet Sample A EC C D E F G H I J K L M MTBL0017 EC-79 TROUBLE DIAGNOSIS [CR (WITH EURO-OBD)] DTC Inspection Priority Chart BBS002U2 If some DTCs are displayed at the same time, perform inspections one by one based on the following priority chart. NOTE: ● If DTC U1001 is displayed with other DTC, first perform the trouble diagnosis for DTC U1001. Refer to EC-134, "DTC U1001 CAN COMMUNICATION LINE" . ● If DTC U1010 is displayed with other DTC, first perform the trouble diagnosis for DTC U1010. Refer to EC-137, "DTC U1010 CAN COMMUNICATION" . Priority 1 2 3 Detected items (DTC) ● U1001 CAN communication line ● U1010 CAN communication ● P0107 P0108 Manifold absolute pressure sensor ● P0112 P0113 Intake air temperature sensor ● P0117 P0118 Engine coolant temperature sensor ● P0122 P0123 P0222 P0223 P1225 P1226 P2135 Throttle position sensor ● P0327 P0328 Knock sensor ● P0335 Crankshaft position sensor (POS) ● P0340 Camshaft position sensor (PHASE) ● P0500 Vehicle speed sensor ● P0605 ECM ● P1171 Intake error ● P1229 Sensor power supply ● P1610-P1615 NATS ● P1706 Park/Neutral position (PNP) switch ● P2122 P2123 P2127 P2128 P2138 Accelerator pedal position sensor ● P0031 P0032 Heated oxygen sensor 1 heater ● P0037 P0038 Heated oxygen sensor 2 heater ● P0132 P0133 P0134 P1143 P1144 Heated oxygen sensor 1 ● P0138 P0139 P1146 P1147 Heated oxygen sensor 2 ● P0444 EVAP canister purge volume control solenoid valve ● P1065 ECM power supply ● P1111 Intake valve timing control solenoid valve ● P1122 Electric throttle control function ● P1124 P1126 Throttle control motor relay ● P1128 Throttle control mother ● P1805 Brake switch ● P0011 Intake valve timing control ● P0171 P0172 Fuel injection system function ● P0300 - P0304 Misfire ● P0420 Three way catalyst function ● P1121 Electric throttle control actuator ● P1211 ESP control unit ● P1212 ESP communication line ● P1217 Engine over temperature (OVERHEAT) EC-80 TROUBLE DIAGNOSIS [CR (WITH EURO-OBD)] Fail-Safe Chart BBS002U3 When the DTC listed bellow is detected, the ECM enters fail-safe mode and the MI lights up. DTC No. P0117 P0118 Detected items Engine operating condition in fail-safe mode Engine coolant temperature sensor circuit Engine coolant temperature will be determined by ECM based on the time after turning ignition switch ON or START. CONSULT-II displays the engine coolant temperature decided by ECM. Condition Engine coolant temperature decided (CONSULT-II display) Just as ignition switch is turned ON or START 40°C (104°F) More than approx. 4 minutes after ignition ON or START 80°C (176°F) Except as shown above A EC C D 40 - 80°C (104 - 176°F) (Depends on the time) E When the fail-safe system for engine coolant temperature sensor is activated, the cooling fan operates while engine is running. P0122 P0123 P0222 P0223 P2135 Throttle position sensor P1121 Electric throttle control actuator The ECM controls the electric throttle control actuator in regulating the throttle opening in order for the idle position to be within +10 degrees. The ECM regulates the opening speed of the throttle valve to be slower than the normal condition. So, the acceleration will be poor. H (When throttle valve opening angle in fail-safe mode is not in specified range:) ECM controls the electric throttle control actuator by regulating the throttle opening to 20 degrees or less. I P1122 Electric throttle control function ECM stops the electric throttle control actuator control, throttle valve is maintained at a fixed opening (approx. 5 degrees) by the return spring. P1124 P1126 Throttle control motor relay ECM stops the electric throttle control actuator control, throttle valve is maintained at a fixed opening (approx. 5 degrees) by the return spring. P1128 Throttle control motor ECM stops the electric throttle control actuator control, throttle valve is maintained at a fixed opening (approx. 5 degrees) by the return spring. P1171 Intake air system P1229 Sensor power supply ECM stops the electric throttle control actuator control, throttle valve is maintained at a fixed opening (approx. 5 degrees) by the return spring. P2122 P2123 P2127 P2128 P2138 Accelerator pedal position sensor The ECM controls the electric throttle control actuator in regulating the throttle opening in order for the idle position to be within +10 degrees. The ECM regulates the opening speed of the throttle valve to be slower than the normal condition. So, the acceleration will be poor. When accelerator pedal is depressed, engine speed will not rise more than 2,500 rpm due to fuel cut. When there is an open circuit on MI circuit, the ECM can not warn the driver by lighting up MI when there is a malfunction on engine control system. Therefore, when electrical controlled throttle and part of ECM related diagnoses is continuously detected as NG for 5 trips, ECM warns the driver that engine control system has a malfunction and MI circuit is open by means of operating fail-safe function. The fail-safe function also operate when above diagnoses except MI circuit are detected and demands the driver to repair the malfunction. Engine operating condition in fail-safe mode G (When electric throttle control actuator does not function properly due to the return spring malfunction:) ECM controls the electric throttle control actuator by regulating the throttle opening around the idle position. The engine speed will not rise more than 2,000 rpm. (When ECM detects the throttle valve is stuck open:) While the vehicle is driving, it slows down gradually by fuel cut. After the vehicle stops, the engine stalls. The engine can restart in Neutral position, and engine speed will not exceed 1,000 rpm or more. ● F Engine speed will not rise more than 2,500 rpm due to the fuel cut EC-81 J K L M TROUBLE DIAGNOSIS [CR (WITH EURO-OBD)] Symptom Matrix Chart BBS002U5 SYSTEM — BASIC ENGINE CONTROL SYSTEM 1 1 2 3 2 Fuel pressure regulator system 3 3 4 4 4 Fuel injector circuit 1 1 2 3 2 Evaporative emission system 3 3 4 4 4 Air Positive crankcase ventilation system 3 3 4 4 4 Incorrect idle speed adjustment 3 3 Electric throttle control actuator 1 1 2 3 3 Incorrect ignition timing adjustment 3 3 1 1 Ignition circuit 1 1 2 Power supply and ground circuit 2 2 Manifold absolute pressure sensor circuit 1 Engine coolant temperature sensor circuit 1 Ignition Throttle position sensor circuit AG AH AJ AK AL AM HA 2 2 4 4 2 2 4 4 4 4 4 1 1 4 2 EC-427 4 EC-72 2 EC-421 4 4 EC-40 4 4 4 1 1 1 EC-66 2 EC-291, EC-293 , EC-299 , EC-305 EC-45 1 1 1 EC-66 2 2 2 2 2 EC-433 3 3 3 3 3 3 EC-128 1 2 2 2 2 2 2 EC-155 1 2 2 2 2 2 2 EC-166 2 EC-171, EC-233 , EC-359 , EC-361 , EC-402 3 1 Knock sensor circuit Crankshaft position sensor (POS) circuit 2 2 Camshaft position sensor (PHASE) circuit 2 2 2 2 2 2 3 2 2 1 2 3 2 2 2 2 2 1 1 2 2 3 4 2 Accelerator pedal position sensor circuit Vehicle speed signal circuit AF Reference page 2 1 Heated oxygen sensor 1 circuit BATTERY DEAD (UNDER CHARGE) Fuel pump circuit EXCESSIVE OIL CONSUMPTION Fuel EXCESSIVE FUEL CONSUMPTION AE OVERHEATS/WATER TEMPERATURE HIGH LACK OF POWER/POOR ACCELERATION AD SLOW/NO RETURN TO IDLE SPARK KNOCK/DETONATION AC IDLING VIBRATION HESITATION/SURGING/FLAT SPOT AB ROUGH IDLE/HUNTING ENGINE STALL AA Warranty symptom code HIGH IDLE/LOW IDLE HARD/NO START/RESTART (EXCP. HA) SYMPTOM 2 3 2 1 EC-363, EC-383 , EC-392 , EC-409 2 2 2 2 2 EC-178, EC-185 , EC-195 , EC-310 , EC-316 3 EC-246 EC-250 EC-257 3 EC-82 3 3 EC-277 TROUBLE DIAGNOSIS [CR (WITH EURO-OBD)] SYMPTOM HARD/NO START/RESTART (EXCP. HA) ENGINE STALL HESITATION/SURGING/FLAT SPOT SPARK KNOCK/DETONATION LACK OF POWER/POOR ACCELERATION HIGH IDLE/LOW IDLE ROUGH IDLE/HUNTING IDLING VIBRATION SLOW/NO RETURN TO IDLE OVERHEATS/WATER TEMPERATURE HIGH EXCESSIVE FUEL CONSUMPTION EXCESSIVE OIL CONSUMPTION BATTERY DEAD (UNDER CHARGE) A AA AB AC AD AE AF AG AH AJ AK AL AM HA ECM 2 2 3 3 3 3 3 3 3 3 3 EC-279, EC-282 Intake valve timing control solenoid valve circuit 3 3 2 1 3 2 2 3 3 EC-286 3 3 Warranty symptom code PNP switch circuit Refrigerant pressure sensor circuit 2 Electrical load signal circuit Air conditioner circuit 2 ABS actuator and electric unit (control unit) 2 3 3 4 1 - 6: The numbers refer to the order of inspection. (continued on next page) 3 EC Reference page C D E 3 3 3 3 3 EC-371 3 3 3 3 4 EC-443 3 3 3 3 3 3 3 3 F G H EC-419 3 2 ATC-26, MTC-23 I BRC-8 or BRC-49 J K L M EC-83 TROUBLE DIAGNOSIS [CR (WITH EURO-OBD)] SYSTEM — ENGINE MECHANICAL & OTHER Fuel ENGINE STALL HESITATION/SURGING/FLAT SPOT SPARK KNOCK/DETONATION LACK OF POWER/POOR ACCELERATION HIGH IDLE/LOW IDLE ROUGH IDLE/HUNTING IDLING VIBRATION SLOW/NO RETURN TO IDLE OVERHEATS/WATER TEMPERATURE HIGH EXCESSIVE FUEL CONSUMPTION EXCESSIVE OIL CONSUMPTION BATTERY DEAD (UNDER CHARGE) Warranty symptom code HARD/NO START/RESTART (EXCP. HA) SYMPTOM AA AB AC AD AE AF AG AH AJ AK AL AM HA Fuel tank FL-8 5 Fuel piping 5 Vapor lock 5 5 5 5 FL-3, EM32 5 — 5 Valve deposit Poor fuel (Heavy weight gasoline, Low octane) Air Reference page — 5 5 5 5 5 5 5 — Air duct Air cleaner Air leakage from air duct (Manifold absolute pressure sensor —electric throttle control actuator) EM-18 5 5 5 5 5 5 5 5 5 5 Electric throttle control actuator Air leakage from intake manifold/ Collector/Gasket Cranking Battery EM-22 1 1 1 1 1 1 1 1 Alternator circuit Engine SC-5 SC-15 Starter circuit 3 SC-45 Signal plate/Flywheel/Drive plate 6 EM-74 PNP switch 4 AT-109, MT-16 Cylinder head Cylinder head gasket 5 5 5 5 5 5 5 4 5 3 EM-60 Cylinder block Piston 4 Piston ring Connecting rod 6 6 6 6 Bearing Crankshaft EC-84 6 6 6 6 EM-74 TROUBLE DIAGNOSIS [CR (WITH EURO-OBD)] SYMPTOM Valve mechanism HARD/NO START/RESTART (EXCP. HA) ENGINE STALL HESITATION/SURGING/FLAT SPOT SPARK KNOCK/DETONATION LACK OF POWER/POOR ACCELERATION HIGH IDLE/LOW IDLE ROUGH IDLE/HUNTING IDLING VIBRATION SLOW/NO RETURN TO IDLE OVERHEATS/WATER TEMPERATURE HIGH EXCESSIVE FUEL CONSUMPTION EXCESSIVE OIL CONSUMPTION BATTERY DEAD (UNDER CHARGE) Warranty symptom code A AA AB AC AD AE AF AG AH AJ AK AL AM HA EC Reference page D E Timing chain EM-50 Camshaft EM-38 Intake valve timing control 5 5 5 5 5 5 5 5 C EM-50 F G Intake valve 3 Exhaust valve Exhaust Exhaust manifold/Tube/Muffler/ Gasket H 5 5 5 5 5 5 5 EM-24, EX3 5 Three way catalyst Lubrication Cooling Oil pan/Oil strainer/Oil pump/Oil filter/Oil gallery EM-60 5 5 5 5 5 5 5 5 2 EM-26, LU9 , LU-10 , LU-5 Oil level (Low)/Filthy oil LU-6 Radiator/Hose/Radiator filler cap CO-12 Thermostat 5 CO-19 Water pump Water gallery CO-17 5 5 5 5 Cooling fan 5 5 2 5 Coolant level (low)/Contaminated coolant NATS (Nissan Anti-theft System) 5 5 I J K CO-7 CO-12 L CO-8 1 BL-215 or EC-44 1 1 - 6: The numbers refer to the order of inspection. EC-85 M TROUBLE DIAGNOSIS [CR (WITH EURO-OBD)] Engine Control Component Parts Location BBS002U6 MBIB1491E 1. Intake valve timing control solenoid valve 2. Fuel injector 3. Refrigerant pressure sensor 4. Ignition coil (with power transistor) and spark plug 5. Heated oxygen sensor 1 6. Crankshaft position sensor (POS) 7. Cooling fan motor 8. IPDM E/R 9. ECM 10. Camshaft position sensor (PHASE) 11. EVAP canister purge volume control solenoid valve 12. Engine coolant temperature sensor 13. Manifold absolute pressure sensor (with intake air temperature sensor) 14. Knock sensor 15. Electric throttle control actuator EC-86 TROUBLE DIAGNOSIS [CR (WITH EURO-OBD)] A EC C D E F G H I J K L M MBIB1498E : Vehicle front 1. Manifold absolute pressure sensor (with intake air temperature sensor) 2. Crankshaft position sensor (POS) 3. Engine coolant temperature sensor 6. IPDM E/R 4. Camshaft position sensor (PHASE) 5. Battery 7. Fuel injector 8. Ignition coil (with power transistor) EC-87 TROUBLE DIAGNOSIS [CR (WITH EURO-OBD)] MBIB1499E 1. Condenser 2. Oil filter 3. Refrigerant pressure sensor 4. Intake manifold 5. Knock sensor 6. Electric throttle control actuator 7. ECM 8. Battery 9. Data link connector EC-88 TROUBLE DIAGNOSIS [CR (WITH EURO-OBD)] A EC C D E F MBIB0320E G H I J K L M MBIB1460E : Vehicle front 1. Exhaust manifold cover 2. Heated oxygen sensor 1 3. Heated oxygen sensor 1 harness connector 4. Heated oxygen sensor 2 harness connector 5. Heated oxygen sensor 2 6. Oil pan EC-89 TROUBLE DIAGNOSIS [CR (WITH EURO-OBD)] MBIB1500E : Vehicle front 1. Park/neutral position switch 2. Cooling fan motor 4. Fuel pump fuse (15A) 5. Fuel level sensor unit and fuel pump 6. harness connector Fuel level sensor unit 7. Fuel pump and fuel filter 8. Fuel pressure regulator Intake valve timing control solenoid valve 10. EVAP canister purge volume control solenoid valve EC-90 3. 9. IPDM E/R TROUBLE DIAGNOSIS [CR (WITH EURO-OBD)] A EC C D E MBIB1501E 1. Accelerator pedal position sensor 4. Brake pedal 2. Accelerator pedal 3. Stop lamp switch F G H I J K L M EC-91 TROUBLE DIAGNOSIS [CR (WITH EURO-OBD)] Vacuum Hose Drawing BBS002TJ MBIB1440E : Vehicle front 1. EVAP canister purge volume control solenoid valve 2. Intake manifold NOTE: Do not use soapy water or any type of solvent while installing vacuum hose or purge hoses. Refer to EC-33, "System Diagram" for Vacuum Control System. EC-92 TROUBLE DIAGNOSIS [CR (WITH EURO-OBD)] Circuit Diagram BBS002U7 A EC C D E F G H I J K L M MBWA1500E EC-93 TROUBLE DIAGNOSIS [CR (WITH EURO-OBD)] MBWA1501E EC-94 TROUBLE DIAGNOSIS [CR (WITH EURO-OBD)] ECM Harness Connector Terminal Layout BBS002U8 A EC C MBIB0045E ECM Terminals and Reference Value BBS002U9 PREPARATION 1. 2. D E ECM is located left hand side of the engine room. Remove ECM harness protector. F G H MBIB0274E 3. 4. When disconnecting ECM harness connector, loosen it with levers as far as they will go as shown at right. Connect a break-out box (SST) and Y-cable adapter (SST) between the ECM and ECM harness connector. ● Use extreme care not to touch 2 pins at one time. ● Data is for comparison and may not be exact. I J K PBIB1512E L ECM INSPECTION TABLE Specification data are reference values and are measured between each terminal and ground. Pulse signal is measured by CONSULT-II. CAUTION: Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM's transistor. Use a ground other than ECM terminals, such as the ground. TERMINAL NO. 1 WIRE COLOR B ITEM ECM ground CONDITION [Engine is running] ● Idle speed EC-95 DATA (DC Voltage) Body ground M TROUBLE DIAGNOSIS [CR (WITH EURO-OBD)] TERMINAL NO. WIRE COLOR ITEM CONDITION DATA (DC Voltage) [Engine is running] 2 GR ● Engine speed: Below 3,800 rpm after the following conditions are met. – Engine: After warming up – Keeping the engine speed between 3,500 and 4,000 rpm for 1 minute and at idle for 1 minute under no load. Heated oxygen sensor 2 heater 0 - 1.0V [Ignition switch: ON] ● Engine stopped [Engine is running] ● 3 LG Throttle control motor relay power supply BATTERY VOLTAGE (11 - 14V) Engine speed: Above 3,800 rpm [Ignition switch: ON] BATTERY VOLTAGE (11 - 14V) 0 - 14V [Ignition switch: ON] 4 L Throttle control motor (Close) ● Engine stopped ● Shift lever position: 1st ● Accelerator pedal: Fully released PBIB0534E 0 - 14V [Ignition switch: ON] 5 P Throttle control motor (Open) ● Engine stopped ● Shift lever position: 1st ● Accelerator pedal: Fully depressed PBIB0533E [Engine is running] ● Warm-up condition ● Idle speed Approximately 3.0V NOTE: The pulse cycle changes depending on rpm at idle. 13 Y PBIB0527E Crankshaft position sensor (POS) Approximately 3.0V [Engine is running] ● Engine speed: 2,000 rpm PBIB0528E EC-96 TROUBLE DIAGNOSIS [CR (WITH EURO-OBD)] TERMINAL NO. WIRE COLOR ITEM CONDITION [Engine is running] ● Warm-up condition ● Idle speed DATA (DC Voltage) 1.0 - 4.0V EC NOTE: The pulse cycle changes depending on rpm at idle. 14 R A C PBIB0525E Camshaft position sensor (PHASE) D 1.0 - 4.0V E [Engine is running] ● Engine speed: 2,000 rpm F PBIB0526E 15 W Knock sensor [Engine is running] ● Idle speed Approximately 2.5V G [Engine is running] ● 16 LG Heated oxygen sensor 2 Revving engine from idle to 3,000rpm quickly after the following conditions are met. – Engine: After warming up – Keeping the engine speed between 3,500 and 4,000 rpm for 1 minute and at idle for 1 minute under no load. H 0 - Approximately 1.0V I BATTERY VOLTAGE J (11 - 14V) [Engine is running] ● 19 LG K Idle speed L EVAP canister purge volume control solenoid valve PBIB0050E Approximately 10V M [Engine is running] ● Engine speed: About 2,000 rpm (More than 100 seconds after starting engine) PBIB0520E EC-97 TROUBLE DIAGNOSIS [CR (WITH EURO-OBD)] TERMINAL NO. WIRE COLOR ITEM CONDITION DATA (DC Voltage) BATTERY VOLTAGE [Engine is running] 22 23 41 42 O L R GR ● Warm-up condition ● Idle speed (11 - 14V) NOTE: The pulse cycle changes depending on rpm at idle. Fuel injector No. 3 Fuel injector No. 1 Fuel injector No. 4 Fuel injector No. 2 PBIB0529E BATTERY VOLTAGE (11 - 14V) [Engine is running] ● Warm-up condition ● Engine speed: 2,000 rpm PBIB0530E Approximately 7.0V [Engine is running] 24 Y Heated oxygen sensor 1 heater ● Warm-up condition ● Engine speed: Below 3,600 rpm PBIB0519E [Engine is running] ● 29 30 B L Engine speed: Above 3,600 rpm BATTERY VOLTAGE (11 - 14V) [Engine is running] Sensor ground (Camshaft position sensor) ● Warm-up condition ● Idle speed Sensor ground (Crankshaft position sensor) ● Warm-up condition ● Idle speed Approximately 0V [Engine is running] 34 O Intake air temperature sensor [Engine is running] 35 BR Heated oxygen sensor 1 ● Warm-up condition ● Engine speed: 2,000 rpm Approximately 0V Approximately 0 - 4.8V Output voltage varies with intake air temperature. [Engine is running] 45 0 - Approximately 1.0V (Periodically change) L Sensor power supply [Ignition switch: ON] Approximately 5V 46 W Sensor power supply (Refrigerant pressure sensor) [Ignition switch: ON] Approximately 5V 47 L Sensor power supply (Throttle position sensor) [Ignition switch: ON] Approximately 5V EC-98 TROUBLE DIAGNOSIS [CR (WITH EURO-OBD)] TERMINAL NO. WIRE COLOR ITEM CONDITION DATA (DC Voltage) A [Ignition switch: ON] 49 Y Throttle position sensor 1 ● Engine stopped ● Shift lever position: 1st ● Accelerator pedal: Fully released EC More than 0.36V C [Ignition switch: ON] ● Engine stopped ● Shift lever position: 1st ● Accelerator pedal: Fully depressed Less than 4.75V D [Engine is running] 51 W Manifold absolute pressure sensor ● Warm-up condition ● Idle speed Approximately 1.5V E Approximately 1.2V F Approximately 0V G [Engine is running] ● Warm-up condition ● Engine speed: 2,000 rpm [Engine is running] 54 56 57 — B Y Sensor ground (Knock sensor) ● Warm-up condition ● Idle speed [Engine is running] Sensor ground (Manifold absolute pressure sensor) ● Warm-up condition ● Idle speed Sensor ground (Refrigerant pressure sensor) ● Warm-up condition ● Idle speed [Engine is running] [Engine is running] 60 61 79 80 Y V G BR H Approximately 0V ● Warm-up condition ● Idle speed I Approximately 0V J 0 - 0.1V K NOTE: The pulse cycle changes depending on rpm at idle. Ignition signal No. 3 Ignition signal No. 1 Ignition signal No. 4 Ignition signal No. 2 PBIB0521E L 0 - 0.2V M [Engine is running] ● Warm-up condition ● Engine speed: 2,000 rpm PBIB0522E EC-99 TROUBLE DIAGNOSIS [CR (WITH EURO-OBD)] TERMINAL NO. WIRE COLOR ITEM CONDITION [Engine is running] ● Warm-up condition ● Idle speed DATA (DC Voltage) BATTERY VOLTAGE (11 - 14V) Approximately 4V - BATTERY 62 LG Intake valve timing control solenoid valve VOLTAGE (11 - 14V) [Engine is running] ● Warm-up condition ● Engine speed: 2,000 rpm PBIB1790E 66 B Sensor ground (Throttle position sensor) [Engine is running] ● Warm-up condition ● Idle speed Approximately 0V [Ignition switch: ON] 68 R Throttle position sensor 2 ● Engine stopped ● Shift lever position: 1st ● Accelerator pedal: Fully released Less than 4.75V [Ignition switch: ON] ● Engine stopped ● Shift lever position: 1st ● Accelerator pedal: Fully depressed More than 0.36V [Engine is running] 69 BR Refrigerant pressure sensor ● Warm-up condition ● Both A/C switch and blower fan switch: ON 1.0 - 4.0V (Compressor operates.) 72 P Engine coolant temperature sensor 73 B Sensor ground (Engine coolant temperature sensor) [Engine is running] Approximately 0 - 4.8V Output voltage varies with engine coolant temperature. [Engine is running] ● Warm-up condition ● Idle speed Approximately 0V [Engine is running] 74 B Sensor ground (Heated oxygen sensor) ● Warm-up condition ● Idle speed Approximately 0V [Engine is running] 82 B Sensor ground (APP sensor 1) ● Warm-up condition ● Idle speed Approximately 0V [Engine is running] 83 85 B LG Sensor ground (APP sensor 2) DATA link connector ● Warm-up condition ● Idle speed [Ignition switch: ON] ● CONSULT-II or GST: Disconnected Approximately 0V BATTERY VOLTAGE (11 - 14V) 86 Y CAN communication line [Ignition switch: ON] 1.0 - 2.5V 90 O Sensor power supply (APP sensor 1) [Ignition switch: ON] Approximately 5V 91 BR Sensor power supply (APP sensor 2) [Ignition switch: ON] Approximately 5V EC-100 TROUBLE DIAGNOSIS [CR (WITH EURO-OBD)] TERMINAL NO. 94 WIRE COLOR L ITEM CAN communication line CONDITION [Ignition switch: ON] DATA (DC Voltage) 2.5 - 4.0V EC [Ignition switch: ON] 98 G Accelerator pedal position sensor 2 ● Engine stopped ● Accelerator pedal: Fully released Engine stopped ● Accelerator pedal: Fully depressed [Ignition switch: OFF] ● 101 R Stop lamp switch Brake pedal: Fully released [Ignition switch: OFF] ● Brake pedal: Slightly depressed [Ignition switch: ON] ● 102 GR PNP switch G Throttle control motor relay Gear position: Neutral [Ignition switch: ON] ● 104 0.3 - 0.6V C [Ignition switch: ON] ● Except the above gear position 1.95 - 2.4V D Approximately 0V BATTERY VOLTAGE (11 - 14V) Approximately 0V BATTERY VOLTAGE (11 - 14V) [Ignition switch: ON] 0 - 1.0V [Ignition switch: ON] 106 109 W O Accelerator pedal position sensor 1 Ignition switch Engine stopped ● Accelerator pedal: Fully released ● Engine stopped ● Accelerator pedal: Fully depressed ECM relay (Self shut-off) 3.9 - 4.7V J [Ignition switch: ON] BATTERY VOLTAGE (11 - 14V) For a few seconds after turning ignition switch OFF [Ignition switch: OFF] More than a few seconds passed after turning ignition switch OFF 0 - 1.0V BATTERY VOLTAGE (11 - 14V) [Ignition switch: ON] ● R Fuel pump relay H I 0V ● 113 G 0.6 - 0.9V [Ignition switch: OFF] ● P F [Ignition switch: ON] [Engine is running] [Ignition switch: OFF] 111 E BATTERY VOLTAGE (11 - 14V) [Ignition switch: OFF] ● A For 1 second after turning ignition switch ON 0 - 1.0V [Engine is running] [Ignition switch: ON] ● More than 1 second after turning ignition switch ON [Engine is running] BATTERY VOLTAGE (11 - 14V) 115 116 B B ECM ground 119 120 G G Power supply for ECM [Ignition switch: ON] BATTERY VOLTAGE (11 - 14V) 121 BR Power supply for ECM (Back-up) [Ignition switch: OFF] BATTERY VOLTAGE (11 - 14V) ● Idle speed : Average voltage for pulse signal (Actual pulse signal can be confirmed by oscilloscope.) EC-101 Body ground K L M TROUBLE DIAGNOSIS [CR (WITH EURO-OBD)] CONSULT-II Function (ENGINE) BBS002UA FUNCTION Diagnostic test mode Function Work support This mode enables a technician to adjust some devices faster and more accurately by following the indications on the CONSULT-II unit. Self-diagnostic results Self-diagnostic results such as 1st trip DTC, DTCs and 1st trip freeze frame data or freeze frame data can be read and erased quickly.* Data monitor Input/Output data in the ECM can be read. Data monitor (SPEC) Input/Output of the specification for Basic fuel schedule, A/F feedback control value and the other data monitor items can be read. CAN diagnostic support monitor The results of transmit/receive diagnosis of CAN communication can be read. Active test Diagnostic Test Mode in which CONSULT-II drives some actuators apart from the ECMs and also shifts some parameters in a specified range. Function test This mode is used to inform customers when their vehicle condition requires periodic maintenance. DTC & SRT confirmation The status of system monitoring tests and the self-diagnosis status/result can be confirmed. ECM part number ECM part number can be read. *: The following emission-related diagnostic information is cleared when the ECM memory is erased. ● Diagnostic trouble codes ● 1st trip diagnostic trouble codes ● Freeze frame data ● 1st trip freeze frame data ● System readiness test (SRT) codes ● Test values EC-102 TROUBLE DIAGNOSIS [CR (WITH EURO-OBD)] ENGINE CONTROL COMPONENT PARTS/CONTROL SYSTEMS APPLICATION A DIAGNOSTIC TEST MODE SELF-DIAGNOSTIC RESULTS INPUT WORK SUPPORT DATA MONITOR × × DTC & SRT CONFIRMATION ACTIVE TEST DTC WORK SUPPORT DTC*1 FREEZE FRAME DATA*2 Crankshaft position sensor (POS) × × Camshaft position sensor (PHASE) × × × Manifold absolute pressure sensor × × × Engine coolant temperature sensor × × × Heated oxygen sensor 1 × × × × × Heated oxygen sensor 2 × × × × × Wheel sensor × × × Accelerator pedal position sensor × × × Throttle position sensor × × × Intake air temperature sensor × × × Knock sensor × Refrigerant pressure sensor × × Closed throttle position switch (accelerator pedal position sensor signal) × × × × × C D × E F G × × Park/neutral position (PNP) switch × × × Stop lamp switch × × × EPS control unit × × Battery voltage × × Electrical load signal × × Fuel injector × × × Power transistor (Ignition timing) × × × × × × × × × × × × × Throttle control motor relay × Throttle control motor × EVAP canister purge volume control solenoid valve × Air conditioner relay Fuel pump relay SRT STATUS EC H Air conditioner switch OUTPUT ENGINE CONTROL COMPONENT PARTS ENGINE CONTROL COMPONENT PARTS Item DATA MONITOR (SPEC) × I J K L × M Cooling fan relay × × × Heated oxygen sensor 1 heater × × × × Heated oxygen sensor 2 heater × × × × Intake valve timing control solenoid valve × × × × × × Calculated load value × X: Applicable *1: This item includes 1st trip DTCs. *2: This mode includes 1st trip freeze frame data or freeze frame data. The items appear on CONSULT-II screen in freeze frame data mode only if a 1st trip DTC or DTC is detected. For details, refer to EC-50 . EC-103 TROUBLE DIAGNOSIS [CR (WITH EURO-OBD)] INSPECTION PROCEDURE Refer to GI-38, "CONSULT-II Data Link Connector (DLC) Circuit" . WORK SUPPORT MODE Work Item WORK ITEM CONDITION USAGE FUEL PRESSURE RELEASE ● FUEL PUMP WILL STOP BY TOUCHING “START” DURING IDLING. CRANK A FEW TIMES AFTER ENGINE STALLS. When releasing fuel pressure from fuel line IDLE AIR VOL LEARN ● THE IDLE AIR VOLUME THAT KEEPS THE ENGINE WITHIN THE SPECIFIED RANGE IS MEMORIZED IN ECM. When learning the idle air volume SELF-LEARNING CONT ● THE COEFFICIENT OF SELF-LEARNING CONTROL MIXTURE RATIO RETURNS TO THE ORIGINAL COEFFICIENT. When clearing the coefficient of self-learning control value TARGET IGN TIM ADJ* ● IDLE CONDITION When adjusting target ignition timing TARGET IDLE RPM ADJ* ● IDLE CONDITION When setting target idle speed *: This function is not necessary in the usual service procedure. SELF-DIAG RESULTS MODE Self Diagnostic Item Regarding items of DTC and 1st trip DTC, refer to EC-48, "EMISSION-RELATED DIAGNOSTIC INFORMATION ITEMS" . Freeze Frame Data and 1st Trip Freeze Frame Data Freeze frame data item* DIAG TROUBLE CODE [PXXXX] Description ● The engine control component part/control system has a trouble code, it is displayed as PXXXX. (Refer to EC-22, "INDEX FOR DTC" .) ● Fuel injection system status at the moment a malfunction is detected is displayed. ● One mode in the following is displayed. Mode2: Open loop due to detected system malfunction Mode3: Open loop due to driving conditions (power enrichment, deceleration enleanment) Mode4: Closed loop - using oxygen sensor(s) as feedback for fuel control Mode5: Open loop - has not yet satisfied condition to go to closed loop CAL/LD VALUE [%] ● The calculated load value at the moment a malfunction is detected is displayed. COOLANT TEMP [°C] or [°F] ● The engine coolant temperature at the moment a malfunction is detected is displayed. ● “Long-term fuel trim” at the moment a malfunction is detected is displayed. ● The long-term fuel trim indicates much more gradual feedback compensation to the base fuel schedule than short-term fuel trim. FUEL SYS-B1 L-FUEL TRM-B1 [%] ● “Short-term fuel trim” at the moment a malfunction is detected is displayed. S-FUEL TRM-B1 [%] ● The short-term fuel trim indicates dynamic or instantaneous feedback compensation to the base fuel schedule. ENGINE SPEED [rpm] ● The engine speed at the moment a malfunction is detected is displayed. VEHICL SPEED [km/h] or [mph] ● The vehicle speed at the moment a malfunction is detected is displayed. B/FUEL SCHDL [msec] ● The base fuel schedule at the moment a malfunction is detected is displayed. INT/A TEMP SE [°C] or [°F] ● The intake air temperature at the moment a malfunction is detected is displayed. *: The items are the same as those of 1st trip freeze frame data. EC-104 TROUBLE DIAGNOSIS [CR (WITH EURO-OBD)] DATA MONITOR MODE Monitored Item Monitored item [Unit] ECM INPUT SIGNALS A ×: Applicable MAIN SIGNALS Description ● ENG SPEED [rpm] × × Indicates the engine speed computed from the signals of the crankshaft position sensor (POS) and camshaft position sensor (PHASE). Remarks ● Accuracy becomes poor if engine speed drops below the idle rpm. ● If the signal is interrupted while the engine is running, an abnormal value may be indicated. ● ● COOLAN TEMP/S [°C] or [°F] × × HO2S1 (B1) [V] × × HO2S2 (B1) [V] × HO2S1 MNTR (B1) [RICH/LEAN] × ● The signal voltage of the heated oxygen sensor 1 is displayed. ● The signal voltage of the heated oxygen sensor 2 is displayed. ● Display of heated oxygen sensor 1 signal during air-fuel ratio feedback control: RICH: means the mixture became “rich”, and control is being affected toward a leaner mixture. LEAN: means the mixture became “lean”, and control is being affected toward a rich mixture. × ● HO2S2 MNTR (B1) [RICH/LEAN] × × A/F ALPHA-B1 [%] The engine coolant temperature (determined by the signal voltage of the engine coolant temperature sensor) is displayed. ● Display of heated oxygen sensor 2 signal: RICH: means the amount of oxygen after three way catalyst is relatively small. LEAN: means the amount of oxygen after three way catalyst is relatively large. The mean value of the air-fuel ratio feedback correction factor per cycle is indicated. VHCL SPEED SE [km/h] or [mph] × × ● The vehicle speed computed from the vehicle speed signal is displayed. BATTERY VOLT [V] × × ● The power supply voltage of ECM is displayed. ● “Base fuel schedule” indicates the fuel injection pulse width programmed into ECM, prior to any learned on board correction. ● The accelerator pedal position sensor signal voltage is displayed. ● The throttle position sensor signal voltage is displayed. ● The intake air temperature (determined by the signal voltage of the intake air temperature sensor) is indicated. ● The signal voltage of the manifold absolute pressure sensor is displayed. B/FUEL SCHDL [msec] × ACCEL SEN 1 [V] × ACCEL SEN 2 [V] × THRTL SEN 1 [V] × THRTL SEN 2 [V] × INT/A TEMP SE [°C] or [°F] × TURBO BST SEN [V] × × × × EC-105 When the engine coolant temperature sensor is open or short-circuited, ECM enters fail-safe mode. The engine coolant temperature determined by the ECM is displayed. EC C D E F G ● ● After turning ON the ignition switch, “RICH” is displayed until air-fuel mixture ratio feedback control begins. H When the air-fuel ratio feedback is clamped, the value just before the clamping is displayed continuously. I ● When the engine is stopped, a certain value is indicated. ● When the engine is stopped, a certain value is indicated. ● This data also includes the data for the air-fuel ratio learning control. J K L M ● ACCEL SEN 2 signal is converted by ECM internally. Thus, it differs from ECM terminal voltage signal. ● THRTL SEN 2 signal is converted by ECM internally. Thus, it differs from ECM terminal voltage signal. TROUBLE DIAGNOSIS [CR (WITH EURO-OBD)] ECM INPUT SIGNALS MAIN SIGNALS START SIGNAL [ON/OFF] × × CLSD THL POS [ON/OFF] × × AIR COND SIG [ON/ OFF] × × P/N POSI SW [ON/OFF] × × PW/ST SIGNAL [ON/OFF] × × Monitored item [Unit] Description ● Indicates start signal status [ON/OFF] computed by the ECM according to the signals of engine speed and battery voltage. ● Indicates idle position [ON/OFF] computed by the ECM according to the accelerator pedal position sensor signal. ● Indicates [ON/OFF] condition of the air conditioner switch as determined by the air conditioner signal. ● Indicates [ON/OFF] condition from the park/ neutral position (PNP) switch signal. ● [ON/OFF] condition of the power steering system (determined by the signal sent from EPS control unit) is indicated. ● Indicates [ON/OFF] condition from the electrical load signal. ON: Rear window defogger switch is ON and/or lighting switch is in 2nd position. OFF: Both rear window defogger switch and lighting switch are OFF. LOAD SIGNAL [ON/ OFF] × IGNITION SW [ON/OFF] × ● Indicates [ON/OFF] condition from ignition switch. HEATER FAN SW [ON/OFF] × ● Indicates [ON/OFF] condition from the heater fan switch signal. BRAKE SW [ON/OFF] × ● Indicates [ON/OFF] condition from the stop lamp switch signal. ● Indicates the actual fuel injection pulse width compensated by ECM according to the input signals. ● Indicates the ignition timing computed by ECM according to the input signals. ● “Calculated load value” indicates the value of the current airflow divided by peak airflow. ● Indicates the EVAP canister purge volume control solenoid valve control value computed by the ECM according to the input signals. ● The opening becomes larger as the value increases. ● Indicates [°CA] of intake camshaft advanced angle. ● The control value of the intake valve timing control solenoid valve (determined by ECM according to the input signals) is indicated. ● The advance angle becomes larger as the value increases. ● The air conditioner relay control condition (determined by ECM according to the input signals) is indicated. × INJ PULSE-B1 [msec] × IGN TIMING [BTDC] × CAL/LD VALUE [%] PURG VOL C/V [%] INT/V TIM (B1) [°CA] INT/V SOL (B1) [%] AIR COND RLY [ON/ OFF] × EC-106 Remarks ● After starting the engine, [OFF] is displayed regardless of the starter signal. ● When the engine is stopped, a certain computed value is indicated. ● When the engine is stopped, a certain value is indicated. TROUBLE DIAGNOSIS [CR (WITH EURO-OBD)] Monitored item [Unit] ECM INPUT SIGNALS MAIN SIGNALS FUEL PUMP RLY [ON/OFF] × THRTL RELAY [ON/ OFF] × COOLING FAN [HI/LOW/OFF] Description ● Indicates the fuel pump relay control condition determined by ECM according to the input signals. ● Indicates the throttle control motor relay control condition determined by the ECM according to the input signals. ● Indicates the condition of the cooling fan (determined by ECM according to the input signals). HI: High speed operation LOW: Low speed operation OFF: Stop × ● HO2S1 HTR (B1) [ON/OFF] ● HO2S2 HTR (B1) [ON/OFF] ● IDL A/V LEARN [YET/CMPLT] TRVL AFTER MIL [km] or [mile] O2 SEN HTR DTY [%] AC PRESS SEN [V] × Remarks EC C D E Indicates [ON/OFF] condition of heated oxygen sensor 1 heater determined by ECM according to the input signals. F Indicates [ON/OFF] condition of heated oxygen sensor 2 heater determined by ECM according to the input signals. G Display the condition of idle air volume learning YET: Idle air volume learning has not been performed yet. CMPLT: Idle air volume learning has already been performed successfully. ● Distance traveled while MI is activated. ● Indicates the heated oxygen sensor 1 heater control valve computed by the ECM according to the input signals. ● The signal voltage from the refrigerant pressure sensor is displayed. A H I J K Voltage [V] Frequency [msec], [Hz] or [%] DUTY-HI DUTY-LOW ● Voltage, frequency, duty cycle or pulse width measured by the probe. PLS WIDTH-HI ● Only “#” is displayed if item is unable to be measured. L ● Figures with “#”s are temporary ones. They are the same figures as an actual piece of data which was just previously measured. M PLS WIDTH-LOW NOTE: ● Any monitored item that does not match the vehicle being diagnosed is deleted from the display automatically. EC-107 TROUBLE DIAGNOSIS [CR (WITH EURO-OBD)] DATA MONITOR (SPEC) MODE Monitored Item Monitored item [Unit] ECM INPUT SIGNALS MAIN SIGNALS Description ● Indicates the engine speed computed from the signal of the crankshaft position sensor (POS) and camshaft position sensor (PHASE). ● “Base fuel schedule” indicates the fuel injection pulse width programmed into ECM, prior to any learned on board correction. × ENG SPEED [rpm] B/FUEL SCHDL [msec] ● × A/F ALPHA-B1 [%] The mean value of the air-fuel ratio feedback correction factor per cycle is indicated. Remarks ● When engine is running specification range is indicated. ● When engine is running specification range is indicated. ● This data also includes the data for the air-fuel ratio learning control. NOTE: ● Any monitored item that does not match the vehicle being diagnosed is deleted from the display automatically. ACTIVE TEST MODE Test Item TEST ITEM CONDITION ● FUEL INJECTION IGNITION TIMING POWER BALANCE COOLING FAN* ENG COOLANT TEMP FUEL PUMP RELAY ● Engine: Return to the original trouble condition Change the amount of fuel injection using CONSULT-II. ● Engine: Return to the original trouble condition ● Timing light: Set ● Retard the ignition timing using CONSULT-II. ● Engine: After warming up, idle the engine. JUDGEMENT If trouble symptom disappears, see CHECK ITEM. If trouble symptom disappears, see CHECK ITEM. CHECK ITEM (REMEDY) ● Harness and connectors ● Fuel injector ● Heated oxygen sensor 1 ● Perform Idle Air Volume Learning. ● Harness and connectors ● Compression ● Fuel injector ● Power transistor ● A/C switch: OFF ● Shift lever: Neutral ● Cut off each fuel injector signal one at a time using CONSULT-II. ● Spark plug ● Ignition coil ● Ignition switch: ON ● Harness and connectors ● Turn the cooling fan “HI”, “LOW” and “OFF” with CONSULT-II. ● Cooling fan relay ● Cooling fan motor ● Harness and connectors ● Engine coolant temperature sensor ● Fuel injector ● Harness and connectors ● Fuel pump relay ● Engine: Return to the original trouble condition ● Change the engine coolant temperature using CONSULT-II. ● Ignition switch: ON (Engine stopped) ● Turn the fuel pump relay ON and OFF using CONSULT-II and listen to operating sound. Engine runs rough or dies. Cooling fan moves and stops. If trouble symptom disappears, see CHECK ITEM. Fuel pump relay makes the operating sound. EC-108 TROUBLE DIAGNOSIS [CR (WITH EURO-OBD)] TEST ITEM PURG VOL CONT/V CONDITION ● Engine: After warming up, run engine at 1,500 rpm. ● Change the EVAP canister purge volume control solenoid valve opening percent using CONSULT-II. ● V/T ASSIGN ANGLE JUDGEMENT ● Engine: Return to the original trouble condition Change intake valve timing using CONSULT-II. CHECK ITEM (REMEDY) A Engine speed changes according to the opening percent. If trouble symptom disappears, see CHECK ITEM. ● Harness and connectors ● Solenoid valve ● Harness and connectors ● Intake valve timing control solenoid valve EC C D *: Leaving cooling fan OFF with CONSULT-II while engine is running may cause the engine to overheat. DTC & SRT CONFIRMATION MODE SRT STATUS Mode E For details, refer to EC-51, "SYSTEM READINESS TEST (SRT) CODE" . SRT Work Support Mode F This mode enables a technician to drive a vehicle to set the SRT while monitoring the SRT status. DTC Work Support Mode Test mode HO2S1 Test item Condition HO2S1 (B1) P0133 EC-185 HO2S1 (B1) P0134 EC-195 HO2S1 (B1) P1143 Refer to corresponding trouble diagnosis for DTC. HO2S1 (B1) P1144 HO2S2 (B1) P0139 HO2S2 Reference page H EC-310 EC-316 EC-210 HO2S2 (B1) P1146 EC-322 HO2S2 (B1) P1147 EC-330 REAL TIME DIAGNOSIS IN DATA MONITOR MODE (RECORDING VEHICLE DATA) Description CONSULT-II has two kinds of triggers and they can be selected by touching “SETTING” in “DATA MONITOR” mode. 1. “AUTO TRIG” (Automatic trigger): ● The malfunction will be identified on the CONSULT-II screen in real time. In other words, DTC/1st trip DTC and malfunction item will be displayed if the malfunction is detected by ECM. At the moment a malfunction is detected by ECM, “MONITOR” in “DATA MONITOR” screen is changed to “Recording Data ... xx%” as shown in the figure, and the data after the malfunction detection is recorded. Then when the percentage reached 100%, “REAL-TIME DIAG” screen is displayed. If “STOP” is touched on the screen during “Recording Data ... xx%”, “REAL-TIME DIAG” screen is also displayed. MBIB0295E The recording time after the malfunction detection and the EC-109 G I J K L M TROUBLE DIAGNOSIS [CR (WITH EURO-OBD)] 2. recording speed can be changed by “TRIGGER POINT” and “Recording Speed”. Refer to CONSULT-II OPERATION MANUAL. “MANU TRIG” (Manual trigger): ● DTC/1st trip DTC and malfunction item will not be displayed automatically on CONSULT-II screen even though a malfunction is detected by ECM. DATA MONITOR can be performed continuously even though a malfunction is detected. SEF707X Operation 1. 2. “AUTO TRIG” ● While trying to detect the DTC/1st trip DTC by performing the DTC Confirmation Procedure, be sure to select to “DATA MONITOR (AUTO TRIG)” mode. You can confirm the malfunction at the moment it is detected. ● While narrowing down the possible causes, CONSULT-II should be set in “DATA MONITOR (AUTO TRIG)” mode, especially in case the incident is intermittent. When you are inspecting the circuit by gently shaking (or twisting) the suspicious connectors, components and harness in the DTC Confirmation Procedure, the moment a malfunction is found the DTC/1st trip DTC will be displayed. (Refer to Incident Simulation Tests in GI-25, "How to Perform Efficient Diagnosis for an Electrical Incident" .) “MANU TRIG” ● If the malfunction is displayed as soon as “DATA MONITOR” is selected, reset CONSULT-II to “MANU TRIG”. By selecting “MANU TRIG” you can monitor and store the data. The data can be utilized for further diagnosis, such as a comparison with the value for the normal operating condition. PBIB0197E EC-110 TROUBLE DIAGNOSIS [CR (WITH EURO-OBD)] Generic Scan Tool (GST) Function BBS002UB A DESCRIPTION Generic Scan Tool (OBDII scan tool) complying with ISO 15031 has 8 different functions explained below. ISO9141 is used as the protocol. The name GST or Generic Scan Tool is used in this service manual. EC C D SEF139P FUNCTION E Diagnostic test mode Service $01 Service $02 Service $03 Function READINESS TESTS This diagnostic service gains access to current emission-related data values, including analog inputs and outputs, digital inputs and outputs, and system status information. (FREEZE DATA) This diagnostic service gains access to emission-related data value which were stored by ECM during the freeze frame. For details, refer to EC-50, "FREEZE FRAME DATA AND 1ST TRIP FREEZE FRAME DATA" . DTCs This diagnostic service gains access to emission-related power train trouble codes which were stored by ECM. This diagnostic service can clear all emission-related diagnostic information. This includes: Service $04 Service $06 Service $07 Service $08 Service $09 CLEAR DIAG INFO ● Clear number of diagnostic trouble codes (Service $01) ● Clear diagnostic trouble codes (Service $03) ● Clear trouble code for freeze frame data (Service $01) ● Clear freeze frame data (Service $02) ● Reset status of system monitoring test (Service $01) ● Clear on board monitoring test results (Service $06 and Service $07) (ON BOARD TESTS) This diagnostic service enables the off board test drive to obtain test results for emissionrelated powertrain components/systems that are continuously monitored during normal driving conditions. 3. K L This diagnostic service is not applicable on this vehicle. This diagnostic service enables the off-board test device to request specific vehicle information such as Vehicle Identification Number (VIN) and Calibration IDs. INSPECTION PROCEDURE 1. 2. H J This diagnostic service accesses the results of on board diagnostic monitoring tests of specific components/systems that are not continuously monitored. (CALIBRATION ID) G I (ON BOARD TESTS) — F Turn ignition switch OFF. Connect GST to data link connector, which is located under drivers side dash panel near the fuse box cover. Turn ignition switch ON. MBIB0275E EC-111 M TROUBLE DIAGNOSIS [CR (WITH EURO-OBD)] 4. Enter the program according to instruction on the screen or in the operation manual. (*: Regarding GST screens in this section, sample screens are shown.) SEF398S 5. Perform each diagnostic mode according to each service procedure. For further information, see the GST Operation Manual of the tool maker. SEF416S CONSULT-II Reference Value in Data Monitor Mode BBS002UC Remarks: ● Specification data are reference values. ● Specification data are output/input values which are detected or supplied by the ECM at the connector. * Specification data may not be directly related to their components signals/values/operations. MONITOR ITEM CONDITION SPECIFICATION ● Run engine and compare CONSULT-II value with the tachometer indication. B/FUEL SCHDL ● See EC-117, "TROUBLE DIAGNOSIS - SPECIFICATION VALUE" . A/F ALPHA-B1 ● See EC-117, "TROUBLE DIAGNOSIS - SPECIFICATION VALUE" . COOLAN TEMP/S ● Engine: After warming up HO2S1 (B1) ● Engine: After warming up ● Revving engine from idle to 3,000 rpm quickly after the following conditions are met. – Engine: After warming up – Keeping the engine speed between 3,500 and 4,000 rpm for 1 minute and at idle for 1 minute under no load. ● Engine: After warming up ● Revving engine from idle to 3,000 rpm quickly after the following conditions are met. – Engine: After warming up – Keeping the engine speed between 3,500 and 4,000 rpm for 1 minute and at idle for 1 minute under no load. ● Turn drive wheels and compare CONSULT-II value with the speedometer indication. Almost the same speed as the speedometer indication. ● Ignition switch: ON (Engine stopped) 11 - 14V ● Ignition switch: ON (Engine stopped) ENG SPEED HO2S2 (B1) HO2S1 MNTR (B1) HO2S2 MNTR (B1) VHCL SPEED SE BATTERY VOLT ACCEL SEN 1 Almost the same speed as the tachometer indication. More than 70°C (158°F) Maintaining engine speed at 2,000 rpm 0 - 0.3V ←→ Approx. 0.6 - 1.0V 0 - 0.3V ←→ Approx. 0.6 - 1.0V Maintaining engine speed at 2,000 rpm LEAN ←→ RICH Changes more than 5 times during 10 seconds. LEAN ←→ RICH Accelerator pedal: Fully released 0.6 - 0.9V Accelerator pedal: Fully depressed 4.0 - 4.8V EC-112 TROUBLE DIAGNOSIS [CR (WITH EURO-OBD)] MONITOR ITEM ACCEL SEN 2*1 CONDITION ● AIR COND SIG P/N POSI SW PW/ST SIGNAL LOAD SIGNAL IGNITION SW HEATER FAN SW BRAKE SW Accelerator pedal: Fully depressed 3.9 - 4.8V More than 0.36V Accelerator pedal: Fully released ● Shift lever: 1st Accelerator pedal: Fully depressed Less than 4.75V ● Engine: After warming up Idle Approximately 1.5V ● Air conditioner switch: OFF ● Shift lever: Neutral 2,500 rpm Approximately 1.2V ● No load ● Ignition switch: ON → START → ON TURBO BST SEN CLSD THL POS 0.6 - 0.9V Ignition switch: ON (Engine stopped) 1 START SIGNAL Accelerator pedal: Fully released ● THRTL SEN 1 THRTL SEN 2* Ignition switch: ON (Engine stopped) SPECIFICATION ● ● ● ● ● ● ● ● Ignition switch: ON (Engine stopped) Engine: After warming up, idle the engine Ignition switch: ON Engine: After warming up, idle the engine Ignition switch: ON Ignition switch: ON ● Engine: After warming up ● Shift lever: Neutral ● Air conditioner switch: OFF ● No load ● Engine: After warming up ● Shift lever: Neutral ● Air conditioner switch: OFF ● No load ● Engine: After warming up ● Shift lever: Neutral ● Air conditioner switch: OFF ● No load ● Engine: After warming up ● Shift lever: Neutral ● Air conditioner switch: OFF ● No load INJ PULSE-B1 IGN TIMING CAL/LD VALUE PURG VOL C/V EC C D OFF → ON → OFF Accelerator pedal: Fully released ON Accelerator pedal: Slightly depressed OFF Air conditioner switch: OFF OFF Air conditioner switch: ON (Compressor operates.) ON Shift lever: Neutral ON Shift lever: Except above OFF Steering wheel: Not being turned. OFF Steering wheel: Being turned. ON Rear window defogger switch is ON and/or lighting switch is in 2nd. ON Rear window defogger switch is OFF and lighting switch is OFF. OFF Ignition switch: ON → OFF → ON Engine: After warming up, idle the engine A E F G H I ON → OFF → ON Heater fan: Operating. ON Heater fan: Not operating OFF Brake pedal: Fully released OFF Brake pedal: Slightly depressed ON Idle 2.0 - 3.0 msec 2,000 rpm 1.9 - 2.9 msec Idle 0° - 10° BTDC 2,000 rpm 25° - 45° BTDC Idle 10% - 35% 2,500 rpm 10% - 35% Idle 0% 2,000 rpm 20 - 30% EC-113 J K L M TROUBLE DIAGNOSIS [CR (WITH EURO-OBD)] MONITOR ITEM CONDITION ● Engine: After warming up ● Shift lever: Neutral ● Air conditioner switch: OFF ● No load ● Engine: After warming up ● Shift lever: Neutral ● Air conditioner switch: OFF ● No load ● Engine: After warming up, idle the engine INT/V TIM (B1) INT/V SOL (B1) AIR COND RLY FUEL PUMP RLY THRTL RELAY TRVL AFTER MIL 2,000 rpm Approx. 0° - 20°CA Idle 0% - 2% 2,000 rpm Approx. 0% - 50% Air conditioner switch: OFF OFF Air conditioner switch: ON (Compressor operates) ON ● Engine running or cranking ● Except above conditions ● Ignition switch: ON ● HO2S2 HTR (B1) −5° - 5°CA For 1 second after turning ignition switch ON COOLING FAN HO2S1 HTR (B1) Idle ● ● Engine: After warming up, idle the engine Air conditioner switch: OFF ON Engine coolant temperature: 94°C (201°F) or less OFF Engine coolant temperature: Between 95°C (203°F) and 104°C (210°F) LOW*2 Engine coolant temperature: 105°C (212°F) or more HIGH*2 Engine: After warming up ● Engine speed: Below 3,600 rpm ● Engine speed: Above 3,600 rpm ● Engine speed: Below 3,800 rpm after the following conditions are met. – Engine: After warming up – Keeping the engine speed between 3,500 and 4,000 rpm for 1 minute and at idle for 1 minute under no load. ● Engine speed: Above 3,800 rpm ● Ignition switch: ON ● Engine coolant temperature when engine started: More than 80°C (176°F) ● Engine speed: Below 3,600 rpm ● Engine: Idle ● Both A/C switch and blower fan switch: ON (Compressor operates) AC PRESS SEN ON OFF ● O2SEN HTR DTY SPECIFICATION ON OFF ON OFF Vehicle has traveled after MI has turned ON. 0 - 65,535 km (0 - 40,723 mile) Approx. 50% 1.0 - 4.0V *1 : Accelerator pedal position sensor 2 signal and throttle position sensor 2 signal are converted by ECM internally. Thus, they differ from ECM terminals voltage signal. *2: Models without air conditioner, cooling fan operates only ON and OFF operation, but CONSULT-II display will change OFF, LOW and HI depends on engine coolant temperature. EC-114 TROUBLE DIAGNOSIS [CR (WITH EURO-OBD)] Major Sensor Reference Graph in Data Monitor Mode BBS002UD A The following are the major sensor reference graphs in “DATA MONITOR” mode. CLSD THL POS, ACCEL SEN 1, THRTL SEN 1 Below is the data for “CLSD THL POS”, “ACCEL SEN 1” and “THRTL SEN 1” when depressing the accelera- EC tor pedal with the ignition switch ON and with shift lever in 1st position. The signal of “ACCEL SEN 1” and “THRTL SEN 1” should rise gradually without any intermittent drop or rise after “CLSD THL POS” is changed from “ON” to “OFF”. C D E F PBIB0198E ENG SPEED, THRTL SEN 1, HO2S2 (B1), HO2S1 (B1), INJ PULSE-B1 Below is the data for “ENG SPEED”, “THRTL SEN 1”, “HO2S2 (B1)”, “HO2S1 (B1)” and “INJ PULSE-B1” when revving engine quickly up to 4,800 rpm under no load after warming up engine sufficiently. Each value is for reference, the exact value may vary. G H I J MBIB0545E K L M EC-115 TROUBLE DIAGNOSIS [CR (WITH EURO-OBD)] PBIB0668E EC-116 TROUBLE DIAGNOSIS - SPECIFICATION VALUE [CR (WITH EURO-OBD)] TROUBLE DIAGNOSIS - SPECIFICATION VALUE Description PFP:00031 A BBS002UE The specification (SP) value indicates the tolerance of the value that is displayed in “DATA MONITOR (SPEC)” mode of CONSULT-II during normal operation of the Engine Control System. When the value in “DATA MONI- EC TOR (SPEC)” mode is within the SP value, the Engine Control System is confirmed OK. When the value in “DATA MONITOR (SPEC)” mode is NOT within the SP value, the Engine Control System may have one or more malfunctions. The SP value is used to detect malfunctions that may affect the Engine Control System, but will not light the C MI. The SP value will be displayed for the following three items: ● B/FUEL SCHDL (The fuel injection pulse width programmed into ECM prior to any learned on board cor- D rection) ● A/F ALPHA-B1 (The mean value of air-fuel ratio feedback correction factor per cycle) E Testing Condition ● ● ● ● ● ● – ● – BBS002UF Vehicle driven distance: More than 5,000 km (3,107 miles) Barometric pressure: 98.3 - 104.3 kPa (0.983 - 1.043 bar, 1.003 - 1.064 kg/cm2 , 14.25 - 15.12 psi) Atmospheric temperature: 20 - 30°C (68 - 86°F) Engine coolant temperature: 75 - 95°C (167 - 203°F) Engine speed: Idle Transmission: Warmed-up After the engine is warmed up to normal operating temperature, drive vehicle for 5 minutes. Electrical load: Not applied Rear window defogger switch, air conditioner switch, lighting switch are OFF. Steering wheel is straight ahead. Inspection Procedure F G H I BBS002UG NOTE: Perform “DATA MONITOR (SPEC)” mode in maximum scale display. 1. Perform EC-66, "Basic Inspection" . 2. Confirm that the testing conditions indicated above are met. 3. Select “B/FUEL SCHDL” and “A/F ALPHA-B1” in “DATA MONITOR (SPEC)” mode with CONSULT-II. 4. Make sure that monitor items are within the SP value. 5. If NG, go to EC-118, "Diagnostic Procedure" . J K L M SEF601Z EC-117 TROUBLE DIAGNOSIS - SPECIFICATION VALUE [CR (WITH EURO-OBD)] Diagnostic Procedure BBS002UH OVERALL SEQUENCE PBIB2384E EC-118 TROUBLE DIAGNOSIS - SPECIFICATION VALUE [CR (WITH EURO-OBD)] A EC C D E F G H I J K L M MBIB1447E EC-119 TROUBLE DIAGNOSIS - SPECIFICATION VALUE [CR (WITH EURO-OBD)] DETAILED PROCEDURE 1. CHECK “A/F ALPHA-B1” 1. 2. 3. Start engine. Confirm that the testing conditions are met. Refer to EC-117, "Testing Condition" . Select “A/F ALPHA-B1” in “DATA MONITOR (SPEC)” mode, and make sure that the indication is within the SP value. NOTE: Check “A/F ALPHA-B1” for approximately 1 minute because they may fluctuate. It is NG if the indication is out of the SP value even a little. OK or NG OK >> GO TO 17. NG (Less than the SP value)>>GO TO 2. NG (More than the SP value)>>GO TO 3. PBIB2369E 2. CHECK “B/FUEL SCHDL” Select “B/FUEL SCHDL” in “DATA MONITOR (SPEC)” mode, and make sure that the indication is within the SP value. OK or NG OK >> GO TO 4. NG (More than the SP value)>>GO TO 19. PBIB2332E 3. CHECK “B/FUEL SCHDL” Select “B/FUEL SCHDL” in “DATA MONITOR (SPEC)” mode, and make sure that the indication is within the SP value. OK or NG OK >> GO TO 6. NG (More than the SP value)>>GO TO 6. NG (Less than the SP value)>>GO TO 25. PBIB2332E 4. CHECK “A/F ALPHA-B1” 1. 2. 3. 4. Stop the engine. Disconnect PCV hose, and then plug it. Start engine. Select “A/F ALPHA-B1” in “DATA MONITOR (SPEC)” mode, and make sure that the indication is within the SP value. OK or NG OK >> GO TO 5. NG >> GO TO 6. EC-120 TROUBLE DIAGNOSIS - SPECIFICATION VALUE [CR (WITH EURO-OBD)] 5. CHANGE ENGINE OIL 1. 2. A Stop the engine. Change engine oil. EC NOTE: This symptom may occur when a large amount of gasoline is mixed with engine oil because of driving conditions (such as when engine oil temperature does not rise enough since a journey distance is too short during winter). The symptom will not be detected after changing engine oil or changing driving con- C dition. >> INSPECTION END D 6. CHECK FUEL PRESSURE Check fuel pressure. (Refer to EC-71, "Fuel Pressure Check" .) OK or NG OK >> GO TO 9. NG (Fuel pressure is too high)>>Replace fuel pressure regulator, refer to EC-71, "Fuel Pressure Check" . GO TO 8. NG (Fuel pressure is too low)>>GO TO 7. E 7. DETECT MALFUNCTIONING PART G 1. – – – 2. Check the following. Clogged and bent fuel hose and fuel tube Clogged fuel filter Fuel pump and its circuit (Refer to EC-427, "FUEL PUMP" .) If NG, repair or replace the malfunctioning part. (Refer to EC-71, "Fuel Pressure Check" .) If OK, replace fuel pressure regulator. F H I J >> GO TO 8. 8. CHECK “A/F ALPHA-B1” K 1. 2. Start engine. Select “A/F ALPHA-B1” in “DATA MONITOR (SPEC)” mode, and make sure that the indication is within the SP value. OK or NG OK >> INSPECTION END NG >> GO TO 9. 9. PERFORM POWER BALANCE TEST 1. 2. Perform “POWER BALANCE” in “ACTIVE TEST” mode. Make sure that the each cylinder produces a momentary engine speed drop. OK or NG OK >> GO TO 12. NG >> GO TO 10. PBIB0133E EC-121 L M TROUBLE DIAGNOSIS - SPECIFICATION VALUE [CR (WITH EURO-OBD)] 10. DETECT MALFUNCTIONING PART 1. – – – – 2. Check the following. Ignition coil and its circuit (Refer to EC-433, "IGNITION SIGNAL" .) Fuel injector and its circuit (Refer to EC-421, "FUEL INJECTOR" .) Intake air leakage Low compression pressure (Refer to EM-60, "COMPRESSION PRESSURE INSPECTION" .) If NG, repair or replace the malfunctioning part. If OK, replace fuel injector. (It may be caused by leakage from fuel injector or clogging.) >> GO TO 11. 11. CHECK “A/F ALPHA-B1” 1. 2. Start engine. Select “A/F ALPHA-B1” in “DATA MONITOR (SPEC)” mode, and make sure that the indication is within the SP value. OK or NG OK >> INSPECTION END NG >> GO TO 12. 12. CHECK HEATED OXYGEN SENSOR 1 FUNCTION 1. 2. 3. Run engine at about 2,000 rpm for about 2 minutes under no load. Select “HO2S1 MNTR (B1)”, in “DATA MONITOR” mode. Running engine at 2,000 rpm under no load (The engine is warmed up to normal operating temperature.), check that the monitor fluctuates between LEAN and RICH more than 5 times during 10 seconds. 1 time 2 times : RICH → LEAN → RICH : RICH → LEAN → RICH → LEAN → RICH OK or NG OK >> GO TO 15. NG >> GO TO 13. SEF820Y 13. CHECK HEATED OXYGEN SENSOR 1 CIRCUIT Check heated oxygen sensor 1 and its circuit. Refer to EC-178, "DTC P0132 HO2S1" . >> GO TO 14. 14. CHECK “A/F ALPHA-B1” 1. 2. Start engine. Select “A/F ALPHA-B1” in “DATA MONITOR (SPEC)” mode, and make sure that the indication is within the SP value. OK or NG OK >> INSPECTION END NG >> GO TO 15. EC-122 TROUBLE DIAGNOSIS - SPECIFICATION VALUE [CR (WITH EURO-OBD)] 15. DISCONNECT AND RECONNECT ECM HARNESS CONNECTOR 1. 2. A Stop the engine. Disconnect ECM harness connector. Check pin terminal and connector for damage, and then reconnect it. EC >> GO TO 16. 16. CHECK “A/F ALPHA-B1” C 1. 2. D Start engine. Select “A/F ALPHA-B1” in “DATA MONITOR (SPEC)” mode, and make sure that the indication is within the SP value. OK or NG OK >> INSPECTION END NG >> Detect malfunctioning part according to EC-82, "Symptom Matrix Chart" . 17. CHECK “B/FUEL SCHDL” E F Select “B/FUEL SCHDL” in “DATA MONITOR (SPEC)” mode, and make sure that the indication is within the SP value. OK or NG OK >> INSPECTION END NG (More than the SP value)>>GO TO 18. NG (Less than the SP value)>>GO TO 27. G H I PBIB2332E 18. DETECT MALFUNCTIONING PART 1. – – – – – 2. – – – J Check for the cause of large engine friction. Refer to the following. Engine oil level too high Engine oil viscosity Belt tension of power steering, alternator, A/C compressor, etc. is excessive Noise from engine Noise from transmission, etc. Check for the cause of insufficient combustion. Refer to the following. Valve clearance malfunction Intake valve timing control function malfunction Camshaft sprocket installation malfunction, etc. >> Repair or replace malfunctioning part, and then GO TO 32. 19. CHECK INTAKE SYSTEM Check for the cause of unsteady air flow passing through throttle body. Refer to the following. ● Crushed air ducts ● Malfunctioning seal of air cleaner element ● Uneven dirt of air cleaner element ● Improper specification of intake air system part OK or NG OK >> GO TO 21. NG >> Repair or replace malfunctioning part, and then GO TO 20. EC-123 K L M TROUBLE DIAGNOSIS - SPECIFICATION VALUE [CR (WITH EURO-OBD)] 20. CHECK “A/F ALPHA-B1”, AND “B/FUEL SCHDL” Select “A/F ALPHA-B1” and “B/FUEL SCHDL” in “DATA MONITOR (SPEC)” mode, and make sure that the indication is within the SP value. OK or NG OK >> INSPECTION END NG (“B/FUEL SCHDL” is more, “A/F ALPHA-B1” is less than the SP value)>>GO TO 21. 21. DISCONNECT AND RECONNECT MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR HARNESS CONNECTOR 1. 2. Stop the engine. Disconnect manifold absolute pressure (MAP) sensor harness connector. Check pin terminal and connector for damage and then reconnect it again. >> GO TO 22. 22. CHECK “A/F ALPHA-B1” 1. 2. Start engine. Select “A/F ALPHA-B1” in “DATA MONITOR (SPEC)” mode, and make sure that the indication is within the SP value. OK or NG OK >> 1. Detect malfunctioning part of manifold absolute pressure (MAP) sensor circuit and repair it. Refer to EC-155, "DTC P0107, P0108 MANIFOLD ABSOLUTE PRESSURE SENSOR" . 2. GO TO 26. NG >> GO TO 23. 23. CHECK “TURBO BST SEN” Select “TURBO BST SEN” in “DATA MONITOR” mode, and make sure that the indication is within the specified value as described below. Idle: 2,500 rpm: Approximately 1.5V Approximately 1.2V OK or NG OK >> GO TO 25. NG (More than the specified value)>>Replace manifold absolute pressure (MAP) sensor, and then GO TO 24. MBIB1448E EC-124 TROUBLE DIAGNOSIS - SPECIFICATION VALUE [CR (WITH EURO-OBD)] 24. CHECK INTAKE SYSTEM A Check for the cause of air suction at downstream of throttle body. Refer to the following. ● Disconnection looseness, or cracks of air duct EC ● Looseness of oil filler cap ● Disconnection of oil level gauge ● Open sticking, breakage, hose disconnection, or cracks of blow-by gas control valve C ● Disconnection or cracks of EVAP canister purge hose, open sticking of EVAP canister purge volume control valve ● Malfunctioning seal of rocker cover gasket D ● Disconnection, looseness, or cracks of hoses, such as vacuum hose, connecting to intake air system parts. ● Malfunctioning seal of intake air system, etc. E >> GO TO 31. 25. REPLACE ECM F 1. 2. G 3. 4. 5. Replace ECM. Perform initialization of NATS system and registration of all NATS ignition key IDs. Refer to BL-218, "ECM Re-communicating Function" . Perform EC-69, "Accelerator Pedal Released Position Learning" . Perform EC-69, "Throttle Valve Closed Position Learning" . Perform EC-69, "Idle Air Volume Learning" . H I >> GO TO 31. 26. CHECK “TURBO BST SEN” J Select “TURBO BST SEN” in “DATA MONITOR” mode, and make sure that the indication is within the specified value as described below. Idle: 2,500 rpm: K Approximately 1.5V Approximately 1.2V L OK or NG OK >> GO TO 31. NG (More than the specified value)>>Replace manifold absolute pressure (MAP) sensor, and then GO TO 32. M MBIB1448E 27. CHECK INTAKE SYSTEM Check for the cause of uneven air flow passing through throttle body. Refer to the following. ● Crushed air ducts ● Malfunctioning seal of air cleaner element ● Uneven dirt of air cleaner element ● Improper specification of intake air system OK or NG OK >> GO TO 29. NG >> Repair or replace malfunctioning part, and then GO TO 28. EC-125 TROUBLE DIAGNOSIS - SPECIFICATION VALUE [CR (WITH EURO-OBD)] 28. CHECK “B/FUEL SCHDL” Select “B/FUEL SCHDL” in “DATA MONITOR (SPEC)” mode, and make sure that the indication is within the SP value. OK or NG OK >> INSPECTION END NG (Less than the SP value)>>GO TO 29. 29. CHECK “TURBO BST SEN” Select “TURBO BST SEN” in “DATA MONITOR” mode, and make sure that the indication is within the specified value as described below. Idle: 2,500 rpm: Approximately 1.5V Approximately 1.2V OK or NG OK >> GO TO 30. NG (Less than the specified value)>>Replace manifold absolute pressure (MAP) sensor, and then GO TO 32. MBIB1448E 30. REPLACE ECM 1. 2. 3. 4. 5. Replace ECM. Perform initialization of NATS system and registration of all NATS ignition key IDs. Refer to BL-218, "ECM Re-communicating Function" . Perform EC-69, "Accelerator Pedal Released Position Learning" . Perform EC-69, "Throttle Valve Closed Position Learning" . Perform EC-69, "Idle Air Volume Learning" . >> GO TO 32. 31. CHECK “A/F ALPHA-B1” AND “B/FUEL SCHDL” Select “A/F ALPHA-B1” and “B/FUEL SCHDL” in “DATA MONITOR (SPEC)” mode, and make sure that the indication is within the SP value. OK or NG OK >> INSPECTION END NG >> Detect malfunctioning part according to EC-82, "Symptom Matrix Chart" . 32. CHECK “B/FUEL SCHDL” Select “B/FUEL SCHDL” in “DATA MONITOR (SPEC)” mode, and then make sure that the indication is within the SP value. OK or NG OK >> INSPECTION END NG >> Detect malfunctioning part according to EC-82, "Symptom Matrix Chart" . EC-126 TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT [CR (WITH EURO-OBD)] TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT Description PFP:00006 A BBS002UI Intermittent incidents may occur. In many cases, the malfunction resolves itself (the part or circuit function returns to normal without intervention). It is important to realize that the symptoms described in the customer's EC complaint often do not recur on (1st trip) DTC visits. Realize also that the most frequent cause of intermittent incident occurrences is poor electrical connections. Because of this, the conditions under which the incident occurred may not be clear. Therefore, circuit checks made as part of the standard diagnostic procedure may C not indicate the specific malfunctioning area. Common Intermittent Incident Report Situations STEP in Work Flow 2 3 or 4 Situation D The CONSULT-II is used. The SELF-DIAG RESULTS screen shows time data other than [0] or [1t]. The symptom described by the customer does not recur. 5 (1st trip) DTC does not appear during the DTC Confirmation Procedure. 10 The Diagnostic Procedure for PXXXX does not indicate the malfunctioning area. Diagnostic Procedure E BBS002UJ 1. INSPECTION START Erase (1st trip) DTCs. Refer to EC-57, "HOW TO ERASE EMISSION-RELATED DIAGNOSTIC INFORMATION" . >> GO TO 2. F G H 2. CHECK GROUND TERMINALS Check ground terminals for corroding or loose connection. Refer to EC-133, "Ground Inspection" . OK or NG OK >> GO TO 3. NG >> Repair or replace. 3. SEARCH FOR ELECTRICAL INCIDENT I J K Perform GI-25, "How to Perform Efficient Diagnosis for an Electrical Incident" , “Incident Simulation Tests”. OK or NG OK >> INSPECTION END NG >> Repair or replace. L M EC-127 POWER SUPPLY AND GROUND CIRCUIT [CR (WITH EURO-OBD)] POWER SUPPLY AND GROUND CIRCUIT Wiring Diagram PFP:24110 BBS002UK MBWA1502E EC-128 POWER SUPPLY AND GROUND CIRCUIT [CR (WITH EURO-OBD)] Specification data are reference values and are measured between each terminal and ground. CAUTION: Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM's transistor. Use a ground other than ECM terminals, such as the ground. TERMINAL NO. 1 115 116 109 EC WIRE COLOR B B B O ITEM ECM ground CONDITION [Engine is running] ● Ignition switch Idle speed ECM relay (Self shut-off) [Ignition switch: ON] BATTERY VOLTAGE (11 - 14V) G G Power supply for ECM For a few seconds after turning ignition switch OFF [Ignition switch: OFF] ● 119 120 C Body ground 0V ● P DATA (DC Voltage) [Ignition switch: OFF] [Engine is running] [Ignition switch: OFF] 111 A More than a few seconds passed after turning ignition switch OFF [Ignition switch: ON] Diagnostic Procedure D E 0 - 1.0V F BATTERY VOLTAGE (11 - 14V) G BATTERY VOLTAGE (11 - 14V) BBS002UL H 1. INSPECTION START Start engine. Is engine running? Yes or No Yes >> GO TO 8. No >> GO TO 2. I J 2. CHECK ECM POWER SUPPLY CIRCUIT-I 1. 2. K Turn ignition switch OFF and then ON. Check voltage between ECM terminal 109 and ground with CONSULT-II or tester. L Voltage: Battery voltage OK or NG OK >> GO TO 4. NG >> GO TO 3. M MBIB0015E 3. DETECT MALFUNCTIONING PART Check the following. ● Harness connectors M1, E101 ● Fuse block (J/B) connector M7 ● 10A fuse ● Harness for open or short between ECM and fuse >> Repair harness or connectors. EC-129 POWER SUPPLY AND GROUND CIRCUIT [CR (WITH EURO-OBD)] 4. CHECK GROUND CONNECTIONS-I 1. 2. Turn ignition switch OFF. Loosen and retighten ground screws on the body. Refer to EC-133, "Ground Inspection" . MBIB1502E 1. Body ground E44 2. Body ground E45 3. Body ground E28 OK or NG OK >> GO TO 5. NG >> Repair or replace ground connections. 5. CHECK ECM GROUND CIRCUIT FOR OPEN AND SHORT-I 1. 2. Disconnect ECM harness connector. Check harness continuity between ECM terminals 1, 115, 116 and ground. Refer to Wiring Diagram. Continuity should exist. 3. Also check harness for short to power. OK or NG OK >> GO TO 7. NG >> GO TO 6. 6. DETECT MALFUNCTIONING PART Check the following. ● Harness connectors F1, E48 ● Harness for open or short between ECM and ground >> Repair open circuit or short to power in harness or connectors. 7. CHECK ECM POWER SUPPLY CIRCUIT-II 1. 2. 3. Reconnect ECM harness connector. Turn ignition switch ON. Check voltage between IPDM E/R harness connector E7 terminal 33 and ground with CONSULT-II or tester. Voltage: Battery voltage OK or NG OK >> Go to EC-433, "IGNITION SIGNAL" . NG >> GO TO 8. MBIB1441E EC-130 POWER SUPPLY AND GROUND CIRCUIT [CR (WITH EURO-OBD)] 8. CHECK ECM POWER SUPPLY CIRCUIT-III 1. 2. A Turn ignition switch ON and then OFF. Check voltage between ECM terminals 119, 120 and ground with CONSULT-II or tester. Voltage: EC After turning ignition switch OFF, battery voltage will exist for a few seconds, then drop approximately 0V. OK or NG OK >> GO TO 13. NG (Battery voltage does not exist.)>>GO TO 9. NG (Battery voltage exists for more than a few seconds.)>>GO TO 11. C D PBIB1630E E 9. CHECK ECM POWER SUPPLY CIRCUIT-IV 1. 2. Turn ignition switch OFF. Check voltage between ECM terminal 111 and ground with CONSULT-II or tester. F G Voltage: Battery voltage OK or NG OK >> GO TO 10. NG >> GO TO 11. H I PBIB1191E 10. CHECK ECM POWER SUPPLY CIRCUIT-VI 1. 2. 3. Disconnect ECM harness connector. Disconnect IPDM E/R harness connector. Check harness continuity between ECM terminals 119, 120 and IPDM E/R terminal 32. Refer to Wiring Diagram. Continuity should exist. K L 4. Also check harness for short to ground and short to power. OK or NG OK >> GO TO 13. NG >> Repair open circuit or short to ground or short to power in harness or connectors. 11. CHECK ECM POWER SUPPLY CIRCUIT-VII 1. 2. 3. J Disconnect ECM harness connector. Disconnect IPDM E/R harness connector. Check harness continuity between ECM terminal 111 and IPDM E/R terminal 29. Refer to Wiring Diagram. Continuity should exist. 4. Also check harness for short to ground and short to power. OK or NG OK >> GO TO 12. NG >> Repair open circuit or short to ground or short to power in harness or connectors. EC-131 M POWER SUPPLY AND GROUND CIRCUIT [CR (WITH EURO-OBD)] 12. CHECK 20A FUSE 1. Disconnect 20A fuse from IPDM E/R. 2. Check 20A fuse. OK or NG OK >> GO TO 16. NG >> Replace 20A fuse. 13. CHECK GROUND CONNECTIONS-II 1. Loosen and retighten ground screws on the body. Refer to EC-133, "Ground Inspection" . MBIB1502E 1. Body ground E44 2. Body ground E45 3. Body ground E28 OK or NG OK >> GO TO 14. NG >> Repair or replace ground connections. 14. CHECK ECM GROUND CIRCUIT FOR OPEN AND SHORT-II 1. 2. Disconnect ECM harness connector. Check harness continuity between ECM terminals 1, 115, 116 and ground. Refer to Wiring Diagram. Continuity should exist. 3. Also check harness for short to power. OK or NG OK >> GO TO 16. NG >> GO TO 15. 15. DETECT MALFUNCTIONING PART Check the following. ● Harness connectors F1, E48 ● Harness for open or short between ECM and ground >> Repair open circuit or short to power in harness or connectors. 16. CHECK INTERMITTENT INCIDENT Refer to EC-127, "TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT" . OK or NG OK >> Replace IPDM E/R. PG-18, "IPDM E/R (INTELLIGENT POWER DISTRIBUTION MODULE ENGINE ROOM)" . NG >> Repair open circuit or short to power in harness or connectors. EC-132 POWER SUPPLY AND GROUND CIRCUIT [CR (WITH EURO-OBD)] Ground Inspection BBS002UM A Ground connections are very important to the proper operation of electrical and electronic circuits. Ground connections are often exposed to moisture, dirt and other corrosive elements. The corrosion (rust) can become an unwanted resistance. This unwanted resistance can change the way a circuit works. Electronically controlled circuits are very sensitive to proper grounding. A loose or corroded ground can drasti- EC cally affect an electronically controlled circuit. A poor or corroded ground can easily affect the circuit. Even when the ground connection looks clean, there can be a thin film of rust on the surface. When inspecting a ground connection follow these rules: C ● Remove the ground bolt or screw. ● Inspect all mating surfaces for tarnish, dirt, rust, etc. D ● Clean as required to assure good contact. ● Reinstall bolt or screw securely. ● Inspect for “add-on” accessories which may be interfering with the ground circuit. ● If several wires are crimped into one ground eyelet terminal, check for proper crimps. Make sure all of the E wires are clean, securely fastened and providing a good ground path. If multiple wires are cased in one eyelet make sure no ground wires have excess wire insulation. F For detailed ground distribution information, refer to PG-38, "Ground Distribution" . G H I J K PBIB1870E L M EC-133 DTC U1001 CAN COMMUNICATION LINE [CR (WITH EURO-OBD)] DTC U1001 CAN COMMUNICATION LINE Description PFP:23710 BBS002UN CAN (Controller Area Network) is a serial communication line for real time application. It is an on-vehicle multiplex communication line with high data communication speed and excellent error detection ability. Many electronic control units are equipped onto a vehicle, and each control unit shares information and links with other control units during operation (not independent). In CAN communication, control units are connected with 2 communication lines (CAN H line, CAN L line) allowing a high rate of information transmission with less wiring. Each control unit transmits/receives data but selectively reads required data only. On Board Diagnosis Logic BBS002UO The MI will not light up for this self-diagnosis. DTC No. Trouble diagnosis name DTC detecting condition ● U1001 1001 CAN communication line ● ECM cannot communicate to other control units. Possible cause ● ECM cannot communicate for more than the specified time. DTC Confirmation Procedure 1. 2. 3. Harness or connectors (CAN communication line is open or shorted.) BBS002UP Turn ignition switch ON and wait at least 3 seconds. Select “DATA MONITOR” mode with CONSULT-II. If 1st trip DTC or DTC is detected, go to EC-136, "Diagnostic Procedure" . EC-134 DTC U1001 CAN COMMUNICATION LINE [CR (WITH EURO-OBD)] Wiring Diagram BBS002UQ A EC C D E F G H I J K L M MBWA1503E EC-135 DTC U1001 CAN COMMUNICATION LINE [CR (WITH EURO-OBD)] Diagnostic Procedure BBS002UR Go to LAN-3, "Precautions When Using CONSULT-II" . EC-136 DTC U1010 CAN COMMUNICATION [CR (WITH EURO-OBD)] DTC U1010 CAN COMMUNICATION Description PFP:23710 A BBS003ZI CAN (Controller Area Network) is a serial communication line for real time application. It is an on-vehicle multiplex communication line with high data communication speed and excellent error detection ability. Many elec- EC tronic control units are equipped onto a vehicle, and each control unit shares information and links with other control units during operation (not independent). In CAN communication, control units are connected with 2 communication lines (CAN H line, CAN L line) allowing a high rate of information transmission with less wiring. C Each control unit transmits/receives data but selectively reads required data only. On Board Diagnosis Logic BBS003ZJ D The MI will not light up for this diagnosis. DTC No. U1010 1010 Trouble diagnosis name CAN communication bus DTC detecting condition Initializing CAN communication bus is malfunctioning. DTC Confirmation Procedure Possible cause ● E ECM BBS003ZK WITH CONSULT-II 1. 2. 3. F Turn ignition switch ON. Select “DATA MONITOR” mode with CONSULT-II. If 1st trip DTC is detected, go to EC-138, "Diagnostic Procedure" . G H I SEF058Y J WITH GST Follow the procedure “WITH CONSULT-II” above. K L M EC-137 DTC U1010 CAN COMMUNICATION [CR (WITH EURO-OBD)] Diagnostic Procedure BBS003ZL 1. INSPECTION START 1. 2. 3. 4. 5. With CONSULT-II Turn ignition switch ON. Select “SELF-DIAG RESULTS” mode with CONSULT-II. Touch “ERASE”. Perform DTC Confirmation Procedure. See EC-137, "DTC Confirmation Procedure" . Is the DTC U1010 displayed again? With GST 1. Turn ignition switch ON. 2. Select “Service $04” with GST. 3. Perform DTC Confirmation Procedure. See EC-137, "DTC Confirmation Procedure" . 4. Is the DTC U1010 displayed again? Yes or No Yes >> GO TO 2. No >> INSPECTION END 2. REPLACE ECM 1. 2. 3. 4. 5. Replace ECM. Perform initialization of NATS system and registration of all NATS ignition key IDs. Refer to BL-218, "ECM Re-communicating Function" . Perform EC-69, "Accelerator Pedal Released Position Learning" . Perform EC-69, "Throttle Valve Closed Position Learning" . Perform EC-69, "Idle Air Volume Learning" . >> INSPECTION END EC-138 DTC P0011 IVT CONTROL [CR (WITH EURO-OBD)] DTC P0011 IVT CONTROL Description PFP:23796 A BBS002US SYSTEM DESCRIPTION Sensor Crankshaft position sensor (POS) Input Signal to ECM ECM Function Actuator EC Engine speed and piston position Camshaft position sensor (PHASE) Engine coolant temperature sensor Engine coolant temperature Wheel sensor Vehicle speed* Intake valve timing control Intake valve timing control solenoid valve *: This signal is sent to the ECM through CAN communication line. C D E F G H I PBIB0540E This mechanism hydraulically controls cam phases continuously with the fixed operating angle of the intake valve. The ECM receives signals such as crankshaft position, camshaft position, engine speed, and engine coolant temperature. Then, the ECM sends ON/OFF pulse duty signals to the intake valve timing control solenoid valve depending on driving status. This makes it possible to control the shut/open timing of the intake valve to increase engine torque in low/mid speed range and output in high-speed range. J K L CONSULT-II Reference Value in Data Monitor Mode BBS002UT Specification data are reference values. MONITOR ITEM CONDITION ● Engine: After warming up ● Shift lever: Neutral ● Air conditioner switch: OFF ● No load ● Engine: After warming up ● Shift lever: Neutral ● Air conditioner switch: OFF ● No load INT/V TIM (B1) INT/V SOL (B1) SPECIFICATION Idle −5° - 5°CA 2,000 rpm Approx. 0° - 20°CA Idle 0% - 2% 2,000 rpm Approx. 0% - 50% EC-139 M DTC P0011 IVT CONTROL [CR (WITH EURO-OBD)] On Board Diagnosis Logic BBS002UU The MI will not light up for this self-diagnosis. DTC No. P0011 0011 Trouble diagnosis name Detecting condition Intake valve timing control performance There is a gap between angle of target and phase-control angle degree. Possible cause ● Crankshaft position sensor (POS) ● Camshaft position sensor (PHASE) ● Intake valve control solenoid valve ● Accumulation of debris to the signal pickup portion of the camshaft ● Timing chain installation ● Foreign matter caught in the oil groove for intake valve timing control FAIL-SAFE MODE When the malfunction is detected, the ECM enters fail-safe mode. Detected items Engine operating condition in fail-safe mode Intake valve timing control The signal is not energized to the solenoid valve and the valve control does not function DTC Confirmation Procedure BBS002UV CAUTION: Always drive at a safe speed. NOTE: ● If DTC P0011 is displayed with DTC P1111, first perform trouble diagnosis for DTC P1111. See EC286 . ● If DTC Confirmation Procedure has been previously conducted, always turn ignition switch OFF and wait at least 10 seconds before conducting the next test. TESTING CONDITION: Before performing the following procedure, confirm that battery voltage is between 10V and 16V at idle. WITH CONSULT-II 1. 2. 3. Turn ignition switch ON and select “DATA MONITOR” mode with CONSULT-II. Start engine and warm it up to the normal operating temperature. Maintain the following conditions from at least 6 consecutive seconds Hold the accelerator pedal as steady as possible ENG SPEED 1,200 - 2,000 rpm (A constant rotation is maintained.) COOLAN TEMP/S 60 - 120°C (140 - 248°F) B/FUEL SCHDL More than 3 msec Shift lever Neutral position 4. 5. 6. PBIB0164E Let engine idle for 10 seconds. If the 1st trip DTC is detected, go to EC-141, "Diagnostic Procedure" . If the 1st trip DTC is not detected, go to next step. Maintain the following conditions for at least 20 consecutive seconds. ENG SPEED 1,700 - 3,175 rpm (A constant rotation is maintained.) COOLAN TEMP/S 70 - 105°C (176 - 194°F) Shift lever 1st or 2nd position Driving location uphill Driving vehicle uphill (Increased engine load will help maintain the driving conditions required for this test.) EC-140 DTC P0011 IVT CONTROL [CR (WITH EURO-OBD)] 7. If 1st trip DTC is detected, go to EC-141, "Diagnostic Procedure" . A WITH GST Follow the procedure “WITH CONSULT-II” above. Diagnostic Procedure BBS002UW EC 1. CHECK OIL PRESSURE WARNING LAMP 1. 2. Start engine. Check oil pressure warning lamp and confirm it is not illuminated. OK or NG OK >> GO TO 2. KG >> Go to LU-6, "OIL PRESSURE CHECK" . C D E F PBIA8559J 2. CHECK INTAKE VALVE TIMING CONTROL SOLENOID VALVE G Refer to EC-142, "Component Inspection" . OK or NG OK >> GO TO 3. NG >> Replace intake valve timing control solenoid valve. H 3. CHECK CRANKSHAFT POSITION SENSOR (POS) I Refer to EC-256, "Component Inspection" . OK or NG OK >> GO TO 4. NG >> Replace crankshaft position sensor (POS). J K 4. CHECK CAMSHAFT POSITION SENSOR (PHASE) Refer to EC-263, "Component Inspection" . OK or NG OK >> GO TO 5. NG >> Replace camshaft position sensor (PHASE). L M 5. CHECK CAMSHAFT (INTAKE) Check the following. ● Accumulation of debris to the signal plate of camshaft rear end ● Chipping signal plate of camshaft rear end OK or NG OK >> GO TO 6. NG >> Remove debris and clean the signal plate of camshaft rear end or replace camshaft. PBIB0565E EC-141 DTC P0011 IVT CONTROL [CR (WITH EURO-OBD)] 6. CHECK TIMING CHAIN INSTALLATION Check service records for any recent repairs that may cause timing chain misaligned. Are there any service records that may cause timing chain misaligned? Yes or No Yes >> Check timing chain installation. Refer to EM-50, "TIMING CHAIN" . No >> GO TO 7. 7. CHECK LUBRICATION CIRCUIT Refer to EM-47, "Inspection of Camshaft Sprocket (INT) Oil Groove" . OK or NG OK >> GO TO 8. NG >> Clean lubrication line. 8. CHECK INTERMITTENT INCIDENT Refer to EC-127, "TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT" . For Wiring Diagram, refer to EC-252 for CKP sensor (POS), EC-259 for CMP sensor (PHASE). >> INSPECTION END Component Inspection BBS002UX INTAKE VALVE TIMING CONTROL SOLENOID VALVE 1. 2. 3. 4. Disconnect intake valve timing control solenoid valve harness connector. Check resistance between intake valve timing control solenoid valve as follows. Terminal Resistance 1 and 2 6.7 - 7.7Ω at 20°C (68°F) 1 or 2 and ground ∞Ω (Continuity should not exist.) If NG, replace intake valve timing control solenoid valve. If OK, go to next step. Remove intake valve timing control solenoid valve. MBIB0027E Provide 12V DC between intake valve timing control solenoid valve terminals and then interrupt it. Make sure that the plunger moves as shown in the figure. CAUTION: Do not apply 12V DC continuously for 5 seconds or more. Doing so may result in damage to the coil in intake valve timing control solenoid valve. If NG, replace intake valve timing control solenoid valve. NOTE: Always replace O-ring when intake valve timing control solenoid valve is removed. PBIB2388E Removal and Installation BBS002UY INTAKE VALVE TIMING CONTROL SOLENOID VALVE Refer to EM-35, "ROCKER COVER" . EC-142 DTC P0031, P0032 HO2S1 HEATER [CR (WITH EURO-OBD)] DTC P0031, P0032 HO2S1 HEATER Description PFP:22690 A BBS002UZ SYSTEM DESCRIPTION Sensor Input Signal to ECM Camshaft position sensor (PHASE) Crankshaft position sensor (POS) Engine speed Engine coolant temperature sensor Engine coolant temperature ECM Function Actuator Heated oxygen sensor 1 heater control EC Heated oxygen sensor 1 heater The ECM performs ON/OFF duty control of the heated oxygen sensor 1 heater corresponding to the engine speed and engine coolant temperature. The duty percent varies with engine coolant temperature when engine is started. C D OPERATION Engine speed rpm Heated oxygen sensor 1 heater Above 3,600 OFF Below 3,600 after warming up ON E F CONSULT-II Reference Value in Data Monitor Mode BBS002V0 Specification data are reference values. MONITOR ITEM HO2S1 HTR (B1) CONDITION ● Engine: After warming up ● Engine speed: Below 3,600 rpm ● Engine speed: Above 3,600 rpm G SPECIFICATION ON H OFF On Board Diagnosis Logic BBS002V1 I DTC No. P0031 0031 P0032 0032 Trouble diagnosis name DTC detecting condition ● Heated oxygen sensor 1 heater control circuit low The current amperage in the heated oxygen sensor 1 heater circuit is out of the normal range. (An excessively low voltage signal is sent to ECM through the heated oxygen sensor 1 heater.) ● Heated oxygen sensor 1 heater The current amperage in the heated oxygen sensor 1 heater circuit is out of the normal range. (An excessively high voltage signal is sent to ECM through the heated oxygen sensor 1 heater.) ● Harness or connectors (The heated oxygen sensor 1 heater circuit is shorted.) ● Heated oxygen sensor 1 heater Heated oxygen sensor 1 heater control circuit high Possible cause Harness or connectors (The heated oxygen sensor 1 heater circuit is open or shorted.) J K L M EC-143 DTC P0031, P0032 HO2S1 HEATER [CR (WITH EURO-OBD)] DTC Confirmation Procedure BBS002V2 NOTE: If DTC Confirmation Procedure has been previously conducted, always turn ignition switch OFF and wait at least 10 seconds before conducting the next test. TESTING CONDITION: Before performing the following procedure, confirm that battery voltage is between 10.5V and 16V at idle. WITH CONSULT-II 1. 2. 3. 4. 5. Start engine and warm it up to normal operating temperature. Turn ignition switch OFF and wait at least 10 seconds. Turn ignition switch ON and select “DATA MONITOR” mode with CONSULT-II. Start engine and run it for at least 6 seconds at idle speed. If 1st trip DTC is detected, go to EC-146, "Diagnostic Procedure" . SEF174Y WITH GST Follow the procedure “WITH CONSULT-II” above. EC-144 DTC P0031, P0032 HO2S1 HEATER [CR (WITH EURO-OBD)] Wiring Diagram BBS002V3 A EC C D E F G H I J K L M MBWA1504E EC-145 DTC P0031, P0032 HO2S1 HEATER [CR (WITH EURO-OBD)] Specification data are reference values and are measured between each terminal and ground. Pulse signal is measured by CONSULT-II. CAUTION: Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM's transistor. Use a ground other than ECM terminals, such as the ground. TERMINAL NO. WIRE COLOR ITEM CONDITION DATA (DC Voltage) Approximately 7.0V [Engine is running] 24 Y Heated oxygen sensor 1 heater ● Warm-up condition. ● Engine speed: Below 3,600 rpm PBIB0519E [Engine is running] ● BATTERY VOLTAGE (11 - 14V) Engine speed: Above 3,600 rpm [Engine is running] 35 BR Heated oxygen sensor 1 ● Warm-up condition ● Engine speed: 2,000 rpm 0 - Approximately 1.0V (Periodically change) [Engine is running] 74 B Sensor ground (Heated oxygen sensor) ● Warm-up condition ● Idle speed Approximately 0V : Average voltage for pulse signal (Actual pulse signal can be confirmed by oscilloscope.) Diagnostic Procedure BBS002V4 1. CHECK GROUND CONNECTIONS 1. 2. Turn ignition switch OFF. Loosen and retighten ground screws on the body. Refer to EC-133, "Ground Inspection" . MBIB1502E 1. Body ground E44 2. Body ground E45 OK or NG OK >> GO TO 2. NG >> Repair or replace ground connections. EC-146 3. Body ground E28 DTC P0031, P0032 HO2S1 HEATER [CR (WITH EURO-OBD)] 2. CHECK HO2S1 POWER SUPPLY CIRCUIT 1. 2. A Disconnect heated oxygen sensor 1 harness connector. Turn ignition switch ON. EC C D MBIB1073E 3. E Check voltage between HO2S1 terminal 2 and ground with CONSULT-II or tester. Voltage: Battery voltage F OK or NG OK >> GO TO 4. NG >> GO TO 3. G PBIA9576J H 3. DETECT MALFUNCTIONING PART Check the following. ● Harness connectors E48, F1 ● IPDM E/R connector E10 ● 10A fuse ● Harness for open or short between heated oxygen sensor 1 and fuse I J K >> Repair harness or connectors. 4. CHECK HO2S1 OUTPUT SIGNAL CIRCUIT FOR OPEN AND SHORT L 1. 2. 3. M Turn ignition switch OFF. Disconnect ECM harness connector. Check harness continuity between ECM terminal 24 and HO2S1 terminal 3. Refer to Wiring Diagram. Continuity should exist. 4. Also check harness for short to ground and short to power. OK or NG OK >> GO TO 5. NG >> Repair open circuit or short to ground or short to power in harness or connectors. 5. CHECK HEATED OXYGEN SENSOR 1 HEATER Refer to EC-148, "Component Inspection" . OK or NG OK >> GO TO 6. NG >> Replace heated oxygen sensor 1. EC-147 DTC P0031, P0032 HO2S1 HEATER [CR (WITH EURO-OBD)] 6. CHECK INTERMITTENT INCIDENT Refer to EC-127, "TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT" . >> INSPECTION END Component Inspection BBS002V5 HEATED OXYGEN SENSOR 1 HEATER 1. Check resistance between HO2S1 terminals as follows. Terminal No. Resistance 2 and 3 3.4 - 4.4 Ω at 25°C (77°F) 1 and 2, 3, 4 ∞Ω (Continuity should not exist) 4 and 1, 2, 3 2. If NG, replace heated oxygen sensor 1. CAUTION: ● Discard any heated oxygen sensor which has been dropped from a height of more than 0.5 m (19.7 in) onto a hard surface such as a concrete floor; use a new one. ● Before installing new oxygen sensor, clean exhaust system threads using Oxygen Sensor Thread Cleaner and approved anti-seize lubricant. MBIB1306E Removal and Installation BBS002V6 HEATED OXYGEN SENSOR 1 Refer to EM-24, "EXHAUST MANIFOLD AND THREE WAY CATALYST" . EC-148 DTC P0037, P0038 HO2S2 HEATER [CR (WITH EURO-OBD)] DTC P0037, P0038 HO2S2 HEATER Description PFP:226A0 A BBS002V7 SYSTEM DESCRIPTION Sensor Input Signal to ECM Camshaft position sensor (PHASE) ECM Function Actuator EC Engine speed Crankshaft position sensor (POS) Engine coolant temperature sensor Engine coolant temperature Manifold absolute pressure (MAP) sensor Amount of intake air Heated oxygen sensor 2 heater control Heated oxygen sensor 2 heater OPERATION D Engine speed rpm Heated oxygen sensor 2 heater Above 3,800 OFF E Below 3,800 rpm after the following conditions are met. ● Engine: After warming up ● Keeping the engine speed between 3,500 and 4,000 rpm for 1 minute and at idle for 1 minute under no load ON F CONSULT-II Reference Value in Data Monitor Mode BBS002V8 G Specification data are reference values. MONITOR ITEM HO2S2 HTR (B1) CONDITION SPECIFICATION ● Engine speed: Below 3,800 rpm after the following conditions are met. – Engine: After warming up – Keeping the engine speed at between 3,500 to 4,000 rpm for 1 minute and at idle for 1 minute under no load ● Engine speed: Above 3,800 rpm H ON I OFF On Board Diagnosis Logic DTC No. P0037 0037 P0038 0038 C BBS002V9 J Trouble diagnosis name DTC detecting condition The current amperage in the heated oxygen sensor 2 heater circuit is out of the normal range. (An excessively low voltage signal is sent to ECM through the heated oxygen sensor 2 heater.) ● Heated oxygen sensor 2 heater control circuit low ● Heated oxygen sensor 2 heater The current amperage in the heated oxygen sensor 2 heater circuit is out of the normal range. (An excessively high voltage signal is sent to ECM through the heated oxygen sensor 2 heater.) ● Harness or connectors (The heated oxygen sensor 2 heater circuit is shorted.) L ● Heated oxygen sensor 2 heater M Heated oxygen sensor 2 heater control circuit high DTC Confirmation Procedure Possible cause Harness or connectors (The heated oxygen sensor 2 heater circuit is open or shorted.) BBS002VA NOTE: If DTC Confirmation Procedure has been previously conducted, always turn ignition switch OFF and wait at least 10 seconds before conducting the next test. TESTING CONDITION: Before performing the following procedure, confirm that battery voltage is between 10.5V and 16V at idle. EC-149 K DTC P0037, P0038 HO2S2 HEATER [CR (WITH EURO-OBD)] WITH CONSULT-II 1. 2. 3. 4. 5. 6. Turn ignition switch ON and select “DATA MONITOR” mode with CONSULT-II. Start engine and warm it up to the normal operating temperature. Turn ignition switch OFF and wait at least 10 seconds. Start engine and keep the engine speed between 3,500 and 4,000 rpm for at least 1 minute under no load. Let engine idle for 1 minute. If 1st trip DTC is detected, go to EC-152, "Diagnostic Procedure" . WITH GST Follow the procedure “WITH CONSULT-II” above. EC-150 SEF058Y DTC P0037, P0038 HO2S2 HEATER [CR (WITH EURO-OBD)] Wiring Diagram BBS002VB A EC C D E F G H I J K L M MBWA1505E EC-151 DTC P0037, P0038 HO2S2 HEATER [CR (WITH EURO-OBD)] Specification data are reference values and are measured between each terminal and ground. CAUTION: Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM's transistor. Use a ground other than ECM terminals, such as the ground. TERMINAL NO. WIRE COLOR ITEM CONDITION DATA (DC Voltage) [Engine is running] 2 GR ● Engine speed: Below 3,800 rpm after the following conditions are met. – Engine: After warming up – Keeping the engine speed between 3,500 and 4,000 rpm for 1 minute and at idle for 1 minute under no load. Heated oxygen sensor 2 heater 0 - 1.0V [Ignition switch: ON] ● Engine stopped BATTERY VOLTAGE (11 - 14V) [Engine is running] ● Engine speed: Above 3,800 rpm [Engine is running] 16 LG Heated oxygen sensor 2 ● Revving engine from idle to 3,000rpm quickly after the following conditions are met. – Engine: After warming up – Keeping the engine speed between 3,500 and 4,000 rpm for 1 minute and at idle for 1 minute under no load. 0 - Approximately 1.0V [Engine is running] 74 B Sensor ground (Heated oxygen sensor) ● Warm-up condition ● Idle speed Approximately 0V Diagnostic Procedure BBS002VC 1. CHECK GROUND CONNECTIONS 1. 2. Turn ignition switch OFF. Loosen and retighten ground screws on the body. Refer to EC-133, "Ground Inspection" . MBIB1502E 1. Body ground E44 2. Body ground E45 OK or NG OK >> GO TO 2. NG >> Repair or replace ground connections. EC-152 3. Body ground E28 DTC P0037, P0038 HO2S2 HEATER [CR (WITH EURO-OBD)] 2. CHECK HO2S2 POWER SUPPLY CIRCUIT A 1. Disconnect heated oxygen sensor 2 harness connector (1). – : Vehicle front Heated oxygen sensor 2 (2) Oil pan (3) Turn ignition switch ON. – – 2. EC C D MBIB1459E 3. E Check voltage between HO2S2 terminal 2 and ground with CONSULT-II or tester. Voltage: Battery voltage F OK or NG OK >> GO TO 4. NG >> GO TO 3. G MBIB1442E H 3. DETECT MALFUNCTIONING PART Check the following. ● Harness connectors E48, F1 ● IPDM E/R connector E10 ● 10A fuse ● Harness for open or short between heated oxygen sensor 2 and fuse I J K >> Repair harness or connectors. 4. CHECK HO2S2 OUTPUT SIGNAL CIRCUIT FOR OPEN AND SHORT L 1. 2. 3. M Turn ignition switch OFF. Disconnect ECM harness connector. Check harness continuity between ECM terminal 2 and HO2S2 terminal 3. Refer to Wiring Diagram. Continuity should exist. 4. Also check harness for short to ground and short to power. OK or NG OK >> GO TO 5. NG >> Repair open circuit or short to ground or short to power in harness or connectors. 5. CHECK HEATED OXYGEN SENSOR 2 HEATER Refer to EC-154, "Component Inspection" . OK or NG OK >> GO TO 6. NG >> Replace heated oxygen sensor 2. EC-153 DTC P0037, P0038 HO2S2 HEATER [CR (WITH EURO-OBD)] 6. CHECK INTERMITTENT INCIDENT Refer to EC-127, "TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT" . >> INSPECTION END Component Inspection BBS002VD HEATED OXYGEN SENSOR 2 HEATER 1. Check resistance between HO2S2 terminals as follows. Terminal No. Resistance 2 and 3 8.0 - 10.0 Ω at 25°C (77°F) 1 and 2, 3, 4 ∞Ω (Continuity should not exist) 4 and 1, 2, 3 2. If NG, replace heated oxygen sensor 2. CAUTION: ● Discard any heated oxygen sensor which has been dropped from a height of more than 0.5 m (19.7 in) onto a hard surface such as a concrete floor; use a new one. ● Before installing new oxygen sensor, clean exhaust system threads using Oxygen Sensor Thread Cleaner and approved anti-seize lubricant. SEF249Y Removal and Installation BBS002VE HEATED OXYGEN SENSOR 2 Refer to EX-3, "EXHAUST SYSTEM" . EC-154 DTC P0107, P0108 MANIFOLD ABSOLUTE PRESSURE SENSOR [CR (WITH EURO-OBD)] DTC P0107, P0108 MANIFOLD ABSOLUTE PRESSURE SENSOR Component Description PFP:22365 A BBS002VF The manifold absolute pressure (MAP) sensor is placed intake manifold corrector. It detects intake manifold pressure and sends the voltage signal to the ECM, ECM uses the signal to compute intake air volume value. The sensor uses a silicon diaphragm which is sensitive to the change in pressure. As the pressure increase, the voltage rises. EC C D MBIB0278E E On Board Diagnosis Logic BBS002VG If DTC P0107 or P0108 is displayed with DTC P1229, first perform the trouble diagnosis for DTC P1229. Refer to EC-363, "DTC P1229 SENSOR POWER SUPPLY" . DTC No. Trouble diagnosis name DTC detecting condition ● P0107 0107 P0108 0108 Manifold absolute pressure sensor circuit low input Manifold absolute pressure sensor circuit high input An excessively low voltage from the sensor is sent to ECM. An excessively high voltage from the sensor is sent to ECM. F Possible cause Harness or connectors (The sensor circuit is open or shorted.) ● Manifold absolute pressure sensor ● Harness or connectors (The sensor circuit is open or shorted) ● Manifold absolute pressure sensor ● Intake air leaks G H I FAIL-SAFE MODE When the malfunction is detected, the ECM enters fail-safe mode. Detected items Manifold absolute pressure sensor circuit J Engine operating condition in fail-safe mode Engine speed will not rise more than 2,500 rpm due to the fuel cut. DTC Confirmation Procedure BBS002VH K NOTE: If DTC Confirmation Procedure has been previously conducted, always turn ignition switch OFF and wait at least 10 seconds before conducting the next test. L WITH CONSULT-II 1. 2. 3. 4. Turn ignition switch ON. Select “DATA MONITOR” mode with CONSULT-II. Wait at least 5 seconds. If 1st trip DTC is detected, go to EC-157, "Diagnostic Procedure" . M SEF058Y WITH GST Follow the procedure “WITH CONSULT-II” above. EC-155 DTC P0107, P0108 MANIFOLD ABSOLUTE PRESSURE SENSOR [CR (WITH EURO-OBD)] Wiring Diagram BBS002VI MBWA1506E EC-156 DTC P0107, P0108 MANIFOLD ABSOLUTE PRESSURE SENSOR [CR (WITH EURO-OBD)] Specification data are reference values and are measured between each terminal and ground. CAUTION: Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM's transistor. Use a ground other than ECM terminals, such as the ground. TERMINAL NO. 45 WIRE COLOR L EC ITEM Sensor power supply (Manifold absolute pressure sensor) CONDITION DATA (DC Voltage) C [Ignition switch: ON] Approximately 5V [Engine is running] 51 56 W B A Manifold absolute pressure sensor Sensor ground (Manifold absolute pressure sensor) ● Warm-up condition ● Idle speed D Approximately 1.5V [Engine is running] ● Warm-up condition ● Engine speed: 2,000 rpm E Approximately 1.2V F [Engine is running] ● Warm-up condition ● Idle speed Approximately 0V G Diagnostic Procedure BBS002VJ 1. INSPECTION START Which malfunction (P0107 or P0108) is duplicated? P0107 or P0108 P0107 >> GO TO 3. P0108 >> GO TO 2. 2. CHECK INTAKE SYSTEM H I J Check the following for connection. ● Air duct ● Vacuum hoses ● Intake air passage between air duct to intake manifold OK or NG OK >> GO TO 3. NG >> Reconnect the parts. K L M EC-157 DTC P0107, P0108 MANIFOLD ABSOLUTE PRESSURE SENSOR [CR (WITH EURO-OBD)] 3. CHECK GROUND CONNECTIONS 1. 2. Turn ignition switch OFF. Loosen and retighten ground screws on the body. Refer to EC-133, "Ground Inspection" . MBIB1502E 1. Body ground E44 2. Body ground E45 3. Body ground E28 OK or NG OK >> GO TO 4. NG >> Repair or replace ground connections. 4. CHECK MAP SENSOR POWER SUPPLY CIRCUIT 1. 2. Disconnect manifold absolute pressure (MAP) sensor harness connector. Turn ignition switch ON. MBIB0276E 3. Check voltage between MAP sensor terminal 2 and ground with CONSULT-II or tester. Voltage: Approximately 5V OK or NG OK >> GO TO 5. NG >> Repair harness or connectors. MBIB0602E EC-158 DTC P0107, P0108 MANIFOLD ABSOLUTE PRESSURE SENSOR [CR (WITH EURO-OBD)] 5. CHECK MAP SENSOR GROUND CIRCUIT FOR OPEN AND SHORT 1. 2. 3. A Turn ignition switch OFF. Disconnect ECM harness connector. Check harness continuity between MAP sensor terminal 4 and ECM terminal 56 Refer to Wiring Diagram. EC Continuity should exist. C 4. Also check harness for short to ground and short to power. OK or NG OK >> GO TO 6. NG >> Repair open circuit or short to ground or short to power in harness or connectors. D 6. CHECK MAP SENSOR INPUT SIGNAL CIRCUIT FOR OPEN AND SHORT 1. E Check harness continuity between MAP sensor terminal 1 and ECM terminal 51. Refer to Wiring Diagram F Continuity should exist. 2. Also check harness for short to ground and short to power. OK or NG OK >> GO TO 7. NG >> Repair open circuit or short to ground or short to power in harness or connectors. G H 7. CHECK MAP SENSOR Refer to EC-159, "Component Inspection" . OK or NG OK >> GO TO 8. NG >> Replace manifold absolute pressure sensor. I J 8. CHECK INTERMITTENT INCIDENT Refer to EC-127, "TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT" . K >> INSPECTION END L Component Inspection BBS002VK MANIFOLD ABSOLUTE PRESSURE SENSOR 1. 2. 3. 4. 5. Reconnect all harness connectors disconnected. Start engine and warm it up to normal operating temperature. Turn ignition switch OFF, wait at least 5 seconds and then turn ON. Check voltage between ECM terminal 51 (manifold absolute pressure sensor signal) and ground. NOTE: ● To avoid the affection of intake manifold vacuum, check the voltage 1 or more minutes past after engine is stopped. ● Because the sensor is absolute pressure sensor, output value may differ depends on atmospheric pressure and altitude. Measure the atmospheric pressure. NOTE: As atmospheric pressure describe on synoptic chart is value at sea level, please compensate the actual pressure with the following chart. EC-159 M SEF006P DTC P0107, P0108 MANIFOLD ABSOLUTE PRESSURE SENSOR [CR (WITH EURO-OBD)] 6. Altitude Compensated pressure 0m 0hPa 200m -24hPa 400m -47hPa 600m -70hPa 800m -92hPa 1,000m -114hPa 1,500m -168hPa 2,000m -218hPa Check the manifold absolute pressure sensor value corresponds to the atmospheric pressure. Atmospheric pressure Voltage 800hPa 3.2 - 3.6V 850hPa 3.4 - 3.8V 900hPa 3.7 - 4.1V 960hPa 3.9 - 4.3V 1,000hPa 4.1 - 4.5V 1,050hPa 4.3 - 4.7V 7. Start engine and let it idle. 8. Check the voltage between ECM terminal 51 and ground at idling and confirm the voltage difference between engine is stopped and at idling is within following chart. MBIB0655E Intake manifold vacuum Voltage difference -40kPa (-300mmHg) 1.6 - 2.0V -53.3kPa (-400mmHg) 2.2 - 2.6V -66.7kPa (-500mm) 2.8 - 3.2V -80kPa (-600mmHg) 3.4 - 3.8V SEF487R Removal and Installation BBS002VL MANIFOLD ABSOLUTE PRESSURE SENSOR Refer to EM-18, "AIR CLEANER AND AIR DUCT" . EC-160 DTC P0112, P0113 IAT SENSOR [CR (WITH EURO-OBD)] DTC P0112, P0113 IAT SENSOR Component Description PFP:22630 A BBS002VM The intake air temperature sensor is built into manifold absolute pressure sensor. The sensor detects intake air temperature and transmits a signal to the ECM. The temperature sensing unit uses a thermistor which is sensitive to the change in temperature. Electrical resistance of the thermistor decreases in response to the temperature rise. EC C D MBIB0276E E Intake air temperature °C (°F) Voltage* V Resistance F kΩ 25 (77) 3.32 1.9 - 2.1 80 (176) 1.23 0.31 - 0.37 G *: This data is reference value and is measured between ECM terminal 34 (Intake air temperature sensor) and ground. H CAUTION: Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM's transistor. Use a ground other than ECM terminals, such as the ground. SEF012P I On Board Diagnosis Logic DTC No. Trouble diagnosis name BBS002VN DTC detecting condition Possible cause P0112 0112 Intake air temperature sensor circuit low input An excessively low voltage from the sensor is sent to ECM. ● Harness or connectors (The sensor circuit is open or shorted.) P0113 0113 Intake air temperature sensor circuit high input An excessively high voltage from the sensor is sent to ECM. ● Intake air temperature sensor FAIL-SAFE MODE J K L When the malfunction is detected, the ECM enters fail-safe mode. Detected items Intake air temperature sensor circuit Engine operating condition in fail-safe mode Intake air temperature is determined as 30°C (86°F). EC-161 M DTC P0112, P0113 IAT SENSOR [CR (WITH EURO-OBD)] DTC Confirmation Procedure BBS002VO NOTE: If DTC Confirmation Procedure has been previously conducted, always turn ignition switch OFF and wait at least 10 seconds before conducting the next test. WITH CONSULT-II 1. 2. 3. 4. Turn ignition switch ON. Select “DATA MONITOR” mode with CONSULT-II. Wait at least 5 seconds. If 1st trip DTC is detected, go to EC-164, "Diagnostic Procedure" . SEF058Y WITH GST Follow the procedure “WITH CONSULT-II” above. EC-162 DTC P0112, P0113 IAT SENSOR [CR (WITH EURO-OBD)] Wiring Diagram BBS002VP A EC C D E F G H I J K L M MBWA1507E EC-163 DTC P0112, P0113 IAT SENSOR [CR (WITH EURO-OBD)] Diagnostic Procedure BBS002VQ 1. CHECK GROUND CONNECTIONS 1. 2. Turn ignition switch OFF. Loosen and retighten ground screws on the body. Refer to EC-133, "Ground Inspection" . MBIB1502E 1. Body ground E44 2. Body ground E45 3. Body ground E28 OK or NG OK >> GO TO 2. NG >> Repair or replace ground connections. 2. CHECK INTAKE AIR TEMPERATURE SENSOR POWER SUPPLY CIRCUIT 1. 2. Disconnect manifold absolute pressure (MAP) sensor (with intake air temperature sensor) harness connector. Turn ignition switch ON. MBIB0276E 3. Check voltage between MAP sensor terminal 3 and ground with CONSULT-II or tester. Voltage: Approximately 5V OK or NG OK >> GO TO 3. NG >> Repair harness or connectors. MBIB0300E EC-164 DTC P0112, P0113 IAT SENSOR [CR (WITH EURO-OBD)] 3. CHECK INTAKE AIR TEMPERATURE SENSOR GROUND CIRCUIT FOR OPEN AND SHORT 1. 2. 3. A Turn ignition switch OFF. Disconnect ECM harness connector. Check harness continuity between MAP sensor terminal 4 and ECM terminal 56. Refer to Wiring Diagram. EC Continuity should exist. C 4. Also check harness for short to ground and short to power. OK or NG OK >> GO TO 4. NG >> Repair open circuit or short to ground or short to power in harness or connectors. D 4. CHECK INTAKE AIR TEMPERATURE SENSOR E Refer to EC-165, "Component Inspection" . OK or NG OK >> GO TO 5. NG >> Replace manifold absolute pressure sensor (with intake air temperature sensor). F 5. CHECK INTERMITTENT INCIDENT G Refer to EC-127, "TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT" . H >> INSPECTION END Component Inspection BBS002VR INTAKE AIR TEMPERATURE SENSOR 1. 2. I Check resistance between manifold absolute pressure sensor terminals 3 and 4 under the following conditions. J Intake air temperature °C (°F) Resistance kΩ 25 (77) 1.9 - 2.1 K If NG, replace manifold absolute pressure sensor (with intake air temperature sensor). L MBIB0276E M SEF012P Removal and Installation BBS002VS MANIFOLD ABSOLUTE PRESSURE SENSOR Refer to EM-18, "AIR CLEANER AND AIR DUCT" . EC-165 DTC P0117, P0118 ECT SENSOR [CR (WITH EURO-OBD)] DTC P0117, P0118 ECT SENSOR Component Description PFP:22630 BBS002VT The engine coolant temperature sensor is used to detect the engine coolant temperature. The sensor modifies a voltage signal from the ECM. The modified signal returns to the ECM as the engine coolant temperature input. The sensor uses a thermistor which is sensitive to the change in temperature. The electrical resistance of the thermistor decreases as temperature increases. SEF594K Engine coolant temperature °C (°F) −10 (14) Voltage* V Resistance 4.4 kΩ 7.0 - 11.4 20 (68) 3.5 2.1 - 2.9 50 (122) 2.2 0.68 - 1.00 90 (194) 0.9 0.236 - 0.260 *: This data is reference value and is measured between ECM terminal 72 (Engine coolant temperature sensor) and ground. SEF012P CAUTION: Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM's transistor. Use a ground other than ECM terminals, such as the ground. On Board Diagnosis Logic BBS002VU These self-diagnoses have the one trip detection logic. DTC No. Trouble Diagnosis Name DTC Detecting Condition Possible Cause P0117 0117 Engine coolant temperature sensor circuit low input An excessively low voltage from the sensor is sent to ECM. ● Harness or connectors (The sensor circuit is open or shorted.) P0118 0118 Engine coolant temperature sensor circuit high input An excessively high voltage from the sensor is sent to ECM. ● Engine coolant temperature sensor FAIL-SAFE MODE When this malfunction is detected, the ECM enters fail-safe mode and the MI lights up. Detected items Engine operating condition in fail-safe mode Engine coolant temperature will be determined by ECM based on the time after turning ignition switch ON or START. CONSULT-II displays the engine coolant temperature decided by ECM. Engine coolant temperature decided (CONSULT-II display) Condition Engine coolant temperature sensor circuit Just as ignition switch is turned ON or START 40°C (104°F) More than approx. 4 minutes after ignition ON or START 80°C (176°F) 40 - 80°C (104 - 176°F) (Depends on the time) Except as shown above When the fail-safe system for engine coolant temperature sensor is activated, the cooling fan operates while engine is running. EC-166 DTC P0117, P0118 ECT SENSOR [CR (WITH EURO-OBD)] DTC Confirmation Procedure BBS002VV NOTE: If DTC Confirmation Procedure has been previously conducted, always turn ignition switch OFF and wait at least 10 seconds before conducting the next test. EC WITH CONSULT-II 1. 2. 3. 4. A Turn ignition switch ON. Select “DATA MONITOR” mode with CONSULT-II. Wait at least 5 seconds. If DTC is detected, go to EC-169, "Diagnostic Procedure" . C D E SEF058Y F WITH GST Follow the procedure “WITH CONSULT-II” above. G H I J K L M EC-167 DTC P0117, P0118 ECT SENSOR [CR (WITH EURO-OBD)] Wiring Diagram BBS002VW MBWA1508E EC-168 DTC P0117, P0118 ECT SENSOR [CR (WITH EURO-OBD)] Diagnostic Procedure BBS002VX 1. CHECK GROUND CONNECTIONS 1. 2. A Turn ignition switch OFF. Loosen and retighten ground screws on the body. Refer to EC-133, "Ground Inspection" . EC C D E MBIB1502E 1. Body ground E44 2. Body ground E45 3. F Body ground E28 OK or NG OK >> GO TO 2. NG >> Repair or replace ground connections. G 2. CHECK ECT SENSOR POWER SUPPLY CIRCUIT 1. 2. H Disconnect engine coolant temperature (ECT) sensor harness connector. Turn ignition switch ON. I J K MBIB0279E 3. L Check voltage between ECT sensor terminal 1 and ground with CONSULT-II or tester. Voltage: Approximately 5V M OK or NG OK >> GO TO 3. NG >> Repair open circuit or short to ground or short to power in harness or connectors. PBIB0080E EC-169 DTC P0117, P0118 ECT SENSOR [CR (WITH EURO-OBD)] 3. CHECK ECT SENSOR GROUND CIRCUIT FOR OPEN AND SHORT 1. 2. 3. Turn ignition switch OFF. Disconnect ECM harness connector. Check harness continuity between ECT sensor terminal 2 and ECM terminal 73. Refer to Wiring Diagram. Continuity should exist. 4. Also check harness for short to ground and short to power. OK or NG OK >> GO TO 4. NG >> Repair open circuit or short to ground or short to power in harness or connectors. 4. CHECK ENGINE COOLANT TEMPERATURE SENSOR Refer to EC-170, "Component Inspection" . OK or NG OK >> GO TO 5. NG >> Replace engine coolant temperature sensor. 5. CHECK INTERMITTENT INCIDENT Refer to EC-127, "TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT" . >> INSPECTION END Component Inspection BBS002VY ENGINE COOLANT TEMPERATURE SENSOR 1. Check resistance between engine coolant temperature sensor terminals 1 and 2 as shown in the figure. PBIB2005E Engine coolant temperature 2. °C (°F) Resistance kΩ 20 (68) 2.1 - 2.9 50 (122) 0.68 - 1.00 90 (194) 0.236 - 0.260 If NG, replace engine coolant temperature sensor. SEF012P Removal and Installation BBS002VZ ENGINE COOLANT TEMPERATURE SENSOR Refer to CO-19, "THERMOSTAT" . EC-170 DTC P0122, P0123 TP SENSOR [CR (WITH EURO-OBD)] DTC P0122, P0123 TP SENSOR Component Description PFP:16119 A BBS002W0 Electric throttle control actuator consists of throttle control motor, throttle position sensor, etc. The throttle position sensor responds to the throttle valve movement. The throttle position sensor has the two sensors. These sensors are a kind of potentiometers which transform the throttle valve position into output voltage, and emit the voltage signal to the ECM. In addition, these sensors detect the opening and closing speed of the throttle valve and feed the voltage signals to the ECM. The ECM judges the current opening angle of the throttle valve from these signals and the ECM controls the throttle control motor to make the throttle valve opening angle properly in response to driving condition. EC C D PBIB0145E E CONSULT-II Reference Value in Data Monitor Mode BBS002W1 Specification data are reference values. MONITOR ITEM CONDITION ● Ignition switch: ON (Engine stopped) Accelerator pedal: Fully released More than 0.36V ● Shift lever: 1st Accelerator pedal: Fully depressed Less than 4.75V THRTL SEN 1 THRTL SEN 2* F SPECIFICATION G *: Throttle position sensor 2 signal is converted by ECM internally. Thus, it differs from ECM terminal voltage signal. On Board Diagnosis Logic BBS002W2 H These self-diagnoses have the one trip detection logic. DTC No. P0122 0122 P0123 0123 Trouble diagnosis name DTC detecting condition Throttle position sensor 2 circuit low input An excessively low voltage from the TP sensor 2 is sent to ECM. Throttle position sensor 2 circuit high input An excessively high voltage from the TP sensor 2 is sent to ECM. Possible cause ● Harness or connectors (TP sensor 2 circuit is open or shorted.) (APP sensor 2 circuit is shorted.) ● Electric throttle control actuator (TP sensor 2) ● Accelerator pedal position sensor (APP sensor 2) I J K L FAIL-SAFE MODE When the malfunction is detected, the ECM enters fail-safe mode and the MI lights up. Engine operation condition in fail-safe mode The ECM controls the electric throttle control actuator in regulating the throttle opening in order for the idle position to be within +10 degrees. The ECM regulates the opening speed of the throttle valve to be slower than the normal condition. So, the acceleration will be poor. EC-171 M DTC P0122, P0123 TP SENSOR [CR (WITH EURO-OBD)] DTC Confirmation Procedure BBS002W3 NOTE: If DTC Confirmation Procedure has been previously conducted, always turn ignition switch OFF and wait at least 10 seconds before conducting the next test. TESTING CONDITION: Before performing the following procedure, confirm that battery voltage is more than 10V at idle. WITH CONSULT-II 1. 2. 3. 4. Turn ignition switch ON. Select “DATA MONITOR” mode with CONSULT-II. Start engine and let it idle for 1 second. If DTC is detected, go to EC-174, "Diagnostic Procedure" . SEF058Y WITH GST Follow the procedure “WITH CONSULT-II” above. EC-172 DTC P0122, P0123 TP SENSOR [CR (WITH EURO-OBD)] Wiring Diagram BBS002W4 A EC C D E F G H I J K L M MBWA1509E EC-173 DTC P0122, P0123 TP SENSOR [CR (WITH EURO-OBD)] Specification data are reference values and are measured between each terminal and ground. CAUTION: Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM's transistor. Use a ground other than ECM terminals, such as the ground. TERMINAL NO. 47 WIRE COLOR L ITEM CONDITION Sensor power supply (Throttle position sensor) DATA (DC Voltage) [Ignition switch: ON] Approximately 5V [Ignition switch: ON] 49 Y ● Engine stopped ● Shift lever position: 1st ● Accelerator pedal: Fully released Throttle position sensor 1 More than 0.36V [Ignition switch: ON] ● Engine stopped ● Shift lever position: 1st ● Accelerator pedal: Fully depressed Less than 4.75V [Engine is running] 66 B Sensor ground (Throttle position sensor) ● Warm-up condition ● Idle speed Approximately 0V [Ignition switch: ON] 68 91 R BR Throttle position sensor 2 Sensor power supply (APP sensor 2) ● Engine stopped ● Shift lever position: 1st ● Accelerator pedal: Fully released Less than 4.75V [Ignition switch: ON] ● Engine stopped ● Shift lever position: 1st ● Accelerator pedal: Fully depressed More than 0.36V [Ignition switch: ON] Approximately 5V Diagnostic Procedure BBS002W5 1. CHECK GROUND CONNECTIONS 1. 2. Turn ignition switch OFF. Loosen and retighten ground screws on the body. Refer to EC-133, "Ground Inspection" . MBIB1502E 1. Body ground E44 2. Body ground E45 OK or NG OK >> GO TO 2. NG >> Repair or replace ground connections. EC-174 3. Body ground E28 DTC P0122, P0123 TP SENSOR [CR (WITH EURO-OBD)] 2. CHECK THROTTLE POSITION SENSOR 2 POWER SUPPLY CIRCUIT-I 1. 2. A Disconnect electric throttle control actuator harness connector. Turn ignition switch ON. EC C D MBIB0308E 3. Check voltage between electric throttle control actuator terminal 1 and ground with CONSULT-II or tester. E Voltage: Approximately 5V F OK or NG OK >> GO TO 7. NG >> GO TO 3. G PBIB0082E H 3. CHECK THROTTLE POSITION SENSOR 2 POWER SUPPLY CIRCUIT-II 1. 2. 3. Turn ignition switch OFF. Disconnect ECM harness connector. Check harness continuity between electric throttle control actuator terminal 1 and ECM terminal 47. Refer to Wiring Diagram. I J Continuity should exist. K OK or NG OK >> GO TO 4. NG >> Repair open circuit. 4. CHECK THROTTLE POSITION SENSOR 2 POWER SUPPLY CIRCUIT-III Check harness for short to power and short to ground, between the following terminals. ECM terminal Sensor terminal Reference Wiring Diagram 47 Electric throttle control actuator terminal 1 EC-173 91 APP sensor terminal 5 EC-394 OK or NG OK >> GO TO 5. NG >> Repair short to ground or short to power in harness or connectors. 5. CHECK APP SENSOR Refer to EC-400, "Component Inspection" . OK or NG OK >> GO TO 11 NG >> GO TO 6. EC-175 L M DTC P0122, P0123 TP SENSOR [CR (WITH EURO-OBD)] 6. REPLACE ACCELERATOR PEDAL ASSEMBLY 1. 2. 3. 4. Replace accelerator pedal assembly. Perform EC-69, "Accelerator Pedal Released Position Learning" . Perform EC-69, "Throttle Valve Closed Position Learning" . Perform EC-69, "Idle Air Volume Learning" . >> INSPECTION END 7. CHECK THROTTLE POSITION SENSOR 2 GROUND CIRCUIT FOR OPEN AND SHORT 1. 2. 3. Turn ignition switch OFF. Disconnect ECM harness connector. Check harness continuity between ECM terminal 66 and electric throttle control actuator terminal 5. Refer to Wiring Diagram. Continuity should exist. 4. Also check harness for short to ground and short to power. OK or NG OK >> GO TO 8. NG >> Repair open circuit or short to ground or short to power in harness or connectors. 8. CHECK THROTTLE POSITION SENSOR 2 INPUT SIGNAL CIRCUIT FOR OPEN AND SHORT 1. Check harness continuity between ECM terminal 68 and electric throttle control actuator terminal 2. Refer to Wiring Diagram. Continuity should exist. 2. Also check harness for short to ground and short to power. OK or NG OK >> GO TO 9. NG >> Repair open circuit or short to ground or short to power in harness or connectors. 9. CHECK THROTTLE POSITION SENSOR Refer to EC-177, "Component Inspection" . OK or NG OK >> GO TO 11. NG >> GO TO 10. 10. REPLACE ELECTRIC THROTTLE CONTROL ACTUATOR 1. 2. 3. Replace the electric throttle control actuator. Perform EC-69, "Throttle Valve Closed Position Learning" . Perform EC-69, "Idle Air Volume Learning" . >> INSPECTION END 11. CHECK INTERMITTENT INCIDENT Refer to EC-127, "TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT" . >> INSPECTION END EC-176 DTC P0122, P0123 TP SENSOR [CR (WITH EURO-OBD)] Component Inspection BBS002W6 A THROTTLE POSITION SENSOR 1. 2. 3. 4. 5. Reconnect all harness connectors disconnected. Perform EC-69, "Throttle Valve Closed Position Learning" . Turn ignition switch ON. Set shift lever to 1st position. Check voltage between ECM terminals 49 (TP sensor 1 signal), 68 (TP sensor 2 signal) and ground under the following conditions. Terminal Accelerator pedal Voltage 49 (Throttle position sensor 1) Fully released More than 0.36V 68 (Throttle position sensor 2) 6. 7. 8. Fully depressed Less than 4.75V Fully released Less than 4.75V Fully depressed More than 0.36V If NG, replace electric throttle control actuator and go to the next step. Perform EC-69, "Throttle Valve Closed Position Learning" . Perform EC-69, "Idle Air Volume Learning" . Removal and Installation EC C D E MBIB1443E F G BBS002W7 ELECTRIC THROTTLE CONTROL ACTUATOR Refer to EM-18, "AIR CLEANER AND AIR DUCT" . H I J K L M EC-177 DTC P0132 HO2S1 [CR (WITH EURO-OBD)] DTC P0132 HO2S1 Component Description PFP:22690 BBS002W8 The heated oxygen sensor 1 is placed into the exhaust manifold. It detects the amount of oxygen in the exhaust gas compared to the outside air. The heated oxygen sensor 1 has a closed-end tube made of ceramic zirconia. The zirconia generates voltage from approximately 1V in richer conditions to 0V in leaner conditions. The heated oxygen sensor 1 signal is sent to the ECM. The ECM adjusts the injection pulse duration to achieve the ideal air-fuel ratio. The ideal air-fuel ratio occurs near the radical change from 1V to 0V. SEF463R SEF288D CONSULT-II Reference Value in Data Monitor Mode BBS002W9 Specification data are reference values. MONITOR ITEM CONDITION SPECIFICATION 0 - 0.3V ←→ Approx. 0.6 - 1.0V HO2S1 (B1) ● HO2S1 MNTR (B1) Engine: After warming up Maintaining engine speed at 2,000 rpm LEAN ←→ RICH Changes more than 5 times during 10 seconds. On Board Diagnosis Logic BBS002WA To judge the malfunction, the diagnosis checks that the heated oxygen sensor 1 output is not inordinately high. SEF301UA DTC No. P0132 0132 Trouble diagnosis name Heated oxygen sensor 1 circuit high voltage DTC detecting condition Possible cause ● Harness or connectors (The sensor circuit is open or shorted.) ● Heated oxygen sensor 1 An excessively high voltage from the sensor is sent to ECM. EC-178 DTC P0132 HO2S1 [CR (WITH EURO-OBD)] DTC Confirmation Procedure BBS002WB NOTE: If DTC Confirmation Procedure has been previously conducted, always turn ignition switch OFF and wait at least 10 seconds before conducting the next test. EC WITH CONSULT-II 1. 2. 3. 4. 5. 6. A Start engine and warm it up to normal operating temperature. Turn ignition switch OFF and wait at least 10 seconds. Turn ignition switch ON. Select “DATA MONITOR” mode with CONSULT-II. Restart engine and let it idle for 2 minutes. If 1st trip DTC is detected, go to EC-181, "Diagnostic Procedure" . C D E F SEF174Y G WITH GST Follow the procedure “WITH CONSULT-II” above. H I J K L M EC-179 DTC P0132 HO2S1 [CR (WITH EURO-OBD)] Wiring Diagram BBS002WC MBWA1510E EC-180 DTC P0132 HO2S1 [CR (WITH EURO-OBD)] Specification data are reference values and are measured between each terminal and ground. Pulse signal is measured by CONSULT-II. A CAUTION: Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM's transistor. Use a ground other than ECM terminals, such as the ground. EC TERMINAL NO. WIRE COLOR ITEM CONDITION DATA (DC Voltage) C Approximately 7.0V [Engine is running] 24 Y Heated oxygen sensor 1 heater ● Warm-up condition ● Engine speed: Below 3,600 rpm D E PBIB0519E [Engine is running] ● BATTERY VOLTAGE (11 - 14V) Engine speed: Above 3,600 rpm F [Engine is running] 35 BR Heated oxygen sensor 1 ● Warm-up condition ● Engine speed: 2,000 rpm 0 - Approximately 1.0V (Periodically change) G [Engine is running] 74 B Sensor ground (Heated oxygen sensor) ● Warm-up condition ● Idle speed Approximately 0V H : Average voltage for pulse signal (Actual pulse signal can be confirmed by oscilloscope.) I Diagnostic Procedure BBS002WD 1. CHECK GROUND CONNECTIONS 1. 2. J Turn ignition switch OFF. Loosen and retighten ground screws on the body. Refer to EC-133, "Ground Inspection" . K L M MBIB1502E 1. Body ground E44 2. Body ground E45 OK or NG OK >> GO TO 2. NG >> Repair or replace ground connections. EC-181 3. Body ground E28 DTC P0132 HO2S1 [CR (WITH EURO-OBD)] 2. RETIGHTEN HEATED OXYGEN SENSOR 1 Loosen and retighten heated oxygen sensor 1 (2). ● ● : Vehicle front Exhaust manifold cover (1) Tightening torque: 50 N·m (5.1 kg-m, 37 ft-lb) >> GO TO 3. MBIB1493E 3. CHECK HO2S1 GROUND CIRCUIT FOR OPEN AND SHORT 1. 2. 3. Disconnect heated oxygen sensor 1 harness connector (1). Disconnect ECM harness connector. Check harness continuity between ECM terminal 74 and HO2S1 terminal 1. Refer to Wiring Diagram. Continuity should exist. 4. Also check harness for short to ground and short to power. OK or NG OK >> GO TO 4. NG >> Repair open circuit or short to ground or short to power in harness or connectors. 4. CHECK HO2S1 INPUT SIGNAL CIRCUIT FOR OPEN AND SHORT 1. Check harness continuity between ECM terminal 35 and HO2S1 terminal 4. Refer to Wiring Diagram. Continuity should exist. 2. Check harness continuity between ECM terminal 35 or HO2S1 terminal 4 and ground. Refer to Wiring Diagram. Continuity should not exist. 3. Also check harness for short to power. OK or NG OK >> GO TO 5. NG >> Repair open circuit or short to ground or short to power in harness or connectors. 5. CHECK HO2S1 CONNECTOR FOR WATER Check connectors for water Water should not exist. OK or NG OK >> GO TO 6. NG >> Repair or replace harness or connectors. EC-182 MBIB1494E DTC P0132 HO2S1 [CR (WITH EURO-OBD)] 6. CHECK HEATED OXYGEN SENSOR 1 A Refer to EC-183, "Component Inspection" . OK or NG OK >> GO TO 7. NG >> Replace heated oxygen sensor 1. EC 7. CHECK INTERMITTENT INCIDENT C Refer to EC-127, "TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT" . D >> INSPECTION END Component Inspection BBS002WE E HEATED OXYGEN SENSOR 1 With CONSULT-II 1. 2. 3. 4. 5. Start engine and warm it up to normal operating temperature. Select “MANU TRIG” and adjust “TRIGGER POINT” to 100% in “DATA MONITOR” mode with CONSULTII. Select “HO2S1 (B1)” and “HO2S1 MNTR (B1)”. Hold engine speed at 2,000 rpm under no load during the following steps. Touch “RECORD” on CONSULT-II screen. F G H I MBIB0301E 6. Check the following. ● “HO2S1 MNTR (B1)” in “DATA MONITOR” mode changes from “RICH” to “LEAN” to “RICH” more than 5 times in 10 seconds. 5 times (cycles) are counted as shown in the figure. ● “HO2S1 (B1)” voltage goes above 0.6V at least once. ● “HO2S1 (B1)” voltage goes below 0.3V at least once. ● “HO2S1 (B1)” voltage never exceeds 1.0V. K L M SEF217YA SEF648Y CAUTION: Discard any heated oxygen sensor which has been dropped from a height of more than 0.5 m (19.7 in) onto a hard surface such as a concrete floor; use a new one. ● EC-183 J DTC P0132 HO2S1 [CR (WITH EURO-OBD)] ● Before installing new oxygen sensor, clean exhaust system threads using Oxygen Sensor Thread Cleaner and approved anti-seize lubricant. Without CONSULT-II 1. 2. 3. Start engine and warm it up to normal operating temperature. Set voltmeter probes between ECM terminal 35 (HO2S1 signal) and ground. Check the following with engine speed held at 2,000 rpm constant under no load. ● The voltage fluctuates between 0 to 0.3V and 0.6 to 1.0V more than 5 times within 10 seconds. ● The maximum voltage is over 0.6V at least one time. ● The minimum voltage is below 0.3V at least one time. ● The voltage never exceeds 1.0V. 1 time: 0 - 0.3V → 0.6 - 1.0V → 0 - 0.3V 2 times: 0 - 0.3V → 0.6 - 1.0V → 0 - 0.3V → 0.6 - 1.0V → 0 0.3V MBIB0018E CAUTION: ● Discard any heated oxygen sensor which has been dropped from a height of more than 0.5 m (19.7 in) onto a hard surface such as a concrete floor; use a new one. ● Before installing new oxygen sensor, clean exhaust system threads using Oxygen Sensor Thread Cleaner and approved anti-seize lubricant. Removal and Installation BBS002WF HEATED OXYGEN SENSOR 1 Refer to EM-24, "EXHAUST MANIFOLD AND THREE WAY CATALYST" . EC-184 DTC P0133 HO2S1 [CR (WITH EURO-OBD)] DTC P0133 HO2S1 Component Description PFP:22690 A BBS002WG The heated oxygen sensor 1 is placed into the exhaust manifold. It detects the amount of oxygen in the exhaust gas compared to the outside air. The heated oxygen sensor 1 has a closed-end tube made of ceramic zirconia. The zirconia generates voltage from approximately 1V in richer conditions to 0V in leaner conditions. The heated oxygen sensor 1 signal is sent to the ECM. The ECM adjusts the injection pulse duration to achieve the ideal air-fuel ratio. The ideal air-fuel ratio occurs near the radical change from 1V to 0V. EC C D SEF463R E F G H SEF288D CONSULT-II Reference Value in Data Monitor Mode BBS002WH I Specification data are reference values. MONITOR ITEM CONDITION J 0 - 0.3V ←→ Approx. 0.6 - 1.0V HO2S1 (B1) ● HO2S1 MNTR (B1) SPECIFICATION Engine: After warming up Maintaining engine speed at 2,000 rpm On Board Diagnosis Logic LEAN ←→ RICH Changes more than 5 times during 10 seconds. K BBS002WI L To judge the malfunction of heated oxygen sensor 1, this diagnosis measures response time of heated oxygen sensor 1 signal. The time is compensated by engine operating (speed and load), fuel feedback control constant, and heated oxygen sensor 1 temperature index. Judgment is based on whether the compensated time (heated oxygen sensor 1 cycling time index) is inordinately long or not. M PBIB2991E EC-185 DTC P0133 HO2S1 [CR (WITH EURO-OBD)] DTC No. P0133 0133 Trouble diagnosis name Heated oxygen sensor 1 circuit slow response DTC detecting condition The response of the voltage signal from the sensor takes more than the specified time. DTC Confirmation Procedure Possible cause ● Harness or connectors (The sensor circuit is open or shorted.) ● Heated oxygen sensor 1 ● Fuel pressure ● Fuel injector ● Intake air leak ● Exhaust gas leak ● Manifold absolute pressure sensor BBS002WJ CAUTION: Always drive vehicle at a safe speed. NOTE: If DTC Confirmation Procedure has been previously conducted, always turn ignition switch OFF and wait at least 10 seconds before conducting the next test. TESTING CONDITION: ● Always perform at a temperature above −10°C (14°F). ● Before performing the following procedure, confirm that battery voltage is more than 11V at idle. WITH CONSULT-II 1. 2. 3. 4. 5. Start engine and warm it up to normal operating temperature. Stop engine and wait at least 10 seconds. Turn ignition switch ON and select “HO2S1 (B1) P0133” of “HO2S1” in “DTC WORK SUPPORT” mode with CONSULT-II. Touch “START”. Start engine and let it idle for at least 3 minutes. NOTE: Never raise engine speed above 3,600 rpm after this step. If the engine speed limit is exceeded, return to step 5. SEF338Z 6. When the following conditions are met, “TESTING” will be displayed on the CONSULT-II screen. Maintain the conditions continuously until “TESTING” changes to “COMPLETED”. (It will take approximately 40 to 60 seconds.) ENG SPEED 2,400 - 3,800 rpm VHCL SPEED SE More than 80 km/h (50 MPH) B/FUEL SCHDL 2.8 - 7.0 msec Shift lever Suitable position If “TESTING” is not displayed after 5 minutes, retry from step 2. EC-186 SEF339Z DTC P0133 HO2S1 [CR (WITH EURO-OBD)] 7. Make sure that “OK” is displayed after touching “SELF-DIAG RESULTS”. If “NG” is displayed, refer to EC-189, "Diagnostic Procedure" . A EC C SEF658Y D Overall Function Check BBS002WK Use this procedure to check the overall function of the heated oxygen sensor 1 circuit. During this check, a 1st trip DTC might not be confirmed. E WITH GST 1. 2. 3. ● Start engine and warm it up to normal operating temperature. Set voltmeter probes between ECM terminal 35 (HO2S1 signal) and ground. Check the following with engine speed held at 2,000 rpm constant under no load. The voltage fluctuates between 0 to 0.3V and 0.6 to 1.0V more than 5 times within 10 seconds. 1 time: 2 times: 4. F G 0 - 0.3V → 0.6 - 1.0V → 0 - 0.3V 0 - 0.3V → 0.6 - 1.0V → 0 - 0.3V → 0.6 - 1.0V → 0 - 0.3V H I If NG, go to EC-189, "Diagnostic Procedure" . MBIB0018E J K L M EC-187 DTC P0133 HO2S1 [CR (WITH EURO-OBD)] Wiring Diagram BBS002WL MBWA1510E EC-188 DTC P0133 HO2S1 [CR (WITH EURO-OBD)] Specification data are reference values and are measured between each terminal and ground. Pulse signal is measured by CONSULT-II. A CAUTION: Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM's transistor. Use a ground other than ECM terminals, such as the ground. EC TERMINAL NO. WIRE COLOR ITEM CONDITION DATA (DC Voltage) C Approximately 7.0V [Engine is running] 24 Y Heated oxygen sensor 1 heater ● Warm-up condition ● Engine speed: Below 3,600 rpm D E PBIB0519E [Engine is running] ● BATTERY VOLTAGE (11 - 14V) Engine speed: Above 3,600 rpm F [Engine is running] 35 BR Heated oxygen sensor 1 ● Warm-up condition ● Engine speed: 2,000 rpm 0 - Approximately 1.0V (Periodically change) G [Engine is running] 74 B Sensor ground (Heated oxygen sensor) ● Warm-up condition ● Idle speed Approximately 0V H : Average voltage for pulse signal (Actual pulse signal can be confirmed by oscilloscope.) I Diagnostic Procedure BBS002WM 1. CHECK GROUND CONNECTIONS 1. 2. J Turn ignition switch OFF. Loosen and retighten ground screws on the body. Refer to EC-133, "Ground Inspection" . K L M MBIB1502E 1. Body ground E44 2. Body ground E45 OK or NG OK >> GO TO 2. NG >> Repair or replace ground connections. EC-189 3. Body ground E28 DTC P0133 HO2S1 [CR (WITH EURO-OBD)] 2. RETIGHTEN HEATED OXYGEN SENSOR 1 Loosen and retighten heated oxygen sensor 1 (2). ● ● : Vehicle front Exhaust manifold cover (1) Tightening torque: 50 N·m (5.1 kg-m, 37 ft-lb) >> GO TO 3. MBIB1493E 3. CHECK FOR EXHAUST GAS LEAK 1. 2. Start engine and run it at idle. Listen for an exhaust gas leak before three way catalyst (Manifold). MBIB0649E OK or NG OK >> GO TO 4. NG >> Repair or replace. 4. CHECK FOR INTAKE AIR LEAK Listen for an intake air leak after the manifold absolute pressure sensor. OK or NG OK >> GO TO 5. NG >> Repair or replace. EC-190 DTC P0133 HO2S1 [CR (WITH EURO-OBD)] 5. CLEAR THE SELF-LEARNING DATA 1. 2. 3. 4. A With CONSULT-II Start engine and warm it up to normal operating temperature. Select “SELF-LEARNING CONT” in “WORK SUPPORT” mode with CONSULT-II. Clear the self-learning control coefficient by touching “CLEAR”. Run engine for at least 10 minutes at idle speed. Is the 1st trip DTC P0171 or P0172 detected? Is it difficult to start engine? EC C D E SEF215Z Without CONSULT-II 1. Start engine and warm it up to normal operating temperature. 2. Turn ignition switch OFF. 3. Disconnect manifold absolute pressure sensor harness connector, and restart and run engine for at least 5 seconds at idle speed. 4. Stop engine and reconnect manifold absolute pressure sensor harness connector. 5. Make sure that DTC P0107 is displayed. 6. Erase the DTC memory. Refer to EC-57, "HOW TO ERASE EMISSION-RELATED DIAGNOSTIC INFORMATION" . 7. Make sure that DTC P0000 is displayed. 8. Run engine for at least 10 minutes at idle speed. Is the 1st trip DTC P0171 or P0172 detected? Is it difficult to start engine? Yes or No Yes >> Perform trouble diagnosis for DTC P0171 or DTC P0172 (Refer to EC-218 or EC-226 ). No >> GO TO 6. F G H I J MBIB0276E K L 6. CHECK HO2S1 GROUND CIRCUIT FOR OPEN AND SHORT 1. 2. 3. 4. Turn ignition switch OFF. Disconnect heated oxygen sensor 1 harness connector (1). Disconnect ECM harness connector. Check harness continuity between ECM terminal 74 and HO2S1 terminal 1. Refer to Wiring Diagram. M Continuity should exist. 5. Also check harness for short to ground and short to power. OK or NG OK >> GO TO 7. NG >> Repair open circuit or short to ground or short to power in harness or connectors. EC-191 MBIB1494E DTC P0133 HO2S1 [CR (WITH EURO-OBD)] 7. CHECK HO2S1 INPUT SIGNAL CIRCUIT FOR OPEN AND SHORT 1. Check harness continuity between ECM terminal 35 and HO2S1 terminal 4. Refer to Wiring Diagram. Continuity should exist. 2. Check harness continuity between ECM terminal 35 or HO2S1 terminal 4 and ground. Refer to Wiring Diagram. Continuity should not exist. 3. Also check harness for short to power. OK or NG OK >> GO TO 8. NG >> Repair open circuit or short to ground or short to power in harness or connectors. 8. CHECK MANIFOLD ABSOLUTE PRESSURE SENSOR Refer to EC-159, "Component Inspection" . OK or NG OK >> GO TO 9. NG >> Replace manifold absolute pressure sensor. 9. CHECK PCV VALVE Refer to EC-45, "Component Inspection" . OK or NG OK >> GO TO 10. NG >> Replace PCV valve. 10. CHECK HEATED OXYGEN SENSOR 1 Refer to EC-193, "Component Inspection" . OK or NG OK >> GO TO 11. NG >> Replace heated oxygen sensor 1. 11. CHECK INTERMITTENT INCIDENT Refer to EC-127, "TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT" . >> INSPECTION END EC-192 DTC P0133 HO2S1 [CR (WITH EURO-OBD)] Component Inspection BBS002WN A HEATED OXYGEN SENSOR 1 With CONSULT-II 1. 2. 3. 4. 5. Start engine and warm it up to normal operating temperature. Select “MANU TRIG” and adjust “TRIGGER POINT” to 100% in “DATA MONITOR” mode with CONSULT- EC II. Select “HO2S1 (B1)” and “HO2S1 MNTR (B1)”. C Hold engine speed at 2,000 rpm under no load during the following steps. Touch “RECORD” on CONSULT-II screen. D E MBIB0301E F 6. Check the following. ● “HO2S1 MNTR (B1)” in “DATA MONITOR” mode changes from “RICH” to “LEAN” to “RICH” more than 5 times in 10 seconds. 5 times (cycles) are counted as shown in the figure. ● “HO2S1 (B1)” voltage goes above 0.6V at least once. ● “HO2S1 (B1)” voltage goes below 0.3V at least once. ● “HO2S1 (B1)” voltage never exceeds 1.0V. G H I SEF217YA J K L SEF648Y CAUTION: Discard any heated oxygen sensor which has been dropped from a height of more than 0.5 m (19.7 in) onto a hard surface such as a concrete floor; use a new one. ● Before installing new oxygen sensor, clean exhaust system threads using Oxygen Sensor Thread Cleaner and approved anti-seize lubricant. ● EC-193 M DTC P0133 HO2S1 [CR (WITH EURO-OBD)] Without CONSULT-II 1. 2. 3. Start engine and warm it up to normal operating temperature. Set voltmeter probes between ECM terminal 35 (HO2S1 signal) and ground. Check the following with engine speed held at 2,000 rpm constant under no load. ● The voltage fluctuates between 0 to 0.3V and 0.6 to 1.0V more than 5 times within 10 seconds. ● The maximum voltage is over 0.6V at least one time. ● The minimum voltage is below 0.3V at least one time. ● The voltage never exceeds 1.0V. 1 time: 0 - 0.3V → 0.6 - 1.0V → 0 - 0.3V 2 times: 0 - 0.3V → 0.6 - 1.0V → 0 - 0.3V → 0.6 - 1.0V → 0 0.3V MBIB0018E CAUTION: ● Discard any heated oxygen sensor which has been dropped from a height of more than 0.5 m (19.7 in) onto a hard surface such as a concrete floor; use a new one. ● Before installing new oxygen sensor, clean exhaust system threads using Oxygen Sensor Thread Cleaner and approved anti-seize lubricant. Removal and Installation BBS002WO HEATED OXYGEN SENSOR 1 Refer to EM-24, "EXHAUST MANIFOLD AND THREE WAY CATALYST" . EC-194 DTC P0134 HO2S1 [CR (WITH EURO-OBD)] DTC P0134 HO2S1 Component Description PFP:22690 A BBS002WP The heated oxygen sensor 1 is placed into the exhaust manifold. It detects the amount of oxygen in the exhaust gas compared to the outside air. The heated oxygen sensor 1 has a closed-end tube made of ceramic zirconia. The zirconia generates voltage from approximately 1V in richer conditions to 0V in leaner conditions. The heated oxygen sensor 1 signal is sent to the ECM. The ECM adjusts the injection pulse duration to achieve the ideal air-fuel ratio. The ideal air-fuel ratio occurs near the radical change from 1V to 0V. EC C D SEF463R E F G H SEF288D CONSULT-II Reference Value in Data Monitor Mode BBS002WQ I Specification data are reference values. MONITOR ITEM CONDITION SPECIFICATION J 0 - 0.3V ←→ Approx. 0.6 - 1.0V HO2S1 (B1) ● HO2S1 MNTR (B1) Engine: After warming up Maintaining engine speed at 2,000 rpm LEAN ←→ RICH Changes more than 5 times during 10 seconds. On Board Diagnosis Logic BBS002WR L Under the condition in which the heated oxygen sensor 1 signal is not input, the ECM circuits will read a continuous approximately 0.3V. Therefore, for this diagnosis, the time that output voltage is within 200 to 400 mV range is monitored, and the diagnosis checks that this time is not inordinately long. M SEF237U DTC No. P0134 0134 Trouble diagnosis name Heated oxygen sensor 1 circuit no activity detected K DTC detecting condition Possible cause ● Harness or connectors (The sensor circuit is open or shorted.) ● Heated oxygen sensor 1 The voltage from the sensor is constantly approx. 0.3V. EC-195 DTC P0134 HO2S1 [CR (WITH EURO-OBD)] DTC Confirmation Procedure BBS002WS CAUTION: Always drive vehicle at a safe speed. NOTE: If DTC Confirmation Procedure has been previously conducted, always turn ignition switch OFF and wait at least 10 seconds before conducting the next test. TESTING CONDITION: Before performing the following procedure, confirm that battery voltage is more than 11V at idle. WITH CONSULT-II 1. 2. 3. 4. Start engine and warm it up to normal operating temperature. Select “HO2S1 (B1) P0134” of “HO2S1” in “DTC WORK SUPPORT” mode with CONSULT-II. Touch “START”. Let it idle for at least 3 minutes. NOTE: Never raise engine speed above 3,600 rpm after this step. If the engine speed limit is exceeded, return to step 4. PBIB0544E 5. When the following conditions are met, “TESTING” will be displayed on the CONSULT-II screen. Maintain the conditions continuously until “TESTING” changes to “COMPLETED”. (It will take approximately 10 to 60 seconds.) ENG SPEED 2,100 - 4,100 rpm VHCL SPEED SE More than 64 km/h (40 MPH) B/FUEL SCHDL 2.0 - 7.8 msec Shift lever Suitable position 6. If “TESTING” is not displayed after 5 minutes, retry from step 2. Make sure that “OK” is displayed after touching “SELF-DIAG RESULTS”. If “NG” is displayed, refer to EC-199, "Diagnostic Procedure" . PBIB0545E SEC750C EC-196 DTC P0134 HO2S1 [CR (WITH EURO-OBD)] Overall Function Check BBS002WT Use this procedure to check the overall function of the heated oxygen sensor 1 circuit. During this check, a 1st trip DTC might not be confirmed. WITH GST 1. 2. 3. ● 4. A EC Start engine and warm it up to normal operating temperature. Set voltmeter probes between ECM terminal 35 (HO2S1 signal) and ground. Check the following with engine speed held at 2,000 rpm constant under no load. The voltage does not remain in the range of 0.2 to 0.4V. If NG, go to EC-199, "Diagnostic Procedure" . C D E MBIB0018E F G H I J K L M EC-197 DTC P0134 HO2S1 [CR (WITH EURO-OBD)] Wiring Diagram BBS002WU MBWA1510E EC-198 DTC P0134 HO2S1 [CR (WITH EURO-OBD)] Specification data are reference values and are measured between each terminal and ground. Pulse signal is measured by CONSULT-II. A CAUTION: Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM's transistor. Use a ground other than ECM terminals, such as the ground. EC TERMINAL NO. WIRE COLOR ITEM CONDITION DATA (DC Voltage) C Approximately 7.0V [Engine is running] 24 Y Heated oxygen sensor 1 heater ● Warm-up condition ● Engine speed: Below 3,600 rpm D E PBIB0519E [Engine is running] ● BATTERY VOLTAGE (11 - 14V) Engine speed Above 3,600 rpm F [Engine is running] 35 BR Heated oxygen sensor 1 ● Warm-up condition ● Engine speed: 2,000 rpm 0 - Approximately 1.0V (Periodically change) G [Engine is running] 74 B Sensor ground (Heated oxygen sensor) ● Warm-up condition ● Idle speed Approximately 0V H : Average voltage for pulse signal (Actual pulse signal can be confirmed by oscilloscope.) I Diagnostic Procedure BBS002WV 1. CHECK GROUND CONNECTIONS 1. 2. J Turn ignition switch OFF. Loosen and retighten ground screws on the body. Refer to EC-133, "Ground Inspection" . K L M MBIB1502E 1. Body ground E44 2. Body ground E45 OK or NG OK >> GO TO 2. NG >> Repair or replace ground connections. EC-199 3. Body ground E28 DTC P0134 HO2S1 [CR (WITH EURO-OBD)] 2. CHECK HO2S1 GROUND CIRCUIT FOR OPEN AND SHORT 1. 2. 3. Disconnect heated oxygen sensor 1 harness connector (1). Disconnect ECM harness connector. Check harness continuity between ECM terminal 74 and HO2S1 terminal 1. Refer to Wiring Diagram. Continuity should exist. 4. Also check harness for short to ground and short to power. OK or NG OK >> GO TO 3. NG >> Repair open circuit or short to ground or short to power in harness or connectors. 3. CHECK HO2S1 INPUT SIGNAL CIRCUIT FOR OPEN AND SHORT 1. Check harness continuity between ECM terminal 35 and HO2S1 terminal 4. Refer to Wiring Diagram. Continuity should exist. 2. Check harness continuity between ECM terminal 35 or HO2S1 terminal 4 and ground. Refer to Wiring Diagram. Continuity should not exist. 3. Also check harness for short to power. OK or NG OK >> GO TO 4. NG >> Repair open circuit or short to ground or short to power in harness or connectors. 4. CHECK HEATED OXYGEN SENSOR 1 Refer to EC-201, "Component Inspection" . OK or NG OK >> GO TO 5. NG >> Replace heated oxygen sensor 1. 5. CHECK INTERMITTENT INCIDENT Refer to EC-127, "TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT" . >> INSPECTION END EC-200 MBIB1494E DTC P0134 HO2S1 [CR (WITH EURO-OBD)] Component Inspection BBS002WW A HEATED OXYGEN SENSOR 1 With CONSULT-II 1. 2. 3. 4. 5. Start engine and warm it up to normal operating temperature. Select “MANU TRIG” and adjust “TRIGGER POINT” to 100% in “DATA MONITOR” mode with CONSULT- EC II. Select “HO2S1 (B1)” and “HO2S1 MNTR (B1)”. C Hold engine speed at 2,000 rpm under no load during the following steps. Touch “RECORD” on CONSULT-II screen. D E MBIB0301E F 6. Check the following. ● “HO2S1 MNTR (B1)” in “DATA MONITOR” mode changes from “RICH” to “LEAN” to “RICH” more than 5 times in 10 seconds. 5 times (cycles) are counted as shown in the figure. ● “HO2S1 (B1)” voltage goes above 0.6V at least once. ● “HO2S1 (B1)” voltage goes below 0.3V at least once. ● “HO2S1 (B1)” voltage never exceeds 1.0V. G H I SEF217YA J K L SEF648Y CAUTION: Discard any heated oxygen sensor which has been dropped from a height of more than 0.5 m (19.7 in) onto a hard surface such as a concrete floor; use a new one. ● Before installing new oxygen sensor, clean exhaust system threads using Oxygen Sensor Thread Cleaner and approved anti-seize lubricant. ● Without CONSULT-II 1. 2. Start engine and warm it up to normal operating temperature. Set voltmeter probes between ECM terminal 35 (HO2S1 signal) and ground. EC-201 M DTC P0134 HO2S1 [CR (WITH EURO-OBD)] 3. Check the following with engine speed held at 2,000 rpm constant under no load. ● The voltage fluctuates between 0 to 0.3V and 0.6 to 1.0V more than 5 times within 10 seconds. ● The maximum voltage is over 0.6V at least one time. ● The minimum voltage is below 0.3V at least one time. ● The voltage never exceeds 1.0V. 1 time: 0 - 0.3V → 0.6 - 1.0V → 0 - 0.3V 2 times: 0 - 0.3V → 0.6 - 1.0V → 0 - 0.3V → 0.6 - 1.0V → 0 0.3V MBIB0018E CAUTION: ● Discard any heated oxygen sensor which has been dropped from a height of more than 0.5 m (19.7 in) onto a hard surface such as a concrete floor; use a new one. ● Before installing new oxygen sensor, clean exhaust system threads using Oxygen Sensor Thread Cleaner and approved anti-seize lubricant. Removal and Installation BBS002WX HEATED OXYGEN SENSOR 1 Refer to EM-24, "EXHAUST MANIFOLD AND THREE WAY CATALYST" . EC-202 DTC P0138 HO2S2 [CR (WITH EURO-OBD)] DTC P0138 HO2S2 Component Description PFP:226A0 A BBS002WY The heated oxygen sensor 2, after three way catalyst (manifold), monitors the oxygen level in the exhaust gas. Even if switching characteristics of the heated oxygen sensor 1 are shifted, the air-fuel ratio is controlled to stoichiometric, by the signal from the heated oxygen sensor 2. This sensor is made of ceramic zirconia. The zirconia generates voltage from approximately 1V in richer conditions to 0V in leaner conditions. Under normal conditions the heated oxygen sensor 2 is not used for engine control operation. EC C D SEF327R E CONSULT-II Reference Value in Data Monitor Mode BBS002WZ Specification data are reference values. MONITOR ITEM HO2S2 (B1) HO2S2 MNTR (B1) F CONDITION SPECIFICATION ● Revving engine from idle to 3,000 rpm quickly after the following conditions are met. 0 - 0.3V ←→ Approx. 0.6 - 1.0V – Engine: After warming up – Keeping the engine speed between 3,500 and 4,000 rpm for 1 minute and at idle for 1 minute under no load. G LEAN ←→ RICH H On Board Diagnosis Logic BBS002X0 The heated oxygen sensor 2 has a much longer switching time between rich and lean than the heated oxygen sensor 1. The oxygen storage capacity before the three way catalyst (manifold) causes the longer switching time. To judge the malfunctions of heated oxygen sensor 2, ECM monitors whether the voltage is unusually high during the various driving condition such as fuel-cut. I J K SEF305UA L DTC No. P0138 0138 Trouble diagnosis name Heated oxygen sensor 2 circuit high voltage DTC detecting condition Possible cause ● Harness or connectors (The sensor circuit is open or shorted.) ● Heated oxygen sensor 2 An excessively high voltage from the sensor is sent to ECM. EC-203 M DTC P0138 HO2S2 [CR (WITH EURO-OBD)] DTC Confirmation Procedure BBS002X1 NOTE: If DTC Confirmation Procedure has been previously conducted, always turn ignition switch OFF and wait at least 10 seconds before conducting the next test. WITH CONSULT-II 1. 2. 3. 4. 5. 6. Turn ignition switch ON and select “DATA MONITOR” mode with CONSULT-II. Start engine and warm it up to the normal operating temperature. Turn ignition switch OFF and wait at least 10 seconds. Start engine and keep the engine speed between 3,500 and 4,000 rpm for at least 1 minute under no load. Let engine idle for 2 minutes. If 1st trip DTC is detected, go to EC-206, "Diagnostic Procedure" . WITH GST Follow the procedure “WITH CONSULT-II” above. EC-204 SEF189Y DTC P0138 HO2S2 [CR (WITH EURO-OBD)] Wiring Diagram BBS002X2 A EC C D E F G H I J K L M MBWA1511E EC-205 DTC P0138 HO2S2 [CR (WITH EURO-OBD)] Specification data are reference values and are measured between each terminal and ground. CAUTION: Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM's transistor. Use a ground other than ECM terminals, such as the ground. TERMINAL NO. WIRE COLOR ITEM CONDITION DATA (DC Voltage) [Engine is running] 2 GR ● Engine speed: Below 3,800 rpm after the following conditions are met. – Engine: After warming up – Keeping the engine speed between 3,500 and 4,000 rpm for 1 minute and at idle for 1 minute under no load. Heated oxygen sensor 2 heater 0 - 1.0V [Ignition switch ON] ● Engine stopped BATTERY VOLTAGE (11 - 14V) [Engine is running] ● Engine speed: Above 3,800 rpm [Engine is running] 16 LG Heated oxygen sensor 2 ● Revving engine from idle to 3,000rpm quickly after the following conditions are met. – Engine: After warming up – Keeping the engine speed between 3,500 and 4,000 rpm for 1 minute and at idle for 1 minute under no load. 0 - Approximately 1.0V [Engine is running] 74 B Sensor ground (Heated oxygen sensor) ● Warm-up condition ● Idle speed Approximately 0V Diagnostic Procedure BBS002X3 1. CHECK GROUND CONNECTIONS 1. 2. Turn ignition switch OFF. Loosen and retighten ground screws on the body. Refer to EC-133, "Ground Inspection" . MBIB1502E 1. Body ground E44 2. Body ground E45 OK or NG OK >> GO TO 2. NG >> Repair or replace ground connections. EC-206 3. Body ground E28 DTC P0138 HO2S2 [CR (WITH EURO-OBD)] 2. CHECK HO2S2 GROUND CIRCUIT FOR OPEN AND SHORT 1. Disconnect heated oxygen sensor 2 harness connector (1). – : Vehicle front Heated oxygen sensor 2 (2) Oil pan (3) Disconnect ECM harness connector. Check harness continuity between ECM terminal 74 and HO2S2 terminal 4. Refer to Wiring Diagram. – – 2. 3. Continuity should exist. EC C D MBIB1459E 4. Also check harness for short to ground and short to power. OK or NG OK >> GO TO 3. NG >> Repair open circuit or short to ground or short to power in harness or connectors. 3. CHECK HO2S2 INPUT SIGNAL CIRCUIT FOR OPEN AND SHORT 1. A Check harness continuity between ECM terminal 16 and HO2S2 terminal 1. Refer to Wiring Diagram. E F G Continuity should exist. 2. Check harness continuity between ECM terminal 16 or HO2S2 terminal 1 and ground. Refer to Wiring Diagram. Continuity should not exist. H I 3. Also check harness for short to power. OK or NG OK >> GO TO 4. NG >> Repair open circuit or short to ground or short to power in harness or connectors. 4. CHECK HO2S2 CONNECTOR FOR WATER J K Check connectors for water. Water should not exist. L OK or NG OK >> GO TO 5. NG >> Repair or replace harness or connectors. 5. CHECK HEATED OXYGEN SENSOR 2 Refer to EC-208, "Component Inspection" . OK or NG OK >> GO TO 6. NG >> Replace heated oxygen sensor 2. 6. CHECK INTERMITTENT INCIDENT Refer to EC-127, "TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT" . >> INSPECTION END EC-207 M DTC P0138 HO2S2 [CR (WITH EURO-OBD)] Component Inspection BBS002X4 HEATED OXYGEN SENSOR 2 With CONSULT-II 1. 2. 3. 4. 5. Turn ignition switch ON and select “DATA MONITOR” mode with CONSULT-II. Start engine and warm it up to the normal operating temperature. Turn ignition switch OFF and wait at least 10 seconds. Start engine and keep the engine speed between 3,500 and 4,000 rpm for at least 1 minute under no load. Let engine idle for 1 minute. SEF174Y 6. Select “FUEL INJECTION” in “ACTIVE TEST” mode, and select “HO2S2(B1)” as the monitor item with CONSULT-II. SEF662Y 7. Check “HO2S2 (B1)” at idle speed when adjusting “FUEL INJECTION” to ±25%. MBIB1402E “HO2S2 (B1)” should be above 0.61V at least once when the “FUEL INJECTION” is +25%. “HO2S2 (B1)” should be below 0.52V at least once when the “FUEL INJECTION” is −25%. CAUTION: ● Discard any heated oxygen sensor which has been dropped from a height of more than 0.5 m (19.7 in) onto a hard surface such as a concrete floor; use a new one. ● Before installing new oxygen sensor, clean exhaust system threads using Oxygen Sensor Thread Cleaner and approved anti-seize lubricant. Without CONSULT-II 1. 2. 3. 4. 5. Start engine and warm it up to the normal operating temperature. Turn ignition switch OFF and wait at least 10 seconds. Start engine and keep the engine speed between 3,500 and 4,000 rpm for at least 1 minute under no load. Let engine idle for 1 minute. Set voltmeter probes between ECM terminal 16 (HO2S2 signal) and ground. EC-208 DTC P0138 HO2S2 [CR (WITH EURO-OBD)] 6. Check the voltage when revving up to 4,000 rpm under no load at least 10 times. A (Depress and release accelerator pedal as soon as possible.) The voltage should be above 0.61V at least once during this procedure. EC If the voltage is above 0.61V at step 6, step 7 is not necessary. 7. Keep vehicle idling for 10 minutes, then check voltage. Or check C the voltage when coasting from 80 km/h (50 MPH) in 3rd gear position. The voltage should be below 0.52V at least once during this MBIB0020E procedure. D 8. If NG, replace heated oxygen sensor 2. CAUTION: ● Discard any heated oxygen sensor which has been dropped from a height of more than 0.5 m (19.7 E in) onto a hard surface such as a concrete floor; use a new one. ● Before installing new oxygen sensor, clean exhaust system threads using Oxygen Sensor Thread Cleaner and approved anti-seize lubricant. F Removal and Installation BBS002X5 HEATED OXYGEN SENSOR 2 G Refer to EX-3, "EXHAUST SYSTEM" . H I J K L M EC-209 DTC P0139 HO2S2 [CR (WITH EURO-OBD)] DTC P0139 HO2S2 Component Description PFP:226A0 BBS002X6 The heated oxygen sensor 2, after three way catalyst (manifold), monitors the oxygen level in the exhaust gas. Even if switching characteristics of the heated oxygen sensor 1 are shifted, the air-fuel ratio is controlled to stoichiometric, by the signal from the heated oxygen sensor 2. This sensor is made of ceramic zirconia. The zirconia generates voltage from approximately 1V in richer conditions to 0V in leaner conditions. Under normal conditions the heated oxygen sensor 2 is not used for engine control operation. SEF327R CONSULT-II Reference Value in Data Monitor Mode BBS002X7 Specification data are reference values. MONITOR ITEM HO2S2 (B1) HO2S2 MNTR (B1) CONDITION SPECIFICATION ● Revving engine from idle to 3,000 rpm quickly after the following conditions are met. 0 - 0.3V ←→ Approx. 0.6 - 1.0V – Engine: After warming up – Keeping the engine speed between 3,500 and 4,000 rpm for 1 minute and at idle for 1 minute under no load. LEAN ←→ RICH On Board Diagnosis Logic BBS002X8 The heated oxygen sensor 2 has a much longer switching time between rich and lean than the heated oxygen sensor 1. The oxygen storage capacity before the three way catalyst (manifold) causes the longer switching time. To judge the malfunctions of heated oxygen sensor 2, ECM monitors whether the switching response of the sensor's voltage is faster than specified during the various driving condition such as fuel-cut. SEF302U DTC No. P0139 0139 Trouble diagnosis name Heated oxygen sensor 2 circuit slow response DTC detecting condition It takes more time for the sensor to respond between rich and lean than the specified time. EC-210 Possible cause ● Harness or connectors (The sensor circuit is open or shorted.) ● Heated oxygen sensor 2 ● Fuel pressure ● Fuel injector ● Intake air leak DTC P0139 HO2S2 [CR (WITH EURO-OBD)] DTC Confirmation Procedure BBS002X9 A CAUTION: Always drive vehicle at a safe speed. NOTE: ● “COMPLETED” will appear on CONSULT-II screen when all tests “COND1”, “COND2” and EC “COND3” are completed. ● If DTC Confirmation Procedure has been previously conducted, always turn ignition switch OFF and wait C at least 10 seconds before conducting the next test. TESTING CONDITION: Never stop engine during this procedure. If the engine is stopped, retry this procedure from step 2 in D Procedure for COND1. WITH CONSULT-II Procedure for COND1 For the best results, perform “DTC WORK SUPPORT” at a temperature of 0 to 30°(32 to 86°F). 1. Start engine and warm it up to normal operating temperature. 2. Turn ignition switch OFF and wait at least 10 seconds. 3. Start engine and keep the engine speed between 3,500 and 4,000 rpm for at least 1 minute under no load. 4. Let engine idle 1 minute. 5. Select “HO2S2 (B1) P0139” of “HO2S2” in “DTC WORK SUPPORT” mode with CONSULT-II. 6. Touch “START”. 7. Start engine and let it idle for at least 30 seconds. 8. Rev engine up to 2,000 rpm 2 or 3 times quickly under no load. If “COMPLETED” appears on CONSULT-II screen, go to step 2 in “Procedure for COND3”. If “COMPLETED” does not appear on CONSULT-II screen, go to the following step. 9. When the following conditions are met, “TESTING” will be displayed at “COND1” on the CONSULT-II screen. Maintain the conditions continuously until “TESTING” changes to “COMPLETED”. (It will take approximately 60 seconds.) ENG SPEED More than 1.0 msec COOLAN TEMP/S 70 - 105 °C (158 - 221°F) Shift level Suitable position F G H I J More than 1,500 rpm B/FUEL SCHDL E K L M PBIB0552E NOTE: ● If “TESTING” is not displayed after 5 minutes, retry from step 2 in Procedure for COND1. ● If “COMPLETED” already appears at “COND2” on CONSULT-II screen before Procedure for COND2 is conducted, it is unnecessary to conduct step 1 in Procedure for COND2. EC-211 DTC P0139 HO2S2 [CR (WITH EURO-OBD)] Procedure for COND2 1. While driving, release accelerator pedal completely from the above condition [step 9] until “INCOMPLETE” at “COND2” on CONSULT-II screen has turned to “COMPLETED”. (It will take approximately 4 seconds.) NOTE: If “COMPLETED” already appears at “COND3” on CONSULT-II screen before Procedure for COND3 is conducted, it is unnecessary to conduct step 1 in Procedure for COND3. PBIB0553E Procedure for COND3 1. 2. a. b. c. d. Stop vehicle and let it idle until “INCOMPLETE” of “COND3” on CONSULT-II screen has turned to “COMPLETED”. (It will take a maximum of approximately 6 minutes.) Make sure that “OK” is displayed after touching “SELF-DIAG RESULTS”. If “NG” is displayed, refer to EC-214, "Diagnostic Procedure" . If “CAN NOT BE DIAGNOSED” is displayed, perform the following. Turn ignition switch OFF and leave the vehicle in a cool place (soak the vehicle). Turn ignition switch ON and select “COOLAN TEMP/S” in “DATA MONITOR” mode with CONSULT-II. Start engine and warm it up while monitoring “COOLAN TEMP/S” indication on CONSULT-II. When “COOLAN TEMP/S” indication reaches to 70°(158°F), go to procedure for COND1 step 3. Overall Function Check SEF668Y BBS002XA Use this procedure to check the overall function of the heated oxygen sensor 2 circuit. During this check, a 1st trip DTC might not be confirmed. WITH GST 1. 2. 3. 4. 5. 6. 7. 8. Start engine and warm it up to the normal operating temperature. Turn ignition switch OFF and wait at least 10 seconds. Start engine and keep the engine between 3,500 and 4,000 rpm for at least 1 minute under no load. Let engine idle for 1 minute. Set voltmeter probes between ECM terminal 16 (HO2S2 signal) and ground. Check the voltage when revving up to 4,000 rpm under no load at least 10 times. (Depress and release accelerator pedal as soon as possible.) A change of voltage should be more than 0.06V for 1 second during this procedure. If the voltage can be confirmed in step 6, step 7 is not necessary. Keep vehicle at idling for 10 minutes, then check the voltage. Or check the voltage when coasting from 80 km/h (50 MPH) in 3rd gear position. A change of voltage should be more than 0.06V for 1 secMBIB0020E ond during this procedure. If NG, go to EC-214, "Diagnostic Procedure" . EC-212 DTC P0139 HO2S2 [CR (WITH EURO-OBD)] Wiring Diagram BBS002XB A EC C D E F G H I J K L M MBWA1511E EC-213 DTC P0139 HO2S2 [CR (WITH EURO-OBD)] Specification data are reference values and are measured between each terminal and ground. CAUTION: Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM's transistor. Use a ground other than ECM terminals, such as the ground. TERMINAL NO. WIRE COLOR ITEM CONDITION DATA (DC Voltage) [Engine is running] 2 GR ● Engine speed: Below 3,800 rpm after the following conditions are met. – Engine: After warming up – Keeping the engine speed between 3,500 and 4,000 rpm for 1 minute and at idle for 1 minute under no load. Heated oxygen sensor 2 heater 0 - 1.0V [Ignition switch ON] ● Engine stopped BATTERY VOLTAGE (11 - 14V) [Engine is running] ● Engine speed: Above 3,800 rpm [Engine is running] 16 LG Heated oxygen sensor 2 ● Revving engine from idle to 3,000rpm quickly after the following conditions are met. – Engine: After warming up – Keeping the engine speed between 3,500 and 4,000 rpm for 1 minute and at idle for 1 minute under no load. 0 - Approximately 1.0V [Engine is running] 74 B Sensor ground (Heated oxygen sensor) ● Warm-up condition ● Idle speed Approximately 0V Diagnostic Procedure BBS002XC 1. CHECK GROUND CONNECTIONS 1. 2. Turn ignition switch OFF. Loosen and retighten ground screws on the body. Refer to EC-133, "Ground Inspection" . MBIB1502E 1. Body ground E44 2. Body ground E45 OK or NG OK >> GO TO 2. NG >> Repair or replace ground connections. EC-214 3. Body ground E28 DTC P0139 HO2S2 [CR (WITH EURO-OBD)] 2. CLEAR THE SELF-LEARNING DATA A With CONSULT-II Start engine and warm it up to normal operating temperature. Select “SELF-LEARNING CONT” in “WORK SUPPORT” mode with CONSULT-II. 3. Clear the self-learning control coefficient by touching “CLEAR”. 4. Run engine for at least 10 minutes at idle speed. Is the 1st trip DTC P0171 or P0172 detected? Is it difficult to start engine? 1. 2. EC C D E SEF215Z Without CONSULT-II 1. Start engine and warm it up to normal operating temperature. 2. Turn ignition switch OFF. 3. Disconnect manifold absolute pressure sensor harness connector, and restart and run engine for at least 5 seconds at idle speed. 4. Stop engine and reconnect manifold absolute pressure sensor harness connector. 5. Make sure that DTC P0107 is displayed. 6. Erase the DTC memory. Refer to EC-57, "HOW TO ERASE EMISSION-RELATED DIAGNOSTIC INFORMATION" . 7. Make sure that DTC P0000 is displayed. 8. Run engine for at least 10 minutes at idle speed. Is the 1st trip DTC P0171 or P0172 detected? Is it difficult to start engine? Yes or No Yes >> Perform trouble diagnosis for DTC P0171 or P0172. Refer to EC-218 or EC-226 . No >> GO TO 3. F G H I MBIB0276E J K 3. CHECK HO2S2 GROUND CIRCUIT FOR OPEN AND SHORT L 1. 2. Turn ignition switch OFF. Disconnect heated oxygen sensor 2 harness connector (1). M – : Vehicle front Heated oxygen sensor 2 (2) Oil pan (3) Disconnect ECM harness connector. Check harness continuity between ECM terminal 74 and HO2S2 terminal 4. Refer to Wiring Diagram. – – 3. 4. Continuity should exist. MBIB1459E 5. Also check harness for short to ground and short to power. OK or NG OK >> GO TO 4. NG >> Repair open circuit or short to ground or short to power in harness or connectors. EC-215 DTC P0139 HO2S2 [CR (WITH EURO-OBD)] 4. CHECK HO2S2 INPUT SIGNAL CIRCUIT FOR OPEN AND SHORT 1. Check harness continuity between ECM terminal 16 and HO2S2 terminal 1. Refer to Wiring Diagram. Continuity should exist. 2. Check harness continuity between ECM terminal 16 or HO2S2 terminal 1 and ground. Refer to Wiring Diagram. Continuity should not exist. 3. Also check harness for short to power. OK or NG OK >> GO TO 5. NG >> Repair open circuit or short to ground or short to power in harness or connectors. 5. CHECK HEATED OXYGEN SENSOR 2 Refer to EC-216, "Component Inspection" . OK or NG OK >> GO TO 6. NG >> Replace heated oxygen sensor 2. 6. CHECK INTERMITTENT INCIDENT Refer to EC-127, "TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT" . >> INSPECTION END Component Inspection BBS002XD HEATED OXYGEN SENSOR 2 With CONSULT-II 1. 2. 3. 4. 5. Turn ignition switch ON and select “DATA MONITOR” mode with CONSULT-II. Start engine and warm it up to the normal operating temperature. Turn ignition switch OFF and wait at least 10 seconds. Start engine and keep the engine speed between 3,500 and 4,000 rpm for at least 1 minute under no load. Let engine idle for 1 minute. SEF174Y 6. Select “FUEL INJECTION” in “ACTIVE TEST” mode, and select “HO2S2 (B1)” as the monitor item with CONSULT-II. SEF662Y EC-216 DTC P0139 HO2S2 [CR (WITH EURO-OBD)] 7. Check “HO2S2 (B1)” at idle speed when adjusting “FUEL INJECTION” to ±25%. A EC C MBIB1402E “HO2S2 (B1)” should be above 0.61V at least once when the “FUEL INJECTION” is +25%. “HO2S2 (B1)” should be below 0.52V at least once when the “FUEL INJECTION” is −25%. CAUTION: ● Discard any heated oxygen sensor which has been dropped from a height of more than 0.5 m (19.7 in) onto a hard surface such as a concrete floor; use a new one. ● Before installing new oxygen sensor, clean exhaust system threads using Oxygen Sensor Thread Cleaner and approved anti-seize lubricant. D E F Without CONSULT-II 1. 2. 3. 4. 5. 6. Start engine and warm it up to the normal operating temperature. Turn ignition switch OFF and wait at least 10 seconds. Start engine and keep the engine speed between 3,500 and 4,000 rpm for at least 1 minute under no load. Let engine idle for 1 minute. Set voltmeter probes between ECM terminal 16 (HO2S2 signal) and ground. Check the voltage when revving up to 4,000 rpm under no load at least 10 times. (Depress and release accelerator pedal as soon as possible.) The voltage should be above 0.61V at least once during this procedure. If the voltage is above 0.61V at step 6, step 7 is not necessary. 7. Keep vehicle idling for 10 minutes, then check voltage. Or check the voltage when coasting from 80 km/h (50 MPH) in 3rd gear position. The voltage should be below 0.52V at least once during this MBIB0020E procedure. 8. If NG, replace heated oxygen sensor 2. CAUTION: ● Discard any heated oxygen sensor which has been dropped from a height of more than 0.5 m (19.7 in) onto a hard surface such as a concrete floor; use a new one. ● Before installing new oxygen sensor, clean exhaust system threads using Oxygen Sensor Thread Cleaner and approved anti-seize lubricant. Removal and Installation BBS002XE HEATED OXYGEN SENSOR 2 Refer to EX-3, "EXHAUST SYSTEM" . EC-217 G H I J K L M DTC P0171 FUEL INJECTION SYSTEM FUNCTION [CR (WITH EURO-OBD)] DTC P0171 FUEL INJECTION SYSTEM FUNCTION On Board Diagnosis Logic PFP:16600 BBS002XF With the Air/Fuel Mixture Ratio Self-Learning Control, the actual mixture ratio can be brought closely to the theoretical mixture ratio based on the mixture ratio feedback signal from the heated oxygen sensor 1. The ECM calculates the necessary compensation to correct the offset between the actual and the theoretical ratios. In case the amount of the compensation value is extremely large (The actual mixture ratio is too lean.), the ECM judges the condition as the fuel injection system malfunction and lights up the MI (2 trip detection logic). Sensor Heated oxygen sensors 1 DTC No. Input Signal to ECM Density of oxygen in exhaust gas (Mixture ratio feedback signal) Trouble diagnosis name Fuel injection system too lean Actuator Fuel injection control DTC detecting condition ● P0171 0171 ECM function ● Fuel injector Possible cause ● Intake air leaks ● Heated oxygen sensor 1 Fuel injection system does not operate properly. ● Fuel injector The amount of mixture ratio compensation is too large. (The mixture ratio is too lean.) ● Exhaust gas leak ● Incorrect fuel pressure ● Lack of fuel ● Manifold absolute pressure sensor ● Incorrect PCV hose connection DTC Confirmation Procedure BBS002XG NOTE: If DTC Confirmation Procedure has been previously conducted, always turn ignition switch OFF and wait at least 10 seconds before conducting the next test. WITH CONSULT-II 1. 2. 3. 4. 5. 6. a. b. Start engine and warm it up to normal operating temperature. Turn ignition switch OFF and wait at least 10 seconds. Turn ignition switch ON and select “SELF-LEARNING CONT” in “WORK SUPPORT” mode with CONSULT-II. Clear the self-learning control coefficient by touching “CLEAR”. Select “DATA MONITOR” mode with CONSULT-II. Start engine again and let it idle for at least 10 minutes. The 1st trip DTC P0171 should be detected at this stage, if a malfunction exists. If so, go to EC-222, "Diagnostic Procedure" . NOTE: If 1st trip DTC is not detected during above procedure, performing the following procedure is advised. Turn ignition switch OFF and wait at least 10 seconds. Start engine and drive the vehicle under the similar conditions to SEF215Z (1st trip) Freeze Frame Data for 10 minutes. Refer to the table below. Hold the accelerator pedal as steady as possible. The similar conditions to (1st trip) Freeze Frame Data means the vehicle operation that the following conditions should be satisfied at the same time. Engine speed Engine speed in the freeze frame data ± 400 rpm Vehicle speed Vehicle speed in the freeze frame data ± 10 km/h (6 MPH) EC-218 DTC P0171 FUEL INJECTION SYSTEM FUNCTION [CR (WITH EURO-OBD)] Engine coolant temperature (T) condition 7. 8. When the freeze frame data shows lower than 70 °C (158 °F), T should be lower than 70 °C (158 °F). A When the freeze frame data shows higher than or equal to 70 °C (158 °F), T should be higher than or equal to 70 °C (158 °F). EC If it is difficult to start engine at step 6, the fuel injection system has a malfunction, too. Crank engine while depressing accelerator pedal. If engine starts, go to EC-222, "Diagnostic Procedure" . If engine does not start, check exhaust and intake air leak visually. C WITH GST 1. 2. 3. 4. 5. 6. 7. 8. 9. a. b. Start engine and warm it up to normal operating temperature. Turn ignition switch OFF and wait at least 10 seconds. Disconnect manifold absolute pressure sensor harness connector. Restart engine and let it idle for at least 5 seconds. Stop engine and reconnect manifold absolute pressure sensor harness connector. Select Service $03 with GST. Make sure DTC P0107 is detected. Select Service $04 with GST and erase the DTC P0107. Start engine again and let it idle for at least 10 minutes. MBIB0276E Select Service $07 with GST. The 1st trip DTC P0171 should be detected at this stage, if a malfunction exists. If so, go to EC222, "Diagnostic Procedure" . NOTE: If 1st trip DTC is not detected during above procedure, performing the following procedure is advised. Turn ignition switch OFF and wait at least 10 seconds. Start engine and drive the vehicle under the similar conditions to (1st trip) Freeze Frame Data for 10 minutes. Refer to the table below. Hold the accelerator pedal as steady as possible. The similar conditions to (1st trip) Freeze Frame Data means the vehicle operation that the following conditions should be satisfied at the same time. Engine speed Engine speed in the freeze frame data ± 400 rpm Vehicle speed Vehicle speed in the freeze frame data ± 10 km/h (6 MPH) Engine coolant temperature (T) condition When the freeze frame data shows lower than 70 °C (158 °F), T should be lower than 70 °C (158 °F). When the freeze frame data shows higher than or equal to 70 °C (158 °F), T should be higher than or equal to 70 °C (158 °F). 10. If it is difficult to start engine at step 8, the fuel injection system has a malfunction. 11. Crank engine while depressing accelerator pedal. If engine starts, go to EC-222, "Diagnostic Procedure" . If engine does not start, check exhaust and intake air leak visually. EC-219 D E F G H I J K L M DTC P0171 FUEL INJECTION SYSTEM FUNCTION [CR (WITH EURO-OBD)] Wiring Diagram BBS002XH MBWA1512E EC-220 DTC P0171 FUEL INJECTION SYSTEM FUNCTION [CR (WITH EURO-OBD)] Specification data are reference values and are measured between each terminal and ground. Pulse signal is measured by CONSULT-II. A CAUTION: Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM's transistor. Use a ground other than ECM terminals, such as the ground. EC TERMINAL NO. WIRE COLOR ITEM CONDITION DATA (DC Voltage) C BATTERY VOLTAGE [Engine is running] 22 23 41 42 O L R GR ● Warm-up condition ● Idle speed (11 - 14V) D NOTE: The pulse cycle changes depending on rpm at idle. Fuel injector No. 3 Fuel injector No. 1 Fuel injector No. 4 Fuel injector No. 2 E PBIB0529E BATTERY VOLTAGE F (11 - 14V) [Engine is running] ● Warm-up condition ● Engine speed: 2,000 rpm G H PBIB0530E Approximately 7.0V I [Engine is running] 24 Y Heated oxygen sensor 1 heater ● Warm-up condition ● Engine speed: Below 3,600 rpm J PBIB0519E [Engine is running] ● Engine speed: Above 3,600 rpm BATTERY VOLTAGE (11 - 14V) [Engine is running] 35 BR Heated oxygen sensor 1 ● Warm-up condition ● Engine speed: 2,000 rpm 0 - Approximately 1.0V (Periodically change) [Engine is running] 74 B Sensor ground (Heated oxygen sensor) ● Warm-up condition ● Idle speed : Average voltage for pulse signal (Actual pulse signal can be confirmed by oscilloscope.) EC-221 K L M Approximately 0V DTC P0171 FUEL INJECTION SYSTEM FUNCTION [CR (WITH EURO-OBD)] Diagnostic Procedure BBS002XI 1. CHECK EXHAUST GAS LEAK 1. 2. Start engine and run it at idle. Listen for an exhaust gas leak before three way catalyst (manifold). MBIB0649E OK or NG OK >> GO TO 2. NG >> Repair or replace. 2. CHECK FOR INTAKE AIR LEAK AND PCV HOSE 1. Listen for an intake air leak after the manifold absolute pressure sensor. 2. Check PCV hose connection. OK or NG OK >> GO TO 3. NG >> Repair or replace. 3. CHECK HEATED OXYGEN SENSOR 1 CIRCUIT FOR OPEN AND SHORT 1. 2. 3. 4. Turn ignition switch OFF. Disconnect heated oxygen sensor 1 (HO2S1) harness connector (1). Disconnect ECM harness connector. Check harness continuity between ECM terminal 35 and HO2S1 terminal 4. Refer to Wiring Diagram. Continuity should exist. 5. Check harness continuity between ECM terminal 35 or HO2S1 terminal 4 and ground. Refer to Wiring Diagram. Continuity should not exist. 6. Also check harness for short to power. OK or NG OK >> GO TO 4. NG >> Repair open circuit or short to ground or short to power in harness or connectors. EC-222 MBIB1494E DTC P0171 FUEL INJECTION SYSTEM FUNCTION [CR (WITH EURO-OBD)] 4. CHECK FUEL PRESSURE 1. 2. A Release fuel pressure to zero. Refer to EC-71, "FUEL PRESSURE RELEASE" . Install fuel pressure gauge and check fuel pressure. Refer to EC-72, "FUEL PRESSURE CHECK" . At idling: Approximately 350 kPa (3.5 bar, 3.57 kg/cm2 , 51 psi) EC OK or NG OK >> GO TO 6. NG >> GO TO 5. C 5. DETECT MALFUNCTIONING PART D Check the following. ● Fuel pump and circuit (Refer to EC-427, "FUEL PUMP" .) ● Fuel pressure regulator (Refer to EC-71, "Fuel Pressure Check" .) ● Fuel lines (Refer to EM-32, "FUEL INJECTOR AND FUEL TUBE" .) ● Fuel filter for clogging E F >> Repair or replace. 6. CHECK MANIFOLD ABSOLUTE PRESSUR SENSOR 1. 2. With CONSULT-II Install all removed parts. Check manifold absolute pressure sensor signal with CONSULT-II. Approximately 1.5V: Approximately 1.2V: 1. 2. H I at idling at 2,500 rpm With GST Install all removed parts. Check manifold absolute pressure sensor signal in Service $01 with GST. Approximately 1.5V: Approximately 1.2V: G J K at idling at 2,500 rpm OK or NG OK >> GO TO 7. NG >> Check connectors for rusted terminals or loose connections in the manifold absolute pressure sensor circuit or ground. Refer to EC-155, "DTC P0107, P0108 MANIFOLD ABSOLUTE PRESSURE SENSOR" . EC-223 L M DTC P0171 FUEL INJECTION SYSTEM FUNCTION [CR (WITH EURO-OBD)] 7. CHECK FUNCTION OF FUEL INJECTORS With CONSULT-II Start engine. Perform “POWER BALANCE” in “ACTIVE TEST” mode with CONSULT-II. 3. Make sure that each fuel circuit produces a momentary engine speed drop. 1. 2. MBIB0302E Without CONSULT-II 1. Start engine. 2. Listen to each fuel injector operating sound. Clicking noise should be heard. PBIB1986E OK or NG OK >> GO TO 8. NG >> Perform trouble diagnosis for FUEL INJECTOR, EC-421, "FUEL INJECTOR" . 8. CHECK FUEL INJECTOR 1. 2. 3. 4. 5. 6. Confirm that the engine is cooled down and there are no fire hazards near the vehicle. Turn ignition switch OFF. Remove fuel tube assembly. Refer to EM-32, "FUEL INJECTOR AND FUEL TUBE" . Keep fuel hose and all fuel injectors connected to fuel tube. The fuel injector harness connectors should remain connected. Disconnect all ignition coil harness connectors. Prepare pans or saucers under each fuel injector. Crank engine for about 3 seconds. Make sure that fuel sprays out from fuel injectors. Fuel should be sprayed evenly for each fuel injector. OK or NG OK >> GO TO 9. NG >> Replace fuel injectors from which fuel does not spray out. Always replace O-ring with new ones. PBIB1726E EC-224 DTC P0171 FUEL INJECTION SYSTEM FUNCTION [CR (WITH EURO-OBD)] 9. CHECK INTERMITTENT INCIDENT A Refer to EC-127, "TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT" . EC >> INSPECTION END C D E F G H I J K L M EC-225 DTC P0172 FUEL INJECTION SYSTEM FUNCTION [CR (WITH EURO-OBD)] DTC P0172 FUEL INJECTION SYSTEM FUNCTION On Board Diagnosis Logic PFP:16600 BBS002XJ With the Air/Fuel Mixture Ratio Self-Learning Control, the actual mixture ratio can be brought closely to the theoretical mixture ratio based on the mixture ratio feedback signal from the heated oxygen sensors 1. The ECM calculates the necessary compensation to correct the offset between the actual and the theoretical ratios. In case the amount of the compensation value is extremely large (The actual mixture ratio is too rich.), the ECM judges the condition as the fuel injection system malfunction and lights up the MI (2 trip detection logic). Sensor Heated oxygen sensors 1 DTC No. P0172 0172 Input Signal to ECM Density of oxygen in exhaust gas (Mixture ratio feedback signal) Trouble diagnosis name Fuel injection system too rich ECM function Actuator Fuel injection control DTC detecting condition ● Fuel injection system does not operate properly. ● The amount of mixture ratio compensation is too large. (The mixture ratio is too rich.) Fuel injector Possible cause ● Heated oxygen sensor 1 ● Fuel injector ● Exhaust gas leak ● Incorrect fuel pressure ● Manifold absolute pressure sensor DTC Confirmation Procedure BBS002XK NOTE: If DTC Confirmation Procedure has been previously conducted, always turn ignition switch OFF and wait at least 10 seconds before conducting the next test. WITH CONSULT-II 1. 2. 3. 4. 5. 6. a. b. Start engine and warm it up to normal operating temperature. Turn ignition switch OFF and wait at least 10 seconds. Turn ignition switch ON and select “SELF-LEARNING CONT” in “WORK SUPPORT” mode with CONSULT-II. Clear the self-learning control coefficient by touching “CLEAR”. Select “DATA MONITOR” mode with CONSULT-II. Start engine again and let it idle for at least 10 minutes. The 1st trip DTC P0172 should be detected at this stage, if a malfunction exists. If so, go to EC-230, "Diagnostic Procedure" . NOTE: If 1st trip DTC is not detected during above procedure, performing the following procedure is advised. Turn ignition switch OFF and wait at least 10 seconds. Start engine and drive the vehicle under the similar conditions to SEF215Z (1st trip) Freeze Frame Data for a certain time. Refer to the table below. Hold the accelerator pedal as steady as possible. The similar conditions to (1st trip) Freeze Frame Data means the vehicle operation that the following conditions should be satisfied at the same time. Engine speed Engine speed in the freeze frame data ± 400 rpm Vehicle speed Vehicle speed in the freeze frame data ± 10 km/h (6 MPH) Engine coolant temperature (T) condition 7. 8. When the freeze frame data shows lower than 70 °C (158 °F), T should be lower than 70 °C (158 °F). When the freeze frame data shows higher than or equal to 70 °C (158 °F), T should be higher than or equal to 70 °C (158 °F). If it is difficult to start engine at step 6, the fuel injection system has a malfunction, too. Crank engine while depressing accelerator pedal. EC-226 DTC P0172 FUEL INJECTION SYSTEM FUNCTION [CR (WITH EURO-OBD)] If engine starts, go to EC-230, "Diagnostic Procedure" . If engine does not start, remove spark plugs and check for fouling, etc. A WITH GST 1. 2. 3. 4. 5. 6. 7. 8. a. b. Start engine and warm it up to normal operating temperature. EC Turn ignition switch OFF and wait at least 10 seconds. Disconnect manifold absolute pressure sensor harness connector. Then restart and run engine for at least 5 seconds at idle C speed. Stop engine and reconnect manifold absolute pressure sensor harness connector. D Select Service $03 with GST. Make sure DTC P0107 is detected. Select Service $04 with GST and erase the DTC P0107. E Start engine again and let it idle for at least 10 minutes. Select Service $07 with GST. The 1st trip DTC P0172 should be MBIB0276E detected at this stage, if a malfunction exists. If so, go to ECF 230, "Diagnostic Procedure" . NOTE: If 1st trip DTC is not detected during above procedure, performing the following procedure is advised. G Turn ignition switch OFF and wait at least 10 seconds. Start engine and drive the vehicle under the similar conditions to (1st trip) Freeze Frame Data for a certain time. Refer to the table below. H Hold the accelerator pedal as steady as possible. The similar conditions to (1st trip) Freeze Frame Data means the vehicle operation that the following conditions should be satisfied at the same time. Engine speed Engine speed in the freeze frame data ± 400 rpm Vehicle speed Vehicle speed in the freeze frame data ± 10 km/h (6 MPH) Engine coolant temperature (T) condition When the freeze frame data shows lower than 70 °C (158 °F), T should be lower than 70 °C (158 °F). When the freeze frame data shows higher than or equal to 70 °C (158 °F), T should be higher than or equal to 70 °C (158 °F). 9. If it is difficult to start engine at step 7, the fuel injection system has a malfunction. 10. Crank engine while depressing accelerator pedal. If engine starts, go to EC-230, "Diagnostic Procedure" . If engine does not start, remove ignition plugs and check for fouling, etc. EC-227 I J K L M DTC P0172 FUEL INJECTION SYSTEM FUNCTION [CR (WITH EURO-OBD)] Wiring Diagram BBS002XL MBWA1512E EC-228 DTC P0172 FUEL INJECTION SYSTEM FUNCTION [CR (WITH EURO-OBD)] Specification data are reference values and are measured between each terminal and ground. Pulse signal is measured by CONSULT-II. A CAUTION: Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM's transistor. Use a ground other than ECM terminals, such as the ground. EC TERMINAL NO. WIRE COLOR ITEM CONDITION DATA (DC Voltage) C BATTERY VOLTAGE [Engine is running] 22 23 41 42 O L R GR ● Warm-up condition ● Idle speed (11 - 14V) D NOTE: The pulse cycle changes depending on rpm at idle. Fuel injector No. 3 Fuel injector No. 1 Fuel injector No. 4 Fuel injector No. 2 E PBIB0529E BATTERY VOLTAGE F (11 - 14V) [Engine is running] ● Warm-up condition ● Engine speed: 2,000 rpm G H PBIB0530E Approximately 7.0V I [Engine is running] 24 Y Heated oxygen sensor 1 heater ● Warm-up condition ● Engine speed: Below 3,600 rpm J PBIB0519E [Engine is running] ● Engine speed: Above 3,600 rpm BATTERY VOLTAGE (11 - 14V) [Engine is running] 35 BR Heated oxygen sensor 1 ● Warm-up condition ● Engine speed: 2,000 rpm 0 - Approximately 1.0V (Periodically change) [Engine is running] 74 B Sensor ground (Heated oxygen sensor) ● Warm-up condition ● Idle speed : Average voltage for pulse signal (Actual pulse signal can be confirmed by oscilloscope.) EC-229 K L M Approximately 0V DTC P0172 FUEL INJECTION SYSTEM FUNCTION [CR (WITH EURO-OBD)] Diagnostic Procedure BBS002XM 1. CHECK EXHAUST GAS LEAK 1. 2. Start engine and run it at idle. Listen for an exhaust gas leak before three way catalyst (manifold). MBIB0649E OK or NG OK >> GO TO 2. NG >> Repair or replace. 2. CHECK FOR INTAKE AIR LEAK Listen for an intake air leak after the manifold absolute pressure sensor. OK or NG OK >> GO TO 3. NG >> Repair or replace. 3. CHECK HEATED OXYGEN SENSOR 1 CIRCUIT FOR OPEN AND SHORT 1. 2. 3. 4. Turn ignition switch OFF. Disconnect heated oxygen sensor 1 (HO2S1) harness connector (1). Disconnect ECM harness connector. Check harness continuity between ECM terminal 35 and HO2S1 terminal 4. Refer to Wiring Diagram. Continuity should exist. 5. Check harness continuity between ECM terminal 35 or HO2S1 terminal 4 and ground. Refer to Wiring Diagram. MBIB1494E Continuity should not exist. 6. Also check harness for short to power. OK or NG OK >> GO TO 4. NG >> Repair open circuit or short to ground or short to power in harness or connectors. 4. CHECK FUEL PRESSURE 1. 2. Release fuel pressure to zero. Refer to EC-71, "FUEL PRESSURE RELEASE" . Install fuel pressure gauge and check fuel pressure. Refer to EC-72, "FUEL PRESSURE CHECK" . At idling: 350 kPa (3.5 bar, 3.57 kg/cm2, 51 psi) OK or NG OK >> GO TO 6. NG >> GO TO 5. EC-230 DTC P0172 FUEL INJECTION SYSTEM FUNCTION [CR (WITH EURO-OBD)] 5. DETECT MALFUNCTIONING PART A Check the following. ● Fuel pump and circuit (Refer to EC-427, "FUEL PUMP" .) ● Fuel pressure regulator (Refer to EC-71, "Fuel Pressure Check" .) ● Fuel lines (Refer to EM-32, "FUEL INJECTOR AND FUEL TUBE" .) ● Fuel filter for clogging EC C >> Repair or replace. 6. CHECK MANIFOLD ABSOLUTE PRESSUR SENSOR 1. 2. With CONSULT-II Install all removed parts. Check manifold absolute pressure sensor signal with CONSULT-II. Approximately 1.5V: Approximately 1.2V: at idling at 2,500 rpm E F With GST 1. Install all removed parts. 2. Check manifold absolute pressure sensor signal in Service $01 with GST. Approximately 1.5V: Approximately 1.2V: D G H at idling at 2,500 rpm OK or NG OK >> GO TO 7. NG >> Check connectors for rusted terminals or loose connections in the manifold absolute pressure sensor circuit or ground. Refer to EC-155, "DTC P0107, P0108 MANIFOLD ABSOLUTE PRESSURE SENSOR" . I J K L M EC-231 DTC P0172 FUEL INJECTION SYSTEM FUNCTION [CR (WITH EURO-OBD)] 7. CHECK FUNCTION OF FUEL INJECTORS With CONSULT-II Start engine. Perform “POWER BALANCE” in “ACTIVE TEST” mode with CONSULT-II. 3. Make sure that each circuit produces a momentary engine speed drop. 1. 2. MBIB0302E Without CONSULT-II 1. Start engine. 2. Listen to each fuel injector operating sound. Clicking noise should be heard. PBIB1986E OK or NG OK >> GO TO 8. NG >> Perform trouble diagnosis for FUEL INJECTOR, refer to EC-421, "FUEL INJECTOR" . 8. CHECK FUEL INJECTOR Remove fuel injector assembly. Refer to EM-32, "FUEL INJECTOR AND FUEL TUBE" . Keep fuel hose and all fuel injectors connected to fuel tube. 2. Confirm that the engine is cooled down and there are no fire hazards near the vehicle. 3. Disconnect fuel injector harness connectors. 4. Disconnect all ignition coil harness connectors. 5. Prepare pans or saucers under each fuel injectors. 6. Crank engine for about 3 seconds. Make sure fuel does not drip from fuel injector. OK or NG OK (Does not drip.)>>GO TO 9. NG (Drips.)>>Replace the fuel injectors from which fuel is dripping. Always replace O-ring with new one. 1. 9. CHECK INTERMITTENT INCIDENT Refer to EC-127, "TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT" . >> INSPECTION END EC-232 DTC P0222, P0223 TP SENSOR [CR (WITH EURO-OBD)] DTC P0222, P0223 TP SENSOR Component Description PFP:16119 A BBS002XN Electric throttle control actuator consists of throttle control motor, throttle position sensor, etc. The throttle position sensor responds to the throttle valve movement. The throttle position sensor has the two sensors. These sensors are a kind of potentiometers which transform the throttle valve position into output voltage, and emit the voltage signal to the ECM. In addition, these sensors detect the opening and closing speed of the throttle valve and feed the voltage signals to the ECM. The ECM judges the current opening angle of the throttle valve from these signals and the ECM controls the throttle control motor to make the throttle valve opening angle properly in response to driving condition. EC C D PBIB0145E E CONSULT-II Reference Value in Data Monitor Mode BBS002XO Specification data are reference values. MONITOR ITEM CONDITION ● Ignition switch: ON (Engine stopped) Accelerator pedal: Fully released More than 0.36V ● Shift lever: 1st Accelerator pedal: Fully depressed Less than 4.75V THRTL SEN 1 THRTL SEN 2* F SPECIFICATION G *: Throttle position sensor 2 signal is converted by ECM internally. Thus, it differs from ECM terminal voltage signal. On Board Diagnosis Logic BBS002XP H These self-diagnoses have the one trip detection logic. DTC No. P0222 0222 P0223 0223 Trouble diagnosis name DTC detecting condition Throttle position sensor 1 circuit low input An excessively low voltage from the TP sensor 1 is sent to ECM. Throttle position sensor 1 circuit high input Possible cause ● Harness or connectors (TP sensor 1 circuit is open or shorted.) (APP sensor 2 circuit is shorted.) ● Electric throttle control actuator (TP sensor 1) ● Accelerator pedal position sensor (APP sensor 2) An excessively high voltage from the TP sensor 1 is sent to ECM. FAIL-SAFE MODE I J K L When the malfunction is detected, the ECM enters fail-safe mode and the MI lights up. Engine operation condition in fail-safe mode The ECM controls the electric throttle control actuator in regulating the throttle opening in order for the idle position to be within +10 degrees. The ECM regulates the opening speed of the throttle valve to be slower than the normal condition. So, the acceleration will be poor. EC-233 M DTC P0222, P0223 TP SENSOR [CR (WITH EURO-OBD)] DTC Confirmation Procedure BBS002XQ NOTE: If DTC Confirmation Procedure has been previously conducted, always turn ignition switch OFF and wait at least 10 seconds before conducting the next test. TESTING CONDITION: Before performing the following procedure, confirm that battery voltage is more than 10V at idle. WITH CONSULT-II 1. 2. 3. 4. Turn ignition switch ON. Select “DATA MONITOR” mode with CONSULT-II. Start engine and let it idle for 1 second. If DTC is detected, go to EC-236, "Diagnostic Procedure" . SEF058Y WITH GST Follow the procedure “WITH CONSULT-II” above. EC-234 DTC P0222, P0223 TP SENSOR [CR (WITH EURO-OBD)] Wiring Diagram BBS002XR A EC C D E F G H I J K L M MBWA1513E EC-235 DTC P0222, P0223 TP SENSOR [CR (WITH EURO-OBD)] Specification data are reference values and are measured between each terminal and ground. CAUTION: Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM's transistor. Use a ground other than ECM terminals, such as the ground. TERMINAL NO. 47 WIRE COLOR L ITEM CONDITION Sensor power supply (Throttle position sensor) DATA (DC Voltage) [Ignition switch: ON] Approximately 5V [Ignition switch: ON] 49 Y ● Engine stopped ● Shift lever position: 1st ● Accelerator pedal: Fully released Throttle position sensor 1 More than 0.36V [Ignition switch: ON] ● Engine stopped ● Shift lever position: 1st ● Accelerator pedal: Fully depressed Less than 4.75V [Engine is running] 66 B Sensor ground (Throttle position sensor) ● Warm-up condition ● Idle speed Approximately 0V [Ignition switch: ON] 68 91 R BR Throttle position sensor 2 Sensor power supply (APP sensor 2) ● Engine stopped ● Shift lever position: 1st ● Accelerator pedal: Fully released Less than 4.75V [Ignition switch: ON] ● Engine stopped ● Shift lever position: 1st ● Accelerator pedal: Fully depressed More than 0.36V [Ignition switch ON] Approximately 5V Diagnostic Procedure BBS002XS 1. RETIGHTEN GROUND CONNECTIONS 1. 2. Turn ignition switch OFF. Loosen and retighten ground screws on the body. Refer to EC-133, "Ground Inspection" . MBIB1502E 1. Body ground E44 2. Body ground E45 OK or NG OK >> GO TO 2. NG >> Repair or replace ground connections. EC-236 3. Body ground E28 DTC P0222, P0223 TP SENSOR [CR (WITH EURO-OBD)] 2. CHECK THROTTLE POSITION SENSOR 1 POWER SUPPLY CIRCUIT-I 1. 2. A Disconnect electric throttle control actuator harness connector. Turn ignition switch ON. EC C D MBIB0308E 3. Check voltage between electric throttle control actuator terminal 1 and ground with CONSULT-II or tester. E Voltage: Approximately 5V F OK or NG OK >> GO TO 7. NG >> GO TO 3. G PBIB0082E H 3. CHECK THROTTLE POSITION SENSOR 1 POWER SUPPLY CIRCUIT-II 1. 2. 3. Turn ignition switch OFF. Disconnect ECM harness connector. Check harness continuity between electric throttle control actuator terminal 1 and ECM terminal 47. Refer to Wiring Diagram. I J Continuity should exist. K OK or NG OK >> GO TO 4. NG >> Repair open circuit. 4. CHECK THROTTLE POSITION SENSOR 1 POWER SUPPLY CIRCUIT-III Check harness for short to power and short to ground, between the following terminals. ECM terminal Sensor terminal Reference Wiring Diagram 47 Electric throttle control actuator terminal 1 EC-235 91 APP sensor terminal 5 EC-394 OK or NG OK >> GO TO 5. NG >> Repair short to ground or short to power in harness or connectors. 5. CHECK APP SENSOR Refer to EC-400, "Component Inspection" . OK or NG OK >> GO TO 11 NG >> GO TO 6. EC-237 L M DTC P0222, P0223 TP SENSOR [CR (WITH EURO-OBD)] 6. REPLACE ACCELERATOR PEDAL ASSEMBLY 1. 2. 3. 4. Replace accelerator pedal assembly. Perform EC-69, "Accelerator Pedal Released Position Learning" . Perform EC-69, "Throttle Valve Closed Position Learning" . Perform EC-69, "Idle Air Volume Learning" . >> INSPECTION END 7. CHECK THROTTLE POSITION SENSOR 1 GROUND CIRCUIT FOR OPEN AND SHORT 1. 2. 3. Turn ignition switch OFF. Disconnect ECM harness connector. Check harness continuity between ECM terminal 66 and electric throttle control actuator terminal 5. Refer to Wiring Diagram. Continuity should exist. 4. Also check harness for short to ground and short to power. OK or NG OK >> GO TO 8. NG >> Repair open circuit or short to ground or short to power in harness or connectors. 8. CHECK THROTTLE POSITION SENSOR 1 INPUT SIGNAL CIRCUIT FOR OPEN AND SHORT 1. Check harness continuity between ECM terminal 49 and electric throttle control actuator terminal 4. Refer to Wiring Diagram. Continuity should exist. 2. Also check harness for short to ground and short to power. OK or NG OK >> GO TO 9. NG >> Repair open circuit or short to ground or short to power in harness or connectors. 9. CHECK THROTTLE POSITION SENSOR Refer to EC-239, "Component Inspection" . OK or NG OK >> GO TO 11. NG >> GO TO 10. 10. REPLACE ELECTRIC THROTTLE CONTROL ACTUATOR 1. 2. 3. Replace the electric throttle control actuator. Perform EC-69, "Throttle Valve Closed Position Learning" . Perform EC-69, "Idle Air Volume Learning" . >> INSPECTION END 11. CHECK INTERMITTENT INCIDENT Refer to EC-127, "TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT" . >> INSPECTION END EC-238 DTC P0222, P0223 TP SENSOR [CR (WITH EURO-OBD)] Component Inspection BBS002XT A THROTTLE POSITION SENSOR 1. 2. 3. 4. 5. Reconnect all harness connectors disconnected. Perform EC-69, "Throttle Valve Closed Position Learning" . Turn ignition switch ON. Set shift lever to 1st position. Check voltage between ECM terminals 49 (TP sensor 1 signal), 68 (TP sensor 2 signal) and ground under the following conditions. Terminal Accelerator pedal Voltage 49 (Throttle position sensor 1) Fully released More than 0.36V 68 (Throttle position sensor 2) 6. 7. 8. Fully depressed Less than 4.75V Fully released Less than 4.75V Fully depressed More than 0.36V If NG, replace electric throttle control actuator and go to the next step. Perform EC-69, "Throttle Valve Closed Position Learning" . Perform EC-69, "Idle Air Volume Learning" . Removal and Installation EC C D E MBIB1443E F G BBS002XU ELECTRIC THROTTLE CONTROL ACTUATOR Refer to EM-18, "AIR CLEANER AND AIR DUCT" . H I J K L M EC-239 DTC P0300 - P0304 MULTIPLE CYLINDER MISFIRE, NO. 1 - 4 CYLINDER MISFIRE [CR (WITH EURO-OBD)] DTC P0300 - P0304 MULTIPLE CYLINDER MISFIRE, NO. 1 - 4 CYLINDER MISFIRE PFP:00000 On Board Diagnosis Logic BBS002XV When a misfire occurs, engine speed will fluctuate. If the engine speed fluctuates enough to cause the crankshaft position (CKP) sensor (POS) signal to vary, ECM can determine that a misfire is occurring. Sensor Crankshaft position sensor (POS) Input Signal to ECM Engine speed ECM Function On board diagnosis of misfire The misfire detection logic consists of the following two conditions. 1. One Trip Detection Logic (Three Way Catalyst Damage) On the first trip that a misfire condition occurs that can damage the three way catalyst (TWC) due to overheating, the MI will blink. When a misfire condition occurs, the ECM monitors the CKP sensor (POS) signal every 200 engine revolutions for a change. When the misfire condition decreases to a level that will not damage the TWC, the MI will turn off. If another misfire condition occurs that can damage the TWC on a second trip, the MI will blink. When the misfire condition decreases to a level that will not damage the TWC, the MI will remain on. If another misfire condition occurs that can damage the TWC, the MI will begin to blink again. 2. Two Trip Detection Logic (Exhaust quality deterioration) For misfire conditions that will not damage the TWC (but will affect vehicle emissions), the MI will only light when the misfire is detected on a second trip. During this condition, the ECM monitors the CKP sensor signal every 1,000 engine revolutions. A misfire malfunction can be detected on any one cylinder or on multiple cylinders. DTC No. Trouble diagnosis name DTC detecting condition P0300 0300 Multiple cylinder misfire detected Multiple cylinder misfire. P0301 0301 No.1 cylinder misfire detected No. 1 cylinder misfires. P0302 0302 No. 2 cylinder misfire detected No. 2 cylinder misfires. P0303 0303 No. 3 cylinder misfire detected P0304 0304 No. 4 cylinder misfire detected No. 3 cylinder misfires. No. 4 cylinder misfires. DTC Confirmation Procedure Possible cause ● Improper spark plug ● Insufficient compression ● Incorrect fuel pressure ● The fuel injector circuit is open or shorted ● Fuel injector ● Intake air leak ● The ignition signal circuit is open or shorted ● Lack of fuel ● Drive plate or flywheel ● Heated oxygen sensor 1 ● Incorrect PCV hose connection BBS002XW CAUTION: Always drive vehicle in safe manner according to traffic conditions and obey all traffic laws when driving. NOTE: If DTC Confirmation Procedure has been previously conducted, always turn ignition switch OFF and wait at least 10 seconds before conducting the next test. EC-240 DTC P0300 - P0304 MULTIPLE CYLINDER MISFIRE, NO. 1 - 4 CYLINDER MISFIRE [CR (WITH EURO-OBD)] WITH CONSULT-II 1. 2. 3. 4. 5. a. b. A Turn ignition switch ON, and select “DATA MONITOR” mode with CONSULT-II. Start engine and warm it up to normal operating temperature. EC Turn ignition switch OFF and wait at least 10 seconds. Restart engine and let it idle for about 15 minutes. If 1st trip DTC is detected, go to EC-241, "Diagnostic Procedure" C . NOTE: If 1st trip DTC is not detected during above procedure, performD ing the following procedure is advised. PBIB0164E Turn ignition switch OFF and wait at least 10 seconds. Start engine and drive the vehicle under the similar conditions to (1st trip) Freeze Frame Data for a certain E time. Refer to the table below. Hold the accelerator pedal as steady as possible. The similar conditions to (1st trip) Freeze Frame Data means the vehicle operation that the following conditions should be satisfied at the same time. Engine speed Engine speed in the freeze frame data ± 400 rpm Vehicle speed Vehicle speed in the feaze frame data ± 10 km/h (6 MPH) Engine coolant temperature (T) condition F G When the freeze frame data shows lower than 70 °C (158 °F), T should be lower than 70 °C (158 °F). H When the freeze frame data shows higher than or equal to 70 °C (158 °F), T should be higher than or equal to 70 °C (158 °F). I The time to driving varies according to the engine speed in the freeze frame data. Engine speed Time J Around 1,000 rpm Approximately 10 minutes Around 2,000 rpm Approximately 5 minutes More than 3,000 rpm Approximately 3.5 minutes K WITH GST Follow the procedure “WITH CONSULT-II” above. L Diagnostic Procedure BBS002XX 1. CHECK FOR INTAKE AIR LEAK AND PCV HOSE M 1. Start engine and run it at idle speed. 2. Listen for the sound of the intake air leak. 3. Check PCV hose connection. OK or NG OK >> GO TO 2. NG >> Repair or replace. 2. CHECK FOR EXHAUST SYSTEM CLOGGING Stop engine and visually check exhaust tube, three way catalyst and muffler for dents. OK or NG OK >> GO TO 3. NG >> Repair or replace. EC-241 DTC P0300 - P0304 MULTIPLE CYLINDER MISFIRE, NO. 1 - 4 CYLINDER MISFIRE [CR (WITH EURO-OBD)] 3. PERFORM POWER BALANCE TEST 1. 2. With CONSULT-II Perform “POWER BALANCE” in “ACTIVE TEST” mode. Is there any cylinder which does not produce a momentary engine speed drop? MBIB0302E Without CONSULT-II When disconnecting each fuel injector harness connector (1) one at a time, is there any cylinder which does not produce a momentary engine speed drop? ● : Vehicle front MBIB1458E Yes or No Yes >> GO TO 4. No >> GO TO 9. 4. CHECK FUEL INJECTOR Does each fuel injector make an operating sound at idle? Yes or No Yes >> GO TO 5. No >> Check fuel injector(s) and circuit(s). Refer to EC-421, "FUEL INJECTOR" . PBIB1986E EC-242 DTC P0300 - P0304 MULTIPLE CYLINDER MISFIRE, NO. 1 - 4 CYLINDER MISFIRE [CR (WITH EURO-OBD)] 5. CHECK FUNCTION OF IGNITION COIL-I A CAUTION: Do the following procedure in the place where ventilation is good without the combustibles. 1. Turn ignition switch OFF. 2. Remove fuel pump fuse in IPDM E/R to release fuel pressure. NOTE: Do not use CONSULT-II to release fuel pressure, or fuel pressure applies again during the following procedure. 3. Start engine. 4. After engine stalls, crank it two or three times to release all fuel pressure. 5. Turn ignition switch ON. 6. Remove all ignition coil harness connectors to avoid the electrical discharge from the ignition coils. 7. Remove ignition coil and spark plug of the cylinder to be checked. 8. Crank engine for five seconds or more to remove combustion gas in the cylinder. 9. Connect spark plug and harness connector to ignition coil. 10. Fix ignition coil using a rope etc. with gap of 13 - 17 mm between the edge of the spark plug and grounded metal portion as shown in the figure. 11. Crank engine for about three seconds, and check whether spark is generated between the spark plug and the grounded metal portion. EC C D E MBIB0277E G H I Spark should be generated. CAUTION: ● Do not approach to the spark plug and the ignition coil within 50cm. Be careful not to get an electrical shock PBIB2325E while checking, because the electrical discharge voltage becomes 20kV or more. ● It might cause to damage the ignition coil if the gap of more than 17 mm is taken. NOTE: When the gap is less than 13 mm, the spark might be generated even if the coil is malfunctioning. OK or NG OK >> GO TO 9. NG >> GO TO 6. J K L M 6. CHECK FUNCTION OF IGNITION COIL-II 1. 2. 3. F Turn ignition switch OFF. Disconnect spark plug and connect a known-good spark plug. Crank engine for about three seconds, and recheck whether spark is generated between the spark plug and the grounded metal portion. Spark should be generated. OK or NG OK >> GO TO 7. NG >> Check ignition coil, power transistor and their circuits, Refer to EC-433, "IGNITION SIGNAL" . EC-243 DTC P0300 - P0304 MULTIPLE CYLINDER MISFIRE, NO. 1 - 4 CYLINDER MISFIRE [CR (WITH EURO-OBD)] 7. CHECK SPARK PLUGS Check the initial spark plug for fouling, etc. OK or NG OK >> Replace spark plug(s) with standard type one(s). For spark plug type, refer to MA-36, "Changing Spark Plugs" . NG >> 1. Repair or clean spark plug. 2. GO TO 8. SEF156I 8. CHECK FUNCTION OF IGNITION COIL-III 1. 2. Reconnect the initial spark plugs. Crank engine for about three seconds, and recheck whether spark is generated between the spark plug and the grounded portion. Spark should be generated. OK or NG OK >> INSPECTION END NG >> Replace spark plug(s) with standard type one(s). For spark plug type, refer to MA-36, "Changing Spark Plugs" . 9. CHECK COMPRESSION PRESSURE Check compression pressure. Refer to EM-60, "COMPRESSION PRESSURE INSPECTION" . OK or NG OK >> GO TO 10. NG >> Check pistons, piston rings, valves, valve seats and cylinder head gaskets. 10. CHECK FUEL PRESSURE 1. 2. 3. Install all removed parts. Release fuel pressure to zero. Refer to EC-71, "FUEL PRESSURE RELEASE" . Install fuel pressure gauge and check fuel pressure. Refer to EC-72, "FUEL PRESSURE CHECK" . At idle: Approx. 350 kPa (3.5 bar, 3.57 kg/cm2 , 51 psi) OK or NG OK >> GO TO 12. NG >> GO TO 11. 11. DETECT MALFUNCTIONING PART Check the following. Fuel pump and circuit (Refer to EC-427, "FUEL PUMP" .) ● Fuel pressure regulator (Refer to EC-71, "Fuel Pressure Check" .) ● Fuel lines (Refer to EM-32, "FUEL INJECTOR AND FUEL TUBE" .) ● Fuel filter for clogging ● >> Repair or replace. EC-244 DTC P0300 - P0304 MULTIPLE CYLINDER MISFIRE, NO. 1 - 4 CYLINDER MISFIRE [CR (WITH EURO-OBD)] 12. CHECK HEATED OXYGEN SENSOR 1 A Refer to EC-183, "Component Inspection" . OK or NG OK >> GO TO 13. NG >> Replace heated oxygen sensor 1. EC 13. CHECK MANIFOLD ABSOLUTE PRESSUR SENSOR With CONSULT-II Check manifold absolute pressure sensor signal in “DATA MONITOR” mode with CONSULT-II. Approximately 1.5V: Approximately 1.2V: D at idling at 2,500 rpm With GST Check manifold absolute pressure sensor signal in Service $01 with GST. Approximately 1.5V: Approximately 1.2V: C at idling at 2,500 rpm E F OK or NG OK >> GO TO 14. NG >> Check connectors for rusted terminals or loose connections in the manifold absolute pressure sensor circuit or ground. Refer to EC-155, "DTC P0107, P0108 MANIFOLD ABSOLUTE PRESSURE SENSOR" . G H 14. CHECK SYMPTOM MATRIX CHART Check items on the rough idle symptom in EC-82, "Symptom Matrix Chart" . OK or NG OK >> GO TO 15. NG >> Repair or replace. I J 15. ERASE THE 1ST TRIP DTC Some tests may cause a 1st trip DTC to be set. Erase the 1st trip DTC from the ECM memory after performing the tests. Refer to EC-57, "HOW TO ERASE EMISSION-RELATED DIAGNOSTIC INFORMATION" . K L >> GO TO 16. 16. CHECK INTERMITTENT INCIDENT M Refer to EC-127, "TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT" . >> INSPECTION END EC-245 DTC P0327, P0328 KS [CR (WITH EURO-OBD)] DTC P0327, P0328 KS Component Description PFP:22060 BBS002XY The knock sensor is attached to the cylinder block. It senses engine knocking using a piezoelectric element. A knocking vibration from the cylinder block is sensed as vibrational pressure. This pressure is converted into a voltage signal and sent to the ECM. MBIB0306E On Board Diagnosis Logic BBS002XZ The MI will not light up for these self-diagnoses. DTC No. Trouble Diagnosis Name DTC Detected Condition Possible Cause P0327 0327 Knock sensor circuit low input An excessively low voltage from the sensor is sent to ECM. ● Harness or connectors (The sensor circuit is open or shorted.) P0328 0328 Knock sensor circuit high input An excessively high voltage from the sensor is sent to ECM. ● Knock sensor DTC Confirmation Procedure BBS002Y0 NOTE: If DTC Confirmation Procedure has been previously conducted, always turn ignition switch OFF and wait at least 10 seconds before conducting the next test. TESTING CONDITION: Before performing the following procedure, confirm that battery voltage is more than 10V at idle. WITH CONSULT-II 1. 2. 3. Turn ignition switch ON and select “DATA MONITOR” mode with CONSULT-II. Start engine and run it for at least 5 seconds at idle speed. If 1st trip DTC is detected, go to EC-248, "Diagnostic Procedure" . SEF058Y WITH GST Follow the procedure “WITH CONSULT-II” above. EC-246 DTC P0327, P0328 KS [CR (WITH EURO-OBD)] Wiring Diagram BBS002Y1 A EC C D E F G H I J K L M MBWA0571E EC-247 DTC P0327, P0328 KS [CR (WITH EURO-OBD)] Specification data are reference values and are measured between each terminal and ground. CAUTION: Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM's transistor. Use a ground other than ECM terminals, such as the ground. TERMINAL NO. 15 WIRE COLOR W ITEM Knock sensor CONDITION [Engine is running] ● Idle speed DATA (DC Voltage) Approximately 2.5V [Engine is running] 54 — Sensor ground (Knock sensor) ● Warm-up condition ● Idle speed Approximately 0V Diagnostic Procedure BBS002Y2 1. CHECK KNOCK SENSOR INPUT SIGNAL CIRCUIT-I 1. 2. 3. Turn ignition switch OFF. Disconnect ECM harness connector. Check resistance between ECM terminal 15 and ground. Refer to Wiring Diagram. NOTE: It is necessary to use an ohmmeter which can measure more than 10 MΩ. Resistance: Approximately 530 - 590kΩ [at 20°C (68°F)] 4. Also check harness for short to ground and short to power. OK or NG OK >> GO TO 4. NG >> GO TO 2. 2. CHECK KNOCK SENSOR INPUT SIGNAL CIRCUIT-II 1. 2. Disconnect knock sensor harness connector. Check harness continuity between ECM terminal 15 and knock sensor terminal 2. Refer to Wiring Diagram. Continuity should exist. 3. Also check harness for short to ground and short to power. OK or NG OK >> GO TO 3. NG >> Repair open circuit or short to ground or short to power in harness or connectors. 3. CHECK KNOCK SENSOR Refer to EC-249, "Component Inspection" . OK or NG OK >> GO TO 6. NG >> Replace knock sensor. EC-248 MBIB0306E DTC P0327, P0328 KS [CR (WITH EURO-OBD)] 4. CHECK GROUND CONNECTIONS 1. A Loosen and retighten ground screws on the body. Refer to EC-133, "Ground Inspection" . EC C D MBIB1502E 1. Body ground E44 2. Body ground E45 3. E Body ground E28 OK or NG OK >> GO TO 5. NG >> Repair or replace ground connections. F 5. CHECK KNOCK SENSOR SHIELD CIRCUIT FOR OPEN AND SHORT G 1. Check harness continuity between ECM terminal 54 and knock sensor terminal 1. Refer to Wiring Diagram. H Continuity should exist 2. Also check harness for short to ground and short to power. OK or NG OK >> GO TO 6. NG >> Repair open circuit or short to ground or short to power in harness or connectors. I J 6. CHECK INTERMITTENT INCIDENT K Refer to EC-127, "TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT" . >> INSPECTION END L Component Inspection BBS002Y3 KNOCK SENSOR Check resistance between knock sensor terminal 2 and ground. NOTE: It is necessary to use an ohmmeter which can measure more than 10 MΩ. M Resistance: Approximately 530 - 590kΩ [at 20°C (68°F)] CAUTION: Do not use any knock sensors that have been dropped or physically damaged. Use only new ones. PBIB0253E Removal and Installation BBS002Y4 KNOCK SENSOR Refer to EM-74, "CYLINDER BLOCK" . EC-249 DTC P0335 CKP SENSOR (POS) [CR (WITH EURO-OBD)] DTC P0335 CKP SENSOR (POS) Component Description PFP:23731 BBS002Y5 The crankshaft position sensor (POS) is located on the cylinder block rear housing facing the gear teeth (cogs) of the signal plate at the end of the crankshaft. It detects the fluctuation of the engine revolution. The sensor consists of a permanent magnet and Hall IC. When the engine is running, the high and low parts of the teeth cause the gap with the sensor to change. The changing gap causes the magnetic field near the sensor to change. Due to the changing magnetic field, the voltage from the sensor changes. The ECM receives the voltage signal and detects the fluctuation of the engine revolution. ECM receives the signals as shown in the figure. PBIB0562E PBIB2382E CONSULT-II Reference Value in Data Monitor Mode BBS002Y6 Specification data are reference values. MONITOR ITEM ENG SPEED CONDITION ● SPECIFICATION Run engine and compare CONSULT-II value with the tachometer indication. Almost the same speed as the tachometer indication. On Board Diagnosis Logic DTC No. Trouble diagnosis name DTC detecting condition ● P0335 0335 Crankshaft position sensor (POS) circuit BBS002Y7 ● ● The crankshaft position sensor (POS) signal is not detected by the ECM during the first few seconds of engine cranking. The proper pulse signal from the crankshaft position sensor (POS) is not sent to ECM while the engine is running. The crankshaft position sensor (POS) signal is not in the normal pattern during engine running. DTC Confirmation Procedure Possible cause ● Harness or connectors (The sensor circuit is open or shorted.) ● Crankshaft position sensor (POS) ● Signal plate BBS002Y8 NOTE: If DTC Confirmation Procedure has been previously conducted, always turn ignition switch OFF and wait at least 10 seconds before conducting the next test. TESTING CONDITION: Before performing the following procedure, confirm that battery voltage is more than 10.5V with ignition switch ON. EC-250 DTC P0335 CKP SENSOR (POS) [CR (WITH EURO-OBD)] WITH CONSULT-II 1. 2. 3. A Turn ignition switch ON and select “DATA MONITOR” mode with CONSULT-II. Crank engine for at least 2 seconds and run it for at least 5 seconds at idle speed. If 1st trip DTC is detected, go to EC-254, "Diagnostic Procedure" . EC C SEF058Y D WITH GST Follow the procedure “WITH CONSULT-II” above. E F G H I J K L M EC-251 DTC P0335 CKP SENSOR (POS) [CR (WITH EURO-OBD)] Wiring Diagram BBS002Y9 MBWA1515E EC-252 DTC P0335 CKP SENSOR (POS) [CR (WITH EURO-OBD)] Specification data are reference values and are measured between each terminal and ground. Pulse signal is measured by CONSULT-II. A CAUTION: Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM's transistor. Use a ground other than ECM terminals, such as the ground. EC TERMINAL NO. WIRE COLOR ITEM CONDITION DATA (DC Voltage) C [Engine is running] ● Warm-up condition ● Idle speed Approximately 3.0V D NOTE: The pulse cycle changes depending on rpm at idle. 13 Y E PBIB0527E Crankshaft position sensor (POS) Approximately 3.0V F [Engine is running] ● Engine speed: 2,000 rpm G PBIB0528E 30 L Sensor ground (Crankshaft position sensor) ● Warm-up condition ● Idle speed ● P ECM relay (Self shut-off) For a few seconds after turning ignition switch OFF [Ignition switch: OFF] ● 119 120 G G Power supply for ECM Approximately 0V I [Engine is running] [Ignition switch: OFF] 111 H [Engine is running] More than a few seconds passed after turning ignition switch OFF [Ignition switch: ON] 0 - 1.0V J BATTERY VOLTAGE (11 - 14V) BATTERY VOLTAGE (11 - 14V) K L : Average voltage for pulse signal (Actual pulse signal can be confirmed by oscilloscope.) M EC-253 DTC P0335 CKP SENSOR (POS) [CR (WITH EURO-OBD)] Diagnostic Procedure BBS002YA 1. CHECK GROUND CONNECTIONS 1. 2. Turn ignition switch OFF. Loosen and retighten ground screws on the body. Refer to EC-133, "Ground Inspection" . MBIB1502E 1. Body ground E44 2. Body ground E45 3. Body ground E28 OK or NG OK >> GO TO 2. NG >> Repair or replace ground connections. 2. CHECK CRANKSHAFT POSITION (CKP) SENSOR (POS) POWER SUPPLY CIRCUIT 1. 2. Disconnect crankshaft position (CKP) sensor (POS) harness connector. Turn ignition switch ON. MBIB1078E 3. Check voltage between CKP sensor (POS) terminal 3 and ground with CONSULT-II or tester. Voltage: Battery voltage OK or NG OK >> GO TO 4. NG >> GO TO 3. SEF479Y 3. DETECT MALFUNCTIONING PART Check the following. ● Harness connectors F1, E48 ● Harness for open or short between crankshaft position sensor (POS) and ECM ● Harness for open or short between crankshaft position sensor (POS) and IPDM E/R >> Repair open circuit or short to ground or short to power in harness or connectors. EC-254 DTC P0335 CKP SENSOR (POS) [CR (WITH EURO-OBD)] 4. CHECK CKP SENSOR (POS) GROUND CIRCUIT FOR OPEN AND SHORT 1. 2. 3. Turn ignition switch OFF. Disconnect ECM harness connector. Check harness continuity between ECM terminal 30 and CKP sensor (POS) terminal 1. Refer to Wiring Diagram. Continuity should exist. EC C 4. Also check harness for short to ground and short to power. OK or NG OK >> GO TO 5. NG >> Repair open circuit or short to ground or short to power in harness or connectors. 5. CHECK CKP SENSOR (POS) INPUT SIGNAL CIRCUIT FOR OPEN AND SHORT 1. A D E Check harness continuity between ECM terminal 13 and CKP sensor (POS) terminal 2. Refer to Wiring Diagram. F Continuity should exist. 2. Also check harness for short to ground and short to power. OK or NG OK >> GO TO 6. NG >> Repair open circuit or short to ground or short to power in harness or connectors. 6. CHECK CRANKSHAFT POSITION SENSOR (POS) Refer to EC-256, "Component Inspection" . OK or NG OK >> GO TO 7. NG >> Replace crankshaft position sensor (POS). G H I J 7. CHECK GEAR TOOTH Visually check for chipping signal plate gear tooth. OK or NG OK >> GO TO 8. NG >> Replace the signal plate. K L 8. CHECK INTERMITTENT INCIDENT Refer to EC-127, "TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT" . >> INSPECTION END EC-255 M DTC P0335 CKP SENSOR (POS) [CR (WITH EURO-OBD)] Component Inspection BBS002YB CRANKSHAFT POSITION SENSOR (POS) 1. 2. 3. 4. Loosen the fixing bolt of the sensor. Disconnect crankshaft position sensor (POS) harness connector. Remove the sensor. Visually check the sensor for chipping. PBIB0563E 5. Check resistance as shown in the figure. Terminal No. (Polarity) Resistance Ω [at 25°C (77°F)] 3 (+) - 1 (-) 3 (+) - 2 (-) Except 0 or ∞ 2 (+) - 1 (-) 6. If NG, replace crankshaft position sensor (POS). MBIB0024E Removal and Installation BBS002YC CRANKSHAFT POSITION SENSOR (POS) Refer to EM-74, "CYLINDER BLOCK" . EC-256 DTC P0340 CMP SENSOR (PHASE) [CR (WITH EURO-OBD)] DTC P0340 CMP SENSOR (PHASE) Component Description PFP:23731 A BBS002YD The camshaft position sensor (PHASE) senses the retraction of camshaft (intake) to identify a particular cylinder. The camshaft position sensor (PHASE) senses the piston position. When the crankshaft position sensor (POS) system becomes inoperative, the camshaft position sensor (PHASE) provides various controls of engine parts instead, utilizing timing of cylinder identification signals. The sensor consists of a permanent magnet and Hall IC. When engine is running, the high and low parts of the teeth cause the gap with the sensor to change. The changing gap causes the magnetic field near the sensor to change. Due to the changing magnetic field, the voltage from the sensor changes. ECM receives the signals as shown in the figure. EC C D PBIB0562E E F G H PBIB2382E I On Board Diagnosis Logic DTC No. Trouble diagnosis name DTC detecting condition ● P0340 0340 Camshaft position sensor (PHASE) circuit BBS002YE The cylinder No. signal is not sent to ECM for the first few seconds during engine cranking. Possible cause J ● Harness or connectors (The sensor circuit is open or shorted.) ● Camshaft position sensor (PHASE) Camshaft (Intake) ● The cylinder No. signal is not set to ECM during engine running. ● ● Starter motor (Refer to SC-45 .) ● The cylinder No. signal is not in the normal pattern during engine running. ● Starting system circuit (Refer to SC-45 .) ● Dead (Weak) battery DTC Confirmation Procedure BBS002YF NOTE: If DTC Confirmation Procedure has been previously conducted, always turn ignition switch OFF and wait at least 10 seconds before conducting the next test. TESTING CONDITION: Before performing the following procedure, confirm that battery voltage is more than 10.5V with ignition switch ON. WITH CONSULT-II 1. Turn ignition switch ON. EC-257 K L M DTC P0340 CMP SENSOR (PHASE) [CR (WITH EURO-OBD)] 2. 3. 4. 5. 6. Select “DATA MONITOR” mode with CONSULT-II. Crank engine for at least 2 seconds and run it for at least 5 seconds at idle speed. If 1st trip DTC is detected, go to EC-260, "Diagnostic Procedure" . If 1st trip DTC is not detected, go to next step. Maintain engine speed at more than 800 rpm for at least 5 seconds. If 1st trip DTC is detected, go to EC-260, "Diagnostic Procedure" . WITH GST Follow the procedure “WITH CONSULT-II” above. EC-258 SEF058Y DTC P0340 CMP SENSOR (PHASE) [CR (WITH EURO-OBD)] Wiring Diagram BBS002YG A EC C D E F G H I J K L M MBWA1516E EC-259 DTC P0340 CMP SENSOR (PHASE) [CR (WITH EURO-OBD)] Specification data are reference values and are measured between each terminal and ground. Pulse signal is measured by CONSULT-II. CAUTION: Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM's transistor. Use a ground other than ECM terminals, such as the ground. TERMINAL NO. WIRE COLOR ITEM CONDITION [Engine is running] ● Warm-up condition ● Idle speed DATA (DC Voltage) 1.0 - 4.0V NOTE: The pulse cycle changes depending on rpm at idle. 14 R PBIB0525E Camshaft position sensor (PHASE) 1.0 - 4.0V [Engine is running] ● Engine speed: 2,000 rpm PBIB0526E 29 B Sensor ground (Camshaft position sensor) [Engine is running] ● Warm-up condition ● Idle speed [Engine is running] [Ignition switch: OFF] ● 111 P ECM relay (Self shut-off) For a few seconds after turning ignition switch OFF [Ignition switch: OFF] ● 119 120 G G Power supply for ECM More than a few seconds passed after turning ignition switch OFF [Ignition switch: ON] Approximately 0V 0 - 1.0V BATTERY VOLTAGE (11 - 14V) BATTERY VOLTAGE (11 - 14V) : Average voltage for pulse signal (Actual pulse signal can be confirmed by oscilloscope.) Diagnostic Procedure BBS002YH 1. CHECK STARTING SYSTEM Turn ignition switch to START position. Does the engine turn over? Does the starter motor operate? Yes or No Yes >> GO TO 2. No >> Check starting system. (Refer to SC-45, "STARTING SYSTEM" .) EC-260 DTC P0340 CMP SENSOR (PHASE) [CR (WITH EURO-OBD)] 2. CHECK GROUND CONNECTIONS 1. 2. A Turn ignition switch OFF. Loosen and retighten ground screws on the body. Refer to EC-133, "Ground Inspection" . EC C D E MBIB1502E 1. Body ground E44 2. Body ground E45 3. Body ground E28 F OK or NG OK >> GO TO 3. NG >> Repair or replace ground connections. G 3. CHECK CAMSHAFT POSITION (CMP) SENSOR (PHASE) POWER SUPPLY CIRCUIT 1. 2. H Disconnect camshaft position (CMP) sensor (PHASE) harness connector. Turn ignition switch ON. I J MBIB0279E 3. Check voltage between CMP sensor (PHASE) terminal 3 and ground with CONSULT-II or tester. K L Voltage: Battery voltage OK or NG OK >> GO TO 5. NG >> GO TO 4. M SEF479Y 4. DETECT MALFUNCTIONING PART Check the following. ● Harness connectors F1, E48 ● Harness for open or short between camshaft position sensor (PHASE) and ECM ● Harness for open or short between camshaft position sensor (PHASE) and IPDM E/R >> Repair open circuit or short to ground or short to power in harness or connectors. EC-261 DTC P0340 CMP SENSOR (PHASE) [CR (WITH EURO-OBD)] 5. CHECK CMP SENSOR (PHASE) GROUND CIRCUIT FOR OPEN AND SHORT 1. 2. 3. Turn ignition switch OFF. Disconnect ECM harness connector. Check harness continuity between ECM terminal 29 and CMP sensor (PHASE) terminal 1. Refer to Wiring Diagram. Continuity should exist. 4. Also check harness for short to ground and short to power. OK or NG OK >> GO TO 6. NG >> Repair open circuit or short to ground or short to power in harness or connectors. 6. CHECK CMP SENSOR (PHASE) INPUT SIGNAL CIRCUIT FOR OPEN AND SHORT 1. Check harness continuity between ECM terminal 14 and CMP sensor (PHASE) terminal 2. Refer to Wiring Diagram. Continuity should exist. 2. Also check harness for short to ground and short to power. OK or NG OK >> GO TO 7. NG >> Repair open circuit or short to ground or short to power in harness or connectors. 7. CHECK CAMSHAFT POSITION SENSOR (PHASE) Refer to EC-263, "Component Inspection" . OK or NG OK >> GO TO 8. NG >> Replace camshaft position sensor (PHASE). 8. CHECK CAMSHAFT (INTAKE) Check the following. Accumulation of debris to the signal plate of camshaft rear end ● Chipping signal plate of camshaft rear end OK or NG OK >> GO TO 9. NG >> Remove debris and clean the signal plate of camshaft rear end or replace camshaft. ● PBIB0565E 9. CHECK INTERMITTENT INCIDENT Refer to EC-127, "TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT" . >> INSPECTION END EC-262 DTC P0340 CMP SENSOR (PHASE) [CR (WITH EURO-OBD)] Component Inspection BBS002YI A CAMSHAFT POSITION SENSOR (PHASE) 1. 2. 3. 4. Loosen the fixing bolt of the sensor. Disconnect camshaft position sensor (PHASE) harness connector. Remove the sensor. Visually check the sensor for chipping. EC C D E PBIB0563E 5. F Check resistance as shown in the figure. Terminal No. (Polarity) Resistance Ω [at 25°C (77°F)] G 3 (+) - 1 (-) 3 (+) - 2 (-) Except 0 or ∞ 2 (+) - 1 (-) H I MBIB0024E Removal and Installation BBS002YJ CAMSHAFT POSITION SENSOR (PHASE) J Refer to EM-38, "CAMSHAFT" . K L M EC-263 DTC P0420 THREE WAY CATALYST FUNCTION [CR (WITH EURO-OBD)] DTC P0420 THREE WAY CATALYST FUNCTION On Board Diagnosis Logic PFP:20905 BBS002YK The ECM monitors the switching frequency ratio of heated oxygen sensors 1 and 2. A three way catalyst (Manifold) with high oxygen storage capacity will indicate a low switching frequency of heated oxygen sensor 2. As oxygen storage capacity decreases, the heated oxygen sensor 2 switching frequency will increase. When the frequency ratio of heated oxygen sensors 1 and 2 approaches a specified limit value, the three way catalyst (Manifold) malfunction is diagnosed. SEF484YF DTC No. P0420 0420 Trouble diagnosis name Catalyst system efficiency below threshold DTC detecting condition ● Three way catalyst (Manifold) does not operate properly. ● Three way catalyst (Manifold) does not have enough oxygen storage capacity. DTC Confirmation Procedure Possible cause ● Three way catalyst (Manifold) ● Exhaust tube ● Intake air leak ● Fuel injector ● Fuel injector leak ● Spark plug ● Improper ignition timing BBS002YL NOTE: If DTC Confirmation Procedure has been previously conducted, always turn ignition switch OFF and wait at least 10 seconds before conducting the next test. WITH CONSULT-II TESTING CONDITION: ● Open engine hood before conducting the following procedure. ● Do not hold engine speed for more than the specified minutes below. 1. Start engine and warm it up to the normal operating temperature. 2. Turn ignition switch OFF and wait at least 10 seconds. 3. Start engine and keep the engine speed between 3,500 and 4,000 rpm for at least 1 minute under no load. 4. Let engine idle for 1 minute. 5. Select “DTC & SRT CONFIRMATION” then “SRT WORK SUPPORT” mode with CONSULT-II. 6. Rev engine up to 2,000 to 3,000 rpm and hold it for 3 consecutive minutes then release the accelerator pedal completely. If “INCMP” of “CATALYST” changed to “COMPLT”, go to step 10 7. Wait 5 seconds at idle. PBIB0566E EC-264 DTC P0420 THREE WAY CATALYST FUNCTION [CR (WITH EURO-OBD)] 8. Rev engine up to 2,000 to 3,000 rpm and maintain it until “INCMP” of “CATALYST” changes to “CMPLT” (It will take approximately 5 minutes). If not “CMPLT”, stop engine and cool it down to less than 70°C (158 °F) and then retest from step 1. A EC C PBIB0567E D a. b. c. d. Turn ignition switch OFF and leave the vehicle in a cool place (soak the vehicle) Turn ignition switch ON and select “COOLAN TEMP/S” in “DATA MONITOR” mode with CONSULT-II. Start engine and warm it up while monitoring “COOLAN TEMP/ S” indication on CONSULT-II. When “COOLAN TEMP/S” indication reaches to 70°(158°F), go to step 3. E F G SEF013Y 9. Select “SELF-DIAG RESULTS” mode with CONSULT-II. 10. Confirm that the 1st trip DTC is not detected. If the 1st trip DTC is detected, go to EC-266, "Diagnostic Procedure" . H I J SEF535Z Overall Function Check K BBS002YM Use this procedure to check the overall function of the three way catalyst (Manifold). During this check, a 1st trip DTC might not be confirmed. L WITH GST 1. 2. 3. 4. 5. 6. 7. Start engine and warm it up to the normal operating temperature. Turn ignition switch OFF and wait at least 10 seconds. Start engine and keep the engine speed between 3,500 and 4,000 rpm for at least 1 minute under no load. Let engine idle for 1 minute. Open engine hood. Set voltmeters probes between ECM terminal 35 (HO2S1 signal) and ground, and ECM terminal 16 (HO2S2 signal) and ground. Keep engine speed at 2,000 rpm constant under no load. MBIB0018E EC-265 M DTC P0420 THREE WAY CATALYST FUNCTION [CR (WITH EURO-OBD)] 8. Make sure that the voltage switching frequency (high & low) between ECM terminal 16 and ground is very less than that of ECM terminal 35 and ground. Switching frequency ratio = A/B A: Heated oxygen sensor 2 voltage switching frequency B: Heated oxygen sensor 1 voltage switching frequency This ratio should be less than 0.75. If the ratio is greater than above, it means three way catalyst (manifold) does not operate properly. Go to EC-266, "Diagnostic Procedure" . NOTE: If the voltage at terminal 35 does not switch periodically more than 5 times within 10 seconds at step 8, perform trouble diagnosis for DTC P0133 first. (See EC-189 .) Diagnostic Procedure MBIB0124E BBS002YN 1. CHECK EXHAUST SYSTEM Visually check exhaust tubes and muffler for dent. OK or NG OK >> GO TO 2. NG >> Repair or replace. 2. CHECK EXHAUST GAS LEAK 1. 2. Start engine and run it at idle. Listen for an exhaust gas leak before the three way catalyst (Manifold). MBIB0649E OK or NG OK >> GO TO 3. NG >> Repair or replace. 3. CHECK INTAKE AIR LEAK Listen for an intake air leak after the manifold absolute pressure sensor. OK or NG OK >> GO TO 4. NG >> Repair or replace. EC-266 DTC P0420 THREE WAY CATALYST FUNCTION [CR (WITH EURO-OBD)] 4. CHECK FUEL INJECTORS 1. 2. 3. A Stop engine and then turn ignition switch ON. Refer to Wiring Diagram for FUEL INJECTOR, EC-422 . Check voltage between ECM terminals 22, 23, 41, 42 and ground with CONSULT-II or tester. Voltage EC : Battery voltage C OK or NG OK >> GO TO 5. NG >> Perform EC-423, "Diagnostic Procedure" . D MBIB0030E E 5. CHECK FUNCTION OF IGNITION COIL-I CAUTION: Do the following procedure in the place where ventilation is good without the combustibles. 1. Turn ignition switch OFF. 2. Remove fuel pump fuse in IPDM E/R to release fuel pressure. NOTE: Do not use CONSULT-II to release fuel pressure, or fuel pressure applies again during the following procedure. 3. Start engine. 4. After engine stalls, crank it two or three times to release all fuel pressure. 5. Turn ignition switch ON. 6. Remove all ignition coil harness connectors to avoid the electrical discharge from the ignition coils. 7. Remove ignition coil and spark plug of the cylinder to be checked. 8. Crank engine for five seconds or more to remove combustion gas in the cylinder. 9. Connect spark plug and harness connector to ignition coil. 10. Fix ignition coil using a rope etc. with gap of 13 - 17 mm between the edge of the spark plug and grounded metal portion as shown in the figure. 11. Crank engine for about three seconds, and check whether spark is generated between the spark plug and the grounded metal portion. F G H I J MBIB0277E Spark should be generated. CAUTION: ● Do not approach to the spark plug and the ignition coil within 50cm. Be careful not to get an electrical shock PBIB2325E while checking, because the electrical discharge voltage becomes 20kV or more. ● It might cause to damage the ignition coil if the gap of more than 17 mm is taken. NOTE: When the gap is less than 13 mm, the spark might be generated even if the coil is malfunctioning. OK or NG OK >> GO TO 9. NG >> GO TO 6. EC-267 K L M DTC P0420 THREE WAY CATALYST FUNCTION [CR (WITH EURO-OBD)] 6. CHECK FUNCTION OF IGNITION COIL-II 1. 2. 3. Turn ignition switch OFF. Disconnect spark plug and connect a known-good spark plug. Crank engine for about three seconds, and recheck whether spark is generated between the spark plug and the grounded metal portion. Spark should be generated. OK or NG OK >> GO TO 7. NG >> Check ignition coil, power transistor and their circuits, Refer to EC-433, "IGNITION SIGNAL" . 7. CHECK SPARK PLUGS Check the initial spark plug for fouling, etc. OK or NG OK >> Replace spark plug(s) with standard type one(s). For spark plug type, refer to MA-36, "Changing Spark Plugs" . NG >> 1. Repair or clean spark plug. 2. GO TO 8. SEF156I 8. CHECK FUNCTION OF IGNITION COIL-III 1. 2. Reconnect the initial spark plugs. Crank engine for about three seconds, and recheck whether spark is generated between the spark plug and the grounded portion. Spark should be generated. OK or NG OK >> INSPECTION END NG >> Replace spark plug(s) with standard type one(s). For spark plug type, refer to MA-36, "Changing Spark Plugs" . 9. CHECK FUEL INJECTOR 1. 2. Turn ignition switch OFF. Remove fuel injector assembly. Refer to EM-32, "FUEL INJECTOR AND FUEL TUBE" . Keep fuel hose and all fuel injectors connected to fuel tube. 3. Reconnect all fuel injector harness connectors. 4. Disconnect all ignition coil harness connectors. 5. Turn ignition switch ON. Make sure fuel does not drip from fuel injector. OK or NG OK (Does not drip.)>>GO TO 10. NG (Drips.)>>Replace the fuel injector(s) from which fuel is dripping. EC-268 DTC P0420 THREE WAY CATALYST FUNCTION [CR (WITH EURO-OBD)] 10. CHECK INTERMITTENT INCIDENT A Refer to EC-127, "TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT" . Trouble is fixed.>>INSPECTION END Trouble is not fixed.>>Replace three way catalyst (Manifold). EC C D E F G H I J K L M EC-269 DTC P0444 EVAP CANISTER PURGE VOLUME CONTROL SOLENOID VALVE [CR (WITH EURO-OBD)] DTC P0444 EVAP CANISTER PURGE VOLUME CONTROL SOLENOID VALVE PFP:14920 Description BBS002YO SYSTEM DESCRIPTION Sensor Input Signal to ECM Crankshaft position sensor (POS) Camshaft position sensor (PHASE) ECM Function Actuator Engine speed*1 Manifold absolute pressure sensor Amount of intake air Engine coolant temperature sensor Engine coolant temperature Battery Battery voltage*1 Throttle position sensor Throttle position Accelerator pedal position sensor Accelerator pedal position Heated oxygen sensor 1 Density of oxygen in exhaust gas (Mixture ratio feedback signal) Wheel sensor Vehicle speed*2 EVAP canister purge flow control EVAP canister purge volume control solenoid valve *1: ECM determines the start signal status by the signals of engine speed and battery voltage. *2: This signal is sent to the ECM through CAN communication line. This system controls flow rate of fuel vapor from the EVAP canister. The opening of the vapor by-pass passage in the EVAP canister purge volume control solenoid valve changes to control the flow rate. The EVAP canister purge volume control solenoid valve repeats ON/OFF operation according to the signal sent from the ECM. The opening of the valve varies for optimum engine control. The optimum value stored in the ECM is determined by considering various engine conditions. When the engine is operating, the flow rate of fuel vapor from the EVAP canister is regulated as the air flow changes. COMPONENT DESCRIPTION The EVAP canister purge volume control solenoid valve uses a ON/ OFF duty to control the flow rate of fuel vapor from the EVAP canister. The EVAP canister purge volume control solenoid valve is moved by ON/OFF pulses from the ECM. The longer the ON pulse, the greater the amount of fuel vapor that will flow through the valve. SEF337U CONSULT-II Reference Value in Data Monitor Mode BBS002YP Specification data are reference values. MONITOR ITEM CONDITION ● Engine: After warming up ● Shift lever: Neutral ● Air conditioner switch: OFF ● No load PURG VOL C/V SPECIFICATION Idle 0% 2,000 rpm 20 - 30% On Board Diagnosis Logic DTC No. P0444 0444 Trouble diagnosis name EVAP canister purge volume control solenoid valve circuit open BBS002YQ DTC detecting condition Possible cause ● Harness or connectors (The solenoid valve circuit is open or shorted.) ● EVAP canister purge volume control solenoid valve An excessively low voltage signal is sent to ECM through the valve EC-270 DTC P0444 EVAP CANISTER PURGE VOLUME CONTROL SOLENOID VALVE [CR (WITH EURO-OBD)] DTC Confirmation Procedure BBS002YR A NOTE: If DTC Confirmation Procedure has been previously conducted, always turn ignition switch OFF and wait at least 10 seconds before conducting the next test. EC TESTING CONDITION: Before performing the following procedure, confirm battery voltage is more than 11V at idle. WITH CONSULT-II 1. 2. 3. 4. C Turn ignition switch ON. Select “DATA MONITOR” mode with CONSULT-II. Start engine and let it idle for at least 13 seconds. If 1st trip DTC is detected, go to EC-274, "Diagnostic Procedure" . D E F SEF058Y G WITH GST Follow the procedure “WITH CONSULT-II” above. H I J K L M EC-271 DTC P0444 EVAP CANISTER PURGE VOLUME CONTROL SOLENOID VALVE [CR (WITH EURO-OBD)] Wiring Diagram BBS002YS MBWA1517E EC-272 DTC P0444 EVAP CANISTER PURGE VOLUME CONTROL SOLENOID VALVE [CR (WITH EURO-OBD)] Specification data are reference values and are measured between each terminal and ground. Pulse signal is measured by CONSULT-II. A CAUTION: Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM's transistor. Use a ground other than ECM terminals, such as the ground. EC TERMINAL NO. WIRE COLOR ITEM CONDITION DATA (DC Voltage) C BATTERY VOLTAGE (11 - 14V) D [Engine is running] ● Idle speed E 19 LG EVAP canister purge volume control solenoid valve PBIB0050E F Approximately 10V [Engine is running] ● G Engine speed: About 2,000 rpm (More than 100 seconds after starting engine) PBIB0520E [Engine is running] [Ignition switch: OFF] ● 111 P ECM relay (Self shut-off) [Ignition switch: OFF] ● 119 120 G G Power supply for ECM For a few seconds after turning ignition switch OFF More than a few seconds passed after turning ignition switch OFF [Ignition switch: ON] 0 - 1.0V BATTERY VOLTAGE (11 - 14V) BATTERY VOLTAGE (11 - 14V) H I J K : Average voltage for pulse signal (Actual pulse signal can be confirmed by oscilloscope.) L M EC-273 DTC P0444 EVAP CANISTER PURGE VOLUME CONTROL SOLENOID VALVE [CR (WITH EURO-OBD)] Diagnostic Procedure BBS002YT 1. CHECK EVAP CANISTER PURGE VOLUME CONTROL SOLENOID VALVE POWER SUPPLY CIRCUIT 1. 2. 3. Turn ignition switch OFF. Disconnect EVAP canister purge volume control solenoid valve harness connector. Turn ignition switch ON. MBIB1076E 4. Check voltage between EVAP canister purge volume control solenoid valve terminal 1 and ground with CONSULT-II or tester. Voltage: Battery voltage OK or NG OK >> GO TO 3. NG >> GO TO 2. PBIB0148E 2. DETECT MALFUNCTIONING PART Check the following. ● Harness connectors E48, F1 ● Harness for open or short between EVAP canister purge volume control solenoid valve and IPDM E/R ● Harness for open or short between EVAP canister purge volume control solenoid valve and ECM >> Repair harness or connectors. 3. CHECK EVAP CANISTER PURGE VOLUME CONTROL SOLENOID VALVE OUTPUT SIGNAL CIRCUIT FOR OPEN AND SHORT 1. 2. 3. Turn ignition switch OFF. Disconnect ECM harness connector. Check harness continuity between ECM terminal 19 and EVAP canister purge volume control solenoid valve terminal 2. Refer to Wiring Diagram. Continuity should exist. 4. Also check harness for short to ground and short to power. OK or NG OK (With CONSULT-II)>>GO TO 4. OK (Without CONSULT-II)>>GO TO 5. NG >> Repair open circuit or short to ground and short to power in harness or connectors. EC-274 DTC P0444 EVAP CANISTER PURGE VOLUME CONTROL SOLENOID VALVE [CR (WITH EURO-OBD)] 4. CHECK EVAP CANISTER PURGE VOLUME CONTROL SOLENOID VALVE OPERATION A With CONSULT-II Reconnect all harness connectors disconnected. Start engine. Perform “PURG VOL CONT/V” in “ACTIVE TEST” mode with CONSULT-II. Check that engine speed varies according to the valve opening. OK or NG OK >> GO TO 6. NG >> GO TO 5. 1. 2. 3. EC C D E PBIB0569E 5. CHECK EVAP CANISTER PURGE VOLUME CONTROL SOLENOID VALVE F Refer to EC-275, "Component Inspection" . OK or NG OK >> GO TO 6. NG >> Replace EVAP canister purge volume control solenoid valve. G H 6. CHECK INTERMITTENT INCIDENT Refer to EC-127, "TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT" . I >> INSPECTION END Component Inspection BBS002YU J EVAP CANISTER PURGE VOLUME CONTROL SOLENOID VALVE With CONSULT-II K Check air passage continuity of EVAP canister purge volume control solenoid valve under the following conditions. Condition (PURG VOL CONT/V value) Air passage continuity between A and B 100% Yes 0% No L M PBIB0149E Without CONSULT-II Check air passage continuity of EVAP canister purge volume control solenoid valve under the following conditions. Condition Air passage continuity between A and B 12V direct current supply between terminals 1 and 2 Yes No supply No PBIB0150E EC-275 DTC P0444 EVAP CANISTER PURGE VOLUME CONTROL SOLENOID VALVE [CR (WITH EURO-OBD)] Removal and Installation BBS002YV EVAP CANISTER PURGE VOLUME CONTROL SOLENOID VALVE Refer to EM-18, "AIR CLEANER AND AIR DUCT" . EC-276 DTC P0500 VSS [CR (WITH EURO-OBD)] DTC P0500 VSS Description PFP:32702 A BBS002YW NOTE: ● If DTC P0500 is displayed with DTC U1001, first perform the trouble diagnosis for DTC U1001. EC Refer to EC-134, "DTC U1001 CAN COMMUNICATION LINE" . ● If DTC P0500 is displayed with DTC U1010, first perform the trouble diagnosis for DTC U1010. Refer to EC-137, "DTC U1010 CAN COMMUNICATION" . C The vehicle speed signal is sent to the combination meter from the “ABS actuator and electric unit (control unit)” through CAN communication line. The combination meter then sends a signal to the ECM through CAN communication line. D On Board Diagnosis Logic DTC No. P0500 0500 Trouble diagnosis name Vehicle speed sensor BBS002YX DTC detecting condition The almost 0 km/h (0 MPH) signal from vehicle speed sensor is sent to ECM even when vehicle is being driven. Possible cause E ● Harness or connectors (The CAN communication line is open or shorted.) ● ABS actuator and electric unit (control unit) ● Wheel sensor ● Combination meter DTC Confirmation Procedure F G BBS002YY CAUTION: Always drive vehicle at a safe speed. NOTE: If DTC Confirmation Procedure has been previously conducted, always turn ignition switch OFF and wait at least 10 seconds before conducting the next test. TESTING CONDITION: Steps 1 and 2 may be conducted with the drive wheels lifted in the shop or by driving the vehicle. If a road test is expected to be easier, it is unnecessary to lift the vehicle. H I J WITH CONSULT-II 1. 2. 3. 4. 5. Start engine. Read “VHCL SPEED SE” in “DATA MONITOR” mode with CONSULT-II. The vehicle speed on CONSULTII should exceed 10 km/h (6 MPH) when rotating wheels with suitable gear position. If NG, go to EC-278, "Diagnostic Procedure" . If OK, go to following step. Select “DATA MONITOR” mode with CONSULT-II. Warm engine up to normal operating temperature. Maintain the following conditions for at least 60 consecutive seconds. ENG SPEED 2,400 - 6,000 rpm COOLAN TEMP/S More than 70°C (158°F) B/FUEL SCHDL 4.3 - 31.8 msec Shift lever Suitable position PW/ST SIGNAL OFF 6. SEF196Y If 1st trip DTC is detected, go to EC-278, "Diagnostic Procedure" . EC-277 K L M DTC P0500 VSS [CR (WITH EURO-OBD)] Overall Function Check BBS002YZ Use this procedure to check the overall function of the vehicle speed signal circuit. During this check, a 1st trip DTC might not be confirmed. WITH GST 1. 2. 3. 4. Lift up drive wheels. Start engine. Read vehicle speed signal in Service $01 with GST. The vehicle speed signal on GST should be able to exceed 10 km/h (6 MPH) when rotating wheels with suitable gear position. If NG, go to EC-278, "Diagnostic Procedure" . Diagnostic Procedure BBS002Z0 1. CHECK DTC WITH ABS ACTUATOR AND ELECTRIC UNIT (CONTROL UNIT) Refer to BRC-8, "TROUBLE DIAGNOSIS" (models with ESP). OK or NG OK >> GO TO 2. NG >> Repair or replace. (models without ESP) or BRC-49, "TROUBLE DIAGNOSIS" 2. CHECK COMBINATION METER Check combination meter function. Refer to DI-4, "COMBINATION METERS" . >> INSPECTION END EC-278 DTC P0605 ECM [CR (WITH EURO-OBD)] DTC P0605 ECM Component Description PFP:23710 A BBS002Z1 The ECM consists of a microcomputer and connectors for signal input and output and for power supply. The ECM controls the engine. EC C D PBIB1164E E On Board Diagnosis Logic BBS002Z2 This self-diagnosis has one or two trip detection logic. DTC No. P0605 0605 Trouble diagnosis name Engine control module DTC detecting condition A) ECM calculation function is malfunctioning. B) ECM EEP-ROM system is malfunctioning. C) ECM self shut-off function is malfunctioning. F Possible cause ● ECM G FAIL-SAFE MODE H ECM enters fail-safe mode when malfunction A is detected. Detected items Malfunction A Engine operation condition in fail-safe mode ECM stops the electric throttle control actuator control, throttle valve is maintained at a fixed opening (approx. 5 degrees) by the return spring. DTC Confirmation Procedure BBS002Z3 Perform PROCEDURE FOR MALFUNCTION A first. If the DTC cannot be confirmed, perform PROCEDURE FOR MALFUNCTION B. If there is no malfunction on PROCEDURE FOR MALFUNCTION B, perform PROCEDURE FOR MALFUNCTION C. NOTE: If DTC Confirmation Procedure has been previously conducted, always turn ignition switch OFF and wait at least 10 seconds before conducting the next test. PROCEDURE FOR MALFUNCTION A With CONSULT-II 1. 2. 3. SEF058Y Follow the procedure “With CONSULT-II” above. EC-279 J K L M Turn ignition switch ON. Select “DATA MONITOR” mode with CONSULT-II. If 1st trip DTC is detected, go to EC-280, "Diagnostic Procedure" . With GST I DTC P0605 ECM [CR (WITH EURO-OBD)] PROCEDURE FOR MALFUNCTION B With CONSULT-II 1. 2. 3. 4. Turn ignition switch ON and wait at least 1 second. Select “DATA MONITOR” mode with CONSULT-II. Turn ignition switch OFF, wait at least 10 seconds and then turn ON. If 1st trip DTC is detected, go to EC-280, "Diagnostic Procedure" . SEF058Y With GST Follow the procedure “With CONSULT-II” above. PROCEDURE FOR MALFUNCTION C With CONSULT-II 1. 2. 3. 4. 5. Turn ignition switch ON and wait at least 1 second. Select “DATA MONITOR” mode with CONSULT-II. Turn ignition switch OFF, wait at least 10 seconds and then turn ON. Repeat step 3 for 32 times. If 1st trip DTC is detected, go to EC-280, "Diagnostic Procedure" . SEF058Y With GST Follow the procedure “With CONSULT-II” above. Diagnostic Procedure BBS002Z4 1. INSPECTION START With CONSULT-II Turn ignition switch ON. Select “SELF DIAG RESULTS” mode with CONSULT-II. Touch “ERASE”. Perform DTC Confirmation Procedure. See EC-279, "DTC Confirmation Procedure" . 5. Is the 1st trip DTC P0605 displayed again? 1. 2. 3. 4. With GST Turn ignition switch ON. Select Service $04 with GST. Perform DTC Confirmation Procedure. See EC-279, "DTC Confirmation Procedure" . 4. Is the 1st trip DTC P0605 displayed again? Yes or No Yes >> GO TO 2. No >> INSPECTION END 1. 2. 3. EC-280 DTC P0605 ECM [CR (WITH EURO-OBD)] 2. REPLACE ECM 1. 2. 3. 4. 5. A Replace ECM. Perform initialization of NATS system and registration of all NATS ignition key IDs. Refer to BL-218, "ECM EC Re-communicating Function" . Perform EC-69, "Accelerator Pedal Released Position Learning" . Perform EC-69, "Throttle Valve Closed Position Learning" . C Perform EC-69, "Idle Air Volume Learning" . >> INSPECTION END D E F G H I J K L M EC-281 DTC P1065 ECM POWER SUPPLY [CR (WITH EURO-OBD)] DTC P1065 ECM POWER SUPPLY Component Description PFP:23710 BBS002Z5 Battery voltage is supplied to the ECM even when the ignition switch is turned OFF for the ECM memory function of the DTC memory, the air-fuel ratio feedback compensation value memory, the idle air volume learning value memory, etc. PBIB1164E On Board Diagnosis Logic DTC No. P1065 1065 Trouble diagnosis name ECM power supply circuit BBS002Z6 DTC detecting condition Possible cause ● Harness or connectors [ECM power supply (back-up) circuit is open or shorted.] ● ECM ECM back-up RAM system does not function properly. DTC Confirmation Procedure BBS002Z7 NOTE: If DTC Confirmation Procedure has been previously conducted, always turn ignition switch OFF and wait at least 10 seconds before conducting the next test. WITH CONSULT-II 1. 2. 3. 4. 5. 6. Turn ignition switch ON and wait at least 1 second. Select “DATA MONITOR” mode with CONSULT-II. Start engine and let it idle for 1 second. Turn ignition switch OFF, wait at least 10 seconds and then turn ON. Repeat steps 3 and 4 for 4 times. If 1st trip DTC is detected, go to EC-284, "Diagnostic Procedure" . SEF058Y WITH GST Follow the procedure “WITH CONSULT-II” above. EC-282 DTC P1065 ECM POWER SUPPLY [CR (WITH EURO-OBD)] Wiring Diagram BBS002Z8 A EC C D E F G H I J K L M MBWA1518E EC-283 DTC P1065 ECM POWER SUPPLY [CR (WITH EURO-OBD)] Specification data are reference values and are measured between each terminal and ground. CAUTION: Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM's transistor. Use a ground other than ECM terminals, such as the ground. TERMINAL NO. 121 WIRE COLOR BR ITEM Power supply for ECM (Back-up) CONDITION [Ignition switch: OFF] Diagnostic Procedure DATA (DC Voltage) BATTERY VOLTAGE (11 - 14V) BBS002Z9 1. CHECK ECM POWER SUPPLY 1. 2. 3. Turn ignition switch OFF. Disconnect ECM harness connector. Check voltage between ECM terminal 121 and ground with CONSULT-II or tester. Voltage: Battery voltage OK or NG OK >> GO TO 3. NG >> GO TO 2. MBIB0026E 2. DETECT MALFUNCTIONING PART Check the following. ● 20A fuse ● IPDM E/R harness connector E7 ● Harness for open or short between ECM and IPDM E/R >> Repair or replace harness or connectors. 3. CHECK INTERMITTENT INCIDENT Refer to EC-127, "TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT" . OK or NG OK >> GO TO 4. NG >> Repair or replace harness or connectors. EC-284 DTC P1065 ECM POWER SUPPLY [CR (WITH EURO-OBD)] 4. PERFORM DTC CONFIRMATION PROCEDURE With CONSULT-II Turn ignition switch ON. Select “SELF DIAG RESULTS” mode with CONSULT-II. Touch “ERASE”. Perform DTC Confirmation Procedure. See EC-282, "DTC Confirmation Procedure" . 5. Is the 1st trip DTC P1065 displayed again? 1. 2. 3. 4. A EC C With GST Turn ignition switch ON. Select Service $04 with GST. Perform DTC Confirmation Procedure. See EC-282, "DTC Confirmation Procedure" . 4. Is the 1st trip DTC P1065 displayed again? Yes or No Yes >> GO TO 5. No >> INSPECTION END D 5. REPLACE ECM G 1. 2. 3. 1. 2. 3. 4. 5. Replace ECM. Perform initialization of NATS system and registration of all NATS ignition key IDs. Refer to BL-218, "ECM Re-communicating Function" . Perform EC-69, "Accelerator Pedal Released Position Learning" . Perform EC-69, "Throttle Valve Closed Position Learning" . Perform EC-69, "Idle Air Volume Learning" . E F H I J >> INSPECTION END K L M EC-285 DTC P1111 IVT CONTROL SOLENOID VALVE [CR (WITH EURO-OBD)] DTC P1111 IVT CONTROL SOLENOID VALVE Component Description PFP:23796 BBS002ZA Intake valve timing control solenoid valve is activated by ON/OFF pulse duty (ratio) signals from the ECM. The intake valve timing control solenoid valve changes the oil amount and direction of flow through intake valve timing control unit or stops oil flow. The longer pulse width advances valve angle. The shorter pulse width retards valve angle. When ON and OFF pulse widths become equal, the solenoid valve stops oil pressure flow to fix the intake valve angle at the control position. PBIB1842E CONSULT-II Reference Value in Data Monitor Mode BBS002ZB Specification data are reference values. MONITOR ITEM CONDITION ● Engine: After warming up ● Shift lever: Neutral ● Air conditioner switch: OFF ● No load INT/V SOL (B1) SPECIFICATION Idle 0% - 2% 2,000 rpm Approx. 0% - 50% On Board Diagnosis Logic DTC No. P1111 1111 Trouble diagnosis name Intake valve timing control solenoid valve circuit BBS002ZC DTC detecting condition Possible cause ● Harness or connectors (Intake valve timing control solenoid valve circuit is open or shorted.) ● Intake valve timing control solenoid valve An improper voltage is sent to the ECM through intake valve timing control solenoid valve. DTC Confirmation Procedure BBS002ZD NOTE: If DTC Confirmation Procedure has been previously conducted, always turn ignition switch OFF and wait at least 10 seconds before conducting the next test. WITH CONSULT-II 1. 2. 3. 4. Turn ignition switch ON. Select “DATA MONITOR” mode with CONSULT-II. Start engine and let it idle for 5 seconds. If 1st trip DTC is detected, go to EC-289, "Diagnostic Procedure" . SEF058Y WITH GST Following the procedure “WITH CONSULT-II” above. EC-286 DTC P1111 IVT CONTROL SOLENOID VALVE [CR (WITH EURO-OBD)] Wiring Diagram BBS002ZE A EC C D E F G H I J K L M MBWA1519E EC-287 DTC P1111 IVT CONTROL SOLENOID VALVE [CR (WITH EURO-OBD)] Specification data are reference values and are measured between each terminal and ground. Pulse signal is measured by CONSULT-II. CAUTION: Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM's transistor. Use a ground other than ECM terminals, such as the ground. TERMINAL NO. WIRE COLOR ITEM CONDITION DATA (DC Voltage) [Engine is running] ● Warm-up condition ● Idle speed BATTERY VOLTAGE (11 - 14V) Approximately 4V - BATTERY 62 LG Intake valve timing control solenoid valve VOLTAGE (11 - 14V) [Engine is running] ● Warm-up condition ● Engine speed: 2,000 rpm PBIB1790E [Engine is running] [Ignition switch: OFF] ● 111 P ECM relay (Self shut-off) [Ignition switch: OFF] ● 119 120 G G Power supply for ECM For a few seconds after turning ignition switch OFF More than a few seconds passed after turning ignition switch OFF [Ignition switch: ON] : Average voltage for pulse signal (Actual pulse signal can be confirmed by oscilloscope.) EC-288 0 - 1.0V BATTERY VOLTAGE (11 - 14V) BATTERY VOLTAGE (11 - 14V) DTC P1111 IVT CONTROL SOLENOID VALVE [CR (WITH EURO-OBD)] Diagnostic Procedure BBS002ZF 1. CHECK INTAKE VALVE TIMING CONTROL SOLENOID VALVE POWER SUPPLY CIRCUIT 1. 2. 3. A Turn ignition switch OFF. Disconnect intake valve timing control solenoid valve harness connector. Turn ignition switch ON. EC C D MBIB0284E 4. Check voltage between intake valve timing control solenoid valve terminal 1 and ground with CONSULT-II or tester. E F Voltage: Battery voltage OK or NG OK >> GO TO 3. NG >> GO TO 2. G H PBIB0285E 2. DETECT MALFUNCTION PART Check the following. ● Harness connectors E48, F1 ● Harness for open or short between intake valve timing control solenoid valve and IPDM E/R I J K >> Repair or replace harness or connectors. 3. CHECK INTAKE VALVE TIMING CONTROL SOLENOID VALVE OUTPUT SIGNAL CIRCUIT FOR L OPEN AND SHORT 1. 2. 3. Turn ignition switch OFF. Disconnect ECM harness connector. Check harness continuity between ECM terminal 62 and intake valve timing control solenoid valve terminal 2. Refer to Wiring Diagram. Continuity should exist. 4. Also check harness for short to ground and short to power. OK or NG OK >> GO TO 4. NG >> Repair open circuit or short to ground or short to power in harness or connectors. 4. CHECK INTAKE VALVE TIMING CONTROL SOLENOID VALVE Refer to EC-290, "Component Inspection" . OK or NG OK >> GO TO 5. NG >> Replace intake valve timing control solenoid valve. EC-289 M DTC P1111 IVT CONTROL SOLENOID VALVE [CR (WITH EURO-OBD)] 5. CHECK INTERMITTENT INCIDENT Refer to EC-127, "TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT" . >> INSPECTION END Component Inspection BBS002ZG INTAKE VALVE TIMING CONTROL SOLENOID VALVE 1. 2. 3. 4. Disconnect intake valve timing control solenoid valve harness connector. Check resistance between intake valve timing control solenoid valve as follows. Terminal Resistance 1 and 2 6.7 - 7.7Ω at 20°C (68°F) 1 or 2 and ground ∞Ω (Continuity should not exist.) If NG, replace intake valve timing control solenoid valve. If OK, go to next step. Remove intake valve timing control solenoid valve. MBIB0027E Provide 12V DC between intake valve timing control solenoid valve terminals and then interrupt it. Make sure that the plunger moves as shown in the figure. CAUTION: Do not apply 12V DC continuously for 5 seconds or more. Doing so may result in damage to the coil in intake valve timing control solenoid valve. If NG, replace intake valve timing control solenoid valve. NOTE: Always replace O-ring when intake valve timing control solenoid valve is removed. PBIB2388E Removal and Installation BBS002ZH INTAKE VALVE TIMING CONTROL SOLENOID VALVE Refer to EM-35, "ROCKER COVER" . EC-290 DTC P1121 ELECTRIC THROTTLE CONTROL ACTUATOR [CR (WITH EURO-OBD)] DTC P1121 ELECTRIC THROTTLE CONTROL ACTUATOR Component Description PFP:16119 A BBS002ZI Electric throttle control actuator consists of throttle control motor, throttle position sensor, etc. The throttle control motor is operated by the ECM and it opens and closes the throttle valve. EC The throttle position sensor detects the throttle valve position, and the opening and closing speed of the throttle valve and feeds the voltage signals to the ECM. The ECM judges the current opening angle of the throttle valve from these signals and the ECM controls the throttle control motor to make the throttle valve opening C angle properly in response to driving condition. On Board Diagnosis Logic BBS002ZJ D This self-diagnosis has the one trip detection logic. DTC No. P1121 1121 Trouble diagnosis name Electric throttle control actuator DTC detecting condition A) Electric throttle control actuator does not function properly due to the return spring malfunction. B) Throttle valve opening angle in fail-safe mode is not in specified range. C) ECM detect the throttle valve is stuck open. Possible cause E ● Electric throttle control actuator F FAIL-SAFE MODE G When the malfunction is detected, the ECM enters fail-safe mode and the MI lights up. Detected items Engine operating condition in fail-safe mode Malfunction A The ECM controls the electric throttle actuator by regulating the throttle opening around the idle position. The engine speed will not rise more than 2,000 rpm. Malfunction B ECM controls the electric throttle control actuator by regulating the throttle opening to 20 degrees or less. Malfunction C While the vehicle is driving, it slows down gradually by fuel cut. After the vehicle stops, the engine stalls. The engine can restart in Neutral position, and engine speed will not exceed 1,000 rpm or more. DTC Confirmation Procedure H I BBS002ZK J NOTE: ● Perform PROCEDURE FOR MALFUNCTION A AND B first. If the DTC cannot be confirmed, perform PROCEDURE FOR MALFUNCTION C. ● If DTC Confirmation Procedure has been previously conducted, always turn ignition switch OFF and wait at least 10 seconds before conducting the next test. K L PROCEDURE FOR MALFUNCTION A AND B With CONSULT-II 1. 2. 3. 4. 5. 6. 7. 8. 9. Turn ignition witch ON and wait at least 1 second. Select “DATA MONITOR” mode with CONSULT-II. Set shift lever to 1st position and wait at least 2 seconds. Set shift lever to Neutral position. Turn ignition switch OFF and wait at least 10 seconds. Turn ignition switch ON and wait at least 1 second. Set shift lever to 1st position and wait at least 2 seconds. Set shift lever to Neutral position. Turn ignition switch OFF, wait at least 10 seconds and then turn ON. 10. If DTC is detected, go to EC-292, "Diagnostic Procedure" . EC-291 M SEF058Y DTC P1121 ELECTRIC THROTTLE CONTROL ACTUATOR [CR (WITH EURO-OBD)] With GST Follow the procedure “With CONSULT-II” above. PROCEDURE FOR MALFUNCTION C With CONSULT-II 1. 2. 3. 4. 5. 6. Turn ignition switch ON and wait at least 1 second. Select “DATA MONITOR” mode with CONSULT-II. Set shift lever to 1st position and wait at least 2 seconds. Set shift lever to Neutral position. Start engine and let it idle for 3 seconds. If DTC is detected, go to EC-292, "Diagnostic Procedure" . SEF058Y With GST Follow the procedure “With CONSULT-II” above. Diagnostic Procedure BBS002ZL 1. CHECK ELECTRIC THROTTLE CONTROL ACTUATOR VISUALLY 1. 2. Remove the intake air duct. Check if a foreign matter is caught between the throttle valve and the housing. OK or NG OK >> GO TO 2. NG >> Remove the foreign matter and clean the electric throttle control actuator inside. MBIB0307E 2. REPLACE ELECTRIC THROTTLE CONTROL ACTUATOR 1. 2. 3. Replace the electric throttle control actuator. Perform EC-69, "Throttle Valve Closed Position Learning" . Perform EC-69, "Idle Air Volume Learning" . >> INSPECTION END EC-292 DTC P1122 ELECTRIC THROTTLE CONTROL FUNCTION [CR (WITH EURO-OBD)] DTC P1122 ELECTRIC THROTTLE CONTROL FUNCTION Description PFP:16119 A BBS002ZM NOTE: If DTC P1122 is displayed with DTC P1121 or P1126, first perform the trouble diagnosis for DTC P1121 EC or P1126. Refer to EC-291 or EC-299 . Electric throttle control actuator consists of throttle control motor, throttle position sensor, etc. The throttle control motor is operated by the ECM and it opens and closes the throttle valve. The current opening angle of the throttle valve is detected by the throttle position sensor and it provides feed- C back to the ECM to control the throttle control motor to make the throttle valve opening angle properly in response to driving condition. D On Board Diagnosis Logic BBS002ZN This self-diagnosis has the one trip detection logic. DTC No. Trouble diagnosis name P1122 1122 Electric throttle control performance DTC detecting condition E Possible cause ● Electric throttle control function does not operate properly. ● Harness or connectors (Throttle control motor circuit is open or shorted.) F Electric throttle control actuator G FAIL-SAFE MODE When the malfunction is detected, the ECM enters fail-safe mode and the MI lights up. Engine operating condition in fail-safe mode H ECM stops the electric throttle control actuator control, throttle valve is maintained at a fixed opening (approx. 5 degrees) by the return spring. DTC Confirmation Procedure BBS002ZO NOTE: If DTC Confirmation Procedure has been previously conducted, always turn ignition switch OFF and wait at least 10 seconds before conducting the next test. TESTING CONDITION: Before performing the following procedure, confirm that battery voltage is more than 11V when engine is running. I J K WITH CONSULT-II 1. 2. 3. 4. Turn ignition switch ON and wait at least 2 seconds. Select “DATA MONITOR” mode with CONSULT-II. Start engine and let it idle for 5 seconds. If DTC is detected, go to EC-295, "Diagnostic Procedure" . L M SEF058Y WITH GST Follow the procedure “WITH CONSULT-II” above. EC-293 DTC P1122 ELECTRIC THROTTLE CONTROL FUNCTION [CR (WITH EURO-OBD)] Wiring Diagram BBS002ZP MBWA1520E EC-294 DTC P1122 ELECTRIC THROTTLE CONTROL FUNCTION [CR (WITH EURO-OBD)] Specification data are reference values and are measured between each terminal and ground. Pulse signal is measured by CONSULT-II. A CAUTION: Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM's transistor. Use a ground other than ECM terminals, such as the ground. EC TERMINAL NO. 3 WIRE COLOR ITEM CONDITION DATA (DC Voltage) C LG Throttle control motor relay power supply BATTERY VOLTAGE (11 - 14V) [Ignition switch: ON] 0 - 14V D [Ignition switch: ON] 4 L Throttle control motor (Close) ● Engine stopped ● Shift lever position: 1st ● Accelerator pedal: Fully released E PBIB0534E F 0 - 14V [Ignition switch: ON] 5 P Throttle control motor (Open) ● Engine stopped ● Shift lever position: 1st ● Accelerator pedal: Fully depressed G H PBIB0533E 104 G Throttle control motor relay [Ignition switch: OFF] BATTERY VOLTAGE (11 - 14V) [Ignition switch: ON] 0 - 1.0V I : Average voltage for pulse signal (Actual pulse signal can be confirmed by oscilloscope.) J Diagnostic Procedure BBS002ZQ 1. CHECK GROUND CONNECTIONS 1. 2. K Turn ignition switch OFF. Loosen and retighten ground screws on the body. Refer to EC-133, "Ground Inspection" . L M MBIB1502E 1. Body ground E44 2. Body ground E45 OK or NG OK >> GO TO 2. NG >> Repair or replace ground connections. EC-295 3. Body ground E28 DTC P1122 ELECTRIC THROTTLE CONTROL FUNCTION [CR (WITH EURO-OBD)] 2. CHECK THROTTLE CONTROL MOTOR RELAY SIGNAL CIRCUIT-I Check voltage between ECM terminal 3 and ground under the following conditions with CONSULT-II or tester. Ignition switch Voltage OFF Approximately 0V ON Battery voltage (11 - 14V) OK or NG OK >> GO TO 9. NG >> GO TO 3. MBIB0028E 3. CHECK THROTTLE CONTROL MOTOR RELAY POWER SUPPLY CIRCUIT-I 1. 2. Turn ignition switch OFF. Check voltage between ECM terminal 104 and ground with CONSULT-II or tester. Voltage: Battery voltage OK or NG OK >> GO TO 6. NG >> GO TO 4. PBIB1171E 4. CHECK THROTTLE CONTROL MOTOR RELAY POWER SUPPLY CIRCUIT-II 1. 2. 3. Disconnect ECM harness connector. Disconnect IPDM E/R harness connector E5. Check continuity between ECM terminal 104 and IPDM E/R terminal 70. Refer to Wiring Diagram. Continuity should exist. 4. Also check harness for short to ground and short to power. OK or NG OK >> GO TO 5. NG >> Repair open circuit or short to ground or short to power in harness or connectors. 5. CHECK FUSE 1. Disconnect 20A fuse. 2. Check 20A fuse for blown. OK or NG OK >> GO TO 8. NG >> Replace 20A fuse. EC-296 DTC P1122 ELECTRIC THROTTLE CONTROL FUNCTION [CR (WITH EURO-OBD)] 6. CHECK THROTTLE CONTROL MOTOR RELAY INPUT SIGNAL CIRCUIT-II 1. 2. 3. A Disconnect ECM harness connector. Disconnect IPDM E/R harness connector E7. Check harness continuity between ECM terminal 3 and IPDM E/R terminal 28. Refer to Wiring Diagram. EC Continuity should exist. C 4. Also check harness for short to ground and short to power. OK or NG OK >> GO TO 8. NG >> GO TO 7. D 7. DETECT MALFUNCTIONING PART E Check the following. ● Harness connectors E48, F1 ● Harness for open or short between ECM and IPDM E/R F >> Repair open circuit or short to ground or short to power in harness or connectors. G 8. CHECK INTERMITTENT INCIDENT Refer to EC-127, "TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT" . OK or NG OK >> Replace IPDM E/R. Refer to PG-18, "IPDM E/R (INTELLIGENT POWER DISTRIBUTION MODULE ENGINE ROOM)" . NG >> Repair or replace harness or connectors. 9. CHECK THROTTLE CONTROL MOTOR OUTPUT SIGNAL CIRCUIT FOR OPEN OR SHORT 1. 2. 3. 4. 3 6 ECM terminal I J Turn ignition switch OFF. Disconnect electric throttle control actuator harness connector. Disconnect ECM harness connector. Check harness continuity between the following terminals. Refer to Wiring Diagram. Electric throttle control actuator terminal H K L Continuity 5 Should not exist 4 Should exist 5 Should exist 4 Should not exist 5. Also check harness for short to ground and short to power. OK or NG OK >> GO TO 10. NG >> Repair or replace. EC-297 M MBIB0308E DTC P1122 ELECTRIC THROTTLE CONTROL FUNCTION [CR (WITH EURO-OBD)] 10. CHECK ELECTRIC THROTTLE CONTROL ACTUATOR VISUALLY 1. 2. Remove the intake air duct. Check if foreign matter is caught between the throttle valve and the housing. OK or NG OK >> GO TO 11. NG >> Remove the foreign matter and clean the electric throttle control actuator inside. MBIB0307E 11. CHECK THROTTLE CONTROL MOTOR Refer to EC-298, "Component Inspection" . OK or NG OK >> GO TO 12. NG >> GO TO 13. 12. CHECK INTERMITTENT INCIDENT Refer to EC-127, "TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT" . OK or NG OK >> GO TO 13. NG >> Repair or replace harness or connectors. 13. REPLACE ELECTRIC THROTTLE CONTROL ACTUATOR 1. 2. 3. Replace the electric throttle control actuator. Perform EC-69, "Throttle Valve Closed Position Learning" . Perform EC-69, "Idle Air Volume Learning" . >> INSPECTION END Component Inspection BBS002ZR THROTTLE CONTROL MOTOR 1. 2. Disconnect electric throttle control actuator harness connector. Check resistance between terminals 3 and 6. Resistance: Approximately 1 - 15 Ω [at 25 °C (77°F)] 3. 4. 5. If NG, replace electric throttle control actuator and go to next step. Perform EC-69, "Throttle Valve Closed Position Learning" . Perform EC-69, "Idle Air Volume Learning" . PBIB0095E Removal and Installation BBS002ZS ELECTRIC THROTTLE CONTROL ACTUATOR Refer to EM-18, "AIR CLEANER AND AIR DUCT" . EC-298 DTC P1124, P1126 THROTTLE CONTROL MOTOR RELAY [CR (WITH EURO-OBD)] DTC P1124, P1126 THROTTLE CONTROL MOTOR RELAY Component Description PFP:16119 A BBS002ZT Power supply for the throttle control motor is provided to the ECM via throttle control motor relay. The throttle control motor relay is ON/OFF controlled by the ECM. When the ignition switch is turned ON, the ECM sends EC an ON signal to throttle control motor relay and battery voltage is provided to the ECM. When the ignition switch is turned OFF, the ECM sends an OFF signal to throttle control motor relay and battery voltage is not provided to the ECM. C CONSULT-II Reference Value in Data Monitor Mode BBS002ZU Specification data are reference values. MONITOR ITEM THRTL RELAY CONDITION ● D SPECIFICATION Ignition switch: ON ON On Board Diagnosis Logic BBS002ZV E These self-diagnoses have the one trip detection logic. DTC No. P1124 1124 P1126 1126 Trouble diagnosis name Throttle control motor relay circuit short Throttle control motor relay circuit open DTC detecting condition F Possible cause ● Harness or connectors (Throttle control motor relay circuit is shorted.) ● Throttle control motor relay ● Harness or connectors (Throttle control motor relay circuit is open.) ● Throttle control motor relay ECM detects the throttle control motor relay is stuck ON. ECM detects a voltage of power source for throttle control motor is excessively low. G H FAIL-SAFE MODE I When the malfunction is detected, the ECM enters fail-safe mode and the MI lights up. Engine operating condition in fail-safe mode ECM stops the electric throttle control actuator control, throttle valve is maintained at a fixed opening (approx. 5 degrees) by the return spring. DTC Confirmation Procedure BBS002ZW NOTE: If DTC Confirmation Procedure has been previously conducted, always turn ignition switch OFF and wait at least 10 seconds before conducting the next test. PROCEDURE FOR DTC P1124 TESTING CONDITION: Before performing the following procedure, confirm that battery voltage is more than 8V. Turn ignition switch ON and wait at least 1 second. Select “DATA MONITOR” mode with CONSULT-II. If DTC is detected, go to EC-302, "Diagnostic Procedure" . SEF058Y With GST Follow the procedure “With CONSULT-II” above. EC-299 K L M With CONSULT-II 1. 2. 3. J DTC P1124, P1126 THROTTLE CONTROL MOTOR RELAY [CR (WITH EURO-OBD)] PROCEDURE FOR DTC P1126 With CONSULT-II 1. 2. 3. 4. Turn ignition switch ON and wait at least 2 seconds. Select “DATA MONITOR” mode with CONSULT-II. Start engine and let it idle for 5 seconds. If DTC is detected, go to EC-302, "Diagnostic Procedure" . SEF058Y With GST Follow the procedure “With CONSULT-II” above. EC-300 DTC P1124, P1126 THROTTLE CONTROL MOTOR RELAY [CR (WITH EURO-OBD)] Wiring Diagram BBS002ZX A EC C D E F G H I J K L M MBWA1521E EC-301 DTC P1124, P1126 THROTTLE CONTROL MOTOR RELAY [CR (WITH EURO-OBD)] Specification data are reference values and are measured between each terminal and ground. Pulse signal is measured by CONSULT-II. CAUTION: Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM's transistor. Use a ground other than ECM terminals, such as the ground. TERMINAL NO. 3 WIRE COLOR LG ITEM Throttle control motor relay power supply CONDITION [Ignition switch: ON] DATA (DC Voltage) BATTERY VOLTAGE (11 - 14V) 0 - 14V [Ignition switch: ON] 4 L Throttle control motor (Close) ● Engine stopped ● Shift lever position: 1st ● Accelerator pedal: Fully released PBIB0534E 0 - 14V [Ignition switch: ON] 5 P Throttle control motor (Open) ● Engine stopped ● Shift lever position: 1st ● Accelerator pedal: Fully depressed PBIB0533E 104 G Throttle control motor relay [Ignition switch: OFF] BATTERY VOLTAGE (11 - 14V) [Ignition switch: ON] 0 - 1.0V : Average voltage for pulse signal (Actual pulse signal can be confirmed by oscilloscope.) Diagnostic Procedure BBS002ZY 1. CHECK THROTTLE CONTROL MOTOR RELAY POWER SUPPLY CIRCUIT-I 1. 2. Turn ignition switch OFF. Check voltage between ECM terminal 104 and ground with CONSULT-II or tester. Voltage: Battery voltage. OK or NG OK >> GO TO 4. NG >> GO TO 2. PBIB1171E EC-302 DTC P1124, P1126 THROTTLE CONTROL MOTOR RELAY [CR (WITH EURO-OBD)] 2. CHECK THROTTLE CONTROL MOTOR RELAY POWER SUPPLY CIRCUIT-II 1. 2. 3. A Disconnect ECM harness connector. Disconnect IPDM E/R harness connector E5. Check continuity between ECM terminal 104 and IPDM E/R terminal 70. EC Continuity should exist. C 4. Also check harness for short to ground and short to power. OK or NG OK >> GO TO 3. NG >> Repair open circuit or short to ground or short to power in harness or connectors. D 3. CHECK FUSE E 1. Disconnect 20A fuse. 2. Check 20A fuse for blown. OK or NG OK >> GO TO 7. NG >> Replace 20A fuse. F 4. CHECK THROTTLE CONTROL MOTOR RELAY INPUT SIGNAL CIRCUIT-I 1. 2. G Reconnect all disconnected connectors. Check voltage between ECM terminal 3 and ground under the following conditions with CONSULT-II or tester. Ignition switch Voltage OFF Approximately 0V ON Battery voltage (11 - 14V) OK or NG OK >> GO TO 7. NG >> GO TO 5. H I J MBIB0028E K 5. CHECK THROTTLE CONTROL MOTOR RELAY INPUT SIGNAL CIRCUIT-II 1. 2. 3. 4. Turn ignition switch OFF. Disconnect ECM harness connector. Disconnect IPDM E/R harness connector E7. Check continuity between ECM terminal 3 and IPDM E/R terminal 28. Refer to Wiring Diagram. Continuity should exist. 5. Also check harness for short to ground and short to power. OK or NG OK >> GO TO 7. NG >> GO TO 6. 6. DETECT MALFUNCTIONING PART Check the following. ● Harness connectors E48, F1 ● Harness for open or short between ECM and IPDM E/R >> Repair open circuit or short to ground or short to power in harness or connectors. EC-303 L M DTC P1124, P1126 THROTTLE CONTROL MOTOR RELAY [CR (WITH EURO-OBD)] 7. CHECK INTERMITTENT INCIDENT Refer to EC-127, "TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT" . OK or NG OK >> Replace IPDM E/R. Refer to PG-18, "IPDM E/R (INTELLIGENT POWER DISTRIBUTION MODULE ENGINE ROOM)" . NG >> Repair or replace harness or connectors. EC-304 DTC P1128 THROTTLE CONTROL MOTOR [CR (WITH EURO-OBD)] DTC P1128 THROTTLE CONTROL MOTOR Component Description PFP:16119 A BBS002ZZ The throttle control motor is operated by the ECM and it opens and closes the throttle valve. The current opening angle of the throttle valve is detected by the throttle position sensor and it provides feed- EC back to the ECM to control the throttle control motor to make the throttle valve opening angle properly in response to driving condition. On Board Diagnosis Logic BBS00300 C This self-diagnosis has the one trip detection logic. DTC No. P1128 1128 Trouble diagnosis name Throttle control motor circuit short DTC detecting condition ECM detects short in both circuits between ECM and throttle control motor. Possible cause D ● Harness or connectors (Throttle control motor circuit is shorted.) ● Electric throttle control actuator (Throttle control motor) E FAIL-SAFE MODE F When the malfunction is detected, the ECM enters fail-safe mode and the MI lights up. Engine operating condition in fail-safe mode ECM stops the electric throttle control actuator control, throttle valve is maintained at a fixed opening (approx. 5 degrees) by the return spring. DTC Confirmation Procedure BBS00301 NOTE: If DTC Confirmation Procedure has been previously conducted, always turn ignition switch OFF and wait at least 10 seconds before conducting the next test. G H I WITH CONSULT-II 1. 2. 3. 4. Turn ignition switch ON and wait at least 2 seconds. Select “DATA MONITOR” mode with CONSULT-II. Start engine and let it idle for 5 seconds. If DTC is detected, go to EC-307, "Diagnostic Procedure" . J K L SEF058Y WITH GST Follow the procedure “WITH CONSULT-II” above. EC-305 M DTC P1128 THROTTLE CONTROL MOTOR [CR (WITH EURO-OBD)] Wiring Diagram BBS00302 MBWA1522E EC-306 DTC P1128 THROTTLE CONTROL MOTOR [CR (WITH EURO-OBD)] Specification data are reference values and are measured between each terminal and ground. Pulse signal is measured by CONSULT-II. A CAUTION: Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM's transistor. Use a ground other than ECM terminals, such as the ground. EC TERMINAL NO. 3 WIRE COLOR ITEM CONDITION DATA (DC Voltage) C LG Throttle control motor relay power supply BATTERY VOLTAGE (11 - 14V) [Ignition switch: ON] 0 - 14V D [Ignition switch: ON] 4 L Throttle control motor (Close) ● Engine stopped ● Shift lever position: 1st ● Accelerator pedal: Fully released E PBIB0534E F 0 - 14V [Ignition switch: ON] 5 P Throttle control motor (Open) ● Engine stopped ● Shift lever position: 1st ● Accelerator pedal: Fully depressed G H PBIB0533E 104 G Throttle control motor relay [Ignition switch: OFF] BATTERY VOLTAGE (11 - 14V) [Ignition switch: ON] 0 - 1.0V I : Average voltage for pulse signal (Actual pulse signal can be confirmed by oscilloscope.) J Diagnostic Procedure BBS00303 1. CHECK GROUND CONNECTIONS 1. 2. K Turn ignition switch OFF. Loosen and retighten ground screws on the body. Refer to EC-133, "Ground Inspection" . L M MBIB1502E 1. Body ground E44 2. Body ground E45 OK or NG OK >> GO TO 2. NG >> Repair or replace ground connections. EC-307 3. Body ground E28 DTC P1128 THROTTLE CONTROL MOTOR [CR (WITH EURO-OBD)] 2. CHECK THROTTLE CONTROL MOTOR OUTPUT SIGNAL CIRCUIT FOR OPEN OR SHORT 1. 2. 3. Disconnect electric throttle control actuator harness connector. Disconnect ECM harness connector. Check harness continuity between the following terminals. Refer to Wiring Diagram. Electric throttle control actuator terminal ECM terminal 3 6 Continuity 4 Should exist 5 Should not exist 4 Should not exist 5 Should exist MBIB0308E 4. Also check harness for short to ground and short to power. OK or NG OK >> GO TO 3. NG >> Repair or replace. 3. CHECK THROTTLE CONTROL MOTOR Refer to EC-308, "Component Inspection" . OK or NG OK >> GO TO 4. NG >> GO TO 5. 4. CHECK INTERMITTENT INCIDENT Refer to EC-127, "TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT" . OK or NG OK >> GO TO 5. NG >> Repair or replace harness or connectors. 5. REPLACE ELECTRIC THROTTLE CONTROL ACTUATOR 1. 2. 3. Replace the electric throttle control actuator. Perform EC-69, "Throttle Valve Closed Position Learning" . Perform EC-69, "Idle Air Volume Learning" . >> INSPECTION END Component Inspection BBS00304 THROTTLE CONTROL MOTOR 1. 2. Disconnect electric throttle control actuator harness connector. Check resistance between terminals 3 and 6. Resistance: Approximately 1 - 15 Ω [at 25 °C (77°F)] 3. 4. 5. If NG, replace electric throttle control actuator and go to next step. Perform EC-69, "Throttle Valve Closed Position Learning" . Perform EC-69, "Idle Air Volume Learning" . PBIB0095E EC-308 DTC P1128 THROTTLE CONTROL MOTOR [CR (WITH EURO-OBD)] Removal and Installation BBS00305 ELECTRIC THROTTLE CONTROL ACTUATOR A Refer to EM-18, "AIR CLEANER AND AIR DUCT" . EC C D E F G H I J K L M EC-309 DTC P1143 HO2S1 [CR (WITH EURO-OBD)] DTC P1143 HO2S1 Component Description PFP:22690 BBS00306 The heated oxygen sensor 1 is placed into the exhaust manifold. It detects the amount of oxygen in the exhaust gas compared to the outside air. The heated oxygen sensor 1 has a closed-end tube made of ceramic zirconia. The zirconia generates voltage from approximately 1V in richer conditions to 0V in leaner conditions. The heated oxygen sensor 1 signal is sent to the ECM. The ECM adjusts the injection pulse duration to achieve the ideal air-fuel ratio. The ideal air-fuel ratio occurs near the radical change from 1V to 0V. SEF463R SEF288D CONSULT-II Reference Value in Data Monitor Mode BBS00307 Specification data are reference values. MONITOR ITEM CONDITION SPECIFICATION 0 - 0.3V ←→ Approx. 0.6 - 1.0V HO2S1 (B1) ● HO2S1 MNTR (B1) Engine: After warming up Maintaining engine speed at 2,000 rpm LEAN ←→ RICH Changes more than 5 times during 10 seconds. On Board Diagnosis Logic BBS00308 To judge the malfunction, the output from the heated oxygen sensor 1 is monitored to determine whether the “rich” output is sufficiently high and whether the “lean” output is sufficiently low. When both the outputs are shifting to the lean side, the malfunction will be detected. SEF300U DTC No. P1143 1143 Trouble diagnosis name Heated oxygen sensor 1 lean shift monitoring DTC detecting condition The maximum and minimum voltage from the sensor are not reached to the specified voltages. EC-310 Possible cause ● Heated oxygen sensor 1 ● Heated oxygen sensor 1 heater ● Fuel pressure ● Fuel injector ● Intake air leak DTC P1143 HO2S1 [CR (WITH EURO-OBD)] DTC Confirmation Procedure BBS00309 A CAUTION: Always drive vehicle at a safe speed. NOTE: If DTC Confirmation Procedure has been previously conducted, always turn ignition switch OFF and wait at EC least 10 seconds before conducting the next test. TESTING CONDITION: C ● Always perform at a temperature above −10°C (14°F). ● Before performing following procedure, confirm that battery voltage is more than 11V at idle. WITH CONSULT-II 1. 2. 3. 4. 5. D Start engine and warm it up to normal operating temperature. Stop engine and wait at least 10 seconds. Turn ignition switch ON and select “HO2S1 (B1) P1143” of “HO2S1” in “DTC WORK SUPPORT” mode with CONSULT-II. Touch “START”. Start engine and let it idle for at least 3 minutes. NOTE: Never raise engine speed above 3,600 rpm after this step. If the engine speed limit is exceeded, return to step 5. E F G H PBIB0546E I 6. When the following conditions are met, “TESTING” will be displayed on the CONSULT-II screen. Maintain the conditions continuously until “TESTING” changes to “COMPLETED”. (It will take approximately 50 seconds or more.) ENG SPEED 1,500 - 3,200 rpm VHCL SPEED SE 50 - 100 km/h (31 - 62 MPH) B/FUEL SCHDL 1.8 - 5.5 msec Shift lever Suitable position 7. J K L If “TESTING” is not displayed after 5 minutes, retry from step 2. Make sure that “OK” is displayed after touching “SELF-DIAG RESULTS”. If “NG” is displayed, refer to EC-312, "Diagnostic Procedure" . PBIB0547E M SEC769C EC-311 DTC P1143 HO2S1 [CR (WITH EURO-OBD)] Overall Function Check BBS0030A Use this procedure to check the overall function of the heated oxygen sensor 1 circuit. During this check, a 1st trip DTC might not be confirmed. WITH GST 1. 2. 3. ● ● 4. Start engine and warm it up to normal operating temperature. Set voltmeter probes between ECM terminal 35 (HO2S1 signal) and ground. Check one of the following with engine speed held at 2,000 rpm constant under no load. The maximum voltage is over 0.6V at least one time. The minimum voltage is over 0.1V at least one time. If NG, go to EC-312, "Diagnostic Procedure" . MBIB0018E Diagnostic Procedure BBS0030B 1. CHECK GROUND CONNECTIONS 1. 2. Turn ignition switch OFF. Loosen and retighten ground screws on the body. Refer to EC-133, "Ground Inspection" . MBIB1502E 1. Body ground E44 2. Body ground E45 3. Body ground E28 OK or NG OK >> GO TO 2. NG >> Repair or replace ground connections. 2. RETIGHTEN HEATED OXYGEN SENSOR 1 Loosen and retighten heated oxygen sensor 1 (2). ● ● : Vehicle front Exhaust manifold cover (1) Tightening torque: 50 N·m (5.1 kg-m, 37 ft-lb) >> GO TO 3. MBIB1493E EC-312 DTC P1143 HO2S1 [CR (WITH EURO-OBD)] 3. CHECK FOR INTAKE AIR LEAK A Listen for an intake air leak after the manifold absolute pressure sensor. OK or NG OK >> GO TO 4. NG >> Repair or replace. EC 4. CLEAR THE SELF-LEARNING DATA 1. 2. 3. 4. C With CONSULT-II Start engine and warm it up to normal operating temperature. Select “SELF-LEARNING CONT” in “WORK SUPPORT” mode with CONSULT-II. Clear the self-learning control coefficient by touching “CLEAR”. Run engine for at least 10 minutes at idle speed. Is the 1st trip DTC P0171 detected? Is it difficult to start engine? D E F G SEF215Z H Without CONSULT-II 1. Start engine and warm it up to normal operating temperature. 2. Turn ignition switch OFF. 3. Disconnect manifold absolute pressure sensor harness connector, and restart and run engine for at least 5 seconds at idle speed. 4. Stop engine and reconnect manifold absolute pressure sensor harness connector. 5. Make sure that DTC P0107 is displayed. 6. Erase the DTC memory. Refer to EC-57, "HOW TO ERASE EMISSION-RELATED DIAGNOSTIC INFORMATION" . 7. Make sure that DTC P0000 is displayed. 8. Run engine for at least 10 minutes at idle speed. Is the 1st trip DTC P0171 detected? Is it difficult to start engine? Yes or No Yes >> Perform trouble diagnosis for DTC P0171. Refer to EC-218 . No >> GO TO 5. 5. CHECK HEATED OXYGEN SENSOR 1 HEATER Refer to EC-148, "Component Inspection" . OK or NG OK >> GO TO 6. NG >> Replace heated oxygen sensor 1. 6. CHECK HEATED OXYGEN SENSOR 1 Refer to EC-314, "Component Inspection" . OK or NG OK >> GO TO 7. NG >> Replace heated oxygen sensor 1. EC-313 I J K L MBIB0276E M DTC P1143 HO2S1 [CR (WITH EURO-OBD)] 7. CHECK INTERMITTENT INCIDENT Refer to EC-127, "TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT" . For circuit, refer to EC-180, "Wiring Diagram" . >> INSPECTION END Component Inspection BBS0030C HEATED OXYGEN SENSOR 1 With CONSULT-II 1. 2. 3. 4. 5. Start engine and warm it up to normal operating temperature. Select “MANU TRIG” and adjust “TRIGGER POINT” to 100% in “DATA MONITOR” mode with CONSULTII. Select “HO2S1 (B1)” and “HO2S1 MNTR (B1)”. Hold engine speed at 2,000 rpm under no load during the following steps. Touch “RECORD” on CONSULT-II screen. MBIB0301E 6. Check the following. ● “HO2S1 MNTR (B1)” in “DATA MONITOR” mode changes from “RICH” to “LEAN” to “RICH” more than 5 times in 10 seconds. 5 times (cycles) are counted as shown in the figure. ● “HO2S1 (B1)” voltage goes above 0.6V at least once. ● “HO2S1 (B1)” voltage goes below 0.3V at least once. ● “HO2S1 (B1)” voltage never exceeds 1.0V. SEF217YA SEF648Y CAUTION: ● Discard any heated oxygen sensor which has been dropped from a height of more than 0.5 m (19.7 in) onto a hard surface such as a concrete floor; use a new one. ● Before installing new oxygen sensor, clean exhaust system threads using Oxygen Sensor Thread Cleaner and approved anti-seize lubricant. EC-314 DTC P1143 HO2S1 [CR (WITH EURO-OBD)] Without CONSULT-II A Start engine and warm it up to normal operating temperature. Set voltmeter probes between ECM terminal 35 (HO2S1 signal) and ground. Check the following with engine speed held at 2,000 rpm conEC stant under no load. ● The voltage fluctuates between 0 to 0.3V and 0.6 to 1.0V more than 5 times within 10 seconds. C ● The maximum voltage is over 0.6V at least one time. ● The minimum voltage is below 0.3V at least one time. ● The voltage never exceeds 1.0V. D 1 time: 0 - 0.3V → 0.6 - 1.0V → 0 - 0.3V 2 times: 0 - 0.3V → 0.6 - 1.0V → 0 - 0.3V → 0.6 - 1.0V → 0 0.3V MBIB0018E E CAUTION: ● Discard any heated oxygen sensor which has been dropped from a height of more than 0.5 m (19.7 in) onto a hard surface such as a concrete floor; use a new one. ● Before installing new oxygen sensor, clean exhaust system threads using Oxygen Sensor Thread F Cleaner and approved anti-seize lubricant. 1. 2. 3. Removal and Installation BBS0030D HEATED OXYGEN SENSOR 1 G Refer to EM-24, "EXHAUST MANIFOLD AND THREE WAY CATALYST" . H I J K L M EC-315 DTC P1144 HO2S1 [CR (WITH EURO-OBD)] DTC P1144 HO2S1 Component Description PFP:22690 BBS0030E The heated oxygen sensor 1 is placed into the exhaust manifold. It detects the amount of oxygen in the exhaust gas compared to the outside air. The heated oxygen sensor 1 has a closed-end tube made of ceramic zirconia. The zirconia generates voltage from approximately 1V in richer conditions to 0V in leaner conditions. The heated oxygen sensor 1 signal is sent to the ECM. The ECM adjusts the injection pulse duration to achieve the ideal air-fuel ratio. The ideal air-fuel ratio occurs near the radical change from 1V to 0V. SEF463R SEF288D CONSULT-II Reference Value in Data Monitor Mode BBS0030F Specification data are reference values. MONITOR ITEM CONDITION SPECIFICATION 0 - 0.3V ←→ Approx. 0.6 - 1.0V HO2S1 (B1) ● HO2S1 MNTR (B1) Engine: After warming up Maintaining engine speed at 2,000 rpm LEAN ←→ RICH Changes more than 5 times during 10 seconds. On Board Diagnosis Logic BBS0030G To judge the malfunction, the output from the heated oxygen sensor 1 is monitored to determine whether the “rich” output is sufficiently high and whether the “lean” output is sufficiently low. When both the outputs are shifting to the rich side, the malfunction will be detected. SEF299U DTC No. P1144 1144 Trouble diagnosis name DTC detecting condition Heated oxygen sensor 1 rich shift monitoring The maximum and minimum voltages from the sensor are beyond the specified voltages. EC-316 Possible cause ● Heated oxygen sensor 1 ● Heated oxygen sensor 1 heater ● Fuel pressure ● Fuel injector DTC P1144 HO2S1 [CR (WITH EURO-OBD)] DTC Confirmation Procedure BBS0030H A CAUTION: Always drive vehicle at a safe speed. NOTE: If DTC Confirmation Procedure has been previously conducted, always turn ignition switch OFF and wait at EC least 10 seconds before conducting the next test. TESTING CONDITION: C ● Always perform at a temperature above −10°C (14°F). ● Before performing the following procedure, confirm that battery voltage is more than 11V at idle. WITH CONSULT-II 1. 2. 3. 4. 5. D Start engine and warm it up to normal operating temperature. Stop engine and wait at least 5 seconds. Turn ignition switch ON and select “HO2S1 (B1) P1144” of “HO2S1” in “DTC WORK SUPPORT” mode with CONSULT-II. Touch “START”. Start engine and let it idle for at least 3 minutes. NOTE: Never raise engine speed above 3,600 rpm after this step. If the engine speed limit is exceeded, return to step 5. E F G H PBIB0548E I 6. When the following conditions are met, “TESTING” will be displayed on the CONSULT-II screen. Maintain the conditions continuously until “TESTING” changes to “COMPLETED”. (It will take approximately 50 seconds or more.) ENG SPEED 1,500 - 3,200 rpm VHCL SPEED SE 50 - 100 km/h (31 - 62 MPH) B/FUEL SCHDL 1.8 - 5.5 msec Shift lever Suitable position 7. J K L If “TESTING” is not displayed after 5 minutes, retry from step 2. Make sure that “OK” is displayed after touching “SELF-DIAG RESULTS”. If “NG” is displayed, refer to EC-318, "Diagnostic Procedure" . PBIB0549E M SEC772C EC-317 DTC P1144 HO2S1 [CR (WITH EURO-OBD)] Overall Function Check BBS0030I Use this procedure to check the overall function of the heated oxygen sensor 1 circuit. During this check, a 1st trip DTC might not be confirmed. WITH GST 1. 2. 3. ● ● 4. Start engine and warm it up to normal operating temperature. Set voltmeter probes between ECM terminal 35 (HO2S1 signal) and ground. Check one of the following with engine speed held at 2,000 rpm constant under no load. The maximum voltage is below 0.8V at least one time. The minimum voltage is below 0.35V at least one time. If NG, go to EC-318, "Diagnostic Procedure" . MBIB0018E Diagnostic Procedure BBS0030J 1. CHECK GROUND CONNECTIONS 1. 2. Turn ignition switch OFF. Loosen and retighten ground screws on the body. Refer to EC-133, "Ground Inspection" . MBIB1502E 1. Body ground E44 2. Body ground E45 3. Body ground E28 OK or NG OK >> GO TO 2. NG >> Repair or replace ground connections. 2. RETIGHTEN HEATED OXYGEN SENSOR 1 Loosen and retighten heated oxygen sensor 1 (2). ● ● : Vehicle front Exhaust manifold cover (1) Tightening torque: 50 N·m (5.1 kg-m, 37 ft-lb) >> GO TO 3. MBIB1493E EC-318 DTC P1144 HO2S1 [CR (WITH EURO-OBD)] 3. CLEAR THE SELF-LEARNING DATA 1. 2. 3. 4. A With CONSULT-II Start engine and warm it up to normal operating temperature. Select “SELF-LEARNING CONT” in “WORK SUPPORT” mode with CONSULT-II. Clear the self-learning control coefficient by touching “CLEAR”. Run engine for at least 10 minutes at idle speed. Is the 1st trip DTC P0172 detected? Is it difficult to start engine? EC C D E SEF215Z Without CONSULT-II 1. Start engine and warm it up to normal operating temperature. 2. Turn ignition switch OFF. 3. Disconnect manifold absolute pressure sensor harness connector, and restart and run engine for at least 5 seconds at idle speed. 4. Stop engine and reconnect manifold absolute pressure sensor harness connector. 5. Make sure that DTC P0107 is displayed. 6. Erase the DTC memory. Refer to EC-57, "HOW TO ERASE EMISSION-RELATED DIAGNOSTIC INFORMATION" . 7. Make sure that DTC P0000 is displayed. 8. Run engine for at least 10 minutes at idle speed. Is the 1st trip DTC P0172 detected? Is it difficult to start engine? Yes or No Yes >> Perform trouble diagnosis for DTC P0172. Refer to EC-226 . No >> GO TO 4. F G H I J MBIB0276E K L 4. CHECK HO2S1 CONNECTOR FOR WATER 1. 2. 3. Turn ignition switch OFF. Disconnect heated oxygen sensor 1 harness connector (1). Check connectors for water. M Water should not exist. OK or NG OK >> GO TO 5. NG >> Repair or replace harness or connectors. MBIB1494E EC-319 DTC P1144 HO2S1 [CR (WITH EURO-OBD)] 5. CHECK HEATED OXYGEN SENSOR 1 HEATER Refer to EC-148, "Component Inspection" . OK or NG OK >> GO TO 6. NG >> Replace heated oxygen sensor 1. 6. CHECK HEATED OXYGEN SENSOR 1 Refer to EC-320, "Component Inspection" . OK or NG OK >> GO TO 7. NG >> Replace heated oxygen sensor 1. 7. CHECK INTERMITTENT INCIDENT Refer to EC-127, "TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT" . For circuit, refer to EC-180, "Wiring Diagram" . >> INSPECTION END Component Inspection BBS0030K HEATED OXYGEN SENSOR 1 With CONSULT-II 1. 2. 3. 4. 5. Start engine and warm it up to normal operating temperature. Select “MANU TRIG” and adjust “TRIGGER POINT” to 100% in “DATA MONITOR” mode with CONSULTII. Select “HO2S1 (B1)” and “HO2S1 MNTR (B1)”. Hold engine speed at 2,000 rpm under no load during the following steps. Touch “RECORD” on CONSULT-II screen. MBIB0301E 6. Check the following. ● “HO2S1 MNTR (B1)” in “DATA MONITOR” mode changes from “RICH” to “LEAN” to “RICH” more than 5 times in 10 seconds. 5 times (cycles) are counted as shown in the figure. ● “HO2S1 (B1)” voltage goes above 0.6V at least once. ● “HO2S1 (B1)” voltage goes below 0.3V at least once. ● “HO2S1 (B1)” voltage never exceeds 1.0V. SEF217YA EC-320 DTC P1144 HO2S1 [CR (WITH EURO-OBD)] A EC C SEF648Y CAUTION: ● Discard any heated oxygen sensor which has been dropped from a height of more than 0.5 m (19.7 in) onto a hard surface such as a concrete floor; use a new one. ● Before installing new oxygen sensor, clean exhaust system threads using Oxygen Sensor Thread Cleaner and approved anti-seize lubricant. Without CONSULT-II 1. 2. 3. Start engine and warm it up to normal operating temperature. Set voltmeter probes between ECM terminal 35 (HO2S1 signal) and ground. Check the following with engine speed held at 2,000 rpm constant under no load. ● The voltage fluctuates between 0 to 0.3V and 0.6 to 1.0V more than 5 times within 10 seconds. ● The maximum voltage is over 0.6V at least one time. ● The minimum voltage is below 0.3V at least one time. ● The voltage never exceeds 1.0V. 1 time: 0 - 0.3V → 0.6 - 1.0V → 0 - 0.3V 2 times: 0 - 0.3V → 0.6 - 1.0V → 0 - 0.3V → 0.6 - 1.0V → 0 0.3V MBIB0018E CAUTION: ● Discard any heated oxygen sensor which has been dropped from a height of more than 0.5 m (19.7 in) onto a hard surface such as a concrete floor; use a new one. ● Before installing new oxygen sensor, clean exhaust system threads using Oxygen Sensor Thread Cleaner and approved anti-seize lubricant. Removal and Installation BBS0030L D E F G H I J K L HEATED OXYGEN SENSOR 1 Refer to EM-24, "EXHAUST MANIFOLD AND THREE WAY CATALYST" . M EC-321 DTC P1146 HO2S2 [CR (WITH EURO-OBD)] DTC P1146 HO2S2 Component Description PFP:226A0 BBS0030M The heated oxygen sensor 2, after three way catalyst (manifold), monitors the oxygen level in the exhaust gas on each bank. Even if switching characteristics of the heated oxygen sensor 1 are shifted, the air-fuel ratio is controlled to stoichiometric, by the signal from the heated oxygen sensor 2. This sensor is made of ceramic zirconia. The zirconia generates voltage from approximately 1V in richer conditions to 0V in leaner conditions. Under normal conditions the heated oxygen sensor 2 is not used for engine control operation. SEF327R CONSULT-II Reference Value in Data Monitor Mode BBS0030N Specification data are reference values. MONITOR ITEM HO2S2 (B1) HO2S2 MNTR (B1) CONDITION SPECIFICATION ● Revving engine from idle to 3,000 rpm quickly after the following conditions are met. 0 - 0.3V ←→ Approx. 0.6 - 1.0V – Engine: After warming up – Keeping the engine speed between 3,500 and 4,000 rpm for 1 minute and at idle for 1 minute under no load. LEAN ←→ RICH On Board Diagnosis Logic BBS0030O The heated oxygen sensor 2 has a much longer switching time between rich and lean than the heated oxygen sensor 1. The oxygen storage capacity of the three way catalyst (manifold) causes the longer switching time. To judge the malfunctions of heated oxygen sensor 2, ECM monitors whether the minimum voltage of sensor is sufficiently low during the various driving condition such as fuel-cut. PBIB1201E DTC No. P1146 1146 Trouble diagnosis name Heated oxygen sensor 2 minimum voltage monitoring DTC detecting condition The minimum voltage from the sensor is not reached to the specified voltage. DTC Confirmation Procedure Possible cause ● Harness or connectors (The sensor circuit is open or shorted.) ● Heated oxygen sensor 2 ● Fuel pressure ● Fuel Injector BBS0030P CAUTION: Always drive vehicle at a safe speed. NOTE: ● “COMPLETED” will appear on CONSULT-II screen when all tests “COND1”, “COND2” and “COND3” are completed. ● If DTC confirmation Procedure has been previously conducted, always turn ignition switch OFF and wait at least 10 seconds before conducting the next test. TESTING CONDITION: Never stop engine during this procedure. If the engine is stopped, retry procedure from step 2 in Procedure for COND1. EC-322 DTC P1146 HO2S2 [CR (WITH EURO-OBD)] WITH CONSULT-II Procedure for COND1 A For the best results, perform “DTC WORK SUPPORT” at a temperature of 0 to 30°C(32 to 86°F). 1. Start engine and warm it up to normal operating temperature. EC 2. Turn ignition switch OFF and wait at least 10 seconds. 3. Start engine and keep the engine speed between 3,500 and 4,000 rpm for at least 1 minute under no load. 4. Let engine idle 1 minute. C 5. Select “HO2S2 (B1) P1146” of “HO2S2” in “DTC WORK SUPPORT” mode with CONSULT-II. 6. Touch “START”. 7. Start engine and let it idle for at least 30 seconds. D 8. Rev engine up to 2,000 rpm 2 or 3 times quickly under no load. If “COMPLETED” appears on CONSULT-II screen, go to step 2 in Procedure for COND3”. If “COMPLETED” does not appear on CONSULT-II screen, go to the following step. E 9. When the following conditions are met, “TESTING” will be displayed at “COND1” on the CONSULT-II screen. Maintain the conditions continuously until “TESTING” changes to “COMPLETED”. (It will take approximately 60 seconds.) F ENG SPEED More than 1,500 rpm B/FUEL SCHDL More than 1.0 msec COOLAN TEMP/S 70 - 105°C Shift lever Suitable position G H I J PBIB0555E NOTE: ● If “TESTING” is not displayed after 5 minutes, retry from step 2 in Procedure for COND1. ● If “COMPLETED” already appears at “COND2” on CONSULT-II screen before Procedure for COND2 is conducted, it is unnecessary to conduct step 1 in Procedure for COND2. Procedure for COND2 1. L M While driving, release accelerator pedal completed from the above condition [step 9] until “INCOMPLETE” at “COND2” on CONSULT-II screen has turned to “COMPLETED” (It will take approximately 4 seconds.) NOTE: If “COMPLETE” already appears at “COND3” on CONSULTII screen before Procedure for COND3 is conducted, it is unnecessary to conduct step 1 in Procedure for COND3. PBIB0556E EC-323 K DTC P1146 HO2S2 [CR (WITH EURO-OBD)] Procedure for COND3 1. 2. a. b. c. d. Stop vehicle and let it idle until “INCOMPLETE” of “COND3” on CONSULT-II screen has turned to “COMPLETED”. (It will take a maximum of approximately 6 minutes.) Make sure that “OK” is displayed after touching “SELF-DIAG RESULTS”. If “NG” is displayed, refer to EC-326, "Diagnostic Procedure" . If “CAN NOT BE DIAGNOSED” is displayed, performed the following. Turn ignition switch OFF and leave the vehicle in a cool place (soak the vehicle). SEC775C Turn ignition switch ON and select “COOLAN TEMP/S” in “DATA MONITOR” mode with CONSULT-II. Start engine and warm it up while monitoring “COOLAN TEMP/S” indication on CONSULT-II. When “COOLAN TEMP/S” indication reaches to 70°C(158°F), go to procedure for COND1 step 3. Overall Function Check BBS0030Q Use this procedure to check the overall function of the heated oxygen sensor 2 circuit. During this check, a 1st trip DTC might not be confirmed. WITH GST 1. 2. 3. 4. 5. 6. 7. 8. Start engine and warm it up to the operating temperature. Turn ignition switch OFF and wait at least 10 seconds. Start engine and keep the engine speed between 3,500 and 4,000 rpm for at least 1 minute under no load. Let engine idle for 1 minute. Set voltmeter probes between ECM terminal 16 (HO2S2 signal) and ground. Check the voltage when revving up to 4,000 rpm under no load at least 10 times. (Depress and release accelerator pedal as soon as possible.) The voltage should be below 0.52V at least once during this procedure. If the voltage can be confirmed in step 6, step 7 is not necessary. Keep vehicle at idling for 10 minutes, then check the voltage. Or check the voltage when coasting from 80 km/h (50 MPH) in 3rd gear position. The voltage should be below 0.52V at least once during this MBIB0020E procedure. If NG, go to EC-326, "Diagnostic Procedure" . EC-324 DTC P1146 HO2S2 [CR (WITH EURO-OBD)] Wiring Diagram BBS0030R A EC C D E F G H I J K L M MBWA1511E EC-325 DTC P1146 HO2S2 [CR (WITH EURO-OBD)] Specification data are reference values and are measured between each terminal and ground. CAUTION: Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM's transistor. Use a ground other than ECM terminals, such as the ground. TERMINAL NO. WIRE COLOR ITEM CONDITION DATA (DC Voltage) [Engine is running] 2 GR ● Engine speed: Below 3,800 rpm after the following conditions are met. – Engine: After warming up – Keeping the engine speed between 3,500 and 4,000 rpm for 1 minute and at idle for 1 minute under no load. Heated oxygen sensor 2 heater 0 - 1.0V [Ignition switch: ON] ● Engine stopped BATTERY VOLTAGE (11 - 14V) [Engine is running] ● Engine speed: Above 3,800 rpm [Engine is running] 16 LG Heated oxygen sensor 2 ● Revving engine from idle to 3,000rpm quickly after the following conditions are met. – Engine: After warming up – Keeping the engine speed between 3,500 and 4,000 rpm for 1 minute and at idle for 1 minute under no load. 0 - Approximately 1.0V [Engine is running] 74 B Sensor ground (Heated oxygen sensor) ● Warm-up condition ● Idle speed Approximately 0V Diagnostic Procedure BBS0030S 1. CHECK GROUND CONNECTIONS 1. 2. Turn ignition switch OFF. Loosen and retighten ground screws on the body. Refer to EC-133, "Ground Inspection" . MBIB1502E 1. Body ground E44 2. Body ground E45 OK or NG OK >> GO TO 2. NG >> Repair or replace ground connections. EC-326 3. Body ground E28 DTC P1146 HO2S2 [CR (WITH EURO-OBD)] 2. CLEAR THE SELF-LEARNING DATA A With CONSULT-II Start engine and warm it up to normal operating temperature. Select “SELF-LEARNING CONT” in “WORK SUPPORT” mode with CONSULT-II. 3. Clear the self-learning control coefficient by touching “CLEAR”. 4. Run engine for at least 10 minutes at idle speed. Is the 1st trip DTC P0172 detected? Is it difficult to start engine? 1. 2. EC C D E SEF215Z Without CONSULT-II 1. Start engine and warm it up to normal operating temperature. 2. Turn ignition switch OFF. 3. Disconnect manifold absolute pressure sensor harness connector, and restart and run engine for at least 5 seconds at idle speed. 4. Stop engine and reconnect manifold absolute pressure sensor harness connector. 5. Make sure that DTC P0107 is displayed. 6. Erase the DTC memory. Refer to EC-57, "HOW TO ERASE EMISSION-RELATED DIAGNOSTIC INFORMATION" . 7. Make sure that DTC P0000 is displayed. 8. Run engine for at least 10 minutes at idle speed. Is the 1st trip DTC P0172 detected? Is it difficult to start engine? Yes or No Yes >> Perform trouble diagnosis for DTC P0172. Refer to EC-226 . No >> GO TO 3. F G H I MBIB0276E J K 3. CHECK HO2S2 GROUND CIRCUIT FOR OPEN AND SHORT L 1. 2. 3. 4. M Turn ignition switch OFF. Disconnect heated oxygen sensor 2 harness connector. Disconnect ECM harness connector. Check harness continuity between ECM terminal 74 and HO2S2 terminal 4. Refer to Wiring Diagram. Continuity should exist. 5. Also check harness for short to ground and short to power. OK or NG OK >> GO TO 4. NG >> Repair open circuit or short to ground or short to power in harness or connectors. EC-327 MBIB0282E DTC P1146 HO2S2 [CR (WITH EURO-OBD)] 4. CHECK HO2S2 INPUT SIGNAL CIRCUIT FOR OPEN AND SHORT 1. Check harness continuity between ECM terminal 16 and HO2S2 terminal 1. Refer to Wiring Diagram. Continuity should exist. 2. Check harness continuity between ECM terminal 16 or HO2S2 terminal 1 and ground. Refer to Wiring Diagram. Continuity should not exist. 3. Also check harness for short to power. OK or NG OK >> GO TO 5. NG >> Repair open circuit or short to ground or short to power in harness or connectors. 5. CHECK HEATED OXYGEN SENSOR 2 Refer to EC-328, "Component Inspection" . OK or NG OK >> GO TO 6. NG >> Replace heated oxygen sensor 2. 6. CHECK INTERMITTENT INCIDENT Refer to EC-127, "TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT" . >> INSPECTION END Component Inspection BBS0030T HEATED OXYGEN SENSOR 2 With CONSULT-II 1. 2. 3. 4. 5. Turn ignition switch ON and select “DATA MONITOR” mode with CONSULT-II. Start engine and warm it up to the normal operating temperature. Turn ignition switch OFF and wait at least 10 seconds. Start engine and keep the engine speed between 3,500 and 4,000 rpm for at least 1 minute under no load. Let engine idle for 1 minute. SEF174Y 6. Select “FUEL INJECTION” in “ACTIVE TEST” mode, and select “HO2S2 (B1)” as the monitor item with CONSULT-II. SEF662Y EC-328 DTC P1146 HO2S2 [CR (WITH EURO-OBD)] 7. Check “HO2S2 (B1)” at idle speed when adjusting “FUEL INJECTION” to ±25%. A EC C MBIB1402E “HO2S2 (B1)” should be above 0.61V at least once when the “FUEL INJECTION” is +25%. “HO2S2 (B1)” should be below 0.52V at least once when the “FUEL INJECTION” is −25%. CAUTION: ● Discard any heated oxygen sensor which has been dropped from a height of more than 0.5 m (19.7 in) onto a hard surface such as a concrete floor; use a new one. ● Before installing new oxygen sensor, clean exhaust system threads using Oxygen Sensor Thread Cleaner and approved anti-seize lubricant. D E F Without CONSULT-II 1. 2. 3. 4. 5. 6. Start engine and warm it up to the normal operating temperature. Turn ignition switch OFF and wait at least 10 seconds. Start engine and keep the engine speed between 3,500 and 4,000 rpm for at least 1 minute under no load. Let engine idle for 1 minute. Set voltmeter probes between ECM terminal 16 (HO2S2 signal) and ground. Check the voltage when revving up to 4,000 rpm under no load at least 10 times. (Depress and release accelerator pedal as soon as possible.) The voltage should be above 0.61V at least once during this procedure. If the voltage is above 0.61V at step 6, step 7 is not necessary. 7. Keep vehicle at idling for 10 minutes, then check voltage. Or check the voltage when coasting from 80 km/h (50 MPH) in 3rd gear position. The voltage should be below 0.52V at least once during this MBIB0020E procedure. 8. If NG, replace heated oxygen sensor 2. CAUTION: ● Discard any heated oxygen sensor which has been dropped from a height of more than 0.5 m (19.7 in) onto a hard surface such as a concrete floor; use a new one. ● Before installing new oxygen sensor, clean exhaust system threads using Oxygen Sensor Thread Cleaner and approved anti-seize lubricant. Removal and Installation BBS0030U HEATED OXYGEN SENSOR 2 Refer to EX-3, "EXHAUST SYSTEM" . EC-329 G H I J K L M DTC P1147 HO2S2 [CR (WITH EURO-OBD)] DTC P1147 HO2S2 Component Description PFP:226A0 BBS0030V The heated oxygen sensor 2, after three way catalyst (manifold), monitors the oxygen level in the exhaust gas on each bank. Even if switching characteristics of the heated oxygen sensor 1 are shifted, the air-fuel ratio is controlled to stoichiometric, by the signal from the heated oxygen sensor 2. This sensor is made of ceramic zirconia. The zirconia generates voltage from approximately 1V in richer conditions to 0V in leaner conditions. Under normal conditions the heated oxygen sensor 2 is not used for engine control operation. SEF327R CONSULT-II Reference Value in Data Monitor Mode BBS0030W Specification data are reference values. MONITOR ITEM HO2S2 (B1) HO2S2 MNTR (B1) CONDITION SPECIFICATION ● Revving engine from idle to 3,000 rpm quickly after the following conditions are met. 0 - 0.3V ←→ Approx. 0.6 - 1.0V – Engine: After warming up – Keeping the engine speed between 3,500 and 4,000 rpm for 1 minute and at idle for 1 minute under no load. LEAN ←→ RICH On Board Diagnosis Logic BBS0030X The heated oxygen sensor 2 has a much longer switching time between rich and lean than the heated oxygen sensor 1. The oxygen storage capacity of the three way catalyst (manifold) causes the longer switching time. To judge the malfunctions of heated oxygen sensor 2, ECM monitors whether the maximum voltage of the sensor is sufficiently high during the various driving condition such as fuelcut. SEF560Z DTC No. P1147 1147 Trouble diagnosis name Heated oxygen sensor 2 maximum voltage monitoring DTC detecting condition The maximum voltage from the sensor is not reached to the specified voltage. EC-330 Possible cause ● Harness or connectors (The sensor circuit open or shorted.) ● Heated oxygen sensor 2 ● Fuel pressure ● Fuel injector ● Intake air leak DTC P1147 HO2S2 [CR (WITH EURO-OBD)] DTC Confirmation Procedure BBS0030Y A CAUTION: Always drive vehicle at a safe speed. NOTE: ● “COMPLETED” will appear on CONSULT-II screen when all tests “COND1”, “COND2” and EC “COND3” are completed. ● If DTC confirmation Procedure has been previously conducted, always turn ignition switch OFF and wait C at least 10 seconds before conducting the next test. TESTING CONDITION: Never stop engine during this procedure. If the engine is stopped, retry procedure from step 2 in ProD cedure for COND1. WITH CONSULT-II Procedure for COND1 For the best results, perform “DTC WORK SUPPORT” at a temperature of 0 to 30°C(32 to 86°F). 1. Start engine and warm it up to normal operating temperature. 2. Turn ignition switch OFF and wait at least 10 seconds. 3. Start engine and keep the engine speed between 3,500 and 4,000 rpm for at least 1 minute under no load. 4. Let engine idle 1 minute. 5. Select “HO2S2 (B1) P1147” of “HO2S2” in “DTC WORK SUPPORT” mode with CONSULT-II. 6. Touch “START”. 7. Start engine and let it idle for at least 30 seconds. 8. Rev engine up to 2,000 rpm 2 or 3 times quickly under no load. If “COMPLETED” appears on CONSULT-II screen, go to step 2 in Procedure for COND3. If “COMPLETED” does not appear on CONSULT-II screen, go to the following step. 9. When the following conditions are met, “TESTING” will be displayed at “COND1” on the CONSULT-II screen. Maintain the conditions continuously until “TESTING” changes to “COMPLETED”. (It will take approximately 60 seconds.) ENG SPEED More than 1.0 msec COOLAN TEMP/S 70 - 105°C Shift lever Suitable position F G H I J More than 1,500 rpm B/FUEL SCHDL E K L M PBIB0557E NOTE: ● If “TESTING” is not displayed after 5 minutes, retry from step 2 in Procedure for COND1. ● If “COMPLETED” already appears at “COND2” on CONSULT-II screen before Procedure for COND2 is conducted, it is unnecessary to conduct step 1 in Procedure for COND2. EC-331 DTC P1147 HO2S2 [CR (WITH EURO-OBD)] Procedure for COND2 1. While driving, release accelerator pedal completed from the above condition [step 9] until “INCOMPLETE” at “COND2” on CONSULT-II screen has turned to “COMPLETED” (It will take approximately 4 seconds.) NOTE: If “COMPLETE” already appears at “COND3” on CONSULTII screen before Procedure for COND3 is conducted, it is unnecessary to conduct step 1 in Procedure for COND3. PBIB0558E Procedure for COND3 1. 2. a. b. c. d. Stop vehicle and let it idle until “INCOMPLETE” of “COND3” on CONSULT-II screen has turned to “COMPLETED”. (It will take a maximum of approximately 6 minutes.) Make sure that “OK” is displayed after touching “SELF-DIAG RESULTS”. If “NG” is displayed, refer to EC-334, "Diagnostic Procedure" . If “CAN NOT BE DIAGNOSED” is displayed, perform the following. Turn ignition switch OFF and leave the vehicle in a cool place (soak the vehicle). SEC778C Turn ignition switch ON and select “COOLAN TEMP/S” in “DATA MONITOR” mode with CONSULT-II. Start engine and warm it up while monitoring “COOLAN TEMP/S” indication on CONSULT-II. When “COOLAN TEMP/S” indication reaches to 70°C(158°F), go to procedure for COND1 step 3. Overall Function Check BBS0030Z Use this procedure to check the overall function of the heated oxygen sensor 2 circuit. During this check, a 1st trip DTC might not be confirmed. WITH GST 1. 2. 3. 4. 5. 6. 7. 8. Start engine and warm it up to the normal operating temperature. Turn ignition switch OFF and wait at least 10 seconds. Start engine and keep the engine speed between 3,500 and 4,000 rpm for at least 1 minute under no load. Let engine idle for 1 minute. Set voltmeter probes between ECM terminal 16 (HO2S2 signal) and ground. Check the voltage when revving up to 4,000 rpm under no load at least 10 times. (Depress and release accelerator pedal as soon as possible.) The voltage should be above 0.61V at least once during this procedure. If the voltage can be confirmed in step 6, step 7 is not necessary. Keep vehicle idling for 10 minutes, then check the voltage. Or check the voltage when coasting from 80 km/h (50 MPH) in 3rd gear position. The voltage should be above 0.61V at least once during this MBIB0020E procedure. If NG, go to EC-334, "Diagnostic Procedure" . EC-332 DTC P1147 HO2S2 [CR (WITH EURO-OBD)] Wiring Diagram BBS00310 A EC C D E F G H I J K L M MBWA1511E EC-333 DTC P1147 HO2S2 [CR (WITH EURO-OBD)] Specification data are reference values and are measured between each terminal and ground. CAUTION: Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM's transistor. Use a ground other than ECM terminals, such as the ground. TERMINAL NO. WIRE COLOR ITEM CONDITION DATA (DC Voltage) [Engine is running] 2 GR ● Engine speed: Below 3,800 rpm after the following conditions are met. – Engine: After warming up – Keeping the engine speed between 3,500 and 4,000 rpm for 1 minute and at idle for 1 minute under no load. Heated oxygen sensor 2 heater 0 - 1.0V [Ignition switch: ON] ● Engine stopped BATTERY VOLTAGE (11 - 14V) [Engine is running] ● Engine speed: Above 3,800 rpm [Engine is running] 16 LG Heated oxygen sensor 2 ● Revving engine from idle to 3,000rpm quickly after the following conditions are met. – Engine: After warming up – Keeping the engine speed between 3,500 and 4,000 rpm for 1 minute and at idle for 1 minute under no load. 0 - Approximately 1.0V [Engine is running] 74 B Sensor ground (Heated oxygen sensor) ● Warm-up condition ● Idle speed Approximately 0V Diagnostic Procedure BBS00311 1. CHECK GROUND CONNECTIONS 1. 2. Turn ignition switch OFF. Loosen and retighten ground screws on the body. Refer to EC-133, "Ground Inspection" . MBIB1502E 1. Body ground E44 2. Body ground E45 OK or NG OK >> GO TO 2. NG >> Repair or replace ground connections. EC-334 3. Body ground E28 DTC P1147 HO2S2 [CR (WITH EURO-OBD)] 2. CLEAR THE SELF-LEARNING DATA A With CONSULT-II Start engine and warm it up to normal operating temperature. Select “SELF-LEARNING CONT” in “WORK SUPPORT” mode with CONSULT-II. 3. Clear the self-learning control coefficient by touching “CLEAR”. 4. Run engine for at least 10 minutes at idle speed. Is the 1st trip DTC P0171 detected? Is it difficult to start engine? 1. 2. EC C D E SEF215Z Without CONSULT-II 1. Start engine and warm it up to normal operating temperature. 2. Turn ignition switch OFF. 3. Disconnect manifold absolute pressure sensor harness connector, and restart and run engine for at least 5 seconds at idle speed. 4. Stop engine and reconnect manifold absolute pressure sensor harness connector. 5. Make sure that DTC P0107 is displayed. 6. Erase the DTC memory. Refer to EC-57, "HOW TO ERASE EMISSION-RELATED DIAGNOSTIC INFORMATION" . 7. Make sure that DTC P0000 is displayed. 8. Run engine for at least 10 minutes at idle speed. Is the 1st trip DTC P0171 detected? Is it difficult to start engine? Yes or No Yes >> Perform trouble diagnosis for DTC P0171. Refer to EC-218 . No >> GO TO 3. F G H I MBIB0276E J K 3. CHECK HO2S2 GROUND CIRCUIT FOR OPEN AND SHORT L 1. 2. 3. 4. M Turn ignition switch OFF. Disconnect heated oxygen sensor 2 harness connector. Disconnect ECM harness connector. Check harness continuity between ECM terminal 74 and HO2S2 terminal 4. Refer to Wiring Diagram. Continuity should exist. 5. Also check harness for short to ground and short to power. OK or NG OK >> GO TO 4. NG >> Repair open circuit or short to ground or short to power in harness or connectors. EC-335 MBIB0282E DTC P1147 HO2S2 [CR (WITH EURO-OBD)] 4. CHECK HO2S2 INPUT SIGNAL CIRCUIT FOR OPEN AND SHORT 1. Check harness continuity between ECM terminal 16 and HO2S2 terminal 1. Refer to Wiring Diagram. Continuity should exist. 2. Check harness continuity between ECM terminal 16 or HO2S2 terminal 1 and ground. Refer to Wiring Diagram. Continuity should not exist. 3. Also check harness for short to power. OK or NG OK >> GO TO 5. NG >> Repair open circuit or short to ground or short to power in harness or connectors. 5. CHECK HEATED OXYGEN SENSOR 2 Refer to EC-336, "Component Inspection" . OK or NG OK >> GO TO 6. NG >> Replace heated oxygen sensor 2. 6. CHECK INTERMITTENT INCIDENT Refer to EC-127, "TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT" . >> INSPECTION END Component Inspection BBS00312 HEATED OXYGEN SENSOR 2 With CONSULT-II 1. 2. 3. 4. 5. Turn ignition switch ON and select “DATA MONITOR” mode with CONSULT-II. Start engine and warm it up to the normal operating temperature. Turn ignition switch OFF and wait at least 10 seconds. Start engine and keep the engine speed between 3,500 and 4,000 rpm for at least 1 minute under no load. Let engine idle for 1 minute. SEF174Y 6. Select “FUEL INJECTION” in “ACTIVE TEST” mode, and select “HO2S2 (B1)” as the monitor item with CONSULT-II. SEF662Y EC-336 DTC P1147 HO2S2 [CR (WITH EURO-OBD)] 7. Check “HO2S2 (B1)” at idle speed when adjusting “FUEL INJECTION” to ±25%. A EC C MBIB1402E “HO2S2 (B1)” should be above 0.61V at least once when the “FUEL INJECTION” is +25%. “HO2S2 (B1)” should be below 0.52V at least once when the “FUEL INJECTION” is −25%. CAUTION: ● Discard any heated oxygen sensor which has been dropped from a height of more than 0.5 m (19.7 in) onto a hard surface such as a concrete floor; use a new one. ● Before installing new oxygen sensor, clean exhaust system threads using Oxygen Sensor Thread Cleaner and approved anti-seize lubricant. D E F Without CONSULT-II 1. 2. 3. 4. 5. 6. Start engine and warm it up to the normal operating temperature. Turn ignition switch OFF and wait at least 10 seconds. Start engine and keep the engine speed between 3,500 and 4,000 rpm for at least 1 minute under no load. Let engine idle for 1 minute. Set voltmeter probes between ECM terminal 16 (HO2S2 signal) and ground. Check the voltage when revving up to 4,000 rpm under no load at least 10 times. (Depress and release accelerator pedal as soon as possible.) The voltage should be above 0.61V at least once during this procedure. If the voltage is above 0.61V at step 6, step 7 is not necessary. 7. Keep vehicle idling for 10 minutes, then check voltage. Or check the voltage when coasting from 80 km/h (50 MPH) in 3rd gear position. The voltage should be below 0.52V at least once during this MBIB0020E procedure. 8. If NG, replace heated oxygen sensor 2. CAUTION: ● Discard any heated oxygen sensor which has been dropped from a height of more than 0.5 m (19.7 in) onto a hard surface such as a concrete floor; use a new one. ● Before installing new oxygen sensor, clean exhaust system threads using Oxygen Sensor Thread Cleaner and approved anti-seize lubricant. Removal and Installation BBS00313 HEATED OXYGEN SENSOR 2 Refer to EX-3, "EXHAUST SYSTEM" . EC-337 G H I J K L M DTC P1171 INTAKE ERROR [CR (WITH EURO-OBD)] DTC P1171 INTAKE ERROR On Board Diagnosis Logic PFP:22365 BBS00314 NOTE: ● If DTC P1171 is displayed with DTC P0108, first perform the trouble diagnosis for DTC P0108. Refer to EC-155, "DTC P0107, P0108 MANIFOLD ABSOLUTE PRESSURE SENSOR" ● If DTC P1171 is displayed with DTC P1229, first perform the trouble diagnosis for DTC P1229. Refer to EC-363, "DTC P1229 SENSOR POWER SUPPLY" . ECM computes two intake air volume values. 1: Computed from manifold absolute pressure signal and intake air temperature signal. 2: Computed from engine revolution signal and throttle position signal. In normal condition, value 1 is used for engine control. If intake air leak occurred between throttle valve and intake air port, manifold absolute pressure sensor signal might increase, and then ECM increases amount of fuel injected. In this case, ECM uses value 2 for engine control instead of value1. ECM monitors the difference between value 1 and value 2. If the difference is extremely large, ECM judges intake air leak occurs and light up the MI This diagnosis has one trip detection logic. DTC No. P1171 1171 Trouble diagnosis name Intake error DTC detecting condition A high voltage from the sensor is sent to ECM under light load driving condition. Possible cause ● Harness or connectors (The manifold absolute pressure sensor circuit is open or shorted.) ● Manifold absolute pressure ● Intake air leaks ● Vacuum hoses FAIL-SAFE MODE When the malfunction is detected, the ECM enters fail-safe mode and MI lights up. Detected items Intake air system Engine operating condition in fail-safe mode When accelerator pedal is depressed, engine speed will not rise more than 2,500 rpm due to fuel cut. DTC Confirmation Procedure BBS00315 NOTE: If DTC Confirmation Procedure has been previously conducted, always turn ignition switch OFF and wait at least 10 seconds before conducting the next test. WITH CONSULT-II 1. 2. 3. 4. Turn ignition switch ON. Select “DATA MONITOR” mode with CONSULT-II. Start engine and wait at least 5 seconds. If DTC is detected, go to EC-340, "Diagnostic Procedure" . SEF058Y WITH GST Follow the procedure “WITH CONSULT-II” above. EC-338 DTC P1171 INTAKE ERROR [CR (WITH EURO-OBD)] Wiring Diagram BBS00316 A EC C D E F G H I J K L M MBWA1506E EC-339 DTC P1171 INTAKE ERROR [CR (WITH EURO-OBD)] Specification data are reference values and are measured between each terminal and ground. CAUTION: Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM's transistor. Use a ground other than ECM terminals, such as the ground. TERMINAL NO. 45 WIRE COLOR L ITEM Sensor power supply (Manifold absolute pressure sensor) CONDITION [Ignition switch: ON] DATA (DC Voltage) Approximately 5V [Engine is running] 51 56 W B Manifold absolute pressure sensor Sensor ground (Manifold absolute pressure sensor) ● Warm-up condition ● Idle speed Approximately 1.5V [Engine is running] ● Warm-up condition ● Engine speed: 2,000 rpm Approximately 1.2V [Engine is running] ● Warm-up condition ● Idle speed Diagnostic Procedure Approximately 0V BBS00317 1. CHECK INTAKE AIR LEAK Listen for an intake air leak after the air cleaner element. OK or NG OK >> GO TO 2. NG >> Repair or replace. 2. CHECK VACUUM HOSE Check intake manifold vacuum hoses for clogging or disconnection. Refer to EC-92, "Vacuum Hose Drawing" . OK or NG OK >> GO TO 3. NG >> Repair or replace. 1. EC-340 DTC P1171 INTAKE ERROR [CR (WITH EURO-OBD)] 3. CHECK GROUND CONNECTIONS 1. 2. A Turn ignition switch OFF. Loosen and retighten ground screws on the body. Refer to EC-133, "Ground Inspection" . EC C D E MBIB1502E 1. Body ground E44 2. Body ground E45 3. Body ground E28 F OK or NG OK >> GO TO 4. NG >> Repair or replace ground connections. G 4. CHECK MAP SENSOR POWER SUPPLY CIRCUIT 1. 2. H Disconnect manifold absolute pressure sensor harness connector. Turn ignition switch ON. I J MBIB0276E 3. Check voltage between manifold absolute pressure sensor terminal 2 and ground with CONSULT-II or tester. K L Voltage: Approximately 5V OK or NG OK >> GO TO 5. NG >> Repair harness or connectors. M MBIB0602E EC-341 DTC P1171 INTAKE ERROR [CR (WITH EURO-OBD)] 5. CHECK MAP SENSOR GROUND CIRCUIT FOR OPEN AND SHORT 1. 2. 3. Turn ignition switch OFF. Disconnect ECM harness connector. Check harness continuity between manifold absolute pressure sensor terminal 4 and ECM terminal 56. Refer to Wiring Diagram. Continuity should exist. 4. Also check harness for short to ground and short to power. OK or NG OK >> GO TO 6. NG >> Repair open circuit or short to ground or short to power in harness or connectors. 6. CHECK MAP SENSOR INPUT SIGNAL CIRCUIT FOR OPEN AND SHORT 1. Check harness continuity between manifold absolute pressure sensor terminal 1 and ECM terminal 51. Refer to Wiring Diagram. Continuity should exist. 2. Also check harness for short to ground and short to power. OK or NG OK >> GO TO 7. NG >> Repair open circuit or short to ground or short to power in harness or connectors. 7. CHECK MAP SENSOR Refer to EC-159, "Component Inspection" . OK or NG OK >> GO TO 8. NG >> Replace manifold absolute pressure sensor. 8. CHECK INTERMITTENT INCIDENT Refer to EC-127, "TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT" . >> INSPECTION END EC-342 DTC P1211 TCS CONTROL UNIT [CR (WITH EURO-OBD)] DTC P1211 TCS CONTROL UNIT Description PFP:47850 A BBS00318 The malfunction information related to TCS is transferred through the CAN communication line from “ABS actuator and electric unit (control unit)” to ECM. EC Be sure to erase the malfunction information such as DTC not only for “ABS actuator and electric unit (control unit)” but also for ECM after TCS related repair. On Board Diagnosis Logic BBS00319 C Freeze frame data is not stored in the ECM for this self-diagnosis. The MI will not light up for this self-diagnosis. D DTC No. P1211 1211 Trouble diagnosis name TCS control unit DTC detecting condition Possible cause ● ABS actuator and electric unit (control unit) ● TCS related parts ECM receives a malfunction information from “ABS actuator and electric unit (control unit)”. DTC Confirmation Procedure BBS0031A TESTING CONDITION: Before performing the following procedure, confirm that battery voltage is more than 10.5V at idle. WITH CONSULT-II 1. 2. 3. 4. E F G Turn ignition switch ON. Select “DATA MONITOR” mode with CONSULT-II. Start engine and let it idle for at least 60 seconds. If 1st trip DTC is detected, go to EC-343, "Diagnostic Procedure" . H I J SEF058Y K WITH GST Follow the procedure “WITH CONSULT-II” above. L Diagnostic Procedure BBS0031B Go to BRC-49, "TROUBLE DIAGNOSIS" . M EC-343 DTC P1212 TCS COMMUNICATION LINE [CR (WITH EURO-OBD)] DTC P1212 TCS COMMUNICATION LINE Description PFP:47850 BBS0031C NOTE: ● If DTC P1212 is displayed with DTC U1001, first perform the trouble diagnosis for DTC U1001. Refer to EC-134, "DTC U1001 CAN COMMUNICATION LINE" . ● If DTC P1212 is displayed with DTC U1010, first perform the trouble diagnosis for DTC U1010. Refer to EC-137, "DTC U1010 CAN COMMUNICATION" . This CAN communication line is used to control the smooth engine operation during the TCS operation. Pulse signals are exchanged between ECM and “ABS actuator and electric unit (control unit)”. Be sure to erase the malfunction information such as DTC not only for “ABS actuator and electric unit (control unit)” but also for ECM after TCS related repair. On Board Diagnosis Logic BBS0031D The MI will not light up for this self-diagnosis. Freeze frame data is not stored in the ECM for this self-diagnosis. DTC No. P1212 1212 Trouble diagnosis name TCS communication line DTC detecting condition ECM can not receive the information from “ABS actuator and electric unit (control unit)” continuously. DTC Confirmation Procedure Possible cause ● Harness or connectors (The CAN communication line is open or shorted.) ● ABS actuator and electric unit (control unit). ● Dead (Weak) battery BBS0031E TESTING CONDITION: Before performing the following procedure, confirm that battery voltage is more than 10.5V at idle. WITH CONSULT-II 1. 2. 3. 4. Turn ignition switch ON. Select “DATA MONITOR” mode with CONSULT-II. Start engine and let it idle for at least 10 seconds. If 1st trip DTC is detected, go to EC-344, "Diagnostic Procedure" . SEF058Y WITH GST Follow the procedure “WITH CONSULT-II” above. Diagnostic Procedure BBS0031F Refer to BRC-49, "TROUBLE DIAGNOSIS" . EC-344 DTC P1217 ENGINE OVER TEMPERATURE [CR (WITH EURO-OBD)] DTC P1217 ENGINE OVER TEMPERATURE System Description PFP:00000 A BBS0031G NOTE: ● If DTC P1217 is displayed with DTC U1001, first perform the trouble diagnosis for DTC U1001. EC Refer to EC-134, "DTC U1001 CAN COMMUNICATION LINE" . ● If DTC P1217 is displayed with DTC U1010, first perform the trouble diagnosis for DTC U1010. Refer to EC-137, "DTC U1010 CAN COMMUNICATION" . C COOLING FAN CONTROL Sensor Input Signal to ECM ECM Function Actuator D Crankshaft position sensor (POS) Camshaft position sensor (PHASE) Engine speed*1 Battery Battery voltage*1 2 Wheel sensor Vehicle speed* Engine coolant temperature sensor Engine coolant temperature Air conditioner switch*3 Air conditioner ON signal*2 Refrigerant pressure sensor*3 Refrigerant pressure E Cooling fan control IPDM E/R (Cooling fan relay) F *1: ECM determines the start signal status by the signals of engine speed and battery voltage. *2: This signal is sent to ECM through CAN communication line. *3: Models with air conditioner. G The ECM controls the cooling fan corresponding to the vehicle speed, engine coolant temperature, refrigerant pressure, and air conditioner ON signal. The control system has 3-step control [HIGH/LOW/OFF] (models with A/C) or 2 step control [ON/OFF] (models without A/C). The ECM controls cooling fan relays through CAN communication line. H I OPERATION Models with A/C J K L M MBIB0650E EC-345 DTC P1217 ENGINE OVER TEMPERATURE [CR (WITH EURO-OBD)] Models without A/C MBIB0656E CONSULT-II Reference Value in Data Monitor Mode BBS0031H Specification data are reference values. MONITOR ITEM AIR COND SIG CONDITION ● ● COOLING FAN ● Engine: After warming up, idle the engine Engine: After warming up, idle the engine Air conditioner switch: OFF SPECIFICATION Air conditioner switch: OFF OFF Air conditioner switch: ON (Compressor operates.) ON Engine coolant temperature: 94°C (201°F) or less OFF Engine coolant temperature: Between 95°C (203°F) and 104°C (210°F) LOW* Engine coolant temperature: 105°C (212°F) or more HI* *: Models without air conditioner, cooling fan operates only ON and OFF operation, but CONSULT-II display will change OFF, LOW and HI depends on engine coolant temperature. On Board Diagnosis Logic BBS0031I If the cooling fan or another component in the cooling system malfunctions, engine coolant temperature will rise. When the engine coolant temperature reaches an abnormally high temperature condition, a malfunction is indicated. This self-diagnosis has the one trip detection logic. DTC No. Trouble diagnosis name DTC detecting condition ● ● P1217 1217 Engine over temperature (Overheat) Possible cause ● Harness or connectors (The cooling fan circuit is open or shorted.) ● Cooling fan Cooling fan does not operate properly (Overheat). ● IPDM E/R (Cooling fan relay) ● Radiator hose Cooling fan system does not operate properly (Overheat). ● Radiator ● Reservoir tank cap (Models with A/C) ● Radiator cap (Models without A/C) ● Water pump ● Thermostat ● Engine coolant was not added to the system using the proper filling method. ● Engine coolant is not within the specified range. For more information, refer to EC-357, "Main 12 Causes of Overheating" . CAUTION: When a malfunction is indicated, be sure to replace the coolant. Refer to CO-9, "Changing Engine coolant" . Also, replace the engine oil. Refer to LU-7, "Changing Engine Oil" . 1. Fill radiator with coolant up to specified level with a filling speed of 2 liters per minute. Be sure to use coolant with the proper mixture ratio. Refer to MA-26, "Engine Coolant Mixture Ratio" . EC-346 DTC P1217 ENGINE OVER TEMPERATURE [CR (WITH EURO-OBD)] 2. After refilling coolant, run engine to ensure that no water-flow noise is emitted. A Overall Function Check BBS0031J Use this procedure to check the overall function of the cooling fan. During this check, a DTC might not be confirmed. EC WARNING: Never remove the radiator cap (Models without A/C) or reservoir tank cap (Models with A/C) when the engine is hot. Serious burns could be caused by high pressure fluid escaping from the radiator (ModC els without A/C) or reservoir tank (Models with A/C). Wrap a thick cloth around cap. Carefully remove the cap by turning it a quarter turn to allow built-up pressure to escape. Then turn the cap all the way off. D WITH CONSULT-II 1. 2. 3. Check the coolant level in the reservoir tank and radiator. Allow engine to cool before checking coolant level. If the coolant level in the reservoir tank and/or radiator is below the proper range, skip the following steps and go to EC-351, "Diagnostic Procedure" . Confirm whether customer filled the coolant or not. If customer filled the coolant, skip the following steps and go to EC-351, "Diagnostic Procedure" . Turn ignition switch ON. E F G SEF621W 4. 5. H Perform “COOLING FAN” in “ACTIVE TEST” mode with CONSULT-II. If the results are NG, go to EC-351, "Diagnostic Procedure" . I J K SEF784Z WITH GST Models with Air Conditioner 1. 2. 3. 4. 5. 6. 7. L Check the coolant level in the reservoir tank and radiator. Allow engine to cool before checking coolant level. If the coolant level in the reservoir tank and/or radiator is below the proper range, skip the following steps and go to EC-351, "Diagnostic Procedure" . Confirm whether customer filled the coolant or not. If customer filled the coolant, skip the following steps and go to EC-351, "Diagnostic Procedure" . Start engine. CAUTION: Be careful not to overheat engine. Set temperature control lever to full cold position. Turn air conditioner switch ON. Turn blower fan switch ON. Run engine at idle for a few minutes with air conditioner operating. CAUTION: Be careful not to overheat engine. EC-347 M SEF621W DTC P1217 ENGINE OVER TEMPERATURE [CR (WITH EURO-OBD)] 8. Make sure that cooling fans operates at low speed. If NG, go to EC-351, "Diagnostic Procedure" . If OK, go to the following step. 9. Turn ignition switch OFF. 10. Turn air conditioner switch and blower fan switch OFF. 11. Disconnect engine coolant temperature sensor harness connector. 12. Connect 150Ω resistor to engine coolant temperature sensor harness connector. MBIB0651E 13. Restart engine and make sure that cooling fan operates at higher speed than low speed. CAUTION: Be careful not to overheat engine. 14. If NG, go to EC-351, "Diagnostic Procedure" . SEF023R Models without Air Conditioner 1. 2. 3. 4. 5. 6. Check the coolant level in the reservoir tank and radiator. Allow engine to cool before checking coolant level. If the coolant level in the reservoir tank and/or radiator is below the proper range, skip the following steps and go to EC-351, "Diagnostic Procedure" . Confirm whether customer filled the coolant or not. If customer filled the coolant, skip the following steps and go to EC-351, "Diagnostic Procedure" . Disconnect engine coolant temperature sensor harness connector. Connect 150Ω resistor to engine coolant temperature sensor harness connector. Start engine and make that cooling fan operates. Be careful not to overheat engine. If NG, go to EC-351, "Diagnostic Procedure" . SEF621W SEF023R EC-348 DTC P1217 ENGINE OVER TEMPERATURE [CR (WITH EURO-OBD)] Wiring Diagram BBS0031K A MODELS WITH AIR CONDITIONER EC C D E F G H I J K L M MBWA1523E EC-349 DTC P1217 ENGINE OVER TEMPERATURE [CR (WITH EURO-OBD)] MODELS WITHOUT AIR CONDITIONER MBWA1524E EC-350 DTC P1217 ENGINE OVER TEMPERATURE [CR (WITH EURO-OBD)] Diagnostic Procedure BBS0031L A PROCEDURE FOR MODELS WITH AIR CONDITIONER 1. INSPECTION START EC Do you have CONSULT-II? Yes or No Yes >> GO TO 2. No >> GO TO 4. C 2. CHECK COOLING FAN LOW SPEED OPERATION D With CONSULT-II 1. Turn ignition switch ON. 2. Perform “COOLING FAN” in “ACTIVE TEST” mode with CONSULT-II and touch “LOW” on the CONSULT-II screen. 3. Make sure that cooling fan operates at low speed. OK or NG OK >> GO TO 3. NG >> Check cooling fan low speed control circuit. (Go to EC353, "Procedure A" .) E F G SEF784Z H 3. CHECK COOLING FAN HIGH SPEED OPERATION I With CONSULT-II 1. Touch “HIGH” on the CONSULT-II screen. 2. Make sure that cooling fan operate at higher speed than low speed. OK or NG OK >> GO TO 6. NG >> Check cooling fan high speed control circuit. (Go to EC354, "Procedure B" .) J K L SEF785Z M 4. CHECK COOLING FAN LOW SPEED OPERATION Without CONSULT-II 1. Start engine and let it idle. 2. Turn air conditioner switch ON. 3. Turn blower fan switch ON. 4. Make sure that cooling fan operates at low speed. OK or NG OK >> GO TO 5. NG >> Check cooling fan low speed control circuit. (Go to EC353, "Procedure A" .) MBIB0651E EC-351 DTC P1217 ENGINE OVER TEMPERATURE [CR (WITH EURO-OBD)] 5. CHECK COOLING FAN HIGH SPEED OPERATION Without CONSULT-II Turn ignition switch OFF. Turn air conditioner switch and blower fan switch OFF. Disconnect engine coolant temperature sensor harness connector. Connect 150Ω resistor to engine coolant temperature sensor harness connector. Restart engine and make sure that cooling fan operate at higher speed than low speed. OK or NG OK >> GO TO 6. NG >> Check cooling fan high speed control circuit. (Go to EC354, "Procedure B" .) 1. 2. 3. 4. 5. SEF023R 6. CHECK COOLING SYSTEM FOR LEAK Refer to CO-8, "ENGINE COOLANT" . OK or NG OK >> GO TO 8. NG >> GO TO 7. 7. DETECT MALFUNCTIONING PART Check the following for leak. ● Hose ● Radiator ● Water pump (Refer to CO-17, "WATER PUMP" .) >> Repair or replace. 8. CHECK RESERVOIR TANK CAP Refer to CO-16, "Checking Reservoir Tank Cap (Models with A/C)" . OK or NG OK >> GO TO 9. NG >> Replace reservoir tank cap. 9. CHECK COMPONENT PARTS Check the following. Thermostat. Refer to CO-19, "THERMOSTAT" . ● Engine coolant temperature sensor. Refer to EC-170, "Component Inspection" . OK or NG OK >> GO TO 10. NG >> Replace malfunctioning component. ● 10. CHECK MAIN 12 CAUSES If the cause cannot be isolated, go to EC-357, "Main 12 Causes of Overheating" . >> INSPECTION END EC-352 DTC P1217 ENGINE OVER TEMPERATURE [CR (WITH EURO-OBD)] Procedure A A 1. CHECK POWER SUPPLY CIRCUIT 1. 2. 3. Turn ignition switch OFF. Disconnect IPDM E/R harness connector E6. Check voltage between IPDM E/R terminal 14 and ground with CONSULT-II or tester. EC C Voltage: Battery voltage OK or NG OK >> GO TO 3. NG >> GO TO 2. D E MBIB1307E 2. DETECT MALFUNCTIONING PART F Check the following. ● 40A fusible link ● Harness for open or short between IPDM E/R and battery G H >> Repair open circuit or short to ground or short to power in harness or connectors. 3. CHECK COOLING FAN MOTORS CIRCUIT 1. 2. I Disconnect cooling fan motor harness connector. Check harness continuity between cooling fan motor terminal 1 and IPDM E/R terminal 10, cooling fan motor terminal 2 and ground. Refer to Wiring Diagram. J Continuity should exist. 3. Also check harness for short to ground and short to power. OK or NG OK >> GO TO 5. NG >> GO TO 4. 4. DETECT MALFUNCTIONING PART K L MBIB1074E M Check the following. ● Harness for open or short between cooling fan motor and IPDM E/R ● Harness for open or short between cooling fan motor and ground ● Harness for open or short between resistor and IPDM E/R ● Harness for open or short between resistor and cooling fan motor ● Resistor E62 >> Repair open circuit or short to ground or short to power in harness or connectors. 5. CHECK COOLING FAN MOTOR Refer to EC-358, "Component Inspection" . OK or NG OK >> GO TO 6. NG >> Replace cooling fan motor. EC-353 DTC P1217 ENGINE OVER TEMPERATURE [CR (WITH EURO-OBD)] 6. CHECK INTERMITTENT INCIDENT Perform EC-127, "TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT" . OK or NG OK >> Replace IPDM E/R. Refer to PG-18, "IPDM E/R (INTELLIGENT POWER DISTRIBUTION MODULE ENGINE ROOM)" . NG >> Repair or replace harness or connector. Procedure B 1. CHECK COOLING FAN MOTORS CIRCUIT 1. 2. 3. 4. Turn ignition switch OFF. Disconnect IPDM E/R harness connector E6. Disconnect cooling fan motor harness connector. Check harness continuity between IPDM E/R terminal 12 and cooling fan motor terminal 1, cooling fan motor terminal 2 and ground. Refer to Wiring Diagram. Continuity should exist. 5. Also check harness for short to ground and short to power. OK or NG OK >> GO TO 3. NG >> GO TO 2. MBIB1074E 2. DETECT MALFUNCTIONING PART Check the following. ● Harness for open or short between cooling fan motor and IPDM E/R ● Harness for open or short between cooling fan motor and ground >> Repair open circuit or short to ground or short to power in harness or connectors. 3. CHECK COOLING FAN MOTOR Refer to EC-358, "Component Inspection" . OK or NG OK >> GO TO 4. NG >> Replace cooling fan motor. 4. CHECK INTERMITTENT INCIDENT Perform EC-127, "TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT" . OK or NG OK >> Replace IPDM E/R. Refer to PG-18, "IPDM E/R (INTELLIGENT POWER DISTRIBUTION MODULE ENGINE ROOM)" . NG >> Repair or replace harness or connector. EC-354 DTC P1217 ENGINE OVER TEMPERATURE [CR (WITH EURO-OBD)] PROCEDURE FOR MODELS WITHOUT AIR CONDITIONER A 1. INSPECTION START Do you have CONSULT-II? Yes or No Yes >> GO TO 2. No >> GO TO 3. EC C 2. CHECK COOLING FAN OPERATION With CONSULT-II 1. Turn ignition switch ON. 2. Perform “COOLING FAN” in “ACTIVE TEST” mode with CONSULT-II and touch “LOW” on the CONSULT-II screen. 3. Make sure that cooling fan operates. OK or NG OK >> GO TO4. NG >> Check cooling fan control circuit. (Go to EC-356, "Procedure A" .) D E F G SEF784Z H 3. CHECK COOLING FAN OPERATION Without CONSULT-II 1. Turn ignition switch OFF. 2. Disconnect engine coolant temperature sensor harness connector. 3. Connect 150Ω resistor to engine coolant temperature sensor harness connector. 4. Restart engine and make sure that cooling fan operates. OK or NG OK >> GO TO 4. NG >> Check cooling fan control circuit. (Go to EC-356, "Procedure A" .) I J K L M SEF023R 4. CHECK COOLING SYSTEM FOR LEAK Refer to CO-8, "ENGINE COOLANT" . OK or NG OK >> GO TO 6. NG >> GO TO 5. EC-355 DTC P1217 ENGINE OVER TEMPERATURE [CR (WITH EURO-OBD)] 5. DETECT MALFUNCTIONING PART Check the following for leak. ● Hose ● Radiator ● Water pump (Refer to CO-17, "WATER PUMP" .) >> Repair or replace. 6. CHECK RADIATOR CAP Refer to CO-15, "Checking Radiator Cap (Models without A/C)" . OK or NG OK >> GO TO 7. NG >> Replace radiator cap. 7. CHECK THERMOSTAT Check the following. Thermostat. Refer to CO-19, "THERMOSTAT" . ● Engine coolant temperature sensor. Refer to EC-170, "Component Inspection" . OK or NG OK >> GO TO 8. NG >> Replace malfunctioning component. ● 8. CHECK MAIN 12 CAUSES If the cause cannot be isolated, go to EC-357, "Main 12 Causes of Overheating" . >> INSPECTION END Procedure A 1. CHECK POWER SUPPLY CIRCUIT 1. 2. 3. Turn ignition switch OFF. Disconnect IPDM E/R harness connector E6. Check voltage between IPDM E/R terminal 14 and ground with CONSULT-II or tester. Voltage: Battery voltage OK or NG OK >> GO TO 3. NG >> GO TO 2. MBIB1307E 2. DETECT MALFUNCTIONING PART Check the following. 40A fusible link ● Harness for open or short between IPDM E/R and battery ● >> Repair open circuit or short to ground or short to power in harness or connectors. EC-356 DTC P1217 ENGINE OVER TEMPERATURE [CR (WITH EURO-OBD)] 3. CHECK COOLING FAN MOTORS CIRCUIT 1. 2. A Disconnect cooling fan motor harness connector. Check harness continuity between cooling fan motor terminal 1 and IPDM E/R terminal 10, cooling fan motor terminal 2 and ground. Refer to wiring diagram. EC C Continuity should exist. 3. Also check harness for short to ground and short to power. OK or NG OK >> GO TO 5. NG >> GO TO 4. D MBIB1074E 4. DETECT MALFUNCTIONING PART E Check the following. ● Harness for open or short between cooling fan motor and IPDM E/R ● Harness for open or short between cooling fan motor and ground F G >> Repair open circuit or short to ground or short to power in harness or connectors. 5. CHECK COOLING FAN MOTOR H Refer to EC-358, "Component Inspection" . OK or NG OK >> GO TO 6. NG >> Replace cooling fan motor. I 6. CHECK INTERMITTENT INCIDENT J Perform EC-127, "TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT" . OK or NG OK >> Replace IPDM E/R. Refer to PG-18, "IPDM E/R (INTELLIGENT POWER DISTRIBUTION MODULE ENGINE ROOM)" . NG >> Repair or replace harness or connector. L Main 12 Causes of Overheating Engine Step OFF 1 Inspection item ● Blocked radiator ● Blocked condenser ● Blocked radiator grille ● Blocked bumper 2 ● 3 4*5 BBS0031M Equipment Standard Reference page ● Visual No blocking Coolant mixture ● Coolant tester 50 - 50% coolant mixture See MA-26, "Engine Coolant Mixture Ratio" . ● Coolant level ● Visual Coolant up to MAX level in reservoir tank and radiator filler neck See CO-8, "LEVEL CHECK" . ● Radiator cap ● Pressure tester 59 - 98 kPa (0.59 - 0.98 bar, 0.6 - 1.0 See CO-15, "Checking Radiator Cap (Models without A/C)" . kg/cm2 , 9 - 14 psi) (Limit) 4*6 ● Reservoir tank cap ● K Pressure tester EC-357 88 kPa (0.88 bar, 0.90 kg/ 2 cm , 12.8psi) — See CO-16, "Checking Reservoir Tank Cap (Models with A/C)" . M DTC P1217 ENGINE OVER TEMPERATURE [CR (WITH EURO-OBD)] Engine Step Inspection item Equipment Standard Reference page ON*2 5 ● Coolant leaks ● Visual No leaks See CO-8, "LEAK CHECK" . ON*2 6 ● Thermostat ● Touch the upper and lower radiator hoses Both hoses should be hot See CO-19, "THERMOSTAT" , and CO-12, "RADIATOR" . ON*1 7 ● Cooling fan ● CONSULT-II Operating See trouble diagnosis for DTC P1217 (EC-351 ). OFF 8 ● Combustion gas leak ● Color checker chemical tester 4 Gas analyzer Negative — ON*3 9 ● Coolant temperature gauge ● Visual Gauge less than 3/4 when driving — ● Coolant overflow to reservoir tank ● Visual No overflow during driving and idling See CO-9, "Changing Engine coolant" . OFF*4 10 ● Coolant return from reservoir tank to radiator ● Visual Should be initial level in reservoir tank See CO-8, "LEVEL CHECK" . OFF 11 ● Cylinder head ● Straight gauge feeler gauge 0.1 mm (0.004 in) Maximum distortion (warping) See EM-60, "CYLINDER HEAD" . 12 ● Cylinder block and pistons ● Visual No scuffing on cylinder walls or piston See EM-74, "CYLINDER BLOCK" . *1: Turn the ignition switch ON. *2: Engine running at 3,000 rpm for 10 minutes. *3: Drive at 90 km/h (55 MPH) for 30 minutes and then let idle for 10 minutes. *4: After 60 minutes of cool down time. *5: Models without A/C. *6: Models with A/C. For more information, refer to CO-5, "OVERHEATING CAUSE ANALYSIS" . Component Inspection BBS0031N COOLING FAN MOTOR 1. 2. Disconnect cooling fan motor harness connector. Supply cooling fan motor terminals with battery voltage and check operation. Terminals Cooling fan motor (+) (-) 1 2 MBIB0607E EC-358 DTC P1225 TP SENSOR [CR (WITH EURO-OBD)] DTC P1225 TP SENSOR Component Description PFP:16119 A BBS0031O Electric throttle control actuator consists of throttle control motor, throttle position sensor, etc. The throttle position sensor responds to the throttle valve movement. The throttle position sensor has the two sensors. These sensors are a kind of potentiometers which transform the throttle valve position into output voltage, and emit the voltage signal to the ECM. In addition, these sensors detect the opening and closing speed of the throttle valve and feed the voltage signals to the ECM. The ECM judges the current opening angle of the throttle valve from these signals and the ECM controls the throttle control motor to make the throttle valve opening angle properly in response to driving condition. EC C D PBIB0145E E On Board Diagnosis Logic BBS0031P The MI will not light up for this self-diagnosis. F DTC No. Trouble diagnosis name DTC detecting condition P1225 1225 Closed throttle position learning performance Closed throttle position learning value is excessively low. DTC Confirmation Procedure Possible cause ● Electric throttle control actuator (TP sensor 1 and 2) G BBS0031Q NOTE: If DTC Confirmation Procedure has been previously conducted, always turn ignition switch OFF and wait at least 10 seconds before conducting the next test. TESTING CONDITION: Before performing the following procedure, confirm that battery voltage is more than 10V at idle. H I WITH CONSULT-II 1. 2. 3. 4. 5. Turn ignition switch ON. Select “DATA MONITOR” mode with CONSULT-II. Turn ignition switch OFF and wait at least 10 seconds. Turn ignition switch ON. If 1st trip DTC is detected, go to EC-360, "Diagnostic Procedure" . J K L M SEF058Y WITH GST Follow the procedure “WITH CONSULT-II” above. EC-359 DTC P1225 TP SENSOR [CR (WITH EURO-OBD)] Diagnostic Procedure BBS0031R 1. CHECK ELECTRIC THROTTLE CONTROL ACTUATOR VISUALLY 1. 2. 3. Turn ignition switch OFF. Remove the intake air duct. Check if foreign matter is caught between the throttle valve and the housing. OK or NG OK >> GO TO 2. NG >> Remove the foreign matter and clean the electric throttle control actuator inside. MBIB0307E 2. REPLACE ELECTRIC THROTTLE CONTROL ACTUATOR 1. 2. 3. Replace the electric throttle control actuator. Perform EC-69, "Throttle Valve Closed Position Learning" . Perform EC-69, "Idle Air Volume Learning" . >> INSPECTION END Removal and Installation BBS0031S ELECTRIC THROTTLE CONTROL ACTUATOR Refer to EM-18, "AIR CLEANER AND AIR DUCT" . EC-360 DTC P1226 TP SENSOR [CR (WITH EURO-OBD)] DTC P1226 TP SENSOR Component Description PFP:16119 A BBS0031T Electric throttle control actuator consists of throttle control motor, throttle position sensor, etc. The throttle position sensor responds to the throttle valve movement. The throttle position sensor has the two sensors. These sensors are a kind of potentiometers which transform the throttle valve position into output voltage, and emit the voltage signal to the ECM. In addition, these sensors detect the opening and closing speed of the throttle valve and feed the voltage signals to the ECM. The ECM judges the current opening angle of the throttle valve from these signals and the ECM controls the throttle control motor to make the throttle valve opening angle properly in response to driving condition. EC C D PBIB0145E E On Board Diagnosis Logic BBS0031U The MI will not light up for this self-diagnosis. F DTC No. Trouble diagnosis name DTC detecting condition P1226 1226 Closed throttle position learning performance Closed throttle position learning is not performed successfully, repeatedly. DTC Confirmation Procedure Possible cause ● Electric throttle control actuator (TP sensor 1 and 2) G BBS0031V NOTE: If DTC Confirmation Procedure has been previously conducted, always turn ignition switch OFF and wait at least 10 seconds before conducting the next test. TESTING CONDITION: Before performing the following procedure, confirm that battery voltage is more than 10V at idle. H I WITH CONSULT-II 1. 2. 3. 4. 5. 6. Turn ignition switch ON. Select “DATA MONITOR” mode with CONSULT-II. Turn ignition switch OFF and wait at least 10 seconds. Turn ignition switch ON. Repeat steps 3 and 4 for 32 times. If 1st trip DTC is detected, go to EC-362, "Diagnostic Procedure" . J K L M SEF058Y WITH GST Follow the procedure “WITH CONSULT-II” above. EC-361 DTC P1226 TP SENSOR [CR (WITH EURO-OBD)] Diagnostic Procedure BBS0031W 1. CHECK ELECTRIC THROTTLE CONTROL ACTUATOR VISUALLY 1. 2. 3. Turn ignition switch OFF. Remove the intake air duct. Check if foreign matter is caught between the throttle valve and the housing. OK or NG OK >> GO TO 2. NG >> Remove the foreign matter and clean the electric throttle control actuator inside. MBIB0307E 2. REPLACE ELECTRIC THROTTLE CONTROL ACTUATOR 1. 2. 3. Replace the electric throttle control actuator. Perform EC-69, "Throttle Valve Closed Position Learning" . Perform EC-69, "Idle Air Volume Learning" . >> INSPECTION END Removal and Installation BBS0031X ELECTRIC THROTTLE CONTROL ACTUATOR Refer to EM-18, "AIR CLEANER AND AIR DUCT" . EC-362 DTC P1229 SENSOR POWER SUPPLY [CR (WITH EURO-OBD)] DTC P1229 SENSOR POWER SUPPLY On Board Diagnosis Logic PFP:16119 A BBS0031Y This self-diagnosis has the one trip detection logic. DTC No. Trouble diagnosis name DTC detecting condition ● P1229 1229 Sensor power supply circuit short EC Possible cause ECM detects a voltage of power source for sensor is excessively low or high. Harness or connectors (APP sensor 1 circuit is shorted.) (Manifold absolute pressure sensor is shorted.) (Refrigerant pressure sensor circuit is shorted.) ● Accelerator pedal position sensor (APP sensor 1) ● Manifold absolute pressure sensor ● Refrigerant pressure sensor C D E FAIL-SAFE MODE F When the malfunction is detected, the ECM enters fail-safe mode and the MI lights up. Engine operation condition in fail-safe mode ECM stops the electric throttle control actuator control, throttle valve is maintained at a fixed opening (approx. 5 degrees) by the return spring. DTC Confirmation Procedure BBS0031Z NOTE: If DTC Confirmation Procedure has been previously conducted, always turn ignition switch OFF and wait at least 10 seconds before conducting the next test. TESTING CONDITION: Before performing the following procedure, confirm that battery voltage is more than 10V at idle. H I J WITH CONSULT-II 1. 2. 3. 4. G Turn ignition switch ON. Select “DATA MONITOR” mode with CONSULT-II. Start engine and let it idle for 1 second. If DTC is detected, go to EC-368, "Diagnostic Procedure" . K L M SEF058Y WITH GST Follow the procedure “WITH CONSULT-II” above. EC-363 DTC P1229 SENSOR POWER SUPPLY [CR (WITH EURO-OBD)] Wiring Diagram BBS00320 LHD MODELS MBWA1525E EC-364 DTC P1229 SENSOR POWER SUPPLY [CR (WITH EURO-OBD)] Specification data are reference values and are measured between each terminal and ground. CAUTION: Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM's transistor. Use a ground other than ECM terminals, such as the ground. TERMINAL NO. WIRE COLOR EC ITEM CONDITION DATA (DC Voltage) 45 L Sensor power supply (Manifold absolute pressure sensor) [Ignition switch: ON] Approximately 5V 46 W Sensor power supply (Refrigerant pressure sensor) [Ignition switch: ON] Approximately 5V B Sensor ground (APP sensor 1) C [Engine is running] 82 ● Warm-up condition ● Idle speed Approximately 0V [Engine is running] 83 B A Sensor ground (APP sensor 2) ● Warm-up condition ● Idle speed D E F Approximately 0V 90 O Sensor power supply (APP sensor 1) [Ignition switch: ON] Approximately 5V 91 BR Sensor power supply (APP sensor 2) [Ignition switch: ON] Approximately 5V G H [Ignition switch: ON] 98 G Accelerator pedal position sensor 2 ● Engine stopped ● Accelerator pedal: Fully released 0.3 - 0.6V I [Ignition switch: ON] ● Engine stopped ● Accelerator pedal: Fully depressed 1.95 - 2.4V J [Ignition switch: ON] 106 W Accelerator pedal position sensor 1 ● Engine stopped ● Accelerator pedal: Fully released 0.6 - 0.9V K [Ignition switch: ON] ● Engine stopped ● Accelerator pedal: Fully depressed 3.9 - 4.7V L M EC-365 DTC P1229 SENSOR POWER SUPPLY [CR (WITH EURO-OBD)] RHD MODELS MBWA1526E EC-366 DTC P1229 SENSOR POWER SUPPLY [CR (WITH EURO-OBD)] Specification data are reference values and are measured between each terminal and ground. CAUTION: Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM's transistor. Use a ground other than ECM terminals, such as the ground. TERMINAL NO. WIRE COLOR EC ITEM CONDITION DATA (DC Voltage) 45 L Sensor power supply (Manifold absolute pressure sensor) [Ignition switch: ON] Approximately 5V 46 W Sensor power supply (Refrigerant pressure sensor) [Ignition switch: ON] Approximately 5V B Sensor ground (APP sensor 1) C [Engine is running] 82 ● Warm-up condition ● Idle speed Approximately 0V [Engine is running] 83 B A Sensor ground (APP sensor 2) ● Warm-up condition ● Idle speed D E F Approximately 0V 90 O Sensor power supply (APP sensor 1) [Ignition switch: ON] Approximately 5V 91 BR Sensor power supply (APP sensor 2) [Ignition switch: ON] Approximately 5V G H [Ignition switch: ON] 98 G Accelerator pedal position sensor 2 ● Engine stopped ● Accelerator pedal: Fully released 0.3 - 0.6V I [Ignition switch: ON] ● Engine stopped ● Accelerator pedal: Fully depressed 1.95 - 2.4V J [Ignition switch: ON] 106 W Accelerator pedal position sensor 1 ● Engine stopped ● Accelerator pedal: Fully released 0.6 - 0.9V K [Ignition switch: ON] ● Engine stopped ● Accelerator pedal: Fully depressed 3.9 - 4.7V L M EC-367 DTC P1229 SENSOR POWER SUPPLY [CR (WITH EURO-OBD)] Diagnostic Procedure BBS00321 1. CHECK GROUND CONNECTIONS 1. 2. Turn ignition switch OFF. Loosen and retighten ground screws on the body. Refer to EC-133, "Ground Inspection" . MBIB1502E 1. Body ground E44 2. Body ground E45 3. Body ground E28 OK or NG OK >> GO TO 2. NG >> Repair or replace ground connections. 2. CHECK ACCELERATOR PEDAL POSITION SENSOR 1 POWER SUPPLY CIRCUIT-I 1. 2. Disconnect accelerator pedal position sensor (APP) sensor harness connector. Turn ignition switch ON. MBIB0285E 3. Check voltage between APP sensor terminal 4 and ground with CONSULT-II or tester. Voltage: Approximately 5V OK or NG OK >> GO TO 7. NG >> GO TO 3. MBIB0304E EC-368 DTC P1229 SENSOR POWER SUPPLY [CR (WITH EURO-OBD)] 3. CHECK ACCELERATOR PEDAL POSITION SENSOR 1 POWER SUPPLY CIRCUIT-II 1. 2. 3. Turn ignition switch OFF. Disconnect ECM harness connector. Check harness continuity between APP sensor terminal 4 and ECM terminal 90. Refer to Wiring Diagram. A EC Continuity should exist. C OK or NG OK >> GO TO 5. NG (LHD models)>>Repair open circuit. NG (RHD models)>>GO TO 4. D 4. DETECT MALFUNCTIONING PART E Check the following. ● Harness connectors M201, M8 ● Harness connectors M1, E101 ● Harness for open or short between APP sensor and ECM F G >> Repair open circuit. 5. CHECK SENSOR POWER SUPPLY CIRCUIT H Check harness for short to power and short to ground, between the following terminals ECM terminal Sensor terminal Reference Wiring Diagram 90 APP sensor terminal 4 EC-364 45 Manifold absolute pressure sensor terminal 2 EC-156 46 Refrigerant pressure sensor terminal 3 EC-444 I J OK or NG OK >> GO TO 6. NG >> Repair short to ground or short to power in harness or connectors. K 6. CHECK COMPONENTS Check the following. ● Manifold absolute pressure sensor (Refer to EC-159, "Component Inspection" .) ● Refrigerant pressure sensor (Refer to ATC-85, "COMPONENT INSPECTION" NENT INSPECTION" .) OK or NG OK >> GO TO 9. NG >> Replace malfunctioning component. 7. CHECK APP SENSOR Refer to EC-400, "Component Inspection" . OK or NG OK >> GO TO 9. NG >> GO TO 8. EC-369 L or MTC-51, "COMPO- M DTC P1229 SENSOR POWER SUPPLY [CR (WITH EURO-OBD)] 8. REPLACE ACCELERATOR PEDAL ASSEMBLY 1. 2. 3. 4. Replace accelerator pedal assembly. Perform EC-69, "Accelerator Pedal Released Position Learning" . Perform EC-69, "Throttle Valve Closed Position Learning" . Perform EC-69, "Idle Air Volume Learning" . >> INSPECTION END 9. CHECK INTERMITTENT INCIDENT Refer to EC-127, "TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT" . >> INSPECTION END EC-370 DTC P1706 PNP SWITCH [CR (WITH EURO-OBD)] DTC P1706 PNP SWITCH Component Description PFP:32006 A BBS00322 When the shift lever position is Neutral, park/neutral position (PNP) switch is ON. ECM detects the position because the continuity of the line (the ON signal) exists. EC CONSULT-II Reference Value in Data Monitor Mode BBS00323 Specification data are reference values. MONITOR ITEM P/N POSI SW C CONDITION ● Ignition switch: ON SPECIFICATION Shift lever: Neutral ON Shift lever: Except above OFF D On Board Diagnosis Logic DTC No. BBS00324 Trouble diagnosis name DTC detecting condition Park/neutral position switch The signal of the park/neutral position (PNP) switch is not changed in the process of engine starting and driving. ● P1706 1706 ● DTC Confirmation Procedure E Possible cause Harness or connectors [The park/neutral position (PNP) switch circuit is open or shorted.] F Park/neutral position (PNP) switch BBS00325 G CAUTION: Always drive vehicle at a safe speed. NOTE: If DTC Confirmation Procedure has been previously conducted, always turn ignition switch OFF and wait at least 10 seconds before conducting the next test. H I WITH CONSULT-II 1. 2. Turn ignition switch ON. Select “P/N POSI SW” in “DATA MONITOR” mode with CONSULT-II. Then check the “P/N POSI SW” signal under the following conditions. Position (Shift lever) Known-good signal Neutral position ON Except the above position OFF 3. 4. 5. If NG, go to EC-374, "Diagnostic Procedure" . If OK, go to following step. Select “DATA MONITOR” mode with CONSULT-II. Start engine and warm it up to normal operating temperature. Maintain the following conditions for at least 60 consecutive seconds. ENG SPEED 1,500 - 4,400 rpm COOLAN TEMP/S More than 70°C (158°F) B/FUEL SCHDL 1.8 - 6.7 msec VHCL SPEED SE More than 46 km/h (29 MPH) Shift lever Suitable position 6. J If 1st trip DTC is detected, go to EC-374, "Diagnostic Procedure" . EC-371 K L SEF212Y SEF213Y M DTC P1706 PNP SWITCH [CR (WITH EURO-OBD)] Overall Function Check BBS00326 Use this procedure to check the overall function of the park/neutral position (PNP) switch circuit. During this check, a 1st trip DTC might not be confirmed. WITH GST 1. 2. Turn ignition switch ON. Check voltage between ECM terminal 102 (PNP switch signal) and ground under the following conditions. Condition (Gear position) Neutral position Except the above position 3. Voltage V (Known-good data) Approx. 0 BATTERY VOLTAGE (11 - 14V) If NG, go to EC-374, "Diagnostic Procedure" . MBIB0029E EC-372 DTC P1706 PNP SWITCH [CR (WITH EURO-OBD)] Wiring Diagram BBS00327 A EC C D E F G H I J K L M MBWA1527E EC-373 DTC P1706 PNP SWITCH [CR (WITH EURO-OBD)] Specification data are reference values and are measured between each terminal and ground. CAUTION: Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM's transistor. Use a ground other than ECM terminals, such as the ground. TERMINAL NO. WIRE COLOR ITEM CONDITION [Ignition switch: ON] ● 102 GR PNP switch Shift lever position: Neutral [Ignition switch: ON] ● Except the above gear position Diagnostic Procedure DATA (DC Voltage) Approximately 0V BATTERY VOLTAGE (11 - 14V) BBS00328 1. CHECK PNP SWITCH CIRCUIT 1. 2. Turn ignition switch ON. Check voltage between IPDM E/R terminal 31 and ground under following condition. Shift lever position Voltage Neutral Battery voltage (11- 14V) Except above position Approximately 0V OK or NG OK >> GO TO 8. NG >> GO TO 2. MBIB0652E 2. CHECK PNP SWITCH POWER SUPPLY CIRCUIT 1. 2. 3. 4. Turn ignition switch OFF. Disconnect PNP switch harness connector. Turn ignition switch ON. Check voltage between PNP switch terminal 2 and ground with CONSULT-II or tester. Voltage: Battery voltage OK or NG OK >> GO TO 4. NG >> GO TO 3. MBIB1444E 3. DETECT MALFUNCTIONING PARTS Check the following. ● 10A fuse ● Harness connectors E48, F1 ● IPDM E/R connector E7 ● Harness for short or open between PNP switch and fuse >> Repair or replace harness or connectors. EC-374 DTC P1706 PNP SWITCH [CR (WITH EURO-OBD)] 4. CHECK HARNESS CONTINUTY BETWEEN PNP SWITCH AND IPDM E/R 1. 2. 3. Turn ignition switch OFF. Disconnect IPDM E/R harness connector E7. Check harness continuity between IPDM E/R terminal 31 and PNP switch terminal 3. Refer to Wiring Diagram. Continuity should exist. A EC C 4. Also check harness for short to ground and short to power. OK or NG OK >> GO TO 6. NG >> GO TO 5. 5. DETECT MALFUNCTIONING PARTS D E Check the following. ● Harness connectors E48, F1 ● Harness for short or open between PNP switch and IPDM E/R >> Repair open circuit or short to ground or short to power in harness or connectors. F G 6. CHECK PNP SWITCH H Refer to MT-16, "Park/Neutral Position Switch" . OK or NG OK >> GO TO 7. NG >> Replace PNP switch. I 7. CHECK INTERMITTENT INCIDENT Refer to EC-127, "TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT" . >> INSPECTION END J K 8. CHECK PNP SWITCH GROUND CIRCUIT FOR OPEN AND SHORT 1. 2. 3. Turn ignition switch OFF. Disconnect IPDM E/R harness connectors E11 and E12. Check harness continuity between IPDM E/R terminal 3, 54 and ground. Refer to Wiring Diagram. Continuity should exist. 4. Also check harness for short to power. OK or NG OK >> GO TO 9. NG >> Repair open circuit or short to power in harness or connectors. EC-375 L M DTC P1706 PNP SWITCH [CR (WITH EURO-OBD)] 9. CHECK PNP SWITCH INPUT SIGNAL CIRCUIT FOR OPEN AND SHORT 1. 2. 3. Disconnect IPDM E/R harness connector E5 Disconnect ECM harness connector. Check harness continuity between ECM terminal 102 and IPDM E/R terminal 64. Refer to Wiring Diagram. Continuity should exist. 4. Also check harness for short to ground and short to power. OK or NG OK >> GO TO 10. NG >> Repair open circuit or short to ground or short to power in harness or connectors. 10. CHECK INTERMITTENT INCIDENT Refer to EC-127, "TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT" . OK or NG OK >> Replace IPDM E/R. Refer to PG-18, "IPDM E/R (INTELLIGENT POWER DISTRIBUTION MODULE ENGINE ROOM)" . NG >> Repair or replace. EC-376 DTC P1805 BRAKE SWITCH [CR (WITH EURO-OBD)] DTC P1805 BRAKE SWITCH Description PFP:25320 A BBS00329 Brake switch signal is applied to the ECM through the stop lamp switch when the brake pedal is depressed. This signal is used mainly to decrease the engine speed when the vehicle is driving. EC C D MBIB0286E E CONSULT-II Reference Value in Data Monitor Mode BBS0032A Specification data are reference values. MONITOR ITEM BRAKE SW CONDITION ● Ignition switch: ON F SPECIFICATION Brake pedal: Fully released OFF Brake pedal: Slightly depressed ON On Board Diagnosis Logic G BBS0032B The MI will not light up for this self-diagnosis. DTC No. Trouble diagnosis name P1805 1805 Brake switch H DTC detecting condition A brake switch signal is not sent to ECM for extremely long time while the vehicle is driving. Possible cause ● Harness or connectors (Stop lamp switch circuit is open or shorted.) ● Stop lamp switch FAIL-SAFE MODE I J When the malfunction is detected, the ECM enters fail-safe mode. Engine operation condition in fail-fail safe mode ECM controls the electric throttle control actuator by regulating the throttle opening to a small range.Therefore,acceleration will be poor. Vehicle condition Driving condition When engine is idling Normal When accelerating Poor acceleration L M DTC Confirmation Procedure BBS0032D WITH CONSULT-II 1. 2. 3. 4. 5. K Turn ignition switch ON. Fully depress the brake pedal for at least 5 seconds. Erase the DTC with CONSULT-II. Select “DATA MONITOR” mode with CONSULT-II. If 1st trip DTC is detected, go to EC-380, "Diagnostic Procedure" . SEF058Y EC-377 DTC P1805 BRAKE SWITCH [CR (WITH EURO-OBD)] WITH GST Follow the procedure “WITH CONSULT-II” above. EC-378 DTC P1805 BRAKE SWITCH [CR (WITH EURO-OBD)] Wiring Diagram BBS0032E A EC C D E F G H I J K L M MBWA1528E EC-379 DTC P1805 BRAKE SWITCH [CR (WITH EURO-OBD)] Specification data are reference values and are measured between each terminal and ground. CAUTION: Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM's transistor. Use a ground other than ECM terminals, such as the ground. TERMINAL NO. WIRE COLOR ITEM CONDITION [Ignition switch: OFF] ● 101 R Stop lamp switch Brake pedal: Fully released [Ignition switch: OFF] ● Brake pedal: Slightly depressed Diagnostic Procedure DATA (DC Voltage) Approximately 0V BATTERY VOLTAGE (11 - 14V) BBS0032F 1. CHECK STOP LAMP SWITCH CIRCUIT 1. 2. Turn ignition switch OFF. Check the stop lamp when depressing and releasing the brake pedal. Brake pedal Stop lamp Fully released Not illuminated Slightly depressed Illuminated OK or NG OK >> GO TO 4. NG >> GO TO 2. 2. CHECK STOP LAMP SWITCH POWER SUPPLY CIRCUIT 1. Disconnect stop lamp switch harness connector. MBIB0286E 2. Check voltage between stop lamp switch terminal 1 and ground with CONSULT-II or tester. Voltage: Battery voltage OK or NG OK >> GO TO 4. NG >> GO TO 3. PBIB0117E EC-380 DTC P1805 BRAKE SWITCH [CR (WITH EURO-OBD)] 3. DETECT MALFUNCTIONING PART A Check the following. ● 10A fuse ● Fuse block (J/B) connector M7 ● Harness connectors M1, E101 (LHD models) ● Harness connectors M8, M201 (RHD models) ● Harness for open and short between stop lamp switch and battery >> Repair open circuit or short to ground or short to power in harness or connectors. EC C D 4. CHECK STOP LAMP SWITCH INPUT SIGNAL CIRCUIT FOR OPEN AND SHORT 1. 2. 3. Disconnect ECM harness connector. Disconnect stop lamp switch harness connector. Check harness continuity between ECM terminal 101 and stop lamp switch terminal 2. Refer to Wiring Diagram. E F Continuity should exist. 4. Also check harness for short to ground and short to power. OK or NG OK >> GO TO 6. NG (LHD models)>>Repair open circuit or short to ground or short to power in harness or connectors. NG (RHD models)>>GO TO 5. 5. DETECT MALFUNCTIONING PART G H I Check the following. ● Harness connectors M8, M201 ● Harness connectors M1, E101 ● Harness for open or short between ECM and stop lamp switch >> Repair open circuit or short to ground or short to power in harness or connectors. 6. CHECK STOP LAMP SWITCH J K L Refer to EC-382, "Component Inspection" . OK or NG OK >> GO TO 7. NG >> Replace stop lamp switch. M 7. CHECK INTERMITTENT INCIDENT Refer to EC-127, "TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT" . >> INSPECTION END EC-381 DTC P1805 BRAKE SWITCH [CR (WITH EURO-OBD)] Component Inspection BBS0032G STOP LAMP SWITCH 1. Disconnect stop lamp switch harness connector. MBIB0286E 2. Check continuity between stop lamp switch terminals 1 and 2 under the following conditions. Conditions Brake pedal: Fully released Brake pedal: Slightly depressed Continuity Should not exist. Should exist. If NG, adjust brake pedal installation, refer to BR-6, "BRAKE PEDAL" , and perform step 2 again. PBIB0118E EC-382 DTC P2122, P2123 APP SENSOR [CR (WITH EURO-OBD)] DTC P2122, P2123 APP SENSOR Component Description PFP:18002 A BBS0032H The accelerator pedal position sensor is installed on the upper end of the accelerator pedal assembly. The sensor detects the acceleraEC tor position and sends a signal to the ECM. Accelerator pedal position sensor has two sensors. These sensors are a kind of potentiometers which transform the accelerator pedal C position into output voltage, and emit the voltage signal to the ECM. In addition, these sensors detect the opening and closing speed of the accelerator pedal and feed the voltage signals to the ECM. The ECM judges the current opening angle of the accelerator pedal from D these signals and controls the throttle control motor based on these signals. PBIB1741E Idle position of the accelerator pedal is determined by the ECM E receiving the signal from the accelerator pedal position sensor. The ECM uses this signal for the engine operation such as fuel cut. CONSULT-II Reference Value in Data Monitor Mode BBS0032I F Specification data are reference values. MONITOR ITEM ACCEL SEN 1 ACCEL SEN 2* CLSD THL POS CONDITION ● ● ● SPECIFICATION Ignition switch: ON (Engine stopped) Accelerator pedal: Fully released 0.6 - 0.9V Accelerator pedal: Fully depressed 4.0 - 4.8V Ignition switch: ON (Engine stopped) Accelerator pedal: Fully released 0.6 - 0.9V Accelerator pedal: Fully depressed 3.9 - 4.8V Ignition switch: ON (Engine stopped) Accelerator pedal: Fully released ON Accelerator pedal: Slightly depressed OFF G H I *: Accelerator pedal position sensor 2 signal is converted by ECM internally. Thus, it differs from ECM terminal voltage. On Board Diagnosis Logic BBS0032J These self-diagnoses have the one trip detection logic. NOTE: If DTC P2122 or P2123 is displayed with DTC P1229, first perform the trouble diagnosis for DTC P1229. Refer to EC-363, "DTC P1229 SENSOR POWER SUPPLY" . DTC No. Trouble diagnosis name DTC detecting condition P2122 2122 Accelerator pedal position sensor 1 circuit low input An excessively low voltage from the APP sensor 1 is sent to ECM. P2123 2123 Accelerator pedal position sensor 1 circuit high input An excessively high voltage from the APP sensor 1 is sent to ECM. Possible cause ● Harness or connectors (APP sensor 1 circuit is open or shorted.) ● Accelerator pedal position sensor (APP sensor 1) FAIL-SAFE MODE When the malfunction is detected, the ECM enters fail-safe mode and the MI lights up. Engine operating condition in fail-safe mode The ECM controls the electric throttle control actuator in regulating the throttle opening in order for the idle position to be within +10 degrees. The ECM regulates the opening speed of the throttle valve to be slower than the normal condition. So, the acceleration will be poor. EC-383 J K L M DTC P2122, P2123 APP SENSOR [CR (WITH EURO-OBD)] DTC Confirmation Procedure BBS0032K NOTE: If DTC Confirmation Procedure has been previously conducted, always turn ignition switch OFF and wait at least 10 seconds before conducting the next test. TESTING CONDITION: Before performing the following procedure, confirm that battery voltage is more than 10V at idle. WITH CONSULT-II 1. 2. 3. 4. Turn ignition switch ON. Select “DATA MONITOR” mode with CONSULT-II. Start engine and let it idle for 1 second. If DTC is detected, go to EC-388, "Diagnostic Procedure" . SEF058Y WITH GST Follow the procedure “WITH CONSULT-II” above. EC-384 DTC P2122, P2123 APP SENSOR [CR (WITH EURO-OBD)] Wiring Diagram BBS0032L A LHD MODELS EC C D E F G H I J K L M MBWA1529E EC-385 DTC P2122, P2123 APP SENSOR [CR (WITH EURO-OBD)] Specification data are reference values and are measured between each terminal and ground. CAUTION: Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM's transistor. Use a ground other than ECM terminals, such as the ground. TERMINAL NO. WIRE COLOR ITEM CONDITION DATA (DC Voltage) [Engine is running] 82 B Sensor ground (APP sensor 1) ● Warm-up condition ● Idle speed Approximately 0V [Ignition switch: ON] 83 B Sensor ground (APP sensor 2) ● Warm-up condition ● Idle speed Approximately 0V 90 O Sensor power supply (APP sensor 1) [Ignition switch: ON] Approximately 5V 91 BR Sensor power supply (APP sensor 2) [Ignition switch: ON] Approximately 5V [Ignition switch: ON] 98 G Accelerator pedal position sensor 2 ● Engine stopped ● Accelerator pedal: Fully released 0.3 - 0.6V [Ignition switch: ON] ● Engine stopped ● Accelerator pedal: Fully depressed 1.95 - 2.4V [Ignition switch: ON] 106 W Accelerator pedal position sensor 1 ● Engine stopped ● Accelerator pedal: Fully released 0.6 - 0.9V [Ignition switch: ON] ● Engine stopped ● Accelerator pedal: Fully depressed EC-386 3.9 - 4.7V DTC P2122, P2123 APP SENSOR [CR (WITH EURO-OBD)] RHD MODELS A EC C D E F G H I J K L M MBWA1530E EC-387 DTC P2122, P2123 APP SENSOR [CR (WITH EURO-OBD)] Specification data are reference values and are measured between each terminal and ground. CAUTION: Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM's transistor. Use a ground other than ECM terminals, such as the ground. TERMINAL NO. WIRE COLOR ITEM CONDITION DATA (DC Voltage) [Engine is running] 82 B Sensor ground (APP sensor 1) ● Warm-up condition ● Idle speed Approximately 0V [Ignition switch: ON] 83 B Sensor ground (APP sensor 2) ● Warm-up condition ● Idle speed Approximately 0V 90 O Sensor power supply (APP sensor 1) [Ignition switch: ON] Approximately 5V 91 BR Sensor power supply (APP sensor 2) [Ignition switch: ON] Approximately 5V [Ignition switch: ON] 98 G Accelerator pedal position sensor 2 ● Engine stopped ● Accelerator pedal: Fully released 0.3 - 0.6V [Ignition switch: ON] ● Engine stopped ● Accelerator pedal: Fully depressed 1.95 - 2.4V [Ignition switch: ON] 106 W Accelerator pedal position sensor 1 ● Engine stopped ● Accelerator pedal: Fully released 0.6 - 0.9V [Ignition switch: ON] ● Engine stopped ● Accelerator pedal: Fully depressed 3.9 - 4.7V Diagnostic Procedure BBS0032M 1. CHECK GROUND CONNECTIONS 1. 2. Turn ignition switch OFF. Loosen and retighten ground screws on the body. Refer to EC-133, "Ground Inspection" . MBIB1502E 1. Body ground E44 2. Body ground E45 OK or NG OK >> GO TO 2. NG >> Repair or replace ground connections. EC-388 3. Body ground E28 DTC P2122, P2123 APP SENSOR [CR (WITH EURO-OBD)] 2. CHECK APP SENSOR 1 POWER SUPPLY CIRCUIT 1. 2. A Disconnect accelerator pedal position (APP) sensor harness connector. Turn ignition switch ON. EC C D MBIB0285E 3. Check voltage between APP sensor terminal 4 and ground with CONSULT-II or tester. E Voltage: Approximately 5V F G MBIB0304E H OK or NG OK >> GO TO 4. NG (LHD models)>>Repair open circuit or short to ground or short to power in harness or connectors. NG (RHD models)>>GO TO 3. I 3. DETECT MALFUNCTIONING PART J Check the following. ● Harness connectors M1, E101 ● Harness connectors M8, M201 ● Harness for open or short between ECM and accelerator pedal position sensor K L >> Repair open circuit or short to ground or short to power in harness or connectors. 4. CHECK APP SENSOR 1 GROUND CIRCUIT FOR OPEN AND SHORT 1. 2. 3. Turn ignition switch OFF. Disconnect ECM harness connector. Check harness continuity between ECM terminal 82 and APP sensor terminal 2. Refer to Wiring Diagram. Continuity should exist. 4. Also check harness for short to ground and short to power. OK or NG OK >> GO TO 6. NG (LHD models)>>Repair open circuit or short to ground or short to power in harness or connectors. NG (RHD models)>>GO TO 5. EC-389 M DTC P2122, P2123 APP SENSOR [CR (WITH EURO-OBD)] 5. DETECT MALFUNCTIONING PART Check the following. ● Harness connectors M1, E101 ● Harness connectors M8, M201 ● Harness for open or short between ECM and accelerator pedal position sensor >> Repair open circuit or short to ground or short to power in harness or connectors. 6. CHECK APP SENSOR 1 INPUT SIGNAL CIRCUIT FOR OPEN AND SHORT 1. Check harness continuity between ECM terminal 106 and APP sensor terminal 3. Refer to Wiring Diagram. Continuity should exist. 2. Also check harness for short to ground and short to power. OK or NG OK >> GO TO 8. NG (LHD models)>>Repair open circuit or short to ground or short to power in harness or connectors. NG (RHD models)>>GO TO 7. 7. DETECT MALFUNCTIONING PART Check the following. Harness connectors M1, E101 ● Harness connectors M8, M201 ● Harness for open or short between ECM and accelerator pedal position sensor ● >> Repair open circuit or short to ground or short to power in harness or connectors. 8. CHECK APP SENSOR Refer to EC-390, "Component Inspection" . OK or NG OK >> GO TO 10. NG >> GO TO 9. 9. REPLACE ACCELERATOR PEDAL ASSEMBLY 1. 2. 3. 4. Replace the accelerator pedal assembly. Perform EC-69, "Accelerator Pedal Released Position Learning" . Perform EC-69, "Throttle Valve Closed Position Learning" . Perform EC-69, "Idle Air Volume Learning" . >> INSPECTION END 10. CHECK INTERMITTENT INCIDENT Refer to EC-127, "TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT" . >> INSPECTION END Component Inspection BBS0032N ACCELERATOR PEDAL POSITION SENSOR 1. 2. Reconnect all harness connectors disconnected. Turn ignition switch ON. EC-390 DTC P2122, P2123 APP SENSOR [CR (WITH EURO-OBD)] 3. Check voltage between ECM terminals 106 (APP sensor 1 signal), 98 (APP sensor 2 signal) and ground under the following conditions. Terminal Accelerator pedal Voltage 106 (Accelerator pedal position sensor 1) Fully released 0.6 - 0.9V Fully depressed 3.9 - 4.7V Fully released 0.3 - 0.6V Fully depressed 1.95 - 2.4V 98 (Accelerator pedal position sensor 2) 4. 5. 6. 7. A EC C MBIB0023E D If NG, replace accelerator pedal assembly and go to the next step. Perform EC-69, "Accelerator Pedal Released Position Learning" . Perform EC-69, "Throttle Valve Closed Position Learning" . Perform EC-69, "Idle Air Volume Learning" . Removal and Installation E BBS0032O ACCELERATOR PEDAL F Refer to ACC-2, "ACCELERATOR CONTROL SYSTEM" . G H I J K L M EC-391 DTC P2127, P2128 APP SENSOR [CR (WITH EURO-OBD)] DTC P2127, P2128 APP SENSOR Component Description PFP:18002 BBS0032P The accelerator pedal position sensor is installed on the upper end of the accelerator pedal assembly. The sensor detects the accelerator position and sends a signal to the ECM. Accelerator pedal position sensor has two sensors. These sensors are a kind of potentiometers which transform the accelerator pedal position into output voltage, and emit the voltage signal to the ECM. In addition, these sensors detect the opening and closing speed of the accelerator pedal and feed the voltage signals to the ECM. The ECM judges the current opening angle of the accelerator pedal from these signals and controls the throttle control motor based on these signals. PBIB1741E Idle position of the accelerator pedal is determined by the ECM receiving the signal from the accelerator pedal position sensor. The ECM uses this signal for the engine operation such as fuel cut. CONSULT-II Reference Value in Data Monitor Mode BBS0032Q Specification data are reference values. MONITOR ITEM ACCEL SEN 1 ACCEL SEN 2* CLSD THL POS CONDITION ● ● ● SPECIFICATION Ignition switch: ON (Engine stopped) Accelerator pedal: Fully released 0.6 - 0.9V Accelerator pedal: Fully depressed 4.0 - 4.8V Ignition switch: ON (Engine stopped) Accelerator pedal: Fully released 0.6 - 0.9V Accelerator pedal: Fully depressed 3.9 - 4.8V Ignition switch: ON (Engine stopped) Accelerator pedal: Fully released ON Accelerator pedal: Slightly depressed OFF *: Accelerator pedal position sensor 2 signal is converted by ECM internally. Thus, it differ from ECM terminal voltage signal. On Board Diagnosis Logic BBS0032R These self-diagnoses have the one trip detection logic. DTC No. Trouble diagnosis name DTC detecting condition Possible cause P2127 2127 Accelerator pedal position sensor 2 circuit low input An excessively low voltage from the APP sensor 2 is sent to ECM. ● Harness or connectors (APP sensor 2 circuit is open or shorted.) (TP sensor circuit is shorted.) P2128 2128 Accelerator pedal position sensor 2 circuit high input An excessively high voltage from the APP sensor 2 is sent to ECM. ● Accelerator pedal position sensor (APP sensor 2) ● Electric throttle control actuator (TP sensor 1 and 2) FAIL-SAFE MODE When the malfunction is detected, the ECM enters fail-safe mode and the MI lights up. Engine operating condition in fail-safe mode The ECM controls the electric throttle control actuator in regulating the throttle opening in order for the idle position to be within +10 degrees. The ECM regulates the opening speed of throttle valve to be slower than the normal condition. So, the acceleration will be poor. EC-392 DTC P2127, P2128 APP SENSOR [CR (WITH EURO-OBD)] DTC Confirmation Procedure BBS0032S A NOTE: If DTC Confirmation Procedure has been previously conducted, always turn ignition switch OFF and wait at least 10 seconds before conducting the next test. EC TESTING CONDITION: Before performing the following procedure, confirm that battery voltage is more than 10V at idle. WITH CONSULT-II 1. 2. 3. 4. C Turn ignition switch ON. Select “DATA MONITOR” mode with CONSULT-II. Start engine and let it idle for 1 second. If DTC is detected, go to EC-397, "Diagnostic Procedure" . D E F SEF058Y WITH GST G Follow the procedure “WITH CONSULT-II” above. H I J K L M EC-393 DTC P2127, P2128 APP SENSOR [CR (WITH EURO-OBD)] Wiring Diagram BBS0032T LHD MODELS MBWA1531E EC-394 DTC P2127, P2128 APP SENSOR [CR (WITH EURO-OBD)] Specification data are reference values and are measured between each terminal and ground. CAUTION: Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM's transistor. Use a ground other than ECM terminals, such as the ground. TERMINAL NO. WIRE COLOR A EC ITEM 47 G Sensor power supply (Throttle position sensor) 82 B Sensor ground (APP sensor 1) CONDITION [Ignition switch: ON] DATA (DC Voltage) Approximately 5V C Approximately 0V D Approximately 0V E F [Engine is running] ● Warm-up condition ● Idle speed [Ignition switch: ON] 83 B Sensor ground (APP sensor 2) ● Warm-up condition ● Idle speed 90 O Sensor power supply (APP sensor 1) [Ignition switch: ON] Approximately 5V 91 BR Sensor power supply (APP sensor 2) [Ignition switch: ON] Approximately 5V G [Ignition switch: ON] 98 G Accelerator pedal position sensor 2 ● Engine stopped ● Accelerator pedal: Fully released 0.3 - 0.6V H [Ignition switch: ON] ● Engine stopped ● Accelerator pedal: Fully depressed 1.95 - 2.4V I [Ignition switch: ON] 106 W Accelerator pedal position sensor 1 ● Engine stopped ● Accelerator pedal: Fully released 0.6 - 0.9V J [Ignition switch: ON] ● Engine stopped ● Accelerator pedal: Fully depressed 3.9 - 4.7V K L M EC-395 DTC P2127, P2128 APP SENSOR [CR (WITH EURO-OBD)] RHD MODELS MBWA1532E EC-396 DTC P2127, P2128 APP SENSOR [CR (WITH EURO-OBD)] Specification data are reference values and are measured between each terminal and ground. CAUTION: Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM's transistor. Use a ground other than ECM terminals, such as the ground. TERMINAL NO. A EC WIRE COLOR ITEM CONDITION 47 G Sensor power supply (Throttle position sensor) 82 B Sensor ground (APP sensor 1) DATA (DC Voltage) [Ignition switch: ON] Approximately 5V C Approximately 0V D Approximately 0V E F [Engine is running] ● Warm-up condition ● Idle speed [Ignition switch: ON] 83 B Sensor ground (APP sensor 2) ● Warm-up condition ● Idle speed 90 O Sensor power supply (APP sensor 1) [Ignition switch: ON] Approximately 5V 91 BR Sensor power supply (APP sensor 2) [Ignition switch: ON] Approximately 5V G [Ignition switch: ON] 98 G Accelerator pedal position sensor 2 ● Engine stopped ● Accelerator pedal: Fully released 0.3 - 0.6V H [Ignition switch: ON] ● Engine stopped ● Accelerator pedal: Fully depressed 1.95 - 2.4V I [Ignition switch: ON] 106 W Accelerator pedal position sensor 1 ● Engine stopped ● Accelerator pedal: Fully released 0.6 - 0.9V J [Ignition switch: ON] ● Engine stopped ● Accelerator pedal: Fully depressed 3.9 - 4.7V K Diagnostic Procedure BBS0032U 1. CHECK GROUND CONNECTIONS 1. 2. L Turn ignition switch OFF. Loosen and retighten ground screws on the body. Refer to EC-133, "Ground Inspection" . M MBIB1502E 1. Body ground E44 2. Body ground E45 OK or NG OK >> GO TO 2. NG >> Repair or replace ground connections. EC-397 3. Body ground E28 DTC P2127, P2128 APP SENSOR [CR (WITH EURO-OBD)] 2. CHECK APP SENSOR 2 POWER SUPPLY CIRCUIT-I 1. 2. Disconnect accelerator pedal position (APP) sensor harness connector. Turn ignition switch ON. MBIB0285E 3. Check voltage between APP sensor terminal 5 and ground with CONSULT-II or tester. Voltage: Approximately 5V OK or NG OK >> GO TO 8. NG >> GO TO 3. MBIB0309E 3. CHECK APP SENSOR 2 POWER SUPPLY CIRCUIT-II 1. 2. 3. Turn ignition switch OFF. Disconnect ECM harness connector. Check harness continuity between APP sensor terminal 5 and ECM terminal 91. Refer to Wiring Diagram. Continuity should exist. OK or NG OK >> GO TO 5. NG (LHD models)>>Repair open circuit. NG (RHD models)>>GO TO 4. 4. DETECT MALFUNCTIONING PART Check the following. ● Harness connectors M201, M8 ● Harness connectors M1, E101 ● Harness for open or short between accelerator pedal position sensor and ECM >> Repair open circuit. EC-398 DTC P2127, P2128 APP SENSOR [CR (WITH EURO-OBD)] 5. CHECK APP SENSOR 2 POWER SUPPLY CIRCUIT-III A Check harness for short to power and short to ground, between the following terminals. ECM terminal Sensor terminal Reference Wiring Diagram 91 APP sensor terminal 5 EC-394 47 Electric throttle control actuator terminal 1 EC-404 OK or NG OK >> GO TO 6. NG >> Repair short to ground or short to power in harness or connectors. EC C D 6. CHECK THROTTLE POSITION SENSOR Refer to EC-408, "Component Inspection" . OK or NG OK >> GO TO 14. NG >> GO TO 7. E F 7. REPLACE ELECTRIC THROTTLE CONTROL ACTUATOR 1. 2. 3. Replace the electric throttle control actuator. Perform EC-69, "Throttle Valve Closed Position Learning" . Perform EC-69, "Idle Air Volume Learning" . G H >> INSPECTION END 8. CHECK APP SENSOR 2 GROUND CIRCUIT FOR OPEN AND SHORT I 1. 2. 3. J Turn ignition switch OFF. Disconnect ECM harness connector. Check harness continuity between ECM terminal 83 and APP sensor terminal 1. Refer to Wiring Diagram. K Continuity should exist. 4. Also check harness for short to ground and short to power. OK or NG OK >> GO TO 10. NG (LHD models)>>Repair open circuit or short to ground or short to power in harness or connectors. NG (RHD models)>>GO TO 9. 9. DETECT MALFUNCTIONING PART Check the following. ● Harness connectors M8, M201 ● Harness connectors M1, E101 ● Harness for open or short between accelerator pedal position sensor and ECM >> Repair open circuit or short to ground or short to power in harness or connectors. EC-399 L M DTC P2127, P2128 APP SENSOR [CR (WITH EURO-OBD)] 10. CHECK APP SENSOR 2 INPUT SIGNAL CIRCUIT FOR OPEN AND SHORT 1. Check harness continuity between ECM terminal 98 and APP sensor terminal 6. Refer to Wiring Diagram. Continuity should exist. 2. Also check harness for short to ground and short to power. OK or NG OK >> GO TO 12. NG (LHD models)>>Repair open circuit or short to ground or short to power in harness or connectors. NG (RHD models)>>GO TO 11. 11. DETECT MALFUNCTIONING PART Check the following. Harness connectors M8, M201 ● Harness connectors M1, E101 ● Harness for open or short between ECM and accelerator pedal position sensor ● >> Repair open circuit or short to ground or short to power in harness or connectors. 12. CHECK APP SENSOR Refer to EC-400, "Component Inspection" . OK or NG OK >> GO TO 14. NG >> GO TO 13. 13. REPLACE ACCELERATOR PEDAL ASSEMBLY 1. 2. 3. 4. Replace the accelerator pedal assembly. Perform EC-69, "Accelerator Pedal Released Position Learning" . Perform EC-69, "Throttle Valve Closed Position Learning" . Perform EC-69, "Idle Air Volume Learning" . >> INSPECTION END 14. CHECK INTERMITTENT INCIDENT Refer to EC-127, "TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT" . >> INSPECTION END Component Inspection BBS0032V ACCELERATOR PEDAL POSITION SENSOR 1. 2. Reconnect all harness connectors disconnected. Turn ignition switch ON. EC-400 DTC P2127, P2128 APP SENSOR [CR (WITH EURO-OBD)] 3. Check voltage between ECM terminals 106 (APP sensor 1 signal), 98 (APP sensor 2 signal) and ground under the following conditions. Terminal Accelerator pedal Voltage 106 (Accelerator pedal position sensor 1) Fully released 0.6 - 0.9V Fully depressed 3.9 - 4.7V Fully released 0.3 - 0.6V Fully depressed 1.95 - 2.4V 98 (Accelerator pedal position sensor 2) 4. 5. 6. 7. A EC C MBIB0023E D If NG, replace accelerator pedal assembly and go to the next step. Perform EC-69, "Accelerator Pedal Released Position Learning" . Perform EC-69, "Throttle Valve Closed Position Learning" . Perform EC-69, "Idle Air Volume Learning" . Removal and Installation E BBS0032W ACCELERATOR PEDAL F Refer to ACC-2, "ACCELERATOR CONTROL SYSTEM" . G H I J K L M EC-401 DTC P2135 TP SENSOR [CR (WITH EURO-OBD)] DTC P2135 TP SENSOR Component Description PFP:16119 BBS0032X Electric throttle control actuator consists of throttle control motor, throttle position sensor, etc. The throttle position sensor responds to the throttle valve movement. The throttle position sensor has the two sensors. These sensors are a kind of potentiometers which transform the throttle valve position into output voltage, and emit the voltage signal to the ECM. In addition, these sensors detect the opening and closing speed of the throttle valve and feed the voltage signals to the ECM. The ECM judges the current opening angle of the throttle valve from these signals and the ECM controls the throttle control motor to make the throttle valve opening angle properly in response to driving condition. PBIB0145E CONSULT-II Reference Value in Data Monitor Mode BBS0032Y Specification data are reference values. MONITOR ITEM CONDITION SPECIFICATION ● Ignition switch: ON (Engine stopped) Accelerator pedal: Fully released More than 0.36V ● Shift lever: 1st Accelerator pedal: Fully depressed Less than 4.75V THRTL SEN 1 THRTL SEN 2* *: Throttle position sensor 2 signal is converted by ECM internally. Thus, it differs from ECM terminal voltage signal. On Board Diagnosis Logic BBS0032Z This self-diagnosis has the one trip detection logic. DTC No. P2135 2135 Trouble diagnosis name Throttle position sensor circuit range/performance DTC detecting condition Rationally incorrect voltage is sent to ECM compared with the signals from TP sensor 1 and TP sensor 2. Possible cause ● Harness or connector (TP sensor 1 and 2 circuit is open or shorted.) (APP sensor 2 circuit is shorted.) ● Electric throttle control actuator (TP sensor 1 and 2) ● Accelerator pedal position sensor (APP sensor 2) FAIL-SAFE MODE When the malfunction is detected, the ECM enters fail-safe mode and the MI lights up. Engine operation condition in fail-safe mode The ECM controls the electric throttle control actuator in regulating the throttle opening in order for the idle position to be within +10 degrees. The ECM regulates the opening speed of the throttle valve to be slower than the normal condition. So, the acceleration will be poor. EC-402 DTC P2135 TP SENSOR [CR (WITH EURO-OBD)] DTC Confirmation Procedure BBS00330 A NOTE: If DTC Confirmation Procedure has been previously conducted, always turn ignition switch OFF and wait at least 10 seconds before conducting the next test. EC TESTING CONDITION: Before performing the following procedure, confirm that battery voltage is more than 10V at idle. WITH CONSULT-II 1. 2. 3. 4. C Turn ignition switch ON. Select “DATA MONITOR” mode with CONSULT-II. Start engine and let it idle for 1 second. If DTC is detected, go to EC-405, "Diagnostic Procedure" . D E F SEF058Y WITH GST G Follow the procedure “WITH CONSULT-II” above. H I J K L M EC-403 DTC P2135 TP SENSOR [CR (WITH EURO-OBD)] Wiring Diagram BBS00331 MBWA1533E EC-404 DTC P2135 TP SENSOR [CR (WITH EURO-OBD)] Specification data are reference values and are measured between each terminal and ground. CAUTION: Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM's transistor. Use a ground other than ECM terminals, such as the ground. TERMINAL NO. 47 WIRE COLOR L ITEM CONDITION Sensor power supply (Throttle position sensor) EC DATA (DC Voltage) [Ignition switch: ON] A Approximately 5V C [Ignition switch: ON] 49 Y ● Engine stopped ● Shift lever position: 1st ● Accelerator pedal: Fully released Throttle position sensor 1 More than 0.36V D [Ignition switch: ON] ● E Engine stopped ● Shift lever position: 1st ● Accelerator pedal: Fully depressed Less than 4.75V F [Engine is running] 66 B Sensor ground (Throttle position sensor) ● Warm-up condition ● Idle speed Approximately 0V G [Ignition switch: ON] 68 R Throttle position sensor 2 ● Engine stopped ● Shift lever position: 1st ● Accelerator pedal: Fully released BR Sensor power supply (APP sensor 2) H [Ignition switch: ON] ● 91 Less than 4.75V I Engine stopped ● Shift lever position: 1st ● Accelerator pedal: Fully depressed More than 0.36V J [Ignition switch: ON] Approximately 5V Diagnostic Procedure BBS00332 1. CHECK GROUND CONNECTIONS 1. 2. Turn ignition switch OFF. Loosen and retighten ground screws on the body. Refer to EC-133, "Ground Inspection" . K L M MBIB1502E 1. Body ground E44 2. Body ground E45 OK or NG OK >> GO TO 2. NG >> Repair or replace ground connections. EC-405 3. Body ground E28 DTC P2135 TP SENSOR [CR (WITH EURO-OBD)] 2. CHECK THROTTLE POSITION SENSOR POWER SUPPLY CIRCUIT 1. 2. Disconnect electric throttle control actuator harness connector. Turn ignition switch ON. MBIB0308E 3. Check voltage between electric throttle control actuator terminal 1 and ground with CONSULT-II or tester. Voltage: Approximately 5V OK or NG OK >> GO TO 7. NG >> GO TO 3. PBIB0082E 3. CHECK THROTTLE POSITION SENSOR POWER SUPPLY CIRCUIT-II 1. 2. 3. Turn ignition switch OFF. Disconnect ECM harness connector. Check harness continuity between electric throttle control actuator terminal 1 and ECM terminal 47. Refer to Wiring Diagram. Continuity should exist. OK or NG OK >> GO TO 4. NG >> Repair open circuit. 4. CHECK THROTTLE POSITION SENSOR POWER SUPPLY CIRCUIT-III Check harness for short to power and short to ground, between the following terminals. ECM terminal Sensor terminal Reference Wiring Diagram 47 Electric throttle control actuator terminal 1 EC-404 91 APP sensor terminal 5 EC-394 OK or NG OK >> GO TO 5. NG >> Repair short to ground or short to power in harness or connectors. 5. CHECK APP SENSOR Refer to EC-400, "Component Inspection" . OK or NG OK >> GO TO 11 NG >> GO TO 6. EC-406 DTC P2135 TP SENSOR [CR (WITH EURO-OBD)] 6. REPLACE ACCELERATOR PEDAL ASSEMBLY 1. 2. 3. 4. Replace accelerator pedal assembly. Perform EC-69, "Accelerator Pedal Released Position Learning" . Perform EC-69, "Throttle Valve Closed Position Learning" . Perform EC-69, "Idle Air Volume Learning" . 7. CHECK THROTTLE POSITION SENSOR GROUND CIRCUIT FOR OPEN AND SHORT Turn ignition switch OFF. Disconnect ECM harness connector. Check harness continuity between ECM terminal 66 and electric throttle control actuator terminal 5. Refer to Wiring Diagram. Continuity should exist. D E F 4. Also check harness for short to ground and short to power. OK or NG OK >> GO TO 8. NG >> Repair open circuit or short to ground or short to power in harness or connectors. 8. CHECK THROTTLE POSITION SENSOR INPUT SIGNAL CIRCUIT FOR OPEN AND SHORT 1. EC C >> INSPECTION END 1. 2. 3. A Check harness continuity between ECM terminal 49 and electric throttle control actuator terminal 4, ECM terminal 68 and electric throttle control actuator terminal 2. Refer to Wiring Diagram. G H I Continuity should exist. 2. Also check harness for short to ground and short to power. OK or NG OK >> GO TO 9. NG >> Repair open circuit or short to ground or short to power in harness or connectors. J K 9. CHECK THROTTLE POSITION SENSOR L Refer to EC-408, "Component Inspection" . OK or NG OK >> GO TO 11. NG >> GO TO 10. M 10. REPLACE ELECTRIC THROTTLE CONTROL ACTUATOR 1. 2. 3. Replace the electric throttle control actuator. Perform EC-69, "Throttle Valve Closed Position Learning" . Perform EC-69, "Idle Air Volume Learning" . >> INSPECTION END 11. CHECK INTERMITTENT INCIDENT Refer to EC-127, "TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT" . >> INSPECTION END EC-407 DTC P2135 TP SENSOR [CR (WITH EURO-OBD)] Component Inspection BBS00333 THROTTLE POSITION SENSOR 1. 2. 3. 4. 5. Reconnect all harness connectors disconnected. Perform EC-69, "Throttle Valve Closed Position Learning" . Turn ignition switch ON. Set shift lever to 1st position. Check voltage between ECM terminals 49 (TP sensor 1 signal), 68 (TP sensor 2 signal) and ground under the following conditions. Terminal Accelerator pedal Voltage 49 (Throttle position sensor 1) Fully released More than 0.36V Fully depressed Less than 4.75V Fully released Less than 4.75V Fully depressed More than 0.36V 68 (Throttle position sensor 2) 6. 7. 8. If NG, replace electric throttle control actuator and go to the next step. Perform EC-69, "Throttle Valve Closed Position Learning" . Perform EC-69, "Idle Air Volume Learning" . Removal and Installation MBIB1443E BBS00334 ELECTRIC THROTTLE CONTROL ACTUATOR Refer to EM-18, "AIR CLEANER AND AIR DUCT" . EC-408 DTC P2138 APP SENSOR [CR (WITH EURO-OBD)] DTC P2138 APP SENSOR Component Description PFP:18002 A BBS00335 The accelerator pedal position sensor is installed on the upper end of the accelerator pedal assembly. The sensor detects the acceleraEC tor position and sends a signal to the ECM. Accelerator pedal position sensor has two sensors. These sensors are a kind of potentiometers which transform the accelerator pedal C position into output voltage, and emit the voltage signal to the ECM. In addition, these sensors detect the opening and closing speed of the accelerator pedal and feed the voltage signals to the ECM. The ECM judges the current opening angle of the accelerator pedal from D these signals and controls the throttle control motor based on these signals. PBIB1741E Idle position of the accelerator pedal is determined by the ECM E receiving the signal from the accelerator pedal position sensor. The ECM uses this signal for the engine operation such as fuel cut. CONSULT-II Reference Value in Data Monitor Mode BBS00336 F Specification data are reference values. MONITOR ITEM ACCEL SEN 1 ACCEL SEN 2* CLSD THL POS CONDITION ● ● ● SPECIFICATION Ignition switch: ON (Engine stopped) Accelerator pedal: Fully released 0.6 - 0.9V Accelerator pedal: Fully depressed 4.0 - 4.8V Ignition switch: ON (Engine stopped) Accelerator pedal: Fully released 0.6 - 0.9V Accelerator pedal: Fully depressed 3.9 - 4.8V Ignition switch: ON (Engine stopped) Accelerator pedal: Fully released ON Accelerator pedal: Slightly depressed OFF G H I *: Accelerator pedal position sensor 2 signal is converted by ECM internally. Thus, it differs from ECM terminal voltage. On Board Diagnosis Logic BBS00337 This self-diagnosis has the one trip detection logic. NOTE: If DTC P2138 is displayed with DTC P1229, first perform trouble diagnosis for DTC P1229. Refer to EC-363, "DTC P1229 SENSOR POWER SUPPLY" . DTC No. Trouble diagnosis name DTC detecting condition Possible cause ● P2138 2138 Accelerator pedal position sensor circuit range/performance Rationally incorrect voltage is sent to ECM compared with the signals from APP sensor 1 and APP sensor 2. Harness or connector (APP sensor 1 and 2 circuit is open or shorted.) (TP sensor circuit is shorted.) ● Accelerator pedal position sensor (APP sensor 1 and 2) ● Electric throttle control actuator (TP sensor 1 and 2) FAIL-SAFE MODE When the malfunction is detected, the ECM enters fail-safe mode and the MI lights up. Engine operating condition in fail-safe mode The ECM controls the electric throttle control actuator in regulating the throttle opening in order for the idle position to be within +10 degrees. The ECM regulates the opening speed of the throttle valve to be slower than the normal condition. So, the acceleration will be poor. EC-409 J K L M DTC P2138 APP SENSOR [CR (WITH EURO-OBD)] DTC Confirmation Procedure BBS00338 NOTE: If DTC Confirmation Procedure has been previously conducted, always turn ignition switch OFF and wait at least 10 seconds before conducting the next test. TESTING CONDITION: Before performing the following procedure, confirm that battery voltage is more than 10V at idle. WITH CONSULT-II 1. 2. 3. 4. Turn ignition switch ON. Select “DATA MONITOR” mode with CONSULT-II. Start engine and let it idle for 1 second. If DTC is detected, go to EC-414, "Diagnostic Procedure" . SEF058Y WITH GST Follow the procedure “WITH CONSULT-II” above. EC-410 DTC P2138 APP SENSOR [CR (WITH EURO-OBD)] Wiring Diagram BBS00339 A LHD MODELS EC C D E F G H I J K L M MBWA1534E EC-411 DTC P2138 APP SENSOR [CR (WITH EURO-OBD)] Specification data are reference values and are measured between each terminal and ground. CAUTION: Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM's transistor. Use a ground other than ECM terminals, such as the ground. TERMINAL NO. WIRE COLOR ITEM CONDITION 47 G Sensor power supply (Throttle position sensor) [Ignition switch: ON] 82 B Sensor ground (APP sensor 1) ● Warm-up condition ● Idle speed DATA (DC Voltage) Approximately 5V [Engine is running] Approximately 0V [Ignition switch: ON] 83 B Sensor ground (APP sensor 2) ● Warm-up condition ● Idle speed Approximately 0V 90 O Sensor power supply (APP sensor 1) [Ignition switch: ON] Approximately 5V 91 BR Sensor power supply (APP sensor 2) [Ignition switch: ON] Approximately 5V [Ignition switch: ON] 98 G Accelerator pedal position sensor 2 ● Engine stopped ● Accelerator pedal: Fully released 0.3 - 0.6V [Ignition switch: ON] ● Engine stopped ● Accelerator pedal: Fully depressed 1.95 - 2.4V [Ignition switch: ON] 106 W Accelerator pedal position sensor 1 ● Engine stopped ● Accelerator pedal: Fully released 0.6 - 0.9V [Ignition switch: ON] ● Engine stopped ● Accelerator pedal: Fully depressed EC-412 3.9 - 4.7V DTC P2138 APP SENSOR [CR (WITH EURO-OBD)] RHD MODELS A EC C D E F G H I J K L M MBWA1535E EC-413 DTC P2138 APP SENSOR [CR (WITH EURO-OBD)] Specification data are reference values and are measured between each terminal and ground. CAUTION: Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM's transistor. Use a ground other than ECM terminals, such as the ground. TERMINAL NO. WIRE COLOR ITEM CONDITION 47 G Sensor power supply (Throttle position sensor) [Ignition switch: ON] 82 B Sensor ground (APP sensor 1) ● Warm-up condition ● Idle speed DATA (DC Voltage) Approximately 5V [Engine is running] Approximately 0V [Ignition switch: ON] 83 B Sensor ground (APP sensor 2) ● Warm-up condition ● Idle speed Approximately 0V 90 O Sensor power supply (APP sensor 1) [Ignition switch: ON] Approximately 5V 91 BR Sensor power supply (APP sensor 2) [Ignition switch: ON] Approximately 5V [Ignition switch: ON] 98 G Accelerator pedal position sensor 2 ● Engine stopped ● Accelerator pedal: Fully released 0.3 - 0.6V [Ignition switch: ON] ● Engine stopped ● Accelerator pedal: Fully depressed 1.95 - 2.4V [Ignition switch: ON] 106 W Accelerator pedal position sensor 1 ● Engine stopped ● Accelerator pedal: Fully released 0.6 - 0.9V [Ignition switch: ON] ● Engine stopped ● Accelerator pedal: Fully depressed 3.9 - 4.7V Diagnostic Procedure BBS0033A 1. CHECK GROUND CONNECTIONS 1. 2. Turn ignition switch OFF. Loosen and retighten ground screws on the body. Refer to EC-133, "Ground Inspection" . MBIB1502E 1. Body ground E44 2. Body ground E45 OK or NG OK >> GO TO 2. NG >> Repair or replace ground connections. EC-414 3. Body ground E28 DTC P2138 APP SENSOR [CR (WITH EURO-OBD)] 2. CHECK APP SENSOR 1 POWER SUPPLY CIRCUIT 1. 2. A Disconnect accelerator pedal position (APP) sensor harness connector. Turn ignition switch ON. EC C D MBIB0285E 3. Check voltage between APP sensor terminal 4 and ground with CONSULT-II or tester. E Voltage: Approximately 5V F G MBIB0304E H OK or NG OK >> GO TO 4. NG (LHD models)>>Repair open circuit or short to ground or short to power in harness or connectors. NG (RHD models)>>GO TO 3. I 3. DETECT MALFUNCTIONING PART J Check the following. ● Harness connectors M1, E101 ● Harness connectors M8, M201 ● Harness for open or short between ECM and accelerator pedal position sensor K L >> Repair open circuit or short to ground or short to power in harness or connectors. 4. CHECK APP SENSOR 2 POWER SUPPLY CIRCUIT-I M Check voltage between APP sensor terminal 5 and ground with CONSULT-II or tester. Voltage: Approximately 5V OK or NG OK >> GO TO 10. NG >> GO TO 5. MBIB0309E EC-415 DTC P2138 APP SENSOR [CR (WITH EURO-OBD)] 5. CHECK APP SENSOR 2 POWER SUPPLY CIRCUIT-II 1. 2. 3. Turn ignition switch OFF. Disconnect ECM harness connector. Check harness continuity between APP sensor terminal 5 and ECM terminal 91. Refer to Wiring Diagram. Continuity should exist. OK or NG OK >> GO TO 7. NG (LHD models)>>Repair open circuit. NG (RHD models)>>GO TO 6. 6. DETECT MALFUNCTIONING PART Check the following. ● Harness connectors M1, E101 ● Harness connectors M8, M201 ● Harness for open or short between accelerator pedal position sensor and ECM >> Repair open circuit. 7. CHECK APP SENSOR 2 POWER SUPPLY CIRCUIT-III Check harness for short to power and short to ground, between the following terminals. ECM terminal Sensor terminal Reference Wiring Diagram 91 APP sensor terminal 5 EC-411 47 Electric throttle control actuator terminal 1 EC-404 OK or NG OK >> GO TO 8. NG >> Repair short to ground or short to power in harness or connectors. 8. CHECK THROTTLE POSITION SENSOR Refer to EC-408, "Component Inspection" . OK or NG OK >> GO TO 16. NG >> GO TO 9. 9. REPLACE ELECTRIC THROTTLE CONTROL ACTUATOR 1. 2. 3. Replace the electric throttle control actuator. Perform EC-69, "Throttle Valve Closed Position Learning" . Perform EC-69, "Idle Air Volume Learning" . >> INSPECTION END EC-416 DTC P2138 APP SENSOR [CR (WITH EURO-OBD)] 10. CHECK APP SENSOR GROUND CIRCUIT FOR OPEN AND SHORT 1. 2. 3. A Turn ignition switch OFF. Disconnect ECM harness connector. Check harness continuity between ECM terminal 82 and APP sensor terminal 2, ECM terminal 83 and EC APP sensor terminal 1. Refer to Wiring Diagram. C Continuity should exist. 4. Also check harness for short to ground and short to power. OK or NG OK >> GO TO 12. NG (LHD models)>>Repair open circuit or short to ground or short to power in harness or connectors. NG (RHD models)>>GO TO 11. D E 11. DETECT MALFUNCTIONING PART Check the following. ● Harness connectors M1, E101 ● Harness connectors M8, M201 ● Harness for open or short between ECM and accelerator pedal position sensor >> Repair open circuit or short to ground or short to power in harness or connectors. F G H 12. CHECK APP SENSOR INPUT SIGNAL CIRCUIT FOR OPEN AND SHORT 1. Check harness continuity between ECM terminal 106 and APP sensor terminal 3, ECM terminal 98 and APP sensor terminal 6. Refer to Wiring Diagram. I J Continuity should exist. 2. Also check harness for short to ground and short to power. OK or NG OK >> GO TO 14. NG (LHD models)>>Repair open circuit or short to ground or short to power in harness or connectors. NG (RHD models)>>GO TO 13. 13. DETECT MALFUNCTIONING PART Check the following. ● Harness connectors M1, E101 ● Harness connectors M8, M201 ● Harness for open or short between ECM and accelerator pedal position sensor >> Repair open circuit or short to ground or short to power in harness or connectors. 14. CHECK APP SENSOR Refer to EC-418, "Component Inspection" . OK or NG OK >> GO TO 16. NG >> GO TO 15. EC-417 K L M DTC P2138 APP SENSOR [CR (WITH EURO-OBD)] 15. REPLACE ACCELERATOR PEDAL ASSEMBLY 1. 2. 3. 4. Replace the accelerator pedal assembly. Perform EC-69, "Accelerator Pedal Released Position Learning" . Perform EC-69, "Throttle Valve Closed Position Learning" . Perform EC-69, "Idle Air Volume Learning" . >> INSPECTION END 16. CHECK INTERMITTENT INCIDENT Refer to EC-127, "TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT" . >> INSPECTION END Component Inspection BBS0033B ACCELERATOR PEDAL POSITION SENSOR 1. 2. 3. Reconnect all harness connectors disconnected. Turn ignition switch ON. Check voltage between ECM terminals 106 (APP sensor 1 signal), 98 (APP sensor 2 signal) and ground under the following conditions. Terminal Accelerator pedal Voltage 106 (Accelerator pedal position sensor 1) Fully released 0.6 - 0.9V Fully depressed 3.9 - 4.7V Fully released 0.3 - 0.6V Fully depressed 1.95 - 2.4V 98 (Accelerator pedal position sensor 2) 4. 5. 6. 7. MBIB0023E If NG, replace accelerator pedal assembly and go to the next step. Perform EC-69, "Accelerator Pedal Released Position Learning" . Perform EC-69, "Throttle Valve Closed Position Learning" . Perform EC-69, "Idle Air Volume Learning" . Removal and Installation BBS0033C ACCELERATOR PEDAL Refer to ACC-2, "ACCELERATOR CONTROL SYSTEM" . EC-418 ELECTRICAL LOAD SIGNAL [CR (WITH EURO-OBD)] ELECTRICAL LOAD SIGNAL Description PFP:25350 A BBS0033Y The electrical load signal (Headlamp switch signal, rear window defogger switch signal, etc.) is transferred through the CAN communication line from IPDM E/R to ECM. EC CONSULT-II Reference Value in Data Monitor Mode BBS0033Z Specification data are reference values. MONITOR ITEM LOAD SIGNAL C CONDITION ● ● HEATER FAN SW Ignition switch: ON Engine: After warming up, idle the engine SPECIFICATION Rear window defogger switch is ON and/or lighting switch is 2nd. ON Rear window defogger switch is OFF and lighting switch is OFF. OFF Heater fan: Operating ON Heater fan: Not operating OFF Diagnostic Procedure D E BBS00340 F 1. CHECK LOAD SIGNAL CIRCUIT OVERALL FUNCTION-I 1. 2. 3. Turn ignition switch ON. Connect CONSULT-II and select “DATA MONITOR” mode. Select “LOAD SIGNAL” and check indication under the following conditions. Condition G H Indication Rear window defogger switch: ON ON Rear window defogger switch: OFF OFF I OK or NG OK >> GO TO 2. NG >> GO TO 4. J PBIB0103E K 2. CHECK LOAD SIGNAL CIRCUIT OVERALL FUNCTION-II Check “LOAD SIGNAL” indication under the following conditions. Condition L Indication Lighting switch: 2nd position ON Lighting switch: OFF OFF M OK or NG OK >> GO TO 3. NG >> GO TO 5. PBIB0103E EC-419 ELECTRICAL LOAD SIGNAL [CR (WITH EURO-OBD)] 3. CHECK HEATER FAN SIGNAL CIRCUIT OVERALL FUNCTION With CONSULT-II Check “HEATER FAN SW” in “DATA MONITOR” mode with CONSULT-II under the following conditions. Condition HEATER FAN SW Heater fan control switch: ON ON Heater fan control switch: OFF OFF OK or NG OK >> INSPECTION END NG >> GO TO 6. PBIB1995E 4. CHECK REAR WINDOW DEFOGGER SYSTEM Refer to GW-12, "REAR WINDOW DEFOGGER" . >> INSPECTION END 5. CHECK HEADLAMP SYSTEM Refer to LT-7, "HEADLAMP -CONVENTIONAL TYPE-" or LT-35, "HEADLAMP - DAYTIME LIGHT SYSTEM ". >> INSPECTION END 6. CHECK HEATER FAN CONTROL SYSTEM Refer to ATC-26, "TROUBLE DIAGNOSIS" or MTC-23, "TROUBLE DIAGNOSIS" . >> INSPECTION END EC-420 FUEL INJECTOR [CR (WITH EURO-OBD)] FUEL INJECTOR Component Description PFP:16600 A BBS0033I The fuel injector is a small, precise solenoid valve. When the ECM supplies a ground to the fuel injector circuit, the coil in the fuel injector is energized. The energized coil pulls the ball valve back and allows fuel to flow through the fuel injector into the intake manifold. The amount of fuel injected depends upon the injection pulse duration. Pulse duration is the length of time the fuel injector remains open. The ECM controls the injection pulse duration based on engine fuel needs. EC C D SEF375Z E CONSULT-II Reference Value in Data Monitor Mode BBS0033J Specification data are reference values. MONITOR ITEM B/FUEL SCHDL CONDITION ● See EC-117, "TROUBLE DIAGNOSIS - SPECIFICATION VALUE" . ● Engine: After warming up ● Shift lever: Neutral ● Air conditioner switch: OFF ● No load INJ PULSE-B1 SPECIFICATION Idle 2.0 - 3.0 msec 2,000 rpm 1.9 - 2.9 msec F G H I J K L M EC-421 FUEL INJECTOR [CR (WITH EURO-OBD)] Wiring Diagram BBS0033K MBWA1538E EC-422 FUEL INJECTOR [CR (WITH EURO-OBD)] Specification data are reference values and are measured between each terminal and ground. Pulse signal is measured by CONSULT-II. A CAUTION: Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM's transistor. Use a ground other than ECM terminals, such as the ground. EC TERMINAL NO. WIRE COLOR ITEM CONDITION DATA (DC Voltage) C BATTERY VOLTAGE [Engine is running] 22 23 41 42 O L R GR ● Warm-up condition ● Idle speed (11 - 14V) D NOTE: The pulse cycle changes depending on rpm at idle. Fuel injector No. 3 Fuel injector No. 1 Fuel injector No. 4 Fuel injector No. 2 E PBIB0529E BATTERY VOLTAGE F (11 - 14V) [Engine is running] ● Warm-up condition ● Engine speed: 2,000 rpm G H PBIB0530E : Average voltage for pulse signal (Actual pulse signal can be confirmed by oscilloscope.) I Diagnostic Procedure BBS0033L 1. INSPECTION START J Turn ignition switch to START. Is any cylinder ignited? Yes or No Yes >> GO TO 2. No >> GO TO 3. K L M EC-423 FUEL INJECTOR [CR (WITH EURO-OBD)] 2. CHECK OVERALL FUNCTION With CONSULT-II Start engine. Perform “POWER BALANCE” in “ACTIVE TEST” mode with CONSULT-II. 3. Make sure that each circuit produces a momentary engine speed drop. 1. 2. MBIB0302E Without CONSULT-II 1. Start engine. 2. Listen to each fuel injector operating sound. Clicking noise should be heard. PBIB1986E OK or NG OK >> INSPECTION END NG >> GO TO 3. EC-424 FUEL INJECTOR [CR (WITH EURO-OBD)] 3. CHECK FUEL INJECTOR POWER SUPPLY CIRCUIT 1. 2. Turn ignition switch OFF. Disconnect fuel injector harness connector (1). – : Vehicle front Turn ignition switch ON. 3. A EC C D MBIB1458E E 4. Check voltage between fuel injector terminal 1 and ground with CONSULT-II or tester. F Voltage: Battery voltage OK or NG OK >> GO TO 5. NG >> GO TO 4. G H PBIB0582E 4. DETECT MALFUNCTIONING PART I Check the following. ● Harness connectors E48, F1 ● 10A fuse ● Harness for open or short between fuel injector and fuse J K >> Repair harness or connectors. 5. CHECK FUEL INJECTOR OUTPUT SIGNAL CIRCUIT FOR OPEN AND SHORT 1. 2. 3. Turn ignition switch OFF. Disconnect ECM harness connector. Check harness continuity between fuel injector terminal 2 and ECM terminals 22, 23, 41, 42. Refer to Wiring Diagram. Continuity should exist. 4. Also check harness for short to ground and short to power. OK or NG OK >> GO TO 6. NG >> Repair open circuit or short to ground or short to power in harness or connectors. 6. CHECK FUEL INJECTOR Refer to EC-426, "Component Inspection" . OK or NG OK >> GO TO 7. NG >> Replace fuel injector. EC-425 L M FUEL INJECTOR [CR (WITH EURO-OBD)] 7. CHECK INTERMITTENT INCIDENT Refer to EC-127, "TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT" . >> INSPECTION END Component Inspection BBS0033M FUEL INJECTOR 1. 2. Disconnect fuel injector harness connector. Check resistance between terminals as shown in the figure. Resistance: 10.4 - 15.3Ω [at 10 - 60°C (50 - 140°F)] PBIB1727E Removal and Installation BBS0033N FUEL INJECTOR Refer to EM-32, "FUEL INJECTOR AND FUEL TUBE" . EC-426 FUEL PUMP [CR (WITH EURO-OBD)] FUEL PUMP Description PFP:17042 A BBS0033O SYSTEM DESCRIPTION Sensor Input Signal to ECM Crankshaft position sensor (POS) Camshaft position sensor (PHASE) Engine speed* Battery Battery voltage* ECM Function Actuator Fuel pump control EC Fuel pump relay C *: ECM determines the start signal status by the signals of engine speed and battery voltage. The ECM activates the fuel pump for several seconds after the ignition switch is turned ON to improve engine startability. If the ECM receives a engine speed signal from the crankshaft position sensor (POS) and camshaft position sensor (PHASE), it knows that the engine is rotating, and causes the pump to operate. If the engine speed signal is not received when the ignition switch is ON, the engine stalls. The ECM stops pump operation and prevents battery discharging, thereby improving safety. The ECM does not directly drive the fuel pump. It controls the ON/OFF fuel pump relay, which in turn controls the fuel pump. Condition D E Fuel pump operation Ignition switch is turned to ON. F Operates for 1 second. Engine running and cranking Operates. When engine is stopped Stops in 1.5 seconds. Except as shown above Stops. G COMPONENT DESCRIPTION H A turbine type design fuel pump is used in the fuel tank. I J K MBIB0291E CONSULT-II Reference Value in Data Monitor Mode BBS0033P L Specification data are reference values. MONITOR ITEM FUEL PUMP RLY CONDITION ● For 1 second after turning ignition switch ON ● Engine running or cranking ● Except above conditions SPECIFICATION ON OFF EC-427 M FUEL PUMP [CR (WITH EURO-OBD)] Wiring Diagram BBS0033Q MBWA1539E EC-428 FUEL PUMP [CR (WITH EURO-OBD)] Specification data are reference values and are measured between each terminal and ground. CAUTION: Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM's transistor. Use a ground other than ECM terminals, such as the ground. TERMINAL NO. EC WIRE COLOR ITEM CONDITION DATA (DC Voltage) [Ignition switch: ON] ● 113 R A Fuel pump relay For 1 second after turning ignition switch ON C 0 - 1.0V [Engine is running] [Ignition switch: ON] ● More than 1 second after turning ignition switch ON D BATTERY VOLTAGE (11 - 14V) E Diagnostic Procedure BBS0033R 1. CHECK OVERALL FUNCTION F 1. 2. Turn ignition switch ON. Pinch fuel feed hose (1) with two fingers. Fuel pressure pulsation should be felt on the fuel hose for 1 second after ignition switch is turned ON. OK or NG OK >> INSPECTION END NG >> GO TO 2. G H I MBIB1496E 2. CHECK FUEL PUMP RELAY POWER SUPPLY CIRCUIT 1. 2. 3. 4. J Turn ignition switch OFF. Disconnect ECM harness connector. Turn ignition switch ON. Check voltage between ECM terminals 113 and ground with CONSULT-II or tester. K L Voltage: Battery voltage OK or NG OK >> GO TO 5. NG >> GO TO 3. M PBIB1187E EC-429 FUEL PUMP [CR (WITH EURO-OBD)] 3. CHECK FUEL PUMP POWER SUPPLY CIRCUIT-I Check voltage between IPDM E/R terminal 69 and ground with CONSULT-II or tester. Voltage: Battery voltage OK or NG OK >> GO TO 4. NG >> GO TO 11. MBIB1445E 4. DETECT MALFUNCTIONING PART Check harness for open or short between IPDM E/R and ECM >> Repair harness or connectors. 5. CHECK FUEL PUMP POWER SUPPLY CIRCUIT-I 1. 2. 3. 4. Turn ignition switch OFF. Reconnect all harness connectors disconnected. Disconnect “fuel level sensor unit and fuel pump” harness connector. Turn ignition switch ON. MBIB0288E 5. Check voltage between “Fuel level sensor unit and fuel pump” terminal 1 and ground with CONSULT-II or tester. Voltage: Battery voltage should exist for 1 second after ignition switch is turned ON. OK or NG OK >> GO TO 9. NG >> GO TO 6. MBIB1446E 6. CHECK 15A FUSE 1. Turn ignition switch OFF. 2. Disconnect 15A fuse. 3. Check 15A fuse. OK or NG OK >> GO TO 7. NG >> Replace fuse. EC-430 FUEL PUMP [CR (WITH EURO-OBD)] 7. CHECK FUEL PUMP POWER SUPPLY CIRCUIT-II 1. 2. A Disconnect IPDM E/R harness connector E10. Check harness continuity between IPDM E/R terminal 20 and “fuel level sensor unit and fuel pump” termiEC nal 1. Refer to Wiring Diagram. Continuity should exist. 3. Also check harness for short to ground and short to power. OK or NG OK >> GO TO 11. NG >> GO TO 8. C D 8. DETECT MALFUNCTIONING PART E Check the following. ● Harness connectors E101, M1 ● Harness connectors M72, B21 ● Harness for open or short between “fuel level sensor unit and fuel pump” and IPDM E/R F >> Repair open circuit or short to ground or short to power in harness or connectors. G 9. CHECK FUEL PUMP GROUND CIRCUIT FOR OPEN AND SHORT 1. 2. H Turn ignition switch OFF. Check harness continuity between “fuel level sensor unit and fuel pump” terminal 3 and ground. Refer to Wiring Diagram. I Continuity should exist. 3. Also check harness for short to power. OK or NG OK >> GO TO 10. NG >> Repair open circuit or short to power in harness or connectors. J K 10. CHECK FUEL PUMP Refer to EC-431, "Component Inspection" . OK or NG OK >> GO TO 11. NG >> Replace “fuel level sensor unit and fuel pump”. L M 11. CHECK INTERMITTENT INCIDENT Refer to EC-127, "TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT" . OK or NG OK >> Replace IPDM E/R. Refer to PG-18, "IPDM E/R (INTELLIGENT POWER DISTRIBUTION MODULE ENGINE ROOM)" . NG >> Repair or replace harness or connector >> INSPECTION END Component Inspection BBS0033S FUEL PUMP 1. Disconnect “fuel level sensor unit and fuel pump” harness connector. EC-431 FUEL PUMP [CR (WITH EURO-OBD)] 2. Check resistance between “fuel level sensor unit and fuel pump” terminals 1 and 3. Resistance: Approximately 0.2 - 5.0Ω [at 25°C (77°F)] MBIB0311E Removal and Installation BBS0033T FUEL PUMP Refer to FL-4, "FUEL LEVEL SENSOR UNIT, FUEL FILTER AND FUEL PUMP ASSEMBLY" . EC-432 IGNITION SIGNAL [CR (WITH EURO-OBD)] IGNITION SIGNAL Component Description PFP:22448 A BBS0033D IGNITION COIL & POWER TRANSISTOR The ignition signal from the ECM is sent to and amplified by the power transistor. The power transistor turns ON and OFF the ignition coil primary circuit. This ON-OFF operation induces the proper high voltage in the coil secondary circuit. EC C D MBIB0272E E F G H I J K L M EC-433 IGNITION SIGNAL [CR (WITH EURO-OBD)] Wiring Diagram BBS0033E MBWA1536E EC-434 IGNITION SIGNAL [CR (WITH EURO-OBD)] Specification data are reference values and are measured between each terminal and ground. CAUTION: Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM's transistor. Use a ground other than ECM terminals, such as the ground. TERMINAL NO. WIRE COLOR EC ITEM CONDITION [Engine is running] [Ignition switch: OFF] ● 111 P ECM relay (Self shut-off) G G Power supply for ECM For a few seconds after turning ignition switch OFF [Ignition switch: OFF] ● 119 120 A More than a few seconds passed after turning ignition switch OFF [Ignition switch: ON] DATA (DC Voltage) C 0 - 1.0V D BATTERY VOLTAGE (11 - 14V) E BATTERY VOLTAGE (11 - 14V) F G H I J K L M EC-435 IGNITION SIGNAL [CR (WITH EURO-OBD)] MBWA1537E EC-436 IGNITION SIGNAL [CR (WITH EURO-OBD)] Specification data are reference values and are measured between each terminal and ground. Pulse signal is measured by CONSULT-II. A CAUTION: Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM's transistor. Use a ground other than ECM terminals, such as the ground. EC TERMINAL NO. WIRE COLOR ITEM CONDITION C [Engine is running] 60 61 79 80 DATA (DC Voltage) Y V G BR ● Warm-up condition ● Idle speed 0 - 0.1V D NOTE: The pulse cycle changes depending on rpm at idle. Ignition signal No. 3 Ignition signal No. 1 Ignition signal No. 4 Ignition signal No. 2 E PBIB0521E 0 - 0.2V F [Engine is running] ● Warm-up condition ● Engine speed: 2,000 rpm G PBIB0522E H : Average voltage for pulse signal (Actual pulse signal can be confirmed by oscilloscope.) Diagnostic Procedure BBS0033F I 1. CHECK ENGINE START Turn ignition switch OFF and restart engine. Is engine running? Yes or No Yes (With CONSULT-II)>>GO TO 2. Yes (Without CONSULT-II)>>GO TO 3. No >> GO TO 4. J K 2. CHECK OVERALL FUNCTION L With CONSULT-II Perform “POWER BALANCE” in “ACTIVE TEST” mode with CONSULT-II. Make sure that each circuit produces a momentary engine speed drop. OK or NG OK >> INSPECTION END NG >> GO TO 10. 1. 2. M MBIB0302E EC-437 IGNITION SIGNAL [CR (WITH EURO-OBD)] 3. CHECK OVERALL FUNCTION Without CONSULT-II Let engine idle. Read the voltage signal between ECM terminals 60, 61, 79, 80 and ground with an oscilloscope. 3. Verify that the oscilloscope screen shows the signal wave as shown in the figure. NOTE: The pulse cycle changes depending on rpm at idle. 1. 2. MBIB0033E PBIB0521E OK or NG OK >> INSPECTION END NG >> GO TO 10. 4. CHECK IGNITION COIL POWER SUPPLY CIRCUIT-I 1. 2. Turn ignition switch OFF, wait at least 10 seconds and then turn ON. Check voltage between ECM terminals 119, 120 and ground with CONSULT-II or tester. Voltage: Battery voltage OK or NG OK >> GO TO 5. NG >> Go to EC-128, "POWER SUPPLY AND GROUND CIRCUIT" . MBIB0034E 5. CHECK IGNITION COIL POWER SUPPLY CIRCUIT-II 1. 2. 3. 4. Turn ignition switch OFF. Disconnect condenser harness connector. Turn ignition switch ON. Check voltage between condenser terminal 1 and ground with CONSULT-II or tester. Voltage: Battery voltage OK or NG OK >> GO TO 8. NG >> GO TO 6. PBIB0624E EC-438 IGNITION SIGNAL [CR (WITH EURO-OBD)] 6. CHECK IGNITION COIL POWER SUPPLY CIRCUIT-III 1. 2. 3. Turn ignition switch OFF. Disconnect IPDM E/R harness connector. Check harness continuity between condenser terminal 1 and IPDM terminal 33. Refer to Wiring Diagram. Continuity should exist. A EC C 4. Also check harness for short to power and short to ground. OK or NG OK >> GO TO 15. NG >> GO TO 7. 7. DETECT MALFUNCTION PART D E Check the following. ● Harness connectors E48, F1 ● Harness for open or short between IPDM E/R and condenser >> Repair open circuit or short to ground or short to power in harness or connectors. F G 8. CHECK CONDENSER GROUND CIRCUIT FOR OPEN AND SHORT 1. 2. Turn ignition switch OFF. Check harness continuity between condenser terminal 2 and ground. Refer to Wiring Diagram. H I Continuity should exist. 3. Also check harness for short to power. OK or NG OK >> GO TO 9. NG >> Repair open circuit or short to power in harness or connector. J K 9. CHECK CONDENSER Refer to EC-441, "Component Inspection" . OK or NG OK >> GO TO 10. NG >> Replace condenser. L M EC-439 IGNITION SIGNAL [CR (WITH EURO-OBD)] 10. CHECK IGNITION COIL POWER SUPPLY CIRCUIT-V 1. 2. 3. 4. Turn ignition switch OFF. Reconnect all harness connectors disconnected. Disconnect ignition coil harness connector. Turn ignition switch ON. MBIB0272E 5. Check voltage between ignition coil terminal 1 and ground with CONSULT-II or tester. Voltage: Battery voltage OK or NG OK >> GO TO 12. NG >> GO TO 11. SEF107S 11. DETECT MALFUNCTIONING PART Check harness for open or short between ignition coil and harness connector F1. >> Repair open circuit or short to ground or short to power in harness or connectors. 12. CHECK IGNITION COIL GROUND CIRCUIT FOR OPEN AND SHORT 1. 2. Turn ignition switch OFF. Check harness continuity between ignition coil terminal 2 and ground. Refer to Wiring Diagram. Continuity should exist. 3. Also check harness for short to power. OK or NG OK >> GO TO 13. NG >> Repair open circuit or short to power in harness or connectors. 13. CHECK IGNITION COIL OUTPUT SIGNAL CIRCUIT FOR OPEN AND SHORT 1. 2. Disconnect ECM harness connector. Check harness continuity between ECM terminals 60, 61, 79, 80 and ignition coil terminal 3. Refer to Wiring Diagram. Continuity should exist. 3. Also check harness for short to ground and short to power. OK or NG OK >> GO TO 14. NG >> Repair open circuit or short to ground or short to power in harness or connectors. EC-440 IGNITION SIGNAL [CR (WITH EURO-OBD)] 14. CHECK IGNITION COIL WITH POWER TRANSISTOR A Refer to EC-441, "Component Inspection" . OK or NG OK >> GO TO 15. NG >> Replace malfunctioning ignition coil with power transistor. EC 15. CHECK INTERMITTENT INCIDENT C Refer to EC-127, "TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT" . OK or NG OK >> Replace IPDM E/R. Refer to PG-18, "IPDM E/R (INTELLIGENT POWER DISTRIBUTION MODULE ENGINE ROOM)" . NG >> Repair or replace Component Inspection D E BBS0033G IGNITION COIL WITH POWER TRANSISTOR CAUTION: Do the following procedure in the place where ventilation is good without the combustible. 1. Turn ignition switch OFF. 2. Disconnect ignition coil harness connector. 3. Check resistance between ignition coil terminals as follows. Terminal No. Resistance Ω [at 25°C (77°F)] 2 and 3 Except 0 or ∞ F G H 1 and 2 1 and 3 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. Except 0 If NG, replace ignition coil with power transistor. If OK, go to next step. Turn ignition switch OFF. Reconnect all harness connectors disconnected. Remove fuel pump fuse in IPDM E/R to release fuel pressure. NOTE: Do not use CONSULT-II to release fuel pressure, or fuel pressure applies again during the following procedure. Start engine. After engine stalls, crank it two or three times to release all fuel pressure. Turn ignition switch OFF. Remove ignition coil harness connectors to avoid the electrical discharge from the ignition coils. Remove ignition coil and spark plug of the cylinder to be checked. Crank engine for 5 seconds or more to remove combustion gas in the cylinder. Connect spark plug and harness connector to ignition coil. EC-441 I J MBIB0032E K L M MBIB0277E IGNITION SIGNAL [CR (WITH EURO-OBD)] 15. Fix ignition coil using a rope etc. with gap of 13 - 17 mm between the edge of the spark plug and grounded metal portion as shown in the figure. 16. Crank engine for about 3 seconds, and check whether spark is generated between the spark plug and the grounded part. Spark should be generated. CAUTION: Do not approach to the spark plug and the ignition coil within 50cm. Be careful not to get an electrical shock while checking, because the electrical discharge voltage PBIB2325E becomes 20kV or more. ● If might cause to damage the ignition coil if the gap of more than 17 mm is taken. NOTE: When the gap is less than 13 mm, the spark might be generated even if the coil is malfunctioning. 17. If NG, replace ignition coil with power transistor. ● CONDENSER 1. 2. 3. Turn ignition switch OFF. Disconnect condenser harness connector. Check resistance between condenser terminals 1 and 2. Resistance: Above 1 MΩ at 25°C (77°F) MBIB0031E Removal and Installation BBS0033H IGNITION COIL WITH POWER TRANSISTOR Refer to EM-29, "IGNITION COIL" . EC-442 REFRIGERANT PRESSURE SENSOR [CR (WITH EURO-OBD)] REFRIGERANT PRESSURE SENSOR Component Description PFP:92136 A BBS0033U The refrigerant pressure sensor (1) is installed at the condenser of the air conditioner system. The sensor uses an electrostatic volume pressure transducer to convert refrigerant pressure to voltage. The voltage signal is sent to ECM, and ECM controls cooling fan system. EC C D MBIB1492E E F G H PBIB2657E I J K L M EC-443 REFRIGERANT PRESSURE SENSOR [CR (WITH EURO-OBD)] Wiring Diagram BBS0033V MBWA1540E EC-444 REFRIGERANT PRESSURE SENSOR [CR (WITH EURO-OBD)] Specification data are reference values and are measured between each terminal and ground. CAUTION: Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM's transistor. Use a ground other than ECM terminals, such as the ground. TERMINAL NO. A EC WIRE COLOR ITEM CONDITION 46 W Sensor power supply (Refrigerant pressure sensor) 57 Y Sensor ground (Refrigerant pressure sensor) DATA (DC Voltage) [Ignition switch: ON] Approximately 5V C Approximately 0V D [Engine is running] ● Warm-up condition ● Idle speed [Engine is running] ● 69 BR Refrigerant pressure sensor ● E Warm-up condition Both A/C switch and blower fan switch: ON. 1.0 - 4.0V (Compressor operates.) F Diagnostic Procedure BBS0033W 1. CHECK REFRIGERANT PRESSURE SENSOR OVERALL FUNCTION 1. 2. 3. G Start engine and warm it up to normal operating temperature. Turn A/C switch and blower fan switch ON. Check voltage between ECM terminal 69 and ground with CONSULT-II or tester. H Voltage: 1.0 - 4.0V I OK or NG OK >> INSPECTION END NG >> GO TO 2. J MBIB0035E K 2. CHECK GROUND CONNECTIONS 1. 2. 3. L Turn A/C switch and blower fan switch OFF. Turn ignition switch OFF. Loosen and retighten ground screws on the body. Refer to EC-133, "Ground Inspection" . M MBIB1502E 1. Body ground E44 2. Body ground E45 OK or NG OK >> GO TO 3. NG >> Repair or replace ground connections. EC-445 3. Body ground E28 REFRIGERANT PRESSURE SENSOR [CR (WITH EURO-OBD)] 3. CHECK REFRIGERANT PRESSURE SENSOR POWER SUPPLY CIRCUIT 1. 2. Disconnect refrigerant pressure sensor (1) harness connector. Turn ignition switch ON. MBIB1492E 3. Check voltage between refrigerant pressure sensor terminal 3 and ground with CONSULT-II or tester. Voltage: Approximately 5V OK or NG OK >> GO TO 5. NG >> GO TO 4. SEF479Y 4. DETECT MALFUNCTIONING PART Check the following. ● Harness connectors E48, F1 ● Harness for open or short between ECM and refrigerant pressure sensor >> Repair harness or connectors. 5. CHECK REFRIGERANT PRESSURE SENSOR GROUND CIRCUIT FOR OPEN AND SHORT 1. 2. 3. Turn ignition switch OFF. Disconnect ECM harness connector. Check harness continuity between ECM terminal 57 and refrigerant pressure sensor terminal 1. Refer to Wiring Diagram. Continuity should exist. 4. Also check harness for short to ground and short to power. OK or NG OK >> GO TO 7. NG >> GO TO 6. 6. DETECT MALFUNCTIONING PART Check the following. ● Harness connectors E48, F1 ● Harness for open or short between ECM and refrigerant pressure sensor >> Repair open circuit or short to ground or short to power in harness or connectors. EC-446 REFRIGERANT PRESSURE SENSOR [CR (WITH EURO-OBD)] 7. CHECK REFRIGERANT PRESSURE SENSOR INPUT SIGNAL CIRCUIT FOR OPEN AND SHORT 1. A Check harness continuity between ECM terminal 69 and refrigerant pressure sensor terminal 2. Refer to Wiring Diagram. EC Continuity should exist. 2. Also check harness for short to ground and short to power. OK or NG OK >> GO TO 9. NG >> GO TO 8. C 8. DETECT MALFUNCTIONING PART D Check the following. ● Harness connectors E48, F1 ● Harness for open or short between ECM and refrigerant pressure sensor E F >> Repair open circuit or short to ground or short to power in harness or connectors. 9. CHECK INTERMITTENT INCIDENT G Refer to EC-127, "TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT" . OK or NG OK >> Replace refrigerant pressure sensor. NG >> Repair or replace. Removal and Installation H BBS0033X REFRIGERANT PRESSURE SENSOR Refer to ATC-142, "Removal and Installation for Refrigerant Pressure Sensor" (Models with A/C) or MTC-88, "Removal and Installation for Refrigerant Pressure Sensor" (Models without A/C). I J K L M EC-447 MI & DATA LINK CONNECTORS [CR (WITH EURO-OBD)] MI & DATA LINK CONNECTORS Wiring Diagram PFP:24814 BBS00341 MBWA1541E EC-448 SERVICE DATA AND SPECIFICATIONS (SDS) [CR (WITH EURO-OBD)] SERVICE DATA AND SPECIFICATIONS (SDS) Fuel Pressure PFP:00030 A BBS00347 Approximately 350 kPa (3.5bar, 3.57kg/cm2 , 51psi) Fuel pressure at idle EC Idle Speed BBS00348 Target idle speed No load* (in Neutral position) Air conditioner: ON In Neutral position 650 ± 50 rpm C 900 rpm or more *: Under the following conditions: ● Air conditioner switch: OFF ● Electric load: OFF (Lights, heater fan & rear window defogger) ● Steering wheel: Kept in straight-ahead position D Calculated Load Value BBS00349 Condition E Calculated load value% (Using CONSULT-II or GST) At idle 10 – 35 At 2,500 rpm 10 – 35 Manifold Absolute Pressure Sensor F BBS0034A Supply voltage G Approximately 5.0V Output voltage at idle 1.4 – 1.5 V* H *: Engine is warmed up to normal operating temperature and running under no load. Intake Air Temperature Sensor BBS00487 Temperature °C (°F) I Resistance kΩ 25 (77) 1.9 – 2.1 Engine Coolant Temperature Sensor Temperature °C (°F) BBS00488 J Resistance kΩ 20 (68) 2.1 – 2.9 50 (122) 0.68 – 1.00 90 (194) 0.236 – 0.260 K L Knock Sensor BBS00489 Resistance [at 20°C (68°F)] Approximately 530 – 590kΩ M Crankshaft Position Sensor (POS) BBS0034F Refer to EC-256, "Component Inspection" . Camshaft Position Sensor (PHASE) BBS0034G Refer to EC-263, "Component Inspection" . Heated Oxygen Sensor 1 Heater BBS0034D Resistance [at 25°C (77°F)] 3.4 – 4.4Ω Heated Oxygen Sensor 2 Heater BBS0034E Resistance [at 25°C (77°F)] 8.0 – 10.0Ω Intake Valve Timing Control Solenoid Valve Resistance [at 20°C (68°F)] BBS0048A 6.7 – 7.7Ω EC-449 SERVICE DATA AND SPECIFICATIONS (SDS) [CR (WITH EURO-OBD)] Throttle Control Motor BBS0034H Resistance [at 25°C (77°F)] Approximately 1 – 15Ω Fuel Injector BBS0034I Resistance [at 10 - 60°C (50 - 140°F)] 10.4 – 15.3Ω Fuel Pump BBS0034J Resistance [at 25°C (77°F)] Approximately 0.2 – 5.0Ω EC-450 INDEX FOR DTC [CR (WITHOUT EURO-OBD)] INDEX FOR DTC DTC No. Index [CR (WITHOUT EURO-OBD)] PFP:00024 A BBS0034L NOTE: ● If DTC U1001 is displayed with other DTC, first perform the trouble diagnosis for DTC U1001. Refer EC to EC-549, "DTC U1001 CAN COMMUNICATION LINE" . ● If DTC U1010 is displayed with other DTC, first perform the trouble diagnosis for DTC U1010. Refer to EC-552, "DTC U1010 CAN COMMUNICATION" . C DTC*1 CONSULT-II Items (CONSULT-II screen terms) ECM*2 Reference page D NO DTC IS DETECTED. FURTHER TESTING MAY BE REQUIRED. EC-480 No DTC Flashing*3 U1001 1001*4 CAN COMM CIRCUIT EC-549 U1010 1010 CONTROL UNIT(CAN) EC-552 P0000 0000 NO DTC IS DETECTED. FURTHER TESTING MAY BE REQUIRED. P0011 0011 INT/V TIM CONT-B1 EC-554 P0107 0107 ABSL PRES SEN/CIRC EC-559 P0108 0108 ABSL PRES SEN/CIRC EC-559 P0117 0117 ECT SEN/CIRC EC-565 P0118 0118 ECT SEN/CIRC EC-565 P0122 0122 TP SEN 2/CIRC EC-570 P0123 0123 TP SEN 2/CIRC EC-570 P0132 0132 HO2S1 (B1) EC-577 P0134 0134 HO2S1 (B1) EC-584 P0138 0138 HO2S2 (B1) EC-591 P0222 0222 TP SEN 1/CIRC EC-598 P0223 0223 TP SEN 1/CIRC EC-598 P0327 0327 KNOCK SEN/CIRC-B1 EC-605 P0328 0328 KNOCK SEN/CIRC-B1 EC-605 P0335 0335 CKP SEN/CIRCUIT EC-609 P0340 0340 CMP SEN/CIRC-B1 EC-616 P0605 0605 ECM EC-623 P1065 1065 ECM BACK UP/CIRCUIT EC-626 P1111 1111 INT/V TIM V/CIR-B1 EC-630 P1121 1121 ETC ACTR EC-635 P1122 1122 ETC FUNCTION/CIRC EC-637 P1124 1124 ETC MOT PWR EC-643 P1126 1126 ETC MOT PWR EC-643 P1128 1128 ETC MOT EC-649 E F — P1171 1171 INTAKE ERROR EC-654 P1211 1211 TCS C/U FUNTN EC-660 P1212 1212 TCS/CIRC EC-661 P1217 1217 ENG OVER TEMP EC-662 P1225 1225 CTP LEARNING EC-676 EC-451 G H I J K L M INDEX FOR DTC [CR (WITHOUT EURO-OBD)] DTC*1 Items (CONSULT-II screen terms) Reference page CONSULT-II ECM*2 P1226 1226 CTP LEARNING EC-678 P1229 1229 SENSOR POWER/CIRC EC-680 P1610 - P1615 1610 - 1615 NATS MALFUNCTION EC-473 P1706 1706 P-N POS SW/CIRCUIT EC-688 P1805 1805 BRAKE SW/CIRCUIT EC-693 P2122 2122 APP SEN 1/CIRC EC-699 P2123 2123 APP SEN 1/CIRC EC-699 P2127 2127 APP SEN 2/CIRC EC-708 P2128 2128 APP SEN 2/CIRC EC-708 P2135 2135 TP SENSOR EC-718 P2138 2138 APP SENSOR EC-725 *1: 1st trip DTC No. is the same as DTC No. *2: In Diagnostic Test Mode II (Self-diagnostic results), this number is controlled by NISSAN. *3: When engine is running. *4: The troubleshooting for this DTC needs CONSULT-II. EC-452 INDEX FOR DTC [CR (WITHOUT EURO-OBD)] Alphabetical Index BBS0034K A NOTE: ● If DTC U1001 is displayed with other DTC, first perform the trouble diagnosis for DTC U1001. Refer to EC-549, "DTC U1001 CAN COMMUNICATION LINE" . ● If DTC U1010 is displayed with other DTC, first perform the trouble diagnosis for DTC U1010. Refer EC to EC-552, "DTC U1010 CAN COMMUNICATION" . Items (CONSULT-II screen terms) DTC*1 Reference page ECM* ABSL PRES SEN/CIRC P0107 0107 EC-559 ABSL PRES SEN/CIRC P0108 0108 EC-559 APP SEN 1/CIRC P2122 2122 EC-699 APP SEN 1/CIRC P2123 2123 EC-699 APP SEN 2/CIRC P2127 2127 EC-708 APP SEN 2/CIRC P2128 2128 EC-708 APP SENSOR P2138 2138 EC-725 BRAKE SW/CIRCUIT P1805 1805 EC-693 4 CAN COMM CIRCUIT U1001 1001* EC-549 CKP SEN/CIRCUIT P0335 0335 EC-609 CMP SEN/CIRC-B1 P0340 0340 EC-616 CONTROL UNIT(CAN) U1010 1010 EC-552 CTP LEARNING P1225 1225 EC-676 CTP LEARNING P1226 1226 EC-678 ECM P0605 0605 EC-623 ECM BACK UP/CIRCUIT P1065 1065 EC-626 ECT SEN/CIRC P0117 0117 EC-565 ECT SEN/CIRC P0118 0118 EC-565 ENG OVER TEMP P1217 1217 EC-662 ETC ACTR P1121 1121 EC-635 ETC FUNCTION/CIRC P1122 1122 EC-637 ETC MOT P1128 1128 EC-649 ETC MOT PWR P1124 1124 EC-643 ETC MOT PWR P1126 1126 EC-643 HO2S1 (B1) P0132 0132 EC-577 HO2S1 (B1) P0134 0134 EC-584 HO2S2 (B1) P0138 0138 EC-591 INT/V TIM CONT-B1 P0011 0011 EC-554 INT/V TIM V/CIR-B1 P1111 1111 EC-630 INTAKE ERROR P1171 1171 EC-654 KNOCK SEN/CIRC-B1 P0327 0327 EC-605 KNOCK SEN/CIRC-B1 P0328 0328 EC-605 NATS MALFUNCTION P1610 - P1615 1610 - 1615 EC-473 NO DTC IS DETECTED. FURTHER TESTING MAY BE REQUIRED. No DTC Flashing*3 EC-480 NO DTC IS DETECTED. FURTHER TESTING MAY BE REQUIRED. P0000 0000 — EC-453 C 2 CONSULT-II D E F G H I J K L M INDEX FOR DTC [CR (WITHOUT EURO-OBD)] Items (CONSULT-II screen terms) DTC*1 Reference page CONSULT-II ECM*2 P-N POS SW/CIRCUIT P1706 1706 EC-688 SENSOR POWER/CIRC P1229 1229 EC-680 TCS C/U FUNCTN P1211 1211 EC-660 TCS/CIRC P1212 1212 EC-661 TP SEN 1/CIRC P0222 0222 EC-598 TP SEN 1/CIRC P0223 0223 EC-598 TP SEN 2/CIRC P0122 0122 EC-570 TP SEN 2/CIRC P0123 0123 EC-570 TP SENSOR P2135 2135 EC-718 *1: 1st trip DTC No. is the same as DTC No. *2: In Diagnostic Test Mode II (Self-diagnostic results), this number is controlled by NISSAN. *3: When engine is running. *4: The troubleshooting for this DTC needs CONSULT-II. EC-454 PRECAUTIONS [CR (WITHOUT EURO-OBD)] PRECAUTIONS PFP:00001 Precautions for Supplemental Restraint System (SRS) “AIR BAG” and “SEAT BELT PRE-TENSIONER” A BBS0047X The Supplemental Restraint System such as “AIR BAG” and “SEAT BELT PRE-TENSIONER”, used along EC with a front seat belt, helps to reduce the risk or severity of injury to the driver and front passenger for certain types of collision. Information necessary to service the system safely is included in the SRS and SB section of this Service Manual. C WARNING: ● To avoid rendering the SRS inoperative, which could increase the risk of personal injury or death in the event of a collision which would result in air bag inflation, all maintenance must be perD formed by an authorized NISSAN/INFINITI dealer. ● Improper maintenance, including incorrect removal and installation of the SRS, can lead to personal injury caused by unintentional activation of the system. For removal of Spiral Cable and Air E Bag Module, see the SRS section. ● Do not use electrical test equipment on any circuit related to the SRS unless instructed to in this Service Manual. SRS wiring harnesses can be identified by yellow and/or orange harnesses or harness connectors. F Maintenance Information BBS005AR If any of following part is replaced, always replace with new* one. If it's not (or fail to do so), the electrical system may not be operated properly. *: New one means a virgin control unit that has never been energized on-board. G RHD MODELS H ● ● ● ● ● ● BCM (Models without Intelligent Key system) Intelligent Key unit (Models with Intelligent Key system) ECM IPDM E/R Combination meter EPS control unit I J LHD MODELS ● ● ● BCM (Models without Intelligent Key system) Intelligent Key unit (Models with Intelligent Key system) ECM Precautions for Procedures without Cowl Top Cover K L BBS0047Y When performing the procedure after removing cowl top cover, cover the lower end of windshield with urethane, etc. M PIIB3706J On Board Diagnostic (OBD) System of Engine BBS0034O The ECM has an on board diagnostic system. It will light up the malfunction indicator (MI) to warn the driver of a malfunction causing emission deterioration. CAUTION: ● Be sure to turn the ignition switch OFF and disconnect the battery ground cable before any repair or inspection work. The open/short circuit of related switches, sensors, solenoid valves, etc. will cause the MI to light up. EC-455 PRECAUTIONS [CR (WITHOUT EURO-OBD)] ● ● ● ● Be sure to connect and lock the connectors securely after work. A loose (unlocked) connector will cause the MI to light up due to the open circuit. (Be sure the connector is free from water, grease, dirt, bent terminals, etc.) Certain systems and components, especially those related to OBD, may use a new style slidelocking type harness connector. For description and how to disconnect, refer to PG-88, "HARNESS CONNECTOR" . Be sure to route and secure the harnesses properly after work. The interference of the harness with a bracket, etc. may cause the MI to light up due to the short circuit. Be sure to erase the unnecessary malfunction information (repairs completed) from the ECM. Precaution ● ● ● ● BBS0034P Always use a 12 volt battery as power source. Do not attempt to disconnect battery cables while engine is running. Before connecting or disconnecting the ECM harness connector, turn ignition switch OFF and disconnect negative battery cable. Failure to do so may damage the ECM because battery voltage is applied to ECM even if ignition switch is turned off. Before removing parts, turn ignition switch OFF and then disconnect negative battery cable. SEF289H ● ● ● – – – – ● Do not disassemble ECM. If battery cable is disconnected, the memory will return to the initial ECM values. The ECM will now start to self-control at its initial values. Engine operation can vary slightly when the cable is disconnected. However, this is not an indication of a malfunction. Do not replace parts because of a slight variation. If the battery is disconnected, the following emission related diagnostic information will be lost within 24 hours. Diagnostic trouble codes 1st trip diagnostic trouble codes Freeze frame data 1st freeze frame data PBIB1164E When connecting ECM harness connector, fasten it securely with levers as far as they will go as shown in the figure. PBIB1512E EC-456 PRECAUTIONS [CR (WITHOUT EURO-OBD)] ● ● ● ● ● ● ● ● ● ● ● When connecting or disconnecting pin connectors into or from ECM, take care not to damage pin terminals (bend or break). Make sure that there are not any bends or breaks on ECM pin terminal, when connecting pin connectors. Securely connect ECM harness connectors. A poor connection can cause an extremely high (surge) voltage to develop in coil and condenser, thus resulting in damage to ICs. Keep engine control system harness at least 10 cm (4 in) away from adjacent harness, to prevent engine control system malfunctions due to receiving external noise, degraded operation of ICs, etc. Keep engine control system parts and harness dry. Before replacing ECM, perform ECM Terminals and Reference Value inspection and make sure ECM functions properly. Refer to EC-512, "ECM Terminals and Reference Value" . Handle manifold absolute pressure sensor carefully to avoid damage. Do not clean air clear element with any type of detergent. Do not disassemble electric throttle control actuator. Even a slight leak in the air intake system can cause serious incidents. Do not shock or jar the camshaft position sensor (PHASE), crankshaft position sensor (POS). After performing each TROUBLE DIAGNOSIS, perform DTC Confirmation Procedure or Overall Function Check. The DTC should not be displayed in the DTC Confirmation Procedure if the repair is completed. The Overall Function Check should be a good result if the repair is completed. A EC C PBIB0090E D E F G MEF040D H I J K SAT652J L M EC-457 PRECAUTIONS [CR (WITHOUT EURO-OBD)] ● ● ● When measuring ECM signals with a circuit tester, connect a break-out box (SST) and Y-cable adapter (SST) between the ECM and ECM harness connector. When measuring ECM signals with a circuit tester, never allow the two tester probes to contact. Accidental contact of probes will cause a short circuit and damage the ECM power transistor. Do not use ECM ground terminals when measuring input/ output voltage. Doing so may result in damage to the ECM's transistor. Use a ground other than ECM terminals, such as the ground. SEF348N ● ● Do not operate fuel pump when there is no fuel in lines. Tighten fuel hose clamps to the specified torque. MBIB0291E ● ● ● Do not depress accelerator pedal when starting. Immediately after starting, do not rev up engine unnecessarily. Do not rev up engine just prior to shutdown. SEF709Y EC-458 PRECAUTIONS [CR (WITHOUT EURO-OBD)] ● – – – – When installing C.B. ham radio or a mobile phone, be sure to observe the following as it may adversely affect electronic control systems depending on installation location. Keep the antenna as far as possible from the electronic control units. Keep the antenna feeder line more than 20 cm (8 in) away from the harness of electronic controls. Do not let them run parallel for a long distance. Adjust the antenna and feeder line so that the standingwave radio can be kept smaller. Be sure to ground the radio to vehicle body. A EC C SEF708Y D E F G H I J K L M EC-459 PREPARATION [CR (WITHOUT EURO-OBD)] PREPARATION Special Service Tools PFP:00002 BBS0034R Tool number Tool name Description EG17650301 Radiator cap tester adapter Adapting radiator cap tester to radiator cap and radiator filler neck a: 28 (1.10) dia. b: 31.4 (1.236) dia. c: 41.3 (1.626) dia. Unit: mm (in) S-NT564 KV10117100 Heated oxygen sensor wrench Loosening or tightening heated oxygen sensors with 22 mm (0.87 in) hexagon nut S-NT379 KV10114400 Heated oxygen sensor wrench Loosening or tightening heated oxygen sensors a: 22 mm (0.87 in) S-NT636 KV109E0010 Break-out box Measuring ECM signals with a circuit tester NT825 KV109E0080 Y-cable adapter Measuring ECM signals with a circuit tester NT826 EC-460 PREPARATION [CR (WITHOUT EURO-OBD)] Commercial Service Tools BBS0034S A Tool name Description Quick connector release Removing fuel tube quick connectors in engine room (Available in SEC. 164 of PARTS CATALOG: Part No. 16441 6N210) EC C PBIC0198E Fuel filler cap adapter Checking fuel tank vacuum relief valve opening pressure D E S-NT653 Socket wrench Removing and installing engine coolant temperature sensor F G H S-NT705 Oxygen sensor thread cleaner Reconditioning the exhaust system threads before installing a new oxygen sensor. Use with anti-seize lubricant shown below. a: 18 mm diameter with pitch 1.5 mm for Zirconia Oxygen Sensor b: 12 mm diameter with pitch 1.25 mm for Titania Oxygen Sensor J Lubricating oxygen sensor thread cleaning tool when reconditioning exhaust system threads. K I AEM488 Anti-seize lubricant i.e.: (PermatexTM 133AR or equivalent meeting MIL specification MIL-A907) L S-NT779 M EC-461 ENGINE CONTROL SYSTEM [CR (WITHOUT EURO-OBD)] ENGINE CONTROL SYSTEM System Diagram PFP:23710 BBS0034T MBIB1551E EC-462 ENGINE CONTROL SYSTEM [CR (WITHOUT EURO-OBD)] Multiport Fuel Injection (MFI) System BBS0034W A INPUT/OUTPUT SIGNAL CHART Sensor Input Signal to ECM Crankshaft position sensor (POS) Camshaft position sensor (PHASE) Engine speed*3 Piston position Manifold absolute pressure sensor Amount of intake air Engine coolant temperature sensor Engine coolant temperature Heated oxygen sensor 1 Density of oxygen in exhaust gas Throttle position sensor Throttle position Accelerator pedal position sensor Accelerator pedal position Park/neutral position (PNP) switch Gear position Knock sensor Engine knocking condition ECM Function Actuator EC C D Fuel injection & mixture ratio control Fuel injector E voltage*3 Battery Battery EPS control unit Power steering operation*2 Heated oxygen sensor 2*1 Density of oxygen in exhaust gas Wheel sensor Vehicle speed*2 Air conditioner switch Air conditioner operation*2 F G *1: This sensor is not used to control the engine system under normal conditions. *2: This signal is sent to the ECM through CAN communication line. *3: ECM determines the start signal status by the signals of engine speed and battery voltage. H SYSTEM DESCRIPTION The amount of fuel injected from the fuel injector is determined by the ECM. The ECM controls the length of time the valve remains open (injection pulse duration). The amount of fuel injected is a program value in the ECM memory. The program value is preset by engine operating conditions. These conditions are determined by input signals (for engine speed and intake air volume) from the crankshaft position sensor (POS), camshaft position sensor (PHASE) and the manifold absolute pressure sensor. I J VARIOUS FUEL INJECTION INCREASE/DECREASE COMPENSATION In addition, the amount of fuel injected is compensated to improve engine performance under various operating conditions as listed below. ● During warm-up ● When starting the engine ● During acceleration ● Hot-engine operation ● High-load, high-speed operation ● During deceleration ● During high engine speed operation MIXTURE RATIO FEEDBACK CONTROL (CLOSED LOOP CONTROL) PBIB2938E EC-463 K L M ENGINE CONTROL SYSTEM [CR (WITHOUT EURO-OBD)] The mixture ratio feedback system provides the best air-fuel mixture ratio for driveability and emission control. The three way catalyst (manifold) can then better reduce CO, HC and NOx emissions. This system uses heated oxygen sensor 1 in the exhaust manifold to monitor whether the engine operation is rich or lean. The ECM adjusts the injection pulse width according to the sensor voltage signal. For more information about heated oxygen sensor 1, refer to EC-577 . This maintains the mixture ratio within the range of stoichiometric (ideal air-fuel mixture). This stage is referred to as the closed loop control condition. Heated oxygen sensor 2 is located downstream of the three way catalyst (manifold). Even if the switching characteristics of heated oxygen sensor 1 shift, the air-fuel ratio is controlled to stoichiometric by the signal from heated oxygen sensor 2. Open Loop Control The open loop system condition refers to when the ECM detects any of the following conditions. Feedback control stops in order to maintain stabilized fuel combustion. ● Deceleration and acceleration ● High-load, high-speed operation ● Malfunction of heated oxygen sensor 1 or its circuit ● Insufficient activation of heated oxygen sensor 1 at low engine coolant temperature ● High engine coolant temperature ● During warm-up ● When starting the engine MIXTURE RATIO SELF-LEARNING CONTROL The mixture ratio feedback control system monitors the mixture ratio signal transmitted from heated oxygen sensor 1. This feedback signal is then sent to the ECM. The ECM controls the basic mixture ratio as close to the theoretical mixture ratio as possible. However, the basic mixture ratio is not necessarily controlled as originally designed. Both manufacturing differences (i.e., manifold absolute pressure sensor silicon diaphragm) and characteristic changes during operation (i.e., fuel injector clogging) directly affect mixture ratio. Accordingly, the difference between the basic and theoretical mixture ratios is monitored in this system. This is then computed in terms of “injection pulse duration” to automatically compensate for the difference between the two ratios. “Fuel trim” refers to the feedback compensation value compared against the basic injection duration. Fuel trim includes short term fuel trim and long term fuel trim. “Short term fuel trim” is the short-term fuel compensation used to maintain the mixture ratio at its theoretical value. The signal from heated oxygen sensor 1 indicates whether the mixture ratio is RICH or LEAN compared to the theoretical value. The signal then triggers a reduction in fuel volume if the mixture ratio is rich, and an increase in fuel volume if it is lean. “Long term fuel trim” is overall fuel compensation carried out long-term to compensate for continual deviation of the short term fuel trim from the central value. Such deviation will occur due to individual engine differences, wear over time and changes in the usage environment. FUEL INJECTION TIMING SEF337W Two types of systems are used. Sequential Multiport Fuel Injection System Fuel is injected into each cylinder during each engine cycle according to the firing order. This system is used when the engine is running. EC-464 ENGINE CONTROL SYSTEM [CR (WITHOUT EURO-OBD)] Simultaneous Multiport Fuel Injection System Fuel is injected simultaneously into all four cylinders twice each engine cycle. In other words, pulse signals of A the same width are simultaneously transmitted from the ECM. The four fuel injectors will then receive the signals two times for each engine cycle. This system is used when the engine is being started and/or if the fail-safe system (CPU) is operating. EC FUEL SHUT-OFF Fuel to each cylinder is cut off during deceleration or operation of the engine at excessively high speeds or operation of the vehicle at excessively high speeds. Electronic Ignition (EI) System BBS0034X INPUT/OUTPUT SIGNAL CHART Sensor C D Input Signal to ECM Crankshaft position sensor (POS) Camshaft position sensor (PHASE) Engine speed*2 Piston position Manifold absolute pressure sensor Amount of intake air Engine coolant temperature sensor Engine coolant temperature Throttle position sensor Throttle position Accelerator pedal position sensor Accelerator pedal position Knock sensor Engine knocking Park/neutral position (PNP) switch Gear position Battery Battery voltage*2 Wheel sensor Vehicle speed*1 ECM Function Actuator E F Ignition timing control Power transistor G H *1: This signal is sent to the ECM through CAN communication line. *2: ECM determines the start signal status by the signals of engine speed and battery voltage. I SYSTEM DESCRIPTION Firing order: 1 - 3 - 4 - 2 The ignition timing is controlled by the ECM to maintain the best air-fuel ratio for every running condition of the engine. The ignition timing data is stored in the ECM. The ECM receives information such as the injection pulse width and camshaft position sensor signal. Computing this information, ignition signals are transmitted to the power transistor. During the following conditions, the ignition timing is revised by the ECM according to the other data stored in the ECM. ● At starting ● During warm-up ● At idle ● At low battery voltage ● During acceleration The knock sensor retard system is designed only for emergencies. The basic ignition timing is programmed within the anti-knocking zone, if recommended fuel is used under dry conditions. The retard system does not operate under normal driving conditions. If engine knocking occurs, the knock sensor monitors the condition. The signal is transmitted to the ECM. The ECM retards the ignition timing to eliminate the knocking condition. Fuel Cut Control (at No Load and High Engine Speed) BBS0034Z INPUT/OUTPUT SIGNAL CHART Sensor Input Signal to ECM Park/neutral position (PNP) switch Neutral position Accelerator pedal position sensor Accelerator pedal position Engine coolant temperature sensor Engine coolant temperature Crankshaft position sensor (POS) Camshaft position sensor (PHASE) Engine speed Wheel sensor Vehicle speed* EC-465 ECM Function Fuel cut control Actuator Fuel injector J K L M ENGINE CONTROL SYSTEM [CR (WITHOUT EURO-OBD)] *: This signal is sent to the ECM through CAN communication line. SYSTEM DESCRIPTION If the engine speed is above 2,500 rpm with no load (for example, the shift position is neutral and engine speed is over 2,500 rpm) fuel will be cut off after some time. The exact time when the fuel is cut off varies based on engine speed. Fuel cut will operate until the engine speed reaches 2,000 rpm, then fuel cut is cancelled. NOTE: This function is different from deceleration control listed under EC-463, "Multiport Fuel Injection (MFI) System" . EC-466 AIR CONDITIONING CUT CONTROL [CR (WITHOUT EURO-OBD)] AIR CONDITIONING CUT CONTROL Input/Output Signal Chart Sensor PFP:23710 A BBS003ZG Input Signal to ECM Air conditioner switch Air conditioner ON signal* Accelerator pedal position sensor Accelerator pedal position Crankshaft position sensor (POS) Camshaft position sensor (PHASE) Engine speed*2 Engine coolant temperature sensor Engine coolant temperature Refrigerant pressure sensor Refrigerant pressure Actuator EC C Air conditioner cut control Air conditioner relay D 1 Wheel sensor Vehicle speed* EPS control unit Power steering operation*1 Battery ECM Function 1 E 2 Battery voltage* *1: This signal is sent to the ECM through CAN communication line. *2: ECM determines the start signal status by the signals of engine speed and battery voltage. F SYSTEM DESCRIPTION This system improves engine operation when the air conditioner is used. Under the following conditions, the air conditioner is turned OFF. ● When the accelerator pedal is fully depressed. ● When cranking the engine. ● At high engine speeds. ● When the engine coolant temperature becomes excessively high. ● When operating power steering during low engine speed or low vehicle speed. ● When engine speed is excessively low. ● When refrigerant pressure is excessively low or high. G H I J K L M EC-467 CAN COMMUNICATION [CR (WITHOUT EURO-OBD)] CAN COMMUNICATION System Description PFP:23710 BBS003ZH CAN (Controller Area Network) is a serial communication line for real time application. It is an on-vehicle multiplex communication line with high data communication speed and excellent error detection ability. Many electronic control units are equipped onto a vehicle, and each control unit shares information and links with other control units during operation (not independent). In CAN communication, control units are connected with 2 communication lines (CAN H line, CAN L line) allowing a high rate of information transmission with less wiring. Each control unit transmits/receives data but selectively reads required data only. Refer to LAN-21, "CAN COMMUNICATION" , about CAN communication for detail. EC-468 EVAPORATIVE EMISSION SYSTEM [CR (WITHOUT EURO-OBD)] EVAPORATIVE EMISSION SYSTEM Description PFP:14950 A BBS003DD SYSTEM DESCRIPTION EC C D E F G PBIB0491E The evaporative emission system is used to reduce hydrocarbons emitted into the atmosphere from the fuel system. This reduction of hydrocarbons is accomplished by activated charcoals in the EVAP canister. The fuel vapor in the sealed fuel tank is led into the EVAP canister which contains activated carbon and the vapor is stored there when the engine is not operating or when refueling to the fuel tank. The vapor in the EVAP canister is purged by the air through the purge line to the intake manifold when the engine is operating. EVAP canister purge volume control solenoid valve is controlled by ECM. When the engine operates, the flow rate of vapor controlled by EVAP canister purge volume control solenoid valve is proportionally regulated as the air flow increases. EVAP canister purge volume control solenoid valve also shuts off the vapor purge line during decelerating and idling. H I J K L M EC-469 EVAPORATIVE EMISSION SYSTEM [CR (WITHOUT EURO-OBD)] EVAPORATIVE EMISSION LINE DRAWING MBIB0544E EC-470 EVAPORATIVE EMISSION SYSTEM [CR (WITHOUT EURO-OBD)] A EC C D E F G H MBIB1450E : Vehicle front 1. : To previous page I EVAP canister J K L M EC-471 EVAPORATIVE EMISSION SYSTEM [CR (WITHOUT EURO-OBD)] Component Inspection BBS003DE EVAP CANISTER Check EVAP canister as follows: 1. Block port (B). 2. Blow air into port (A) and check that it flows freely out of port (C). 3. Release blocked port (B). 4. Apply vacuum pressure to port (B) and check that vacuum pressure exists at the ports (A) and (C). 5. Block port (A) and (B). 6. Apply pressure to port (C) and check that there is no leakage. PBIB2961E FUEL CHECK VALVE 1. 2. 3. Blow air through connector on fuel tank side. A considerable resistance should be felt and a portion of air flow should be directed toward the EVAP canister side. Blow air through connector on EVAP canister side. Air flow should be smoothly directed toward fuel tank side. If fuel check valve is suspected of not properly functioning in steps 1 and 2 above, replace it. SEF552Y FUEL TANK VACUUM RELIEF VALVE (BUILT INTO FUEL FILLER CAP) 1. Wipe clean valve housing. SEF989X 2. Check valve opening pressure and vacuum. Pressure: Vacuum: 3. 15.3 - 20.0 kPa (0.153 - 0.200 bar, 0.156 - 0.204 kg/cm2 , 2.22 - 2.90 psi) −6.0 to −3.4 kPa (−0.060 to −0.034 bar, −0.061 to −0.035 kg/cm2 , −0.87 to −0.49 psi) If out of specification, replace fuel filler cap as an assembly. SEF943S EVAP CANISTER PURGE VOLUME CONTROL SOLENOID VALVE Refer to EC-743, "Component Inspection" . EC-472 NATS (NISSAN ANTI-THEFT SYSTEM) [CR (WITHOUT EURO-OBD)] NATS (NISSAN ANTI-THEFT SYSTEM) Description ● ● ● PFP:25386 A BBS00359 If the security indicator lights up with the ignition switch in the ON position or “NATS MALFUNCTION” is displayed on EC “SELF-DIAG RESULTS” screen, perform self-diagnostic results mode with CONSULT-II using NATS program card. Refer to BL-215, "NATS (Nissan Anti-Theft System)" . C Confirm no self-diagnostic results of NATS is displayed before touching “ERASE” in “SELF-DIAG RESULTS” mode with CONSULT-II. D When replacing ECM, initialization of NATS system and registration of all NATS ignition key IDs must be carried out SEF515Y with CONSULT-II using NATS program card. Therefore, be sure to receive all keys from vehicle owner. E Regarding the procedures of NATS initialization and all NATS ignition key ID registration, refer to CONSULT-II Operation Manual, NATS. F G H I J K L M EC-473 POSITIVE CRANKCASE VENTILATION [CR (WITHOUT EURO-OBD)] POSITIVE CRANKCASE VENTILATION Description PFP:11810 BBS003DF SYSTEM DESCRIPTION PBIB0492E This system returns blow-by gas to the intake manifold. The positive crankcase ventilation (PCV) valve is provided to conduct crankcase blow-by gas to the intake manifold. During partial throttle operation of the engine, the intake manifold sucks the blow-by gas through the PCV valve. Normally, the capacity of the valve is sufficient to handle any blow-by and a small amount of ventilating air. The ventilating air is then drawn from the air inlet tubes into the crankcase. In this process the air passes through the hose connecting air inlet tubes to rocker cover. Under full-throttle condition, the manifold vacuum is insufficient to draw the blow-by flow through the valve. The flow goes through the hose connection in the reverse direction. On vehicles with an excessively high blow-by, the valve does not meet the requirement. This is because some of the flow will go through the hose connection to the air inlet tubes under all conditions. PBIB1588E Component Inspection BBS003DG PCV (POSITIVE CRANKCASE VENTILATION) VALVE With engine running at idle, remove PCV valve from rocker cover. A properly working valve makes a hissing noise as air passes through it. A strong vacuum should be felt immediately when a finger is placed over valve inlet. PBIB1589E EC-474 POSITIVE CRANKCASE VENTILATION [CR (WITHOUT EURO-OBD)] PCV VALVE VENTILATION HOSE 1. 2. A Check hoses and hose connections for leaks. Disconnect all hoses and clean with compressed air. If any hose cannot be freed of obstructions, replace. EC C S-ET277 D E F G H I J K L M EC-475 ON BOARD DIAGNOSTIC (OBD) SYSTEM [CR (WITHOUT EURO-OBD)] ON BOARD DIAGNOSTIC (OBD) SYSTEM Introduction PFP:00028 BBS00356 The ECM has an on board diagnostic system, which detects malfunctions related to engine sensors or actuators. The ECM also records various emission-related diagnostic information including: Emission-related diagnostic information Diagnostic Trouble Code (DTC) Freeze Frame data 1st Trip Diagnostic Trouble Code (1st Trip DTC) 1st Trip Freeze Frame data The above information can be checked using procedures listed in the table below. ×: Applicable —: Not applicable DTC 1st trip DTC Freeze Frame data 1st trip Freeze Frame data CONSULT-II × × × × ECM × ×* — — *: When DTC and 1st trip DTC simultaneously appear on the display, they cannot be clearly distinguished from each other. The malfunction indicator (MI) on the instrument panel lights up when the same malfunction is detected in two consecutive trips (Two trip detection logic), or when the ECM enters fail-safe mode. (Refer to EC-498 .) Two Trip Detection Logic BBS00357 When a malfunction is detected for the first time, 1st trip DTC and 1st trip Freeze Frame data are stored in the ECM memory. The MI will not light up at this stage. <1st trip> If the same malfunction is detected again during the next drive, the DTC and Freeze Frame data are stored in the ECM memory, and the MI lights up. The MI lights up at the same time when the DTC is stored. <2nd trip> The “trip” in the “Two Trip Detection Logic” means a driving mode in which self-diagnosis is performed during vehicle operation. When there is an open circuit on MI circuit, the ECM can not warn the driver by lighting up MI when there is a malfunction on engine control system. Therefore, when electrical controlled throttle and part of ECM related diagnoses are continuously detected as NG for 5 trips, ECM warns the driver that engine control system has malfunction and MI circuit is open by means of operating fail-safe function. The fail-safe function also operate when above diagnoses except MI circuit are detected and demands the driver to repair the malfunction. Engine operating condition in fail-safe mode Engine speed will not rise more than 2,500 rpm due to the fuel cut Emission-related Diagnostic Information BBS00358 EMISSION-RELATED DIAGNOSTIC INFORMATION ITEMS Items (CONSULT-II screen terms) ×: Applicable —: Not applicable DTC*1 Trip MI lighting up Reference page 1001*3 2 — EC-549 U1010 1010 2 — EC-552 NO DTC IS DETECTED. FURTHER TESTING MAY BE REQUIRED. P0000 0000 — — — INT/V TIM CONT-B1 P0011 0011 2 — EC-554 ABSL PRES SEN/CIRC P0107 0107 2 × EC-559 ABSL PRES SEN/CIRC P0108 0108 2 × EC-559 ECT SEN/CIRC P0117 0117 2 × EC-565 ECT SEN/CIRC P0118 0118 2 × EC-565 TP SEN 2/CIRC P0122 0122 1 × EC-570 CONSULT-II ECM*2 CAN COMM CIRCUIT U1001 CONTROL UNIT(CAN) EC-476 ON BOARD DIAGNOSTIC (OBD) SYSTEM [CR (WITHOUT EURO-OBD)] Items (CONSULT-II screen terms) DTC*1 Trip MI lighting up Reference page 0123 1 × EC-570 P0132 0132 2 × EC-577 HO2S1 (B1) P0134 0134 2 × EC-584 HO2S2 (B1) P0138 0138 2 × EC-591 TP SEN 1/CIRC P0222 0222 1 × EC-598 CONSULT-II ECM*2 TP SEN 2/CIRC P0123 HO2S1 (B1) TP SEN 1/CIRC P0223 0223 1 × EC-598 KNOCK SEN/CIRC-B1 P0327 0327 2 — EC-605 KNOCK SEN/CIRC-B1 P0328 0328 2 — EC-605 CKP SEN/CIRCUIT P0335 0335 2 × EC-609 CMP SEN/CIRC-B1 P0340 0340 2 × EC-616 ECM P0605 0605 1 or 2 × or — EC-623 ECM BACK UP/CIRCUIT P1065 1065 2 × EC-626 INT/V TIM V/CIR-B1 P1111 1111 2 × EC-630 ETC ACTR P1121 1121 1 × EC-635 ETC FUNCTION/CIRC P1122 1122 1 × EC-637 ETC MOT PWR P1124 1124 1 × EC-643 ETC MOT PWR P1126 1126 1 × EC-643 ETC MOT P1128 1128 1 × EC-649 INTAKE ERROR P1171 1171 1 × EC-654 TCS C/U FUNCTN P1211 1211 2 — EC-660 TCS/CIRC P1212 1212 2 — EC-661 ENG OVER TEMP P1217 1217 1 × EC-662 CTP LEARNING P1225 1225 2 — EC-676 CTP LEARNING P1226 1226 2 — EC-678 SENSOR POWER/CIRC P1229 1229 1 × EC-680 NATS MALFUNCTION P1610 - P1615 1610 - 1615 2 — BL-215 P-N POS SW/CIRCUIT P1706 1706 2 × EC-688 BRAKE SW/CIRCUIT P1805 1805 1 × EC-693 APP SEN 1/CIRC P2122 2122 1 × EC-699 APP SEN 1/CIRC P2123 2123 1 × EC-699 APP SEN 2/CIRC P2127 2127 1 × EC-708 APP SEN 2/CIRC P2128 2128 1 × EC-708 TP SENSOR P2135 2135 1 × EC-718 APP SENSOR P2138 2138 1 × EC-725 *1: 1st trip DTC No. is the same as DTC No. *2: In Diagnostic Test Mode II (Self-diagnostic results), this number is controlled by NISSAN. *3: The troubleshooting for this DTC needs CONSULT-II. DTC AND 1ST TRIP DTC The 1st trip DTC (whose number is the same as the DTC number) is displayed for the latest self-diagnostic result obtained. If the ECM memory was cleared previously, and the 1st trip DTC did not reoccur, the 1st trip DTC will not be displayed. If a malfunction is detected during the 1st trip, the 1st trip DTC is stored in the ECM memory. The MI will not light up (two trip detection logic). If the same malfunction is not detected in the 2nd trip (meeting the required driving pattern), the 1st trip DTC is cleared from the ECM memory. If the same malfunction is detected in the 2nd trip, both the 1st trip DTC and DTC are stored in the ECM memory and the MI lights up. In other words, EC-477 A EC C D E F G H I J K L M ON BOARD DIAGNOSTIC (OBD) SYSTEM [CR (WITHOUT EURO-OBD)] the DTC is stored in the ECM memory and the MI lights up when the same malfunction occurs in two consecutive trips. If a 1st trip DTC is stored and a non-diagnostic operation is performed between the 1st and 2nd trips, only the 1st trip DTC will continue to be stored. For fail-safe items, DTC is stored in the ECM memory even in the 1st trip. Procedures for clearing the DTC and the 1st trip DTC from the ECM memory are described in EC-478, "HOW TO ERASE EMISSION-RELATED DIAGNOSTIC INFORMATION" When a 1st trip DTC is detected, check, print out or write down and erase (1st trip) DTC and Freeze Frame data as specified in Work Flow procedure Step 2, refer to EC-492, "WORK FLOW" . Then perform DTC Confirmation Procedure or Overall Function Check to try to duplicate the malfunction. If the malfunction is duplicated, the item requires repair. How to Read DTC and 1st Trip DTC DTC and 1st trip DTC can be read by the following methods. With CONSULT-II CONSULT-II displays the DTC in “SEFL-DIAG RESULTS” mode. Examples: P0117, P0340, P1065, etc. (CONSULT-II also displays the malfunctioning component or system.) Without CONSULT-II The number of blinks of the MI in the Diagnostic Test Mode II (Self-Diagnostic Results) indicates the DTC. Example: 0107, 0340, 1065 etc. ● 1st trip DTC No. is the same as DTC No. ● Output of a DTC indicates a malfunction. However, the Diagnostic Test Mode II do not indicate whether the malfunction is still occurring or has occurred in the past and has returned to normal. CONSULT-II can identify malfunction status as shown below. Therefore, using CONSULT-II (if available) is recommended. A sample of CONSULT-II display for DTC and 1st trip DTC is shown below. DTC or 1st trip DTC of a malfunction is displayed in SELF-DIAGNOSTIC RESULTS mode of CONSULT-II. Time data indicates how many times the vehicle was driven after the last detection of a DTC. If the DTC is being detected currently, the time data will be [0]. If a 1st trip DTC is stored in the ECM, the time data will be [1t]. PBIB0911E FREEZE FRAME DATA AND 1ST TRIP FREEZE FRAME DATA The ECM records the driving conditions such as fuel system status, calculated load value, engine coolant temperature, short term fuel trim, long term fuel trim, engine speed, vehicle speed, base fuel schedule and intake air temperature at the moment a malfunction is detected. Data which are stored in the ECM memory, along with the 1st trip DTC, are called 1st trip freeze frame data. The data, stored together with the DTC data, are called freeze frame data and displayed on CONSULT-II. For details, see EC-521, "Freeze Frame Data and 1st Trip Freeze Frame Data" . Only one set of freeze frame data (either 1st trip freeze frame data or freeze frame data) can be stored in the ECM. 1st trip freeze frame data is stored in the ECM memory along with the 1st trip DTC. There is no priority for 1st trip freeze frame data and it is updated each time a different 1st trip DTC is detected. However, once freeze frame data (2nd trip detection/MI on) is stored in the ECM memory, 1st trip freeze frame data is no longer stored. Remember, only one set of freeze frame data can be stored in the ECM. Both 1st trip freeze frame data and freeze frame data (along with the DTCs) are cleared when the ECM memory is erased. Procedures for clearing the ECM memory are described in EC-478, "HOW TO ERASE EMISSION-RELATED DIAGNOSTIC INFORMATION" . HOW TO ERASE EMISSION-RELATED DIAGNOSTIC INFORMATION How to Erase DTC With CONSULT-II EC-478 ON BOARD DIAGNOSTIC (OBD) SYSTEM [CR (WITHOUT EURO-OBD)] The emission related diagnostic information in the ECM can be erased by selecting “ERASE” in the “SELFDIAG RESULTS” mode with CONSULT-II. A 1. If the ignition switch stays ON after repair work, be sure to turn ignition switch OFF once. Wait at least 10 seconds and then turn it ON (engine stopped) again. 2. Touch “ENGINE”. EC 3. Touch “SELF-DIAG RESULTS”. 4. Touch “ERASE”. (The DTC in the ECM will be erased.) C D E F G H MBIB1303E Without CONSULT-II 1. If the ignition switch stays ON after repair work, be sure to turn ignition switch OFF once. 2. Wait at least 10 seconds and then turn it ON (engine stopped) again. 3. Change the diagnostic test mode from Mode II to Mode I by depressing the accelerator pedal. Refer to EC-480, "HOW TO SWITCH DIAGNOSTIC TEST MODE" . ● If the battery is disconnected, the emission-related diagnostic information will be lost within 24 hours. ● The following data are cleared when the ECM memory is erased. – Diagnostic trouble codes – 1st trip diagnostic trouble codes – Freeze frame data – 1st trip freeze frame data Actual work procedures are explained using a DTC as an example. Be careful so that not only the DTC, but all of the data listed above, are cleared from the ECM memory during work procedures. Malfunction Indicator (MI) BBS0035A DESCRIPTION The MI is located on the instrument panel. 1. The MI will light up when the ignition switch is turned ON without the engine running. This is a bulb check. If the MI does not light up, refer to DI-32, "WARNING LAMPS" or see EC-800 . 2. When the engine is started, the MI should go off. If the MI remains on, the on board diagnostic system has detected an engine system malfunction. SAT652J EC-479 I J K L M ON BOARD DIAGNOSTIC (OBD) SYSTEM [CR (WITHOUT EURO-OBD)] ON BOARD DIAGNOSTIC SYSTEM FUNCTION The on board diagnostic system has the following four functions. Diagnostic Test Mode KEY and ENG. Status Function Explanation of Function Mode I Ignition switch in ON position BULB CHECK This function checks the MI bulb for damage (blown, open circuit, etc.). If the MI does not come on, check MI circuit. Engine running MALFUNCTION WARNING This is a usual driving condition. When a malfunction is detected twice in two consecutive driving cycles (two trip detection logic), the MI will light up to inform the driver that a malfunction has been detected. One trip detection diagnosis will light up or blink the MI in the 1st trip. Ignition switch in ON position SELF-DIAGNOSTIC RESULTS This function allows DTCs and 1st trip DTCs to be read. HEATED OXYGEN SENSOR 1 MONITOR This function allows the fuel mixture condition (lean or rich), monitored by heated oxygen sensor 1, to be read. Engine stopped Mode II Engine stopped Engine running When there is an open circuit on MI circuit, the ECM can not warn the driver by lighting up MI when there is malfunction on engine control system. Therefore, when electrical controlled throttle and part of ECM related diagnoses are continuously detected as NG for 5 trips, ECM warns the driver that engine control system has a malfunction and MI circuit is open by means of operating fail-safe function. The fail-safe function also operate when above diagnoses except MI circuit are detected and demands the driver to repair the a malfunction. Engine operating condition in fail-safe mode Engine speed will not rise more than 2,500 rpm due to the fuel cut MI Flashing without DTC If the ECM is in Diagnostic Test Mode II, MI may flash when engine is running. In this case, check ECM diagnostic test mode. EC-480, "HOW TO SWITCH DIAGNOSTIC TEST MODE" . How to switch the diagnostic test (function) modes, and details of the above functions are described later, EC480, "HOW TO SWITCH DIAGNOSTIC TEST MODE" . The following emission-related diagnostic information is cleared when the ECM memory is erased. ● Diagnostic trouble codes ● 1st trip diagnostic trouble codes ● Freeze frame data ● 1st trip freeze frame data HOW TO SWITCH DIAGNOSTIC TEST MODE NOTE: ● It is better to count the time accurately with a clock. ● It is impossible to switch the diagnostic mode when an accelerator pedal position sensor circuit has a malfunction. EC-480 ON BOARD DIAGNOSTIC (OBD) SYSTEM [CR (WITHOUT EURO-OBD)] ● Always ECM returns to Diagnostic Test Mode I after ignition switch is turned OFF. A How to Set Diagnostic Test Mode II (Self-diagnostic Results) 1. 2. a. b. 3. 4. Confirm that accelerator pedal is fully released, turn ignition switch ON and wait 3 seconds. Repeat the following procedure quickly five times within 5 seconds. EC Fully depress the accelerator pedal. Fully release the accelerator pedal. Wait 7 seconds, fully depress the accelerator pedal and keep it for approx. 10 seconds until the MI starts C blinking. Fully release the accelerator pedal. ECM has entered to Diagnostic Test Mode II (Self-diagnostic results). D E F G PBIB0092E How to Set Diagnostic Test Mode II (Heated Oxygen Sensor 1 Monitor) 1. 2. Set the ECM in Diagnostic Test Mode II (Self-diagnostic results). Refer to EC-481, "How to Set Diagnostic Test Mode II (Self-diagnostic Results)" . Start Engine. ECM has entered to Diagnostic Test Mode II (Heated oxygen sensor 1 monitor). H I How to Erase Diagnostic Test Mode II (Self-diagnostic Results) 1. 2. 3. Set ECM in Diagnostic Test Mode II (Self-diagnostic results). Refer to EC-481, "How to Set Diagnostic Test Mode II (Self-diagnostic Results)" . Fully depress the accelerator pedal and keep it for more than 10 seconds. The emission-related diagnostic information has been erased from the backup memory in the ECM. Fully release the accelerator pedal, and confirm the DTC 0000 is displayed. J K DIAGNOSTIC TEST MODE I — BULB CHECK In this mode, the MI on the instrument panel should stay ON. If it remains OFF, check the bulb. Refer to DI-32, "WARNING LAMPS" or see EC-800 . L DIAGNOSTIC TEST MODE I — MALFUNCTION WARNING MI ● Condition ON When the malfunction is detected. OFF No malfunction. These DTC numbers are clarified in Diagnostic Test Mode II (SELF-DIAGNOSTIC RESULTS) DIAGNOSTIC TEST MODE II — SELF-DIAGNOSTIC RESULTS In this mode, the DTC and 1st trip DTC are indicated by the number of blinks of the MI as shown below. The DTC and 1st trip DTC are displayed at the same time. If the MI does not illuminate in diagnostic test mode I (Malfunction warning), all displayed items are 1st trip DTCs. If only one code is displayed when the MI illuminates in diagnostic test mode II (SELF-DIAGNOSTIC RESULTS), it is a DTC; if two or more codes are dis- EC-481 M ON BOARD DIAGNOSTIC (OBD) SYSTEM [CR (WITHOUT EURO-OBD)] played, they may be either DTCs or 1st trip DTCs. DTC No. is same as that of 1st trip DTC. These unidentified codes can be identified by using the CONSULT-II. A DTC will be used as an example for how to read a code. PBIA3905E A particular trouble code can be identified by the number of four-digit numeral flashes. The “zero” is indicated by the number of ten flashes. The length of time the 1,000th-digit numeral flashes on and off is 1.2 seconds consisting of an ON (0.6-second) - OFF (0.6-second) cycle. The 100th-digit numeral and lower digit numerals consist of a 0.3-second ON and 0.3-second OFF cycle. A change from one digit numeral to another occurs at an interval of 1.0-second OFF. In other words, the later numeral appears on the display 1.3 seconds after the former numeral has disappeared. A change from one trouble code to another occurs at an interval of 1.8-second OFF. In this way, all the detected malfunctions are classified by their DTC numbers. The DTC 0000 refers to no malfunction. (See EC-451, "INDEX FOR DTC" ) How to Erase Diagnostic Test Mode II (Self-diagnostic Results) The DTC can be erased from the back up memory in the ECM by depressing accelerator pedal. Refer to EC480, "HOW TO SWITCH DIAGNOSTIC TEST MODE" . ● If the battery is disconnected, the DTC will be lost from the backup memory within 24 hours. ● Be careful not to erase the stored memory before starting trouble diagnoses. DIAGNOSTIC TEST MODE II — HEATED OXYGEN SENSOR 1 MONITOR In this mode, the MI displays the condition of the fuel mixture (lean or rich) which is monitored by the heated oxygen sensor 1. MI Fuel mixture condition in the exhaust gas ON Lean OFF Rich *Remains ON or OFF Any condition Air-fuel ratio feedback control condition Closed loop system Open loop system *: Maintains conditions just before switching to open loop. To check the heated oxygen sensor 1 function, start engine in the Diagnostic Test Mode II and warm it up until engine coolant temperature indicator points to the middle of the gauge. Next run engine at about 2,000 rpm for about 2 minutes under no load conditions. Then make sure that the MI comes ON more than 5 times within 10 seconds with engine running at 2,000 rpm under no load. EC-482 BASIC SERVICE PROCEDURE [CR (WITHOUT EURO-OBD)] BASIC SERVICE PROCEDURE Basic Inspection PFP:00018 A BBS0035E 1. INSPECTION START 1. 2. – – – – – – 3. – – – – 4. Check service records for any recent repairs that may indicate a related malfunction, or a current need for scheduled maintenance. Open engine hood and check the following: Harness connectors for improper connections Wiring harness for improper connections, pinches and cut Vacuum hoses for splits, kinks and improper connections Hoses and ducts for leaks Air cleaner clogging Gasket Confirm that electrical or mechanical loads are not applied. Headlamp switch is OFF. SEF983U Air conditioner switch is OFF. Rear window defogger switch is OFF. Steering wheel is in the straight-ahead position, etc. Start engine and warm it up until engine coolant temperature indicator points the middle of gauge. Ensure engine stays below 1,000 rpm. EC C D E F G H I J SEF976U 5. Run engine at about 2,000 rpm for about 2 minutes under no load. 6. Make sure that no DTC is displayed with CONSULT-II. OK or NG OK >> GO TO 3. NG >> GO TO 2. K L M SEF977U 2. REPAIR OR REPLACE Repair or replace components as necessary according to corresponding Diagnostic Procedure. >> GO TO 3 EC-483 BASIC SERVICE PROCEDURE [CR (WITHOUT EURO-OBD)] 3. CHECK TARGET IDLE SPEED 1. 2. With CONSULT-II Run engine at about 2,000 rpm for about 2 minutes under no load. Rev engine (2,000 to 3,000 rpm) two or three times under no load, then run engine at idle speed for about 1 minute. PBIA8513J 3. Read idle speed in “DATA MONITOR” mode with CONSULT-II. Refer to EC-486, "IDLE SPEED" . 650 ± 50 rpm (in Neutral position) SEF058Y Without CONSULT-II Run engine at about 2,000 rpm for about 2 minutes under no load. Rev engine (2,000 to 3,000 rpm) two or three times under no load, then run engine at idle speed for about 1 minute. 3. Check idle speed. Refer to EC-486, "IDLE SPEED" . 1. 2. 650 ± 50 rpm (in Neutral position) OK or NG OK >> INSPECTION END NG >> GO TO 4. 4. PERFORM ACCELERATOR PEDAL RELEASED POSITION LEARNING 1. 2. Stop engine. Perform EC-486, "Accelerator Pedal Released Position Learning" . >> GO TO 5. 5. PERFORM THROTTLE VALVE CLOSED POSITION LEARNING Perform EC-486, "Throttle Valve Closed Position Learning" . >> GO TO 6. EC-484 BASIC SERVICE PROCEDURE [CR (WITHOUT EURO-OBD)] 6. PERFORM IDLE AIR VOLUME LEARNING A Refer to EC-486, "Idle Air Volume Learning" . Is Idle Air Volume Learning carried out successfully? Yes or No Yes >> GO TO 7. No >> 1. Follow the instruction of Idle Air Volume Learning. 2. GO TO 4. EC C 7. CHECK TARGET IDLE SPEED AGAIN With CONSULT-II 1. Start engine and warm it up to normal operating temperature. 2. Read idle speed in “DATA MONITOR” mode with CONSULT-II. Refer to EC-486, "IDLE SPEED" . D E 650 ± 50 rpm (in Neutral position) Without CONSULT-II 1. Start engine and warm it up to normal operating temperature. 2. Check idle speed. Refer to EC-486, "IDLE SPEED" . F G 650 ± 50 rpm (in Neutral position) OK or NG OK >> INSPECTION END NG >> GO TO 8. H 8. DETECT MALFUNCTIONING PART I Check the following. ● Check camshaft position sensor (PHASE) and circuit. Refer to EC-616 . ● Check crankshaft position sensor (POS) and circuit. Refer to EC-609 . OK or NG OK >> GO TO 9. NG >> 1. Repair or replace. 2. GO TO 4. 2. K L 9. CHECK ECM FUNCTION 1. J Substitute another known-good ECM to check ECM function. (ECM may be the cause of an incident, but this is a rare case.) Perform initialization of NATS system and registration of all NATS ignition key IDs. Refer to EC-473, "Description" . >> GO TO 4. EC-485 M BASIC SERVICE PROCEDURE [CR (WITHOUT EURO-OBD)] Idle Speed Check BBS00351 IDLE SPEED With CONSULT-II Check idle speed in “DATA MONITOR” mode with CONSULT-II. SEF058Y Without CONSULT-II Check idle speed by installing the pulse type tachometer clamp on the loop wire or on suitable high-tension wire which installed between No. 1 ignition coil and No. 1 spark plug. Accelerator Pedal Released Position Learning BBS00352 DESCRIPTION Accelerator Pedal Released Position Learning is an operation to learn the fully released position of the accelerator pedal by monitoring the accelerator pedal position sensor output signal. It must be performed each time harness connector of accelerator pedal position sensor or ECM is disconnected. OPERATION PROCEDURE 1. 2. 3. 4. 5. Make sure that accelerator pedal is fully released. Turn ignition switch ON and wait at least 2 seconds. Turn ignition switch OFF and wait at least 10 seconds. Turn ignition switch ON and wait at least 2 seconds. Turn ignition switch OFF and wait at least 10 seconds. Throttle Valve Closed Position Learning BBS00353 DESCRIPTION Throttle Valve Closed Position Learning is an operation to learn the fully closed position of the throttle valve by monitoring the throttle position sensor output signal. It must be performed each time harness connector of electric throttle control actuator or ECM is disconnected. OPERATION PROCEDURE 1. 2. 3. Make sure that accelerator pedal is fully released. Turn ignition switch ON. Turn ignition switch OFF and wait at least 10 seconds. Make sure that throttle valve moves during above 10 seconds by confirming the operating sound. Idle Air Volume Learning BBS00354 DESCRIPTION Idle Air Volume Learning is an operation to learn the idle air volume that keeps each engine within the specific range. It must be performed under any of the following conditions: ● Each time electric throttle control actuator or ECM is replaced. ● Idle speed is out of specification. PREPARATION Before performing Idle Air Volume Learning, make sure that all of the following conditions are satisfied. Learning will be cancelled if any of the following conditions are missed for even a moment. ● Battery voltage: More than 12.9V (At idle) ● Engine coolant temperature: 70 - 100°C (158 - 212°F) ● PNP switch: ON ● Electric load switch: OFF EC-486 BASIC SERVICE PROCEDURE [CR (WITHOUT EURO-OBD)] (Air conditioner, headlamp, rear window defogger) On vehicles equipped with daytime light systems, set lighting switch to the 1st position to light A only small lamps. Steering wheel: Neutral (Straight-ahead position) Vehicle speed: Stopped EC Transmission: Warmed-up Drive vehicle for 10 minutes. C ● ● ● – OPERATION PROCEDURE With CONSULT-II 1. 2. 3. 4. 5. Perform EC-486, "Accelerator Pedal Released Position Learning" . Perform EC-486, "Throttle Valve Closed Position Learning" . Start engine and warm it up to normal operating temperature. Check that all items listed under the topic PREPARATION (previously mentioned) are in good order. Select “IDLE AIR VOL LEARN” in “WORK SUPPORT” mode. D E F G H SEF217Z 6. I Touch “START” and wait 20 seconds. J K SEF454Y 7. 8. Make sure that “CMPLT” is displayed on CONSULT-II screen. If “CMPLT” is not displayed, Idle Air Volume Learning will not be carried out successfully. In this case, find the cause of the incident by referring to the Diagnostic Procedure below. Rev up the engine two or three times and make sure that idle speed is within the specifications. ITEM SPECIFICATION Idle speed 650 ± 50 rpm (in Neutral position) M MBIB0238E Without CONSULT-II NOTE: ● It is better to count the time accurately with a clock. ● It is impossible to switch the diagnostic mode when an accelerator pedal position sensor circuit has a malfunction. 1. Perform EC-486, "Accelerator Pedal Released Position Learning" . 2. Perform EC-486, "Throttle Valve Closed Position Learning" . EC-487 L BASIC SERVICE PROCEDURE [CR (WITHOUT EURO-OBD)] 3. 4. 5. 6. 7. a. b. 8. Start engine and warm it up to normal operating temperature. Check that all items listed under the topic PREPARATION (previously mentioned) are in good order. Turn ignition switch OFF and wait at least 10 seconds. Confirm that accelerator pedal is fully released, turn ignition switch ON and wait 3 seconds. Repeat the following procedure quickly five times within 5 seconds. Fully depress the accelerator pedal. Fully release the accelerator pedal. Wait 7 seconds, fully depress the accelerator pedal and keep it for approx. 20 seconds until the MI stops blinking and turned ON. 9. Fully release the accelerator pedal within 3 seconds after the MI turned ON. 10. Start engine and let it idle. 11. Wait 20 seconds. PBIB0665E 12. Rev up the engine two or three times and make sure that idle speed is within the specifications. ITEM SPECIFICATION Idle speed 650 ± 50 rpm (in Neutral position) 13. If idle speed is not within the specification, Idle Air Volume Learning will not be carried out successfully. In this case, find the cause of the incident by referring to the Diagnostic Procedure below. DIAGNOSTIC PROCEDURE If idle air volume learning cannot be performed successfully, proceed as follows: 1. Check that throttle valve is fully closed. 2. Check PCV valve operation. 3. Check that downstream of throttle valve is free from air leakage. 4. When the above three items check out OK, engine component parts and their installation condition are questionable. Check and eliminate the cause of the incident. It is useful to perform EC-532, "TROUBLE DIAGNOSIS - SPECIFICATION VALUE" . 5. If any of the following conditions occur after the engine has started, eliminate the cause of the incident and perform Idle Air Volume Learning all over again: ● Engine stalls. ● Erroneous idle. Fuel Pressure Check BBS00355 FUEL PRESSURE RELEASE With CONSULT-II 1. Turn ignition switch ON. EC-488 BASIC SERVICE PROCEDURE [CR (WITHOUT EURO-OBD)] 2. 3. 4. 5. Perform “FUEL PRESSURE RELEASE” in “WORK SUPPORT” mode with CONSULT-II. Start engine. After engine stalls, crank it two or three times to release all fuel pressure. Turn ignition switch OFF. A EC C SEF214Y D Without CONSULT-II 1. 2. 3. 4. 5. Remove fuel pump fuse located in IPDM E/R. Start engine. After engine stalls, crank it two or three times to release all fuel pressure. Turn ignition switch OFF. Reinstall fuel pump fuse after servicing fuel system. E F G MBIB0277E FUEL PRESSURE CHECK H CAUTION: ● Before disconnecting fuel line, release fuel pressure from fuel line to eliminate danger. ● The fuel hose connection method used when taking fuel pressure check must not be used for other purposes. ● Be careful not to scratch or put debris around connection area when servicing, so that the quick connector maintains sealability with O-rings inside. ● When installing fuel hose quick connector, refer to EM-18, "AIR CLEANER AND AIR DUCT" . NOTE: Prepare pans or saucers under the disconnected fuel line because the fuel may spill out. The fuel pressure cannot be completely released because E11 models do not have fuel return system. 1. Release fuel pressure to zero. Refer to EC-488, "FUEL PRESSURE RELEASE" . 2. Prepare fuel hose and fuel hose clamp for fuel pressure check, and connect fuel pressure gauge. ● Use suitable fuel hose for fuel pressure check (genuine NISSAN fuel hose without quick connector). ● To avoid unnecessary force or tension to hose, use moderately long fuel hose for fuel pressure check. ● Do not use the fuel hose for checking fuel pressure with damage or cracks on it. ● Use Pressure Gauge to check fuel pressure. 3. Remove fuel hose. Refer to EM-18, "AIR CLEANER AND AIR DUCT" . ● Do not twist or kink fuel hose because it is plastic hose. ● Do not remove fuel hose from quick connector. ● Keep the original fuel hose to be free from intrusion of dust or foreign substances with a suitable cover. EC-489 I J K L M BASIC SERVICE PROCEDURE [CR (WITHOUT EURO-OBD)] 4. Install the fuel pressure gauge as shown in the figure. ● Wipe off oil or dirt from hose insertion part using cloth moistened with gasoline. ● Apply proper amount of gasoline between top of the fuel tube and No.1 spool. ● Insert fuel hose for fuel pressure check until it touches the No.1 spool on fuel tube. ● Use NISSAN genuine hose clamp (part number: 16439 N4710 or 16439 40U00). ● When reconnecting fuel line, always use new clamps. ● When reconnecting fuel hose, check the original fuel hose for damage and abnormality. ● Use a torque driver to tighten clamps. ● Install hose clamp to the position within 1 - 2 mm (0.04 - 0.08 in). – A: Fuel pressure gauge Tightening torque: 1 - 1.5 N·m (0.1 - 0.15 kg-m, 9 - 13 in-lb) Make sure that clamp screw does not contact adjacent parts. After connecting fuel hose for fuel pressure check, pull the hose with a force of approximately 98 N (10 kg, 22 lb) to confirm fuel tube does not come off. MBIB1495E Turn ignition switch ON, and check for fuel leakage. Start engine and check for fuel leakage. Read the indication of fuel pressure gauge. ● Do not perform fuel pressure check with system operating. Fuel pressure gauge may indicate false readings. ● During fuel pressure check, confirm for fuel leakage from fuel connection every 3 minutes. ● 5. 6. 7. 8. PBIB0669E At idling: Approximately 350 kPa (3.5 bar, 3.57 kg/cm2 , 51 psi) 9. If result is unsatisfactory, go to next step. 10. Check the following. ● Fuel hoses and fuel tubes for clogging ● Fuel filter for clogging ● Fuel pump ● Fuel pressure regulator for clogging If OK, replace fuel pressure regulator. If NG, repair or replace. EC-490 TROUBLE DIAGNOSIS [CR (WITHOUT EURO-OBD)] TROUBLE DIAGNOSIS Trouble Diagnosis Introduction PFP:00004 A BBS0035B INTRODUCTION The engine has an ECM to control major systems such as fuel control, ignition control, idle air control system, etc. The ECM accepts input signals from sensors and instantly drives actuators. It is essential that both input and output signals are proper and stable. At the same time, it is important that there are no malfunctions such as vacuum leaks, fouled spark plugs, or other malfunctions with the engine. EC C D MEF036D It is much more difficult to diagnose an incident that occurs intermittently rather than continuously. Most intermittent incidents are caused by poor electric connections or improper wiring. In this case, careful checking of suspected circuits may help prevent the replacement of good parts. E F G H SEF233G I A visual check only may not find the cause of the incidents. A road test with CONSULT-II or a circuit tester connected should be performed. Follow the Work Flow on EC-492 . Before undertaking actual checks, take a few minutes to talk with a customer who approaches with a driveability complaint. The customer can supply good information about such incidents, especially intermittent ones. Find out what symptoms are present and under what conditions they occur. A Diagnostic Worksheet like the example on EC-496 should be used. Start your diagnosis by looking for conventional malfunctions first. This will help troubleshoot driveability malfunctions on an electronically controlled engine vehicle. J K L SEF234G M EC-491 TROUBLE DIAGNOSIS [CR (WITHOUT EURO-OBD)] WORK FLOW Overall Sequence PBIB2267E EC-492 TROUBLE DIAGNOSIS [CR (WITHOUT EURO-OBD)] Detailed Flow A 1. GET INFORMATION FOR SYMPTOM Get the detailed information from the customer about the symptom (the condition and the environment when EC the incident/malfunction occurred) using the EC-495, "DIAGNOSTIC WORKSHEET" . >> GO TO 2. C 2. CHECK DTC*1 1. Check DTC*1 . 2. Perform the following procedure if DTC*1 is displayed. – Record DTC*1 and freeze frame data*2 . (Print them out with CONSULT-II.) – D Erase DTC*1 . (Refer to EC-478, "HOW TO ERASE EMISSION-RELATED DIAGNOSTIC INFORMATION" .) Study the relationship between the cause detected by DTC*1 and the symptom described by the customer. (Symptom Matrix Chart is useful. Refer to EC-499, "Symptom Matrix Chart" .) 3. Check related service bulletins for information. Is any symptom described and any DTC detected? – Symptom is described, DTC*1 is displayed>>GO TO 3. Symptom is described, DTC*1 is not displayed>>GO TO 4. Symptom is not described, DTC*1 is displayed>>GO TO 5. E F G H 3. CONFIRM THE SYMPTOM I Try to confirm the symptom described by the customer (except MI ON). DIAGNOSIS WORK SHEET is useful to verify the incident. Connect CONSULT-II to the vehicle in “DATA MONITOR (AUTO TRIG)” mode and check real time diagnosis results. Verify relation between the symptom and the condition when the symptom is detected. J K >> GO TO 5. 4. CONFIRM THE SYMPTOM L Try to confirm the symptom described by the customer. DIAGNOSIS WORK SHEET is useful to verify the incident. Connect CONSULT-II to the vehicle in “DATA MONITOR (AUTO TRIG)” mode and check real time diagnosis results. Verify relation between the symptom and the condition when the symptom is detected. >> GO TO 6. EC-493 M TROUBLE DIAGNOSIS [CR (WITHOUT EURO-OBD)] 5. PERFORM DTC CONFIRMATION PROCEDURE Perform DTC Confirmation Procedure for the displayed DTC*1 , and then make sure that DTC*1 is detected again. At this time, always connect CONSULT-II to the vehicle, and check diagnostic results in real time on “DATA MONITOR (AUTO TRIG)”. If two or more DTCs*1 are detected, refer to EC-497, "DTC Inspection Priority Chart" and determine trouble diagnosis order. NOTE: ● Freeze frame data*2 is useful if the DTC*1 is not detected. ● Perform Overall Function Check if DTC Confirmation Procedure is not included on Service Manual. This simplified check procedure is an effective alternative though DTC*1 cannot be detected during this check. If the result of Overall Function Check is NG, it is the same as the detection of DTC*1 by DTC Confirmation Procedure. Is DTC*1 detected? Yes >> GO TO 10. No >> Check according to EC-542, "TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT" . 6. PERFORM BASIC INSPECTION Perform EC-483, "Basic Inspection" . With CONSULT-II>>GO TO 7. Without CONSULT-II>>GO TO 9. 7. PERFORM DATA MONITOR (SPEC) MODE With CONSULT-II Make sure that “B/FUEL SCHDL”, and “A/F ALPHA-B1” are within the SP value using CONSULT-II “DATA MONITOR (SPEC)” mode. Refer to EC-533, "Diagnostic Procedure" . Are they within the SP value? Yes >> GO TO 9. No >> GO TO 8. SEF601Z 8. DETECT MALFUNCTIONING PART BY TROUBLE DIAGNOSIS - SPECIFICATION VALUE Detect malfunctioning part according to EC-532, "TROUBLE DIAGNOSIS - SPECIFICATION VALUE" . Is malfunctioning part detected? Yes >> GO TO 11. No >> GO TO 9. 9. DETECT MALFUNCTIONING SYSTEM BY SYMPTOM MATRIX CHART Detect malfunctioning system according to EC-499, "Symptom Matrix Chart" based on the confirmed symptom in step 4, and determine the trouble diagnosis order based on possible causes and symptom. >> GO TO 10. EC-494 TROUBLE DIAGNOSIS [CR (WITHOUT EURO-OBD)] 10. DETECT MALFUNCTIONING PART BY DIAGNOSTIC PROCEDURE A Inspect according to Diagnostic Procedure of the system. NOTE: The Diagnostic Procedure in EC section described based on open circuit inspection. A short circuit inspection EC is also required for the circuit check in the Diagnostic Procedure. For details, refer to Circuit Inspection in GI25, "How to Perform Efficient Diagnosis for an Electrical Incident" . Is malfunctioning part detected? C Yes >> GO TO 11. No >> Monitor input data from related sensors or check voltage of related ECM terminals using CONSULT-II. Refer to EC-512, "ECM Terminals and Reference Value" , EC-527, "CONSULT-II Refer- D ence Value in Data Monitor Mode" . 11. REPAIR OR REPLACE THE MALFUNCTIONING PART 1. 2. 3. E Repair or replace the malfunctioning part. Reconnect parts or connectors disconnected during Diagnostic Procedure again after repair and replacement. Check DTC. If DTC is displayed, erase it, refer to EC-478, "HOW TO ERASE EMISSION-RELATED DIAGNOSTIC INFORMATION" . F G >> GO TO 12. 12. FINAL CHECK H When DTC was detected in step 2, perform DTC Confirmation Procedure or Overall Function Check again, and then make sure that the malfunction have been repaired securely. When symptom was described from the customer, refer to confirmed symptom in step 3 or 4, and make sure that the symptom is not detected. OK or NG I NG (DTC*1 is detected)>>GO TO 10. NG (Symptom remains)>>GO TO 6. OK >> 1. Before returning the vehicle to the customer, make sure to erase unnecessary DTC*1 in ECM. (Refer to EC-478, "HOW TO ERASE EMISSION-RELATED DIAGNOSTIC INFORMATION" .) 2. INSPECTION END *1: Include 1st trip DTC. *2: Include 1st trip freeze frame data. DIAGNOSTIC WORKSHEET Description K L M There are many operating conditions that lead to the malfunction of engine components. A good grasp of such conditions can make troubleshooting faster and more accurate. In general, each customer feels differently about an incident. It is important to fully understand the symptoms or conditions for a customer complaint. Utilize a diagnostic worksheet like the one on the next page in order to organize all the information for troubleshooting. SEF907L EC-495 J TROUBLE DIAGNOSIS [CR (WITHOUT EURO-OBD)] Worksheet Sample MTBL0017 EC-496 TROUBLE DIAGNOSIS [CR (WITHOUT EURO-OBD)] DTC Inspection Priority Chart BBS0035C A If some DTCs are displayed at the same time, perform inspections one by one based on the following priority chart. NOTE: ● If DTC U1001 is displayed with other DTC, first perform the trouble diagnosis for DTC U1001. Refer EC to EC-549, "DTC U1001 CAN COMMUNICATION LINE" . ● If DTC U1010 is displayed with other DTC, first perform the trouble diagnosis for DTC U1010. Refer C to EC-552, "DTC U1010 CAN COMMUNICATION" . Priority 1 2 3 Detected items (DTC) ● U1001 CAN communication line ● U1010 CAN communication ● P0107 P0108 Manifold absolute pressure sensor ● P0117 P0118 Engine coolant temperature sensor ● P0122 P0123 P0222 P0223 P1225 P1226 P2135 Throttle position sensor ● P0327 P0328 Knock sensor ● P0335 Crankshaft position sensor (POS) ● P0340 Camshaft position sensor (PHASE) ● P0605 ECM ● P1171 Intake error ● P1229 Sensor power supply ● P1610-P1615 NATS ● P1706 Park/Neutral position (PNP) switch ● P2122 P2123 P2127 P2128 P2138 Accelerator pedal position sensor ● P0132 P0134 Heated oxygen sensor 1 ● P0138 Heated oxygen sensor 2 ● P1065 ECM power supply ● P1111 Intake valve timing control solenoid valve ● P1122 Electric throttle control function ● P1124 P1126 Throttle control motor relay ● P1128 Throttle control mother ● P1805 Brake switch ● P0011 Intake valve timing control ● P1121 Electric throttle control actuator ● P1211 ESP control unit ● P1212 ESP communication line ● P1217 Engine over temperature (OVERHEAT) D E F G H I J K L EC-497 M TROUBLE DIAGNOSIS [CR (WITHOUT EURO-OBD)] Fail-Safe Chart BBS0035D When the DTC listed bellow is detected, the ECM enters fail-safe mode and the MI lights up. DTC No. Detected items Engine operating condition in fail-safe mode P0122 P0123 P0222 P0223 P2135 Throttle position sensor The ECM controls the electric throttle control actuator in regulating the throttle opening in order for the idle position to be within +10 degrees. The ECM regulates the opening speed of the throttle valve to be slower than the normal condition. So, the acceleration will be poor. P1121 Electric throttle control actuator (When electric throttle control actuator does not function properly due to the return spring malfunction:) ECM controls the electric throttle control actuator by regulating the throttle opening around the idle position. The engine speed will not rise more than 2,000 rpm. (When throttle valve opening angle in fail-safe mode is not in specified range:) ECM controls the electric throttle control actuator by regulating the throttle opening to 20 degrees or less. (When ECM detects the throttle valve is stuck open:) While the vehicle is driving, it slows down gradually by fuel cut. After the vehicle stops, the engine stalls. The engine can restart in Neutral position and engine speed will not exceed 1,000 rpm or more. P1122 Electric throttle control function ECM stops the electric throttle control actuator control, throttle valve is maintained at a fixed opening (approx. 5 degrees) by the return spring. P1124 P1126 Throttle control motor relay ECM stops the electric throttle control actuator control, throttle valve is maintained at a fixed opening (approx. 5 degrees) by the return spring. P1128 Throttle control motor ECM stops the electric throttle control actuator control, throttle valve is maintained at a fixed opening (approx. 5 degrees) by the return spring. P1171 P1229 P1805 P2122 P2123 P2127 P2128 P2138 ● Intake air system Sensor power supply Brake switch Accelerator pedal position sensor When accelerator pedal is depressed, engine speed will not rise more than 2,500 rpm due to fuel cut. ECM stops the electric throttle control actuator control, throttle valve is maintained at a fixed opening (approx. 5 degrees) by the return spring. ECM controls the electric throttle control actuator by regulating the throttle opening to a small range. Therefore, acceleration will be poor. Vehicle condition Driving condition When engine is idling Normal When accelerating Poor acceleration The ECM controls the electric throttle control actuator in regulating the throttle opening in order for the idle position to be within +10 degrees. The ECM regulates the opening speed of the throttle valve to be slower than the normal condition. So, the acceleration will be poor. When there is an open circuit on MI circuit, the ECM can not warn the driver by lighting up MI when there is a malfunction on engine control system. Therefore, when electrical controlled throttle and part of ECM related diagnoses is continuously detected as NG for 5 trips, ECM warns the driver that engine control system has a malfunction and MI circuit is open by means of operating fail-safe function. The fail-safe function also operate when above diagnoses except MI circuit are detected and demands the driver to repair the malfunction. Engine operating condition in fail-safe mode Engine speed will not rise more than 2,500 rpm due to the fuel cut EC-498 TROUBLE DIAGNOSIS [CR (WITHOUT EURO-OBD)] Symptom Matrix Chart BBS0035F A SYSTEM — BASIC ENGINE CONTROL SYSTEM 1 1 2 3 2 Fuel pressure regulator system 3 3 4 4 4 Fuel injector circuit 1 1 2 3 2 Evaporative emission system 3 3 4 4 4 Air Positive crankcase ventilation system 3 3 4 4 4 Incorrect idle speed adjustment 3 3 Electric throttle control actuator 1 1 2 3 3 Incorrect ignition timing adjustment 3 3 1 1 Ignition circuit 1 1 2 Main power supply and ground circuit 2 2 Manifold absolute pressure sensor circuit 1 Engine coolant temperature sensor circuit 1 Ignition Throttle position sensor circuit AF AG AH AJ AK AL AM HA 2 2 4 4 2 2 4 4 4 4 4 1 1 4 3 4 2 C Reference page F EC-750 4 EC-488 2 EC-744 4 4 EC-469 4 4 4 1 1 1 EC-483 2 EC-635, EC-637 , EC-643 , EC-649 1 1 1 EC-483 2 2 2 2 2 EC-784 3 3 3 3 3 3 EC-543 1 2 2 2 2 2 2 EC-559 1 2 2 2 2 2 2 EC-565 2 EC-570, EC-598 , EC-676 , EC-678 , EC-718 Accelerator pedal position sensor circuit 1 Knock sensor circuit 2 3 2 1 2 3 2 2 2 2 2 2 2 2 3 1 2 2 2 EC-680, EC-699 , EC-708 , EC-725 2 2 2 EC-577, EC-584 , EC-756 3 EC-605 Crankshaft position sensor (POS) circuit 2 2 EC-609 Camshaft position sensor (PHASE) circuit 2 2 EC-616 Vehicle speed signal circuit ECM 2 2 3 2 3 3 3 3 EC-499 3 3 3 3 3 G H EC-474 1 3 2 1 D E 2 2 2 EC 2 1 Heated oxygen sensor 1 circuit BATTERY DEAD (UNDER CHARGE) Fuel pump circuit EXCESSIVE OIL CONSUMPTION Fuel EXCESSIVE FUEL CONSUMPTION AE OVERHEATS/WATER TEMPERATURE HIGH LACK OF POWER/POOR ACCELERATION AD SLOW/NO RETURN TO IDLE SPARK KNOCK/DETONATION AC IDLING VIBRATION HESITATION/SURGING/FLAT SPOT AB ROUGH IDLE/HUNTING ENGINE STALL AA Warranty symptom code HIGH IDLE/LOW IDLE HARD/NO START/RESTART (EXCP. HA) SYMPTOM 3 EC-799 3 EC-623, EC-626 I J K L M TROUBLE DIAGNOSIS [CR (WITHOUT EURO-OBD)] LACK OF POWER/POOR ACCELERATION HIGH IDLE/LOW IDLE ROUGH IDLE/HUNTING IDLING VIBRATION SLOW/NO RETURN TO IDLE OVERHEATS/WATER TEMPERATURE HIGH EXCESSIVE FUEL CONSUMPTION EXCESSIVE OIL CONSUMPTION BATTERY DEAD (UNDER CHARGE) AF AG AH AJ AK AL AM HA 2 1 3 2 2 3 3 EC-554 3 3 3 3 3 3 3 EC-688 3 3 3 3 4 EC-794 3 3 3 3 3 3 3 3 HESITATION/SURGING/FLAT SPOT AE ENGINE STALL AD HARD/NO START/RESTART (EXCP. HA) Warranty symptom code SPARK KNOCK/DETONATION SYMPTOM AA AB AC 3 3 Intake valve timing control solenoid valve circuit PNP switch circuit Refrigerant pressure sensor circuit 2 Electrical load signal circuit Air conditioner circuit 2 2 ABS actuator and electric unit (control unit) 3 3 3 Reference page EC-735 3 2 ATC-26 or MTC-23 BRC-8 or BRC-49 4 1 - 6: The numbers refer to the order of inspection. (continued on next page) SYSTEM — ENGINE MECHANICAL & OTHER Fuel ENGINE STALL HESITATION/SURGING/FLAT SPOT SPARK KNOCK/DETONATION LACK OF POWER/POOR ACCELERATION HIGH IDLE/LOW IDLE ROUGH IDLE/HUNTING IDLING VIBRATION SLOW/NO RETURN TO IDLE OVERHEATS/WATER TEMPERATURE HIGH EXCESSIVE FUEL CONSUMPTION EXCESSIVE OIL CONSUMPTION BATTERY DEAD (UNDER CHARGE) Warranty symptom code HARD/NO START/RESTART (EXCP. HA) SYMPTOM AA AB AC AD AE AF AG AH AJ AK AL AM HA Fuel tank FL-8 5 Fuel piping 5 Vapor lock 5 5 5 5 5 FL-3, EM32 — 5 Valve deposit Poor fuel (Heavy weight gasoline, Low octane) Reference page — 5 5 5 5 EC-500 5 5 5 — TROUBLE DIAGNOSIS [CR (WITHOUT EURO-OBD)] SYMPTOM Air HARD/NO START/RESTART (EXCP. HA) ENGINE STALL HESITATION/SURGING/FLAT SPOT SPARK KNOCK/DETONATION LACK OF POWER/POOR ACCELERATION HIGH IDLE/LOW IDLE ROUGH IDLE/HUNTING IDLING VIBRATION SLOW/NO RETURN TO IDLE OVERHEATS/WATER TEMPERATURE HIGH EXCESSIVE FUEL CONSUMPTION EXCESSIVE OIL CONSUMPTION BATTERY DEAD (UNDER CHARGE) Warranty symptom code A AA AB AC AD AE AF AG AH AJ AK AL AM HA EC Reference page C D E F Air duct Air cleaner Air leakage from air duct (Manifold absolute pressure sensor —electric throttle control actuator) EM-18 5 5 5 5 5 5 5 5 5 5 H Electric throttle control actuator Air leakage from intake manifold/ Collector/Gasket Cranking Engine EM-22 Battery Alternator circuit SC-5 1 1 1 1 1 1 1 1 3 SC-45 Signal plate/Flywheel/Drive plate 6 EM-74 PNP switch 4 AT-293, MT-16 5 5 5 5 5 5 5 Cylinder head gasket 5 4 EM-60 4 6 6 6 6 6 6 6 6 EM-74 Connecting rod Bearing Crankshaft Timing chain EM-50 Camshaft EM-38 Intake valve timing control 5 5 5 5 5 5 5 EM-50 5 Intake valve 3 EM-60 Exhaust valve Exhaust Exhaust manifold/Tube/Muffler/ Gasket K L Piston Valve mechanism J 3 Cylinder block Piston ring I SC-15 Starter circuit Cylinder head G 5 5 5 5 5 Three way catalyst EC-501 5 5 5 EM-24, EX3 M TROUBLE DIAGNOSIS [CR (WITHOUT EURO-OBD)] Lubrication ENGINE STALL HESITATION/SURGING/FLAT SPOT SPARK KNOCK/DETONATION LACK OF POWER/POOR ACCELERATION HIGH IDLE/LOW IDLE ROUGH IDLE/HUNTING IDLING VIBRATION SLOW/NO RETURN TO IDLE OVERHEATS/WATER TEMPERATURE HIGH EXCESSIVE FUEL CONSUMPTION EXCESSIVE OIL CONSUMPTION BATTERY DEAD (UNDER CHARGE) Warranty symptom code HARD/NO START/RESTART (EXCP. HA) SYMPTOM AA AB AC AD AE AF AG AH AJ AK AL AM HA Oil pan/Oil strainer/Oil pump/Oil filter/Oil gallery 5 5 5 5 5 5 5 5 Oil level (Low)/Filthy oil Cooling CO-12 Thermostat 5 CO-19 Water pump CO-17 5 5 5 5 5 Cooling fan 5 5 2 5 Coolant level (low)/Contaminated coolant NATS (Nissan Anti-theft System) EM-26, LU9 , LU-10 , LU-5 LU-6 Radiator/Hose/Radiator filler cap Water gallery 2 Reference page 5 CO-7 CO-12 CO-8 1 EC-473 or BL-215 1 1 - 6: The numbers refer to the order of inspection. EC-502 TROUBLE DIAGNOSIS [CR (WITHOUT EURO-OBD)] Engine Control Component Parts Location BBS0035G A EC C D E F G H I J K L M MBIB1491E 1. Intake valve timing control solenoid valve 2. Fuel injector 3. Refrigerant pressure sensor 4. Ignition coil (with power transistor) and spark plug 5. Heated oxygen sensor 1 6. Crankshaft position sensor (POS) 7. Cooling fan motor 8. IPDM E/R 9. ECM 10. Camshaft position sensor (PHASE) 11. EVAP canister purge volume control solenoid valve 12. Engine coolant temperature sensor 13. Manifold absolute pressure sensor (with intake air temperature sensor) 14. Knock sensor 15. Electric throttle control actuator EC-503 TROUBLE DIAGNOSIS [CR (WITHOUT EURO-OBD)] MBIB1498E : Vehicle front 1. Manifold absolute pressure sensor (with intake air temperature sensor) 2. Crankshaft position sensor (POS) 3. Engine coolant temperature sensor 6. IPDM E/R 4. Camshaft position sensor (PHASE) 5. Battery 7. Fuel injector 8. Ignition coil (with power transistor) EC-504 TROUBLE DIAGNOSIS [CR (WITHOUT EURO-OBD)] A EC C D E F G H I J K L M MBIB1499E 1. Condenser 2. Oil filter 3. Refrigerant pressure sensor 4. Intake manifold 5. Knock sensor 6. Electric throttle control actuator 7. ECM 8. Battery 9. Data link connector EC-505 TROUBLE DIAGNOSIS [CR (WITHOUT EURO-OBD)] MBIB0320E MBIB1460E : Vehicle front 1. Exhaust manifold cover 2. Heated oxygen sensor 1 3. Heated oxygen sensor 1 harness connector 4. Heated oxygen sensor 2 harness connector 5. Heated oxygen sensor 2 6. Oil pan EC-506 TROUBLE DIAGNOSIS [CR (WITHOUT EURO-OBD)] A EC C D E F G H I J K L M MBIB1500E : Vehicle front 1. Park/neutral position switch 2. Cooling fan motor 3. IPDM E/R 4. Fuel pump fuse (15A) 5. Fuel level sensor unit and fuel pump harness connector 6. Fuel level sensor unit 7. Fuel pump and fuel filter 8. Fuel pressure regulator 9. Intake valve timing control solenoid valve 10. EVAP canister purge volume control solenoid valve EC-507 TROUBLE DIAGNOSIS [CR (WITHOUT EURO-OBD)] MBIB1501E 1. Accelerator pedal position sensor 4. Brake pedal 2. Accelerator pedal EC-508 3. Stop lamp switch TROUBLE DIAGNOSIS [CR (WITHOUT EURO-OBD)] Vacuum Hose Drawing BBS0034U A EC C D E F G H I J K L M MBIB1440E : Vehicle front 1. EVAP canister purge volume control solenoid valve 2. Intake manifold NOTE: Do not use soapy water or any type of solvent while installing vacuum hose or purge hoses. Refer to EC-462, "System Diagram" for Vacuum Control System. EC-509 TROUBLE DIAGNOSIS [CR (WITHOUT EURO-OBD)] Circuit Diagram BBS0035H MBWA1500E EC-510 TROUBLE DIAGNOSIS [CR (WITHOUT EURO-OBD)] A EC C D E F G H I J K L M MBWA1501E EC-511 TROUBLE DIAGNOSIS [CR (WITHOUT EURO-OBD)] ECM Harness Connector Terminal Layout BBS0035I MBIB0045E ECM Terminals and Reference Value BBS0035J PREPARATION 1. 2. ECM is located left hand side of the engine room. Remove ECM harness protector. MBIB0274E 3. 4. When disconnecting ECM harness connector, loosen it with levers as far as they will go as shown in the figure. Connect a break-out box (SST) and Y-cable adapter (SST) between the ECM and ECM harness connector. ● Use extreme care not to touch 2 pins at one time. ● Data is for comparison and may not be exact. PBIB1512E ECM INSPECTION TABLE Specification data are reference values and are measured between each terminal and ground. Pulse signal is measured by CONSULT-II. CAUTION: Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM's transistor. Use a ground other than ECM terminals, such as the ground. TERMINAL NO. 1 WIRE COLOR B ITEM ECM ground CONDITION [Engine is running] ● Idle speed EC-512 DATA (DC Voltage) Body ground TROUBLE DIAGNOSIS [CR (WITHOUT EURO-OBD)] TERMINAL NO. WIRE COLOR ITEM CONDITION DATA (DC Voltage) A [Engine is running] 2 GR ● Engine speed: Below 3,800 rpm after the following conditions are met. – Engine: After warming up – Keeping the engine speed between 3,500 and 4,000 rpm for 1 minute and at idle for 1 minute under no load. Heated oxygen sensor 2 heater EC 0 - 1.0V C [Ignition switch: ON] ● Engine stopped [Engine is running] ● 3 LG Throttle control motor relay power supply D BATTERY VOLTAGE (11 - 14V) E Engine speed: Above 3,800 rpm [Ignition switch: ON] BATTERY VOLTAGE (11 - 14V) F 0 - 14V [Ignition switch: ON] 4 L Throttle control motor (Close) ● Engine stopped ● Shift lever position: 1st ● Accelerator pedal: Fully released G PBIB0534E H 0 - 14V I [Ignition switch: ON] 5 P Throttle control motor (Open) ● Engine stopped ● Shift lever position: 1st ● Accelerator pedal: Fully depressed J PBIB0533E [Engine is running] ● Warm-up condition ● Idle speed K Approximately 3.0V L NOTE: The pulse cycle changes depending on rpm at idle. 13 Y PBIB0527E Crankshaft position sensor (POS) Approximately 3.0V [Engine is running] ● Engine speed: 2,000 rpm PBIB0528E EC-513 M TROUBLE DIAGNOSIS [CR (WITHOUT EURO-OBD)] TERMINAL NO. WIRE COLOR ITEM CONDITION [Engine is running] ● Warm-up condition ● Idle speed DATA (DC Voltage) 1.0 - 4.0V NOTE: The pulse cycle changes depending on rpm at idle. 14 R PBIB0525E Camshaft position sensor (PHASE) 1.0 - 4.0V [Engine is running] ● Engine speed: 2,000 rpm PBIB0526E 15 W Knock sensor [Engine is running] ● Idle speed Approximately 2.5V [Engine is running] 16 LG Heated oxygen sensor 2 ● Revving engine from idle to 3,000rpm quickly after the following conditions are met. – Engine: After warming up – Keeping the engine speed between 3,500 and 4,000 rpm for 1 minute and at idle for 1 minute under no load. 0 - Approximately 1.0V BATTERY VOLTAGE (11 - 14V) [Engine is running] ● 19 LG Idle speed EVAP canister purge volume control solenoid valve PBIB0050E Approximately 10V [Engine is running] ● Engine speed: About 2,000 rpm (More than 100 seconds after starting engine) PBIB0520E EC-514 TROUBLE DIAGNOSIS [CR (WITHOUT EURO-OBD)] TERMINAL NO. WIRE COLOR ITEM CONDITION DATA (DC Voltage) A BATTERY VOLTAGE [Engine is running] 22 23 41 42 O L R GR ● Warm-up condition ● Idle speed EC (11 - 14V) C NOTE: The pulse cycle changes depending on rpm at idle. Fuel injector No. 3 Fuel injector No. 1 Fuel injector No. 4 Fuel injector No. 2 PBIB0529E D BATTERY VOLTAGE (11 - 14V) E [Engine is running] ● Warm-up condition ● Engine speed: 2,000 rpm F PBIB0530E G Approximately 7.0V [Engine is running] 24 Y Heated oxygen sensor 1 heater ● Warm-up condition ● Engine speed: Below 3,600 rpm H I PBIB0519E [Engine is running] ● 29 30 34 B L O Engine speed: Above 3,600 rpm BATTERY VOLTAGE (11 - 14V) Sensor ground (Camshaft position sensor) ● Warm-up condition ● Idle speed Sensor ground (Crankshaft position sensor) ● Warm-up condition ● Idle speed Intake air temperature sensor [Engine is running] Approximately 0V K [Engine is running] Approximately 0V L Approximately 0 - 4.8V Output voltage varies with intake air temperature. [Engine is running] 35 45 BR Heated oxygen sensor 1 J [Engine is running] ● Warm-up condition ● Engine speed: 2,000 rpm 0 - Approximately 1.0V (Periodically change) L Sensor power supply [Ignition switch: ON] Approximately 5V 46 W Sensor power supply (Refrigerant pressure sensor) [Ignition switch: ON] Approximately 5V 47 L Sensor power supply (Throttle position sensor) [Ignition switch: ON] Approximately 5V EC-515 M TROUBLE DIAGNOSIS [CR (WITHOUT EURO-OBD)] TERMINAL NO. WIRE COLOR ITEM CONDITION DATA (DC Voltage) [Ignition switch: ON] 49 Y Throttle position sensor 1 ● Engine stopped ● Shift lever position: 1st ● Accelerator pedal: Fully released More than 0.36V [Ignition switch: ON] ● Engine stopped ● Shift lever position: 1st ● Accelerator pedal: Fully depressed Less than 4.75V [Engine is running] 51 W Manifold absolute pressure sensor ● Warm-up condition ● Idle speed Approximately 1.5V [Engine is running] ● Warm-up condition ● Engine speed: 2,000 rpm Approximately 1.2V [Engine is running] 54 56 57 — B Y Sensor ground (Knock sensor) ● Warm-up condition ● Idle speed Sensor ground (Manifold absolute pressure sensor) [Engine is running] Sensor ground (Refrigerant pressure sensor) [Engine is running] ● Warm-up condition ● Idle speed ● Warm-up condition ● Idle speed [Engine is running] 60 61 79 80 Y V G BR ● Warm-up condition ● Idle speed Approximately 0V Approximately 0V Approximately 0V 0 - 0.1V NOTE: The pulse cycle changes depending on rpm at idle. Ignition signal No. 3 Ignition signal No. 1 Ignition signal No. 4 Ignition signal No. 2 PBIB0521E 0 - 0.2V [Engine is running] ● Warm-up condition ● Engine speed: 2,000 rpm PBIB0522E EC-516 TROUBLE DIAGNOSIS [CR (WITHOUT EURO-OBD)] TERMINAL NO. WIRE COLOR ITEM CONDITION DATA (DC Voltage) A [Engine is running] ● Warm-up condition ● Idle speed BATTERY VOLTAGE (11 - 14V) EC Approximately 4V - BATTERY 62 LG Intake valve timing control solenoid valve C VOLTAGE (11 - 14V) [Engine is running] ● Warm-up condition ● Engine speed: 2,000 rpm D PBIB1790E 66 B Sensor ground (Throttle position sensor) E [Engine is running] ● Warm-up condition ● Idle speed Approximately 0V F [Ignition switch: ON] 68 R Throttle position sensor 2 ● Engine stopped ● Shift lever position: 1st ● Accelerator pedal: Fully released Less than 4.75V H [Ignition switch: ON] ● Engine stopped ● Shift lever position: 1st ● Accelerator pedal: Fully depressed G More than 0.36V I [Engine is running] 69 BR Refrigerant pressure sensor ● Warm-up condition ● Both A/C switch and blower fan switch: ON 1.0 - 4.0V J (Compressor operates.) 72 P Engine coolant temperature sensor 73 B Sensor ground (Engine coolant temperature sensor) [Engine is running] Approximately 0 - 4.8V Output voltage varies with engine coolant temperature. [Engine is running] ● Warm-up condition ● Idle speed Approximately 0V [Engine is running] 74 B Sensor ground (Heated oxygen sensor) ● Warm-up condition ● Idle speed 82 B ● Warm-up condition ● Idle speed Approximately 0V [Engine is running] 83 85 B LG Sensor ground (APP sensor 2) DATA link connector ● Warm-up condition ● Idle speed [Ignition switch: ON] ● CONSULT-II: Disconnected Approximately 0V BATTERY VOLTAGE (11 - 14V) 86 Y CAN communication line [Ignition switch: ON] 1.0 - 2.5V 90 O Sensor power supply (APP sensor 1) [Ignition switch: ON] Approximately 5V 91 BR Sensor power supply (APP sensor 2) [Ignition switch: ON] Approximately 5V EC-517 L M Approximately 0V [Engine is running] Sensor ground (APP sensor 1) K TROUBLE DIAGNOSIS [CR (WITHOUT EURO-OBD)] TERMINAL NO. 94 WIRE COLOR L ITEM CAN communication line CONDITION [Ignition switch: ON] DATA (DC Voltage) 2.5 - 4.0V [Ignition switch: ON] 98 G Accelerator pedal position sensor 2 ● Engine stopped ● Accelerator pedal: Fully released [Ignition switch: ON] ● Engine stopped ● Accelerator pedal: Fully depressed [Ignition switch: OFF] ● 101 R Stop lamp switch Brake pedal: Fully released [Ignition switch: OFF] ● Brake pedal: Slightly depressed [Ignition switch: ON] ● 102 GR PNP switch G Throttle control motor relay Gear position: Neutral [Ignition switch: ON] ● 104 0.3 - 0.6V Except the above gear position 1.95 - 2.4V Approximately 0V BATTERY VOLTAGE (11 - 14V) Approximately 0V BATTERY VOLTAGE (11 - 14V) [Ignition switch: OFF] BATTERY VOLTAGE (11 - 14V) [Ignition switch: ON] 0 - 1.0V [Ignition switch: ON] 106 109 W O Accelerator pedal position sensor 1 Ignition switch ● Engine stopped ● Accelerator pedal: Fully released [Ignition switch: ON] ● Engine stopped ● Accelerator pedal: Fully depressed 0V [Ignition switch: ON] BATTERY VOLTAGE (11 - 14V) ● P ECM relay (Self shut-off) 3.9 - 4.7V [Ignition switch: OFF] [Engine is running] [Ignition switch: OFF] 111 0.6 - 0.9V For a few seconds after turning ignition switch OFF [Ignition switch: OFF] ● More than a few seconds passed after turning ignition switch OFF 0 - 1.0V BATTERY VOLTAGE (11 - 14V) [Ignition switch: ON] ● 113 R Fuel pump relay For 1 second after turning ignition switch ON 0 - 1.0V [Engine is running] [Ignition switch: ON] ● More than 1 second after turning ignition switch ON [Engine is running] BATTERY VOLTAGE (11 - 14V) 115 116 B B ECM ground 119 120 G G Power supply for ECM [Ignition switch: ON] BATTERY VOLTAGE (11 - 14V) 121 BR Power supply for ECM (Back-up) [Ignition switch: OFF] BATTERY VOLTAGE (11 - 14V) ● Idle speed : Average voltage for pulse signal (Actual pulse signal can be confirmed by oscilloscope.) EC-518 Body ground TROUBLE DIAGNOSIS [CR (WITHOUT EURO-OBD)] CONSULT-II Function (ENGINE) BBS0035K A FUNCTION Diagnostic test mode Function Work support This mode enables a technician to adjust some devices faster and more accurately by following the indications on the CONSULT-II unit. Self-diagnostic results Self-diagnostic results such as 1st trip DTC, DTCs and 1st trip freeze frame data or freeze frame data can be read and erased quickly.* Data monitor Input/Output data in the ECM can be read. Data monitor (SPEC) Input/Output of the specification for Basic fuel schedule, A/F feedback control value and the other data monitor items can be read. CAN diagnostic support monitor The results of transmit/receive diagnosis of CAN communication can be read. Active test Diagnostic Test Mode in which CONSULT-II drives some actuators apart from the ECMs and also shifts some parameters in a specified range. Function test This mode is used to inform customers when their vehicle condition requires periodic maintenance. ECM part number ECM part number can be read. EC C D E F *: The following emission-related diagnostic information is cleared when the ECM memory is erased. ● Diagnostic trouble codes ● 1st trip diagnostic trouble codes ● Freeze frame data ● 1st trip freeze frame data G H ENGINE CONTROL COMPONENT PARTS/CONTROL SYSTEMS APPLICATION DIAGNOSTIC TEST MODE WORK SUPPORT I DATA MONITOR DATA MONITOR (SPEC) DTC*1 FREEZE FRAME DATA*2 Crankshaft position sensor (POS) × × × × Camshaft position sensor (PHASE) × × × Manifold absolute pressure sensor × × × Engine coolant temperature sensor × × × Heated oxygen sensor 1 × × × Heated oxygen sensor 2 × × × × × × × Wheel sensor INPUT ENGINE CONTROL COMPONENT PARTS Item SELF-DIAGNOSTIC RESULTS Accelerator pedal position sensor × × × Throttle position sensor × × × × × Refrigerant pressure sensor × × Closed throttle position switch (accelerator pedal position sensor signal) × × Air conditioner switch × × × Intake air temperature sensor Knock sensor × Park/neutral position (PNP) switch × × × Stop lamp switch × × × EPS control unit × × Battery voltage × × Electrical load signal × × EC-519 ACTIVE TEST J K × L M TROUBLE DIAGNOSIS [CR (WITHOUT EURO-OBD)] DIAGNOSTIC TEST MODE SELF-DIAGNOSTIC RESULTS DATA MONITOR DATA MONITOR (SPEC) ACTIVE TEST Fuel injector × × × Power transistor (Ignition timing) × × × × × EVAP canister purge volume control solenoid valve × × Air conditioner relay × × × × × × Item WORK SUPPORT OUTPUT ENGINE CONTROL COMPONENT PARTS DTC*1 Throttle control motor relay × Throttle control motor × Fuel pump relay × × × Heated oxygen sensor 1 heater × × Heated oxygen sensor 2 heater × × × × Cooling fan relay Intake valve timing control solenoid valve × FREEZE FRAME DATA*2 × × × X: Applicable *1: This item includes 1st trip DTCs. *2: This mode includes 1st trip freeze frame data or freeze frame data. The items appear on CONSULT-II screen in freeze frame data mode only if a 1st trip DTC or DTC is detected. For details, refer to EC-478 . EC-520 TROUBLE DIAGNOSIS [CR (WITHOUT EURO-OBD)] INSPECTION PROCEDURE A Refer to GI-38, "CONSULT-II Data Link Connector (DLC) Circuit" . WORK SUPPORT MODE Work Item EC WORK ITEM CONDITION FUEL PRESSURE RELEASE IDLE AIR VOL LEARN ● ● SELF-LEARNING CONT ● USAGE FUEL PUMP WILL STOP BY TOUCHING START DURING IDLING. CRANK A FEW TIMES AFTER ENGINE STALLS. When releasing fuel pressure from fuel line THE IDLE AIR VOLUME THAT KEEPS THE ENGINE WITHIN THE SPECIFIED RANGE IS MEMORIZED IN ECM. When learning the idle air volume THE COEFFICIENT OF SELF-LEARNING CONTROL MIXTURE RATIO RETURNS TO THE ORIGINAL COEFFICIENT. When clearing the coefficient of self-learning control value C D TARGET IGN TIM ADJ* ● IDLE CONDITION When adjusting target ignition timing TARGET IDLE RPM ADJ* ● IDLE CONDITION When setting target idle speed E F *: This function is not necessary in the usual service procedure. G SELF-DIAG RESULTS MODE Self Diagnostic Item Regarding items of DTC and 1st trip DTC, refer to EC-476, "EMISSION-RELATED DIAGNOSTIC INFORMATION ITEMS" . H Freeze Frame Data and 1st Trip Freeze Frame Data Freeze frame data item* DIAG TROUBLE CODE [PXXXX] Description ● The engine control component part/control system has a trouble code, it is displayed as PXXXX. (Refer to EC-451, "INDEX FOR DTC" .) ● Fuel injection system status at the moment a malfunction is detected is displayed. ● One mode in the following is displayed. Mode2: Open loop due to detected system malfunction Mode3: Open loop due to driving conditions (power enrichment, deceleration enleanment) Mode4: Closed loop - using oxygen sensor(s) as feedback for fuel control Mode5: Open loop - has not yet satisfied condition to go to closed loop FUEL SYS-B1 CAL/LD VALUE [%] ● The calculated load value at the moment a malfunction is detected is displayed. COOLANT TEMP [°C] or [°F] ● The engine coolant temperature at the moment a malfunction is detected is displayed. ● “Long-term fuel trim” at the moment a malfunction is detected is displayed. ● The long-term fuel trim indicates much more gradual feedback compensation to the base fuel schedule than short-term fuel trim. L-FUEL TRM-B1 [%] ● “Short-term fuel trim” at the moment a malfunction is detected is displayed. S-FUEL TRM-B1 [%] ● The short-term fuel trim indicates dynamic or instantaneous feedback compensation to the base fuel schedule. ENGINE SPEED [rpm] ● The engine speed at the moment a malfunction is detected is displayed. VEHICL SPEED [km/h] or [mph] ● The vehicle speed at the moment a malfunction is detected is displayed. B/FUEL SCHDL [msec] ● The base fuel schedule at the moment a malfunction is detected is displayed. INT/A TEMP SE [°C] or [°F] ● The intake air temperature at the moment a malfunction is detected is displayed. *: The items are the same as those of 1st trip freeze frame data. EC-521 I J K L M TROUBLE DIAGNOSIS [CR (WITHOUT EURO-OBD)] DATA MONITOR MODE Monitored Item Monitored item [Unit] ECM INPUT SIGNALS ×: Applicable MAIN SIGNALS Description ● ENG SPEED [rpm] × × COOLAN TEMP/S [°C] or [°F] × × HO2S1 (B1) [V] × × HO2S2 (B1) [V] × HO2S1 MNTR (B1) [RICH/LEAN] × ● The engine coolant temperature (determined by the signal voltage of the engine coolant temperature sensor) is displayed. ● The signal voltage of the heated oxygen sensor 1 is displayed. ● The signal voltage of the heated oxygen sensor 2 is displayed. ● Display of heated oxygen sensor 1 signal during air-fuel ratio feedback control: RICH: means the mixture became “rich”, and control is being affected toward a leaner mixture. LEAN: means the mixture became “lean”, and control is being affected toward a rich mixture. × ● HO2S2 MNTR (B1) [RICH/LEAN] × A/F ALPHA-B1 [%] Indicates the engine speed computed from the signals of the crankshaft position sensor (POS) and camshaft position sensor (PHASE). × ● Display of heated oxygen sensor 2 signal: RICH: means the amount of oxygen after three way catalyst is relatively small. LEAN: means the amount of oxygen after three way catalyst is relatively large. The mean value of the air-fuel ratio feedback correction factor per cycle is indicated. VHCL SPEED SE [km/h] or [mph] × × ● The vehicle speed computed from the vehicle speed signal is displayed. BATTERY VOLT [V] × × ● The power supply voltage of ECM is displayed. ● “Base fuel schedule” indicates the fuel injection pulse width programmed into ECM, prior to any learned on board correction. ● The accelerator pedal position sensor signal voltage is displayed. ● The throttle position sensor signal voltage is displayed. ● The intake air temperature (determined by the signal voltage of the intake air temperature sensor) is indicated. ● The signal voltage of the manifold absolute pressure sensor is displayed. B/FUEL SCHDL [msec] × ACCEL SEN 1 [V] × ACCEL SEN 2 [V] × THRTL SEN 1 [V] × THRTL SEN 2 [V] × INT/A TEMP SE [°C] or [°F] × TURBO BST SEN [V] × × × × EC-522 Remarks ● Accuracy becomes poor if engine speed drops below the idle rpm. ● If the signal is interrupted while the engine is running, an abnormal value may be indicated. ● When the engine coolant temperature sensor is open or short-circuited, ECM enters fail-safe mode. The engine coolant temperature determined by the ECM is displayed. ● After turning ON the ignition switch, “RICH” is displayed until air-fuel mixture ratio feedback control begins. ● When the air-fuel ratio feedback is clamped, the value just before the clamping is displayed continuously. ● When the engine is stopped, a certain value is indicated. ● When the engine is stopped, a certain value is indicated. ● This data also includes the data for the air-fuel ratio learning control. ● ACCEL SEN 2 signal is converted by ECM internally. Thus, it differs from ECM terminal voltage signal. ● THRTL SEN 2 signal is converted by ECM internally. Thus, it differs from ECM terminal voltage signal. TROUBLE DIAGNOSIS [CR (WITHOUT EURO-OBD)] ECM INPUT SIGNALS MAIN SIGNALS START SIGNAL [ON/OFF] × × CLSD THL POS [ON/OFF] × × AIR COND SIG [ON/ OFF] × × P/N POSI SW [ON/OFF] × × PW/ST SIGNAL [ON/OFF] × × Monitored item [Unit] Description Indicates start signal status [ON/OFF] computed by the ECM according to the signals of engine speed and battery voltage. ● Indicates idle position [ON/OFF] computed by the ECM according to the accelerator pedal position sensor signal. ● Indicates [ON/OFF] condition of the air conditioner switch as determined by the air conditioner signal. ● Indicates [ON/OFF] condition from the park/ neutral position (PNP) switch signal. E ● [ON/OFF] condition of the power steering system (determined by the signal sent from EPS control unit) is indicated. F ● Indicates [ON/OFF] condition from the electrical load signal. ON: Rear window defogger switch is ON and/or lighting switch is in 2nd position. OFF: Both rear window defogger switch and lighting switch are OFF. × IGNITION SW [ON/OFF] × ● Indicates [ON/OFF] condition from ignition switch. HEATER FAN SW [ON/OFF] × ● Indicates [ON/OFF] condition from the heater fan switch signal. BRAKE SW [ON/OFF] × ● Indicates [ON/OFF] condition from the stop lamp switch signal. ● Indicates the actual fuel injection pulse width compensated by ECM according to the input signals. ● Indicates the ignition timing computed by ECM according to the input signals. ● Indicates the EVAP canister purge volume control solenoid valve control value computed by the ECM according to the input signals. × × IGN TIMING [BTDC] × PURG VOL C/V [%] INT/V TIM (B1) [°CA] ● The opening becomes larger as the value increases. ● Indicates [°CA] of intake camshaft advanced angle. ● The control value of the intake valve timing control solenoid valve (determined by ECM according to the input signals) is indicated. ● The advance angle becomes larger as the value increases. ● The air conditioner relay control condition (determined by ECM according to the input signals) is indicated. ● Indicates the fuel pump relay control condition determined by ECM according to the input signals. INT/V SOL (B1) [%] AIR COND RLY [ON/ OFF] × FUEL PUMP RLY [ON/OFF] × EC-523 ● After starting the engine, [OFF] is displayed regardless of the starter signal. A ● LOAD SIGNAL [ON/ OFF] INJ PULSE-B1 [msec] Remarks EC C D G H I J ● When the engine is stopped, a certain computed value is indicated. ● When the engine is stopped, a certain value is indicated. K L M TROUBLE DIAGNOSIS [CR (WITHOUT EURO-OBD)] Monitored item [Unit] ECM INPUT SIGNALS THRTL RELAY [ON/ OFF] MAIN SIGNALS Description ● Indicates the throttle control motor relay control condition determined by the ECM according to the input signals. ● Indicates the condition of the cooling fan (determined by ECM according to the input signals). HI: High speed operation LOW: Low speed operation OFF: Stop ● Indicates [ON/OFF] condition of heated oxygen sensor 1 heater determined by ECM according to the input signals. ● Indicates [ON/OFF] condition of heated oxygen sensor 2 heater determined by ECM according to the input signals. ● Display the condition of idle air volume learning YET: Idle air volume learning has not been performed yet. CMPLT: Idle air volume learning has already been performed successfully. ● Distance traveled while MI is activated. ● Indicates the heated oxygen sensor 1 heater control valve computed by the ECM according to the input signals. ● The signal voltage from the refrigerant pressure sensor is displayed. × COOLING FAN [HI/LOW/OFF] × HO2S1 HTR (B1) [ON/OFF] HO2S2 HTR (B1) [ON/OFF] IDL A/V LEARN [YET/CMPLT] TRVL AFTER MIL [km] or [mile] O2 SEN HTR DTY [%] AC PRESS SEN [V] × Remarks Voltage [V] Frequency [msec], [Hz] or [%] DUTY-HI DUTY-LOW ● Voltage, frequency, duty cycle or pulse width measured by the probe. PLS WIDTH-HI ● Only “#” is displayed if item is unable to be measured. ● Figures with “#”s are temporary ones. They are the same figures as an actual piece of data which was just previously measured. PLS WIDTH-LOW NOTE: ● Any monitored item that does not match the vehicle being diagnosed is deleted from the display automatically. EC-524 TROUBLE DIAGNOSIS [CR (WITHOUT EURO-OBD)] DATA MONITOR (SPEC) MODE Monitored Item Monitored item [Unit] ECM INPUT SIGNALS A MAIN SIGNALS Description ● × ENG SPEED [rpm] ● B/FUEL SCHDL [msec] ● × A/F ALPHA-B1 [%] Remarks Indicates the engine speed computed from the signal of the crankshaft position sensor (POS) and camshaft position sensor (PHASE). “Base fuel schedule” indicates the fuel injection pulse width programmed into ECM, prior to any learned on board correction. The mean value of the air-fuel ratio feedback correction factor per cycle is indicated. EC C ● When engine is running specification range is indicated. ● When engine is running specification range is indicated. ● This data also includes the data for the air-fuel ratio learning control. D E F NOTE: ● Any monitored item that does not match the vehicle being diagnosed is deleted from the display automatically. G ACTIVE TEST MODE Test Item TEST ITEM CONDITION ● FUEL INJECTION IGNITION TIMING ● COOLING FAN* ENG COOLANT TEMP FUEL PUMP RELAY Change the amount of fuel injection using CONSULT-II. ● Engine: Return to the original trouble condition ● Timing light: Set ● Retard the ignition timing using CONSULT-II. ● POWER BALANCE Engine: Return to the original trouble condition JUDGEMENT If trouble symptom disappears, see CHECK ITEM. If trouble symptom disappears, see CHECK ITEM. CHECK ITEM (REMEDY) ● Harness and connectors ● Fuel injector ● Heated oxygen sensor 1 ● Perform Idle Air Volume Learning. ● Harness and connectors ● Compression ● Fuel injector ● Power transistor J ● A/C switch: OFF ● Shift lever: Neutral ● Cut off each fuel injector signal one at a time using CONSULT-II. ● Spark plug ● Ignition coil ● Ignition switch: ON ● Harness and connectors ● Turn the cooling fan “HI”, “LOW” and “OFF” with CONSULT-II. ● Cooling fan relay ● Cooling fan motor ● Harness and connectors ● Engine coolant temperature sensor ● Fuel injector ● Harness and connectors ● Fuel pump relay Engine: Return to the original trouble condition ● Change the engine coolant temperature using CONSULT-II. ● Ignition switch: ON (Engine stopped) ● Turn the fuel pump relay ON and OFF using CONSULT-II and listen to operating sound. I K Engine: After warming up, idle the engine. ● H Engine runs rough or dies. Cooling fan moves and stops. If trouble symptom disappears, see CHECK ITEM. Fuel pump relay makes the operating sound. EC-525 L M TROUBLE DIAGNOSIS [CR (WITHOUT EURO-OBD)] TEST ITEM PURG VOL CONT/V CONDITION ● Engine: After warming up, run engine at 1,500 rpm. ● Change the EVAP canister purge volume control solenoid valve opening percent using CONSULT-II. ● V/T ASSIGN ANGLE ● Engine: Return to the original trouble condition Change intake valve timing using CONSULT-II. JUDGEMENT Engine speed changes according to the opening percent. If trouble symptom disappears, see CHECK ITEM. CHECK ITEM (REMEDY) ● Harness and connectors ● Solenoid valve ● Harness and connectors ● Intake valve timing control solenoid valve *: Leaving cooling fan OFF with CONSULT-II while engine is running may cause the engine to overheat. REAL TIME DIAGNOSIS IN DATA MONITOR MODE (RECORDING VEHICLE DATA) Description CONSULT-II has two kinds of triggers and they can be selected by touching “SETTING” in “DATA MONITOR” mode. 1. “AUTO TRIG” (Automatic trigger): ● The malfunction will be identified on the CONSULT-II screen in real time. In other words, DTC/1st trip DTC and malfunction item will be displayed if the malfunction is detected by ECM. At the moment a malfunction is detected by ECM, “MONITOR” in “DATA MONITOR” screen is changed to “Recording Data ... xx%” as shown in the figure, and the data after the malfunction detection is recorded. Then when the percentage reached 100%, “REAL-TIME DIAG” screen is displayed. If “STOP” is touched on the screen during “Recording Data ... xx%”, “REAL-TIME DIAG” screen is also displayed. MBIB0295E The recording time after the malfunction detection and the recording speed can be changed by “TRIGGER POINT” and “Recording Speed”. Refer to CONSULT-II OPERATION MANUAL. 2. “MANU TRIG” (Manual trigger): ● DTC/1st trip DTC and malfunction item will not be displayed automatically on CONSULT-II screen even though a malfunction is detected by ECM. DATA MONITOR can be performed continuously even though a malfunction is detected. SEF707X Operation 1. 2. “AUTO TRIG” ● While trying to detect the DTC/1st trip DTC by performing the DTC Confirmation Procedure, be sure to select to “DATA MONITOR (AUTO TRIG)” mode. You can confirm the malfunction at the moment it is detected. ● While narrowing down the possible causes, CONSULT-II should be set in “DATA MONITOR (AUTO TRIG)” mode, especially in case the incident is intermittent. When you are inspecting the circuit by gently shaking (or twisting) the suspicious connectors, components and harness in the DTC Confirmation Procedure, the moment a malfunction is found the DTC/1st trip DTC will be displayed. (Refer to Incident Simulation Tests in GI-25, "How to Perform Efficient Diagnosis for an Electrical Incident" .) “MANU TRIG” ● If the malfunction is displayed as soon as “DATA MONITOR” is selected, reset CONSULT-II to “MANU TRIG”. By selecting “MANU TRIG” you can monitor and store the data. The data can be utilized for further diagnosis, such as a comparison with the value for the normal operating condition. EC-526 TROUBLE DIAGNOSIS [CR (WITHOUT EURO-OBD)] A EC C D E F G H PBIB0197E I CONSULT-II Reference Value in Data Monitor Mode BBS0035L Remarks: ● Specification data are reference values. ● Specification data are output/input values which are detected or supplied by the ECM at the connector. * Specification data may not be directly related to their components signals/values/operations. MONITOR ITEM CONDITION ENG SPEED ● Run engine and compare CONSULT-II value with the tachometer indication. B/FUEL SCHDL See EC-EC-532, "TROUBLE DIAGNOSIS - SPECIFICATION VALUE" . A/F ALPHA-B1 See EC-EC-532, "TROUBLE DIAGNOSIS - SPECIFICATION VALUE" . COOLAN TEMP/S ● Engine: After warming up HO2S1 (B1) ● Engine: After warming up ● Revving engine from idle to 3,000 rpm quickly after the following conditions are met. – Engine: After warning up – Keeping the engine speed between 3,500 and 4,000 rpm for 1 minute and at idle for 1 minute under no load. ● Engine: After warming up ● Revving engine from idle to 3,000 rpm quickly after the following conditions are met. – Engine: After warning up – Keeping the engine speed between 3,500 and 4,000 rpm for 1 minute and at idle for 1 minute under no load. ● Turn drive wheels and compare CONSULT-II value with the speedometer indication. HO2S2 (B1) HO2S1 MNTR (B1) HO2S2 MNTR (B1) VHCL SPEED SE J SPECIFICATION Almost the same speed as the tachometer indication. K L More than 70°C (158°F) Maintaining engine speed at 2,000 rpm 0 - 0.3V ←→ Approx. 0.6 - 1.0V 0 - 0.3V ←→ Approx. 0.6 - 1.0V Maintaining engine speed at 2,000 rpm LEAN ←→ RICH Changes more than 5 times during 10 seconds. LEAN ←→ RICH EC-527 Almost the same speed as the speedometer indication. M TROUBLE DIAGNOSIS [CR (WITHOUT EURO-OBD)] MONITOR ITEM BATTERY VOLT ACCEL SEN 1 ACCEL SEN 2*1 CONDITION ● Ignition switch: ON (Engine stopped) ● Ignition switch: ON (Engine stopped) Accelerator pedal: Fully released 0.6 - 0.9V Accelerator pedal: Fully depressed 4.0 - 4.8V Ignition switch: ON (Engine stopped) Accelerator pedal: Fully released 0.6 - 0.9V Accelerator pedal: Fully depressed 3.9 - 4.8V ● Ignition switch: ON (Engine stopped) Accelerator pedal: Fully released More than 0.36V ● Shift lever: 1st Accelerator pedal: Fully depressed Less than 4.75V ● Engine: After warming up Idle Approximately 1.5V ● Air conditioner switch: OFF ● Shift lever: Neutral 2,500 rpm Approximately 1.2V ● No load ● Ignition switch: ON → START → ON THRTL SEN 2*1 TURBO BST SEN CLSD THL POS AIR COND SIG P/N POSI SW PW/ST SIGNAL LOAD SIGNAL IGNITION SW HEATER FAN SW BRAKE SW 11 - 14V ● THRTL SEN 1 START SIGNAL SPECIFICATION ● ● ● ● ● ● ● ● Ignition switch: ON (Engine stopped) Engine: After warming up, idle the engine Ignition switch: ON Engine: After warming up, idle the engine Ignition switch: ON Ignition switch: ON ● Engine: After warming up ● Air conditioner switch: OFF ● Shift lever: Neutral ● No load ● Engine: After warming up ● Air conditioner switch: OFF ● Shift lever: Neutral ● No load ● Engine: After warming up ● Shift lever: Neutral ● Air conditioner switch: OFF ● No load ● Engine: After warming up ● Air conditioner switch: OFF ● Shift lever: Neutral ● No load INJ PULSE-B1 IGN TIMING PURG VOL C/V INT/V TIM (B1) Accelerator pedal: Fully released ON Accelerator pedal: Slightly depressed OFF Air conditioner switch: OFF OFF Air conditioner switch: ON (Compressor operates.) ON Shift lever: Neutral ON Shift lever: Except above OFF Steering wheel: Not being turned. OFF Steering wheel: Being turned. ON Rear window defogger switch is ON and/or lighting switch is in 2nd. ON Rear window defogger switch is OFF and lighting switch is OFF. OFF Ignition switch: ON → OFF → ON Engine: After warming up, idle the engine OFF → ON → OFF ON → OFF → ON Heater fan: Operating. ON Heater fan: Not operating OFF Brake pedal: Fully released OFF Brake pedal: Slightly depressed ON Idle 2.0 - 3.0 msec 2,000 rpm 1.9 - 2.9 msec Idle 0° - 10° BTDC 2,000 rpm 25° - 45° BTDC Idle 0% 2,000 rpm 20 - 30% Idle −5° - 5°CA 2,000 rpm Approx. 0° - 20°CA EC-528 TROUBLE DIAGNOSIS [CR (WITHOUT EURO-OBD)] MONITOR ITEM CONDITION ● Engine: After warming up ● Air conditioner switch: OFF ● Shift lever: Neutral ● No load ● Engine: After warming up, idle the engine INT/V SOL (B1) AIR COND RLY FUEL PUMP RLY THRTL RELAY Approx. 0% - 50% Air conditioner switch: OFF OFF Air conditioner switch: ON (Compressor operates) ON Engine running or cranking ● Except above conditions OFF ● Ignition switch: ON ON ● Engine: After warming up, idle the engine Air conditioner switch: OFF A EC C D E OFF Engine coolant temperature: Between 95°C (203°F) and 104°C (210°F) LOW*2 Engine coolant temperature: 105°C (212°F) or more HIGH*2 F G Engine: After warming up ON Engine speed: Below 3,600 rpm ● Engine speed: Above 3,600 rpm ● Engine speed: Below 3,800 rpm after the following conditions are met. – Engine: After warming up – Keeping the engine speed at between 3,500 to 4,000 rpm for 1 minute and at idle for 1 minute under no load ● Engine speed: Above 3,800 rpm ● Ignition switch: ON ● Engine coolant temperature when engine started: More than 80°C (176°F) ● Engine speed: Below 3,600 rpm ● Ignition switch: ON (Engine stopped) ● Engine: Idle ● ON Engine coolant temperature: 94°C (201°F) or less ● O2SEN HTR DTY AC PRESS SEN 2,000 rpm For 1 second after turning ignition switch ON ● TRVL AFTER MIL 0% - 2% ● ● HO2S2 HTR (B1) Idle ● COOLING FAN HO2S1 HTR (B1) SPECIFICATION OFF H ON I OFF Vehicle has traveled after MI has turned ON. 0 - 65,535 km (0 - 40,723 mile) J Approx. 50% K Approx. 0V L Both A/C switch and blower fan switch: ON (Compressor operates) 1.0 - 4.0V *1: Accelerator pedal position sensor 2 signal and throttle position sensor 2 signal are converted by ECM internally. Thus, they differ from ECM terminals voltage signal. *2: Models without air conditioner, cooling fan operates only ON and OFF operation, but CONSULT-II display will change OFF, LOW and HI depends on engine coolant temperature. EC-529 M TROUBLE DIAGNOSIS [CR (WITHOUT EURO-OBD)] Major Sensor Reference Graph in Data Monitor Mode BBS0035M The following are the major sensor reference graphs in “DATA MONITOR” mode. CLSD THL POS, ACCEL SEN 1, THRTL SEN 1 Below is the data for “CLSD THL POS”, “ACCEL SEN 1” and “THRTL SEN 1” when depressing the accelerator pedal with the ignition switch ON and with shift lever in 1st position. The signal of “ACCEL SEN 1” and “THRTL SEN 1” should rise gradually without any intermittent drop or rise after “CLSD THL POS” is changed from “ON” to “OFF”. PBIB0198E ENG SPEED, THRTL SEN 1, HO2S2 (B1), HO2S1 (B1), INJ PULSE-B1 Below is the data for “ENG SPEED”, “THRTL SEN 1”, “HO2S2 (B1)”, “HO2S1 (B1)” and “INJ PULSE-B1” when revving engine quickly up to 4,800 rpm under no load after warming up engine sufficiently. Each value is for reference, the exact value may vary. MBIB0545E EC-530 TROUBLE DIAGNOSIS [CR (WITHOUT EURO-OBD)] A EC C D E F G H I J K L M PBIB0668E EC-531 TROUBLE DIAGNOSIS - SPECIFICATION VALUE [CR (WITHOUT EURO-OBD)] TROUBLE DIAGNOSIS - SPECIFICATION VALUE Description PFP:00031 BBS0035N The specification (SP) value indicates the tolerance of the value that is displayed in “DATA MONITOR (SPEC)” mode of CONSULT-II during normal operation of the Engine Control System. When the value in “DATA MONITOR (SPEC)” mode is within the SP value, the Engine Control System is confirmed OK. When the value in “DATA MONITOR (SPEC)” mode is NOT within the SP value, the Engine Control System may have one or more malfunctions. The SP value is used to detect malfunctions that may affect the Engine Control System, but will not light the MI. The SP value will be displayed for the following three items: ● B/FUEL SCHDL (The fuel injection pulse width programmed into ECM prior to any learned on board correction) ● A/F ALPHA-B1 (The mean value of air-fuel ratio feedback correction factor per cycle) Testing Condition ● ● ● ● ● ● – ● – BBS0035O Vehicle driven distance: More than 5,000 km (3,107 miles) Barometric pressure: 98.3 - 104.3 kPa (0.983 - 1.043 bar, 1.003 - 1.064 kg/cm2 , 14.25 - 15.12 psi) Atmospheric temperature: 20 - 30°C (68 - 86°F) Engine coolant temperature: 75 - 95°C (167 - 203°F) Engine speed: Idle Transmission: Warmed-up After the engine is warmed up to normal operating temperature, drive vehicle for 5 minutes. Electrical load: Not applied Rear window defogger switch, air conditioner switch, lighting switch are OFF. Steering wheel is straight ahead. Inspection Procedure BBS0035P NOTE: Perform “DATA MONITOR (SPEC)” mode in maximum scale display. 1. Perform EC-483, "Basic Inspection" . 2. Confirm that the testing conditions indicated above are met. 3. Select “B/FUEL SCHDL” and “A/F ALPHA-B1” in “DATA MONITOR (SPEC)” mode with CONSULT-II. 4. Make sure that monitor items are within the SP value. 5. If NG, go to EC-533, "Diagnostic Procedure" . SEF601Z EC-532 TROUBLE DIAGNOSIS - SPECIFICATION VALUE [CR (WITHOUT EURO-OBD)] Diagnostic Procedure BBS0035Q A OVERALL SEQUENCE EC C D E F G H I J K L M PBIB2384E EC-533 TROUBLE DIAGNOSIS - SPECIFICATION VALUE [CR (WITHOUT EURO-OBD)] MBIB1447E EC-534 TROUBLE DIAGNOSIS - SPECIFICATION VALUE [CR (WITHOUT EURO-OBD)] DETAILED PROCEDURE A 1. CHECK “A/F ALPHA-B1” 1. 2. 3. Start engine. Confirm that the testing conditions are met. Refer to EC-532, "Testing Condition" . Select “A/F ALPHA-B1” in “DATA MONITOR (SPEC)” mode, and make sure that the indication is within the SP value. NOTE: Check “A/F ALPHA-B1” for approximately 1 minute because they may fluctuate. It is NG if the indication is out of the SP value even a little. OK or NG OK >> GO TO 17. NG (Less than the SP value)>>GO TO 2. NG (More than the SP value)>>GO TO 3. EC C D E PBIB2369E 2. CHECK “B/FUEL SCHDL” F Select “B/FUEL SCHDL” in “DATA MONITOR (SPEC)” mode, and make sure that the indication is within the SP value. OK or NG OK >> GO TO 4. NG (More than the SP value)>>GO TO 19. G H I PBIB2332E J 3. CHECK “B/FUEL SCHDL” Select “B/FUEL SCHDL” in “DATA MONITOR (SPEC)” mode, and make sure that the indication is within the SP value. OK or NG OK >> GO TO 6. NG (More than the SP value)>>GO TO 6. NG (Less than the SP value)>>GO TO 25. K L M PBIB2332E 4. CHECK “A/F ALPHA-B1” 1. 2. 3. 4. Stop the engine. Disconnect PCV hose, and then plug it. Start engine. Select “A/F ALPHA-B1” in “DATA MONITOR (SPEC)” mode, and make sure that the indication is within the SP value. OK or NG OK >> GO TO 5. NG >> GO TO 6. EC-535 TROUBLE DIAGNOSIS - SPECIFICATION VALUE [CR (WITHOUT EURO-OBD)] 5. CHANGE ENGINE OIL 1. 2. Stop the engine. Change engine oil. NOTE: This symptom may occur when a large amount of gasoline is mixed with engine oil because of driving conditions (such as when engine oil temperature does not rise enough since a journey distance is too short during winter). The symptom will not be detected after changing engine oil or changing driving condition. >> INSPECTION END 6. CHECK FUEL PRESSURE Check fuel pressure. (Refer to EC-488, "Fuel Pressure Check" .) OK or NG OK >> GO TO 9. NG (Fuel pressure is too high)>>Replace fuel pressure regulator, refer to EC-488, "Fuel Pressure Check" . GO TO 8. NG (Fuel pressure is too low)>>GO TO 7. 7. DETECT MALFUNCTIONING PART 1. – – – 2. Check the following. Clogged and bent fuel hose and fuel tube Clogged fuel filter Fuel pump and its circuit (Refer to EC-750, "FUEL PUMP" .) If NG, repair or replace the malfunctioning part. (Refer to EC-488, "Fuel Pressure Check" .) If OK, replace fuel pressure regulator. >> GO TO 8. 8. CHECK “A/F ALPHA-B1” 1. 2. Start engine. Select “A/F ALPHA-B1” in “DATA MONITOR (SPEC)” mode, and make sure that the indication is within the SP value. OK or NG OK >> INSPECTION END NG >> GO TO 9. 9. PERFORM POWER BALANCE TEST 1. 2. Perform “POWER BALANCE” in “ACTIVE TEST” mode. Make sure that the each cylinder produces a momentary engine speed drop. OK or NG OK >> GO TO 12. NG >> GO TO 10. PBIB0133E EC-536 TROUBLE DIAGNOSIS - SPECIFICATION VALUE [CR (WITHOUT EURO-OBD)] 10. DETECT MALFUNCTIONING PART 1. – – – – 2. A Check the following. Ignition coil and its circuit (Refer to EC-784, "IGNITION SIGNAL" .) Fuel injector and its circuit (Refer to EC-744, "FUEL INJECTOR" .) Intake air leakage Low compression pressure (Refer to EM-60, "COMPRESSION PRESSURE INSPECTION" .) If NG, repair or replace the malfunctioning part. If OK, replace fuel injector. (It may be caused by leakage from fuel injector or clogging.) EC C D >> GO TO 11. 11. CHECK “A/F ALPHA-B1” E 1. 2. Start engine. Select “A/F ALPHA-B1” in “DATA MONITOR (SPEC)” mode, and make sure that the indication is within the SP value. OK or NG OK >> INSPECTION END NG >> GO TO 12. F G 12. CHECK HEATED OXYGEN SENSOR 1 FUNCTION 1. 2. 3. H Run engine at about 2,000 rpm for about 2 minutes under no load. Select “HO2S1 MNTR (B1)”, in “DATA MONITOR” mode. Running engine at 2,000 rpm under no load (The engine is warmed up to normal operating temperature.), check that the monitor fluctuates between LEAN and RICH more than 5 times during 10 seconds. 1 time 2 times I J : RICH → LEAN → RICH : RICH → LEAN → RICH → LEAN → RICH K OK or NG OK >> GO TO 15. NG >> GO TO 13. SEF820Y L 13. CHECK HEATED OXYGEN SENSOR 1 CIRCUIT Check heated oxygen sensor 1 and its circuit. Refer to EC-577, "DTC P0132 HO2S1" . >> GO TO 14. 14. CHECK “A/F ALPHA-B1” 1. 2. Start engine. Select “A/F ALPHA-B1” in “DATA MONITOR (SPEC)” mode, and make sure that the indication is within the SP value. OK or NG OK >> INSPECTION END NG >> GO TO 15. EC-537 M TROUBLE DIAGNOSIS - SPECIFICATION VALUE [CR (WITHOUT EURO-OBD)] 15. DISCONNECT AND RECONNECT ECM HARNESS CONNECTOR 1. 2. Stop the engine. Disconnect ECM harness connector. Check pin terminal and connector for damage, and then reconnect it. >> GO TO 16. 16. CHECK “A/F ALPHA-B1” 1. 2. Start engine. Select “A/F ALPHA-B1” in “DATA MONITOR (SPEC)” mode, and make sure that the indication is within the SP value. OK or NG OK >> INSPECTION END NG >> Detect malfunctioning part according to EC-499, "Symptom Matrix Chart" . 17. CHECK “B/FUEL SCHDL” Select “B/FUEL SCHDL” in “DATA MONITOR (SPEC)” mode, and make sure that the indication is within the SP value. OK or NG OK >> INSPECTION END NG (More than the SP value)>>GO TO 18. NG (Less than the SP value)>>GO TO 27. PBIB2332E 18. DETECT MALFUNCTIONING PART 1. – – – – – 2. – – – Check for the cause of large engine friction. Refer to the following. Engine oil level too high Engine oil viscosity Belt tension of power steering, alternator, A/C compressor, etc. is excessive Noise from engine Noise from transmission, etc. Check for the cause of insufficient combustion. Refer to the following. Valve clearance malfunction Intake valve timing control function malfunction Camshaft sprocket installation malfunction, etc. >> Repair or replace malfunctioning part, and then GO TO 32. 19. CHECK INTAKE SYSTEM Check for the cause of unsteady air flow passing through throttle body. Refer to the following. ● Crushed air ducts ● Malfunctioning seal of air cleaner element ● Uneven dirt of air cleaner element ● Improper specification of intake air system part OK or NG OK >> GO TO 21. NG >> Repair or replace malfunctioning part, and then GO TO 20. EC-538 TROUBLE DIAGNOSIS - SPECIFICATION VALUE [CR (WITHOUT EURO-OBD)] 20. CHECK “A/F ALPHA-B1”, AND “B/FUEL SCHDL” A Select “A/F ALPHA-B1” and “B/FUEL SCHDL” in “DATA MONITOR (SPEC)” mode, and make sure that the indication is within the SP value. EC OK or NG OK >> INSPECTION END NG (“B/FUEL SCHDL” is more, “A/F ALPHA-B1” is less than the SP value)>>GO TO 21. C DISCONNECT AND RECONNECT MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR HARNESS CONNECTOR 21. 1. 2. Stop the engine. Disconnect manifold absolute pressure (MAP) sensor harness connector. Check pin terminal and connector for damage and then reconnect it again. D E >> GO TO 22. 22. CHECK “A/F ALPHA-B1” F 1. 2. G Start engine. Select “A/F ALPHA-B1” in “DATA MONITOR (SPEC)” mode, and make sure that the indication is within the SP value. OK or NG OK >> 1. Detect malfunctioning part of manifold absolute pressure (MAP) sensor circuit and repair it. Refer to EC-559, "DTC P0107, P0108 MANIFOLD ABSOLUTE PRESSURE SENSOR" . 2. GO TO 26. NG >> GO TO 23. H I 23. CHECK “TURBO BST SEN” J Select “TURBO BST SEN” in “DATA MONITOR” mode, and make sure that the indication is within the specified value as described below. Idle: 2,500 rpm: K Approximately 1.5V Approximately 1.2V OK or NG OK >> GO TO 25. NG (More than the specified value)>>Replace manifold absolute pressure (MAP) sensor, and then GO TO 24. L M MBIB1448E EC-539 TROUBLE DIAGNOSIS - SPECIFICATION VALUE [CR (WITHOUT EURO-OBD)] 24. CHECK INTAKE SYSTEM Check for the cause of air suction at downstream of throttle body. Refer to the following. ● Disconnection looseness, or cracks of air duct ● Looseness of oil filler cap ● Disconnection of oil level gauge ● Open sticking, breakage, hose disconnection, or cracks of blow-by gas control valve ● Disconnection or cracks of EVAP canister purge hose, open sticking of EVAP canister purge volume control valve ● Malfunctioning sealing of rocker cover gasket ● Disconnection, looseness, or cracks of hoses, such as vacuum hose, connecting to intake air system parts. ● Malfunctioning sealing of intake air system, etc. >> GO TO 31. 25. REPLACE ECM 1. 2. 3. 4. 5. Replace ECM. Perform initialization of NATS system and registration of all NATS ignition key IDs. Refer to BL-218, "ECM Re-communicating Function" . Perform EC-486, "Accelerator Pedal Released Position Learning" . Perform EC-486, "Throttle Valve Closed Position Learning" . Perform EC-486, "Idle Air Volume Learning" . >> GO TO 31. 26. CHECK “TURBO BST SEN” Select “TURBO BST SEN” in “DATA MONITOR” mode, and make sure that the indication is within the specified value as described below. Idle: 2,500 rpm: Approximately 1.5V Approximately 1.2V OK or NG OK >> GO TO 31. NG (More than the specified value)>>Replace manifold absolute pressure (MAP) sensor, and then GO TO 32. MBIB1448E 27. CHECK INTAKE SYSTEM Check for the cause of uneven air flow passing through throttle body. Refer to the following. ● Crushed air ducts ● Malfunctioning seal of air cleaner element ● Uneven dirt of air cleaner element ● Improper specification of intake air system OK or NG OK >> GO TO 29. NG >> Repair or replace malfunctioning part, and then GO TO 28. EC-540 TROUBLE DIAGNOSIS - SPECIFICATION VALUE [CR (WITHOUT EURO-OBD)] 28. CHECK “B/FUEL SCHDL” A Select “B/FUEL SCHDL” in “DATA MONITOR (SPEC)” mode, and make sure that the indication is within the SP value. EC OK or NG OK >> INSPECTION END NG (Less than the SP value)>>GO TO 29. C CHECK “TURBO BST SEN” 29. Select “TURBO BST SEN” in “DATA MONITOR” mode, and make sure that the indication is within the specified value as described below. Idle: 2,500 rpm: D Approximately 1.5V Approximately 1.2V E OK or NG OK >> GO TO 30. NG (Less than the specified value)>>Replace manifold absolute pressure (MAP) sensor, and then GO TO 32. F MBIB1448E 30. REPLACE ECM 1. 2. 3. 4. 5. Replace ECM. Perform initialization of NATS system and registration of all NATS ignition key IDs. Refer to BL-218, "ECM Re-communicating Function" . Perform EC-486, "Accelerator Pedal Released Position Learning" . Perform EC-486, "Throttle Valve Closed Position Learning" . Perform EC-486, "Idle Air Volume Learning" . G H I J >> GO TO 32. 31. CHECK “A/F ALPHA-B1” AND “B/FUEL SCHDL” Select “A/F ALPHA-B1” and “B/FUEL SCHDL” in “DATA MONITOR (SPEC)” mode, and make sure that the indication is within the SP value. OK or NG OK >> INSPECTION END NG >> Detect malfunctioning part according to EC-499, "Symptom Matrix Chart" . 32. CHECK “B/FUEL SCHDL” Select “B/FUEL SCHDL” in “DATA MONITOR (SPEC)” mode, and then make sure that the indication is within the SP value. OK or NG OK >> INSPECTION END NG >> Detect malfunctioning part according to EC-499, "Symptom Matrix Chart" . EC-541 K L M TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT [CR (WITHOUT EURO-OBD)] TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT Description PFP:00006 BBS0035R Intermittent incidents may occur. In many cases, the malfunction resolves itself (the part or circuit function returns to normal without intervention). It is important to realize that the symptoms described in the customer's complaint often do not recur on (1st trip) DTC visits. Realize also that the most frequent cause of intermittent incident occurrences is poor electrical connections. Because of this, the conditions under which the incident occurred may not be clear. Therefore, circuit checks made as part of the standard diagnostic procedure may not indicate the specific malfunctioning area. Common Intermittent Incident Report Situations STEP in Work Flow 2 3 or 4 Situation The CONSULT-II is used. The SELF-DIAG RESULTS screen shows time data other than [0] or [1t]. The symptom described by the customer does not recur. 5 (1st trip) DTC does not appear during the DTC Confirmation Procedure. 10 The Diagnostic Procedure for PXXXX does not indicate the malfunctioning area. Diagnostic Procedure BBS0035S 1. INSPECTION START Erase (1st trip) DTCs. Refer to EC-478, "HOW TO ERASE EMISSION-RELATED DIAGNOSTIC INFORMATION" . >> GO TO 2. 2. CHECK GROUND TERMINALS Check ground terminals for corroding or loose connection. Refer to EC-EC-548, "Ground Inspection" . OK or NG OK >> GO TO 3. NG >> Repair or replace. 3. SEARCH FOR ELECTRICAL INCIDENT Perform GI-25, "How to Perform Efficient Diagnosis for an Electrical Incident" , “Incident Simulation Tests”. OK or NG OK >> INSPECTION END NG >> Repair or replace. EC-542 POWER SUPPLY AND GROUND CIRCUIT [CR (WITHOUT EURO-OBD)] POWER SUPPLY AND GROUND CIRCUIT Wiring Diagram PFP:24110 A BBS0035T EC C D E F G H I J K L M MBWA1502E EC-543 POWER SUPPLY AND GROUND CIRCUIT [CR (WITHOUT EURO-OBD)] Specification data are reference values and are measured between each terminal and ground. CAUTION: Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM's transistor. Use a ground other than ECM terminals, such as the ground. TERMINAL NO. 1 115 116 109 WIRE COLOR B B B O ITEM ECM ground CONDITION [Engine is running] ● Ignition switch Idle speed 0V [Ignition switch: ON] BATTERY VOLTAGE (11 - 14V) ● P ECM relay (Self shut-off) G G Power supply for ECM For a few seconds after turning ignition switch OFF [Ignition switch: OFF] ● 119 120 Body ground [Ignition switch: OFF] [Engine is running] [Ignition switch: OFF] 111 DATA (DC Voltage) More than a few seconds passed after turning ignition switch OFF [Ignition switch: ON] Diagnostic Procedure 0 - 1.0V BATTERY VOLTAGE (11 - 14V) BATTERY VOLTAGE (11 - 14V) BBS0035U 1. INSPECTION START Start engine. Is engine running? Yes or No Yes >> GO TO 8. No >> GO TO 2. 2. CHECK ECM POWER SUPPLY CIRCUIT-I 1. 2. Turn ignition switch OFF and then ON. Check voltage between ECM terminal 109 and ground with CONSULT-II or tester. Voltage: Battery voltage OK or NG OK >> GO TO 4. NG >> GO TO 3. MBIB0015E 3. DETECT MALFUNCTIONING PART Check the following. Harness connectors M1, E101 ● Fuse block (J/B) connector M7 ● 10A fuse ● Harness for open or short between ECM and fuse ● >> Repair harness or connectors. EC-544 POWER SUPPLY AND GROUND CIRCUIT [CR (WITHOUT EURO-OBD)] 4. CHECK GROUND CONNECTIONS-I 1. 2. A Turn ignition switch OFF. Loosen and retighten ground screws on the body. Refer to EC-548, "Ground Inspection" . EC C D MBIB1502E 1. Body ground E44 2. Body ground E45 3. E Body ground E28 OK or NG OK >> GO TO 5. NG >> Repair or replace ground connections. F 5. CHECK ECM GROUND CIRCUIT FOR OPEN AND SHORT-I G 1. 2. Disconnect ECM harness connector. Check harness continuity between ECM terminals 1, 115, 116 and ground. Refer to Wiring Diagram. H Continuity should exist. I 3. Also check harness for short to power. OK or NG OK >> GO TO 7. NG >> GO TO 6. J 6. DETECT MALFUNCTIONING PART K Check the following. ● Harness connectors F1, E48 ● Harness for open or short between ECM and ground L >> Repair open circuit or short to power in harness or connectors. M 7. CHECK ECM POWER SUPPLY CIRCUIT-II 1. 2. 3. Reconnect ECM harness connector. Turn ignition switch ON. Check voltage between IPDM E/R harness connector E7 terminal 33 and ground with CONSULT-II or tester. Voltage: Battery voltage OK or NG OK >> Go to EC-433, "IGNITION SIGNAL" . NG >> GO TO 8. MBIB1441E EC-545 POWER SUPPLY AND GROUND CIRCUIT [CR (WITHOUT EURO-OBD)] 8. CHECK ECM POWER SUPPLY CIRCUIT-III 1. 2. Turn ignition switch ON and then OFF. Check voltage between ECM terminals 119, 120 and ground with CONSULT-II or tester. Voltage: After turning ignition switch OFF, battery voltage will exist for a few seconds, then drop approximately 0V. OK or NG OK >> GO TO 13. NG (Battery voltage does not exist.)>>GO TO 9. NG (Battery voltage exists for more than a few seconds.)>>GO TO 11. PBIB1630E 9. CHECK ECM POWER SUPPLY CIRCUIT-IV 1. 2. Turn ignition switch OFF. Check voltage between ECM terminal 111 and ground with CONSULT-II or tester. Voltage: Battery voltage OK or NG OK >> GO TO 10. NG >> GO TO 11. PBIB1191E 10. CHECK ECM POWER SUPPLY CIRCUIT-VI 1. 2. 3. Disconnect ECM harness connector. Disconnect IPDM E/R harness connector. Check harness continuity between ECM terminals 119, 120 and IPDM E/R terminal 32. Refer to Wiring Diagram. Continuity should exist. 4. Also check harness for short to ground and short to power. OK or NG OK >> GO TO 13. NG >> Repair open circuit or short to ground or short to power in harness or connectors. 11. CHECK ECM POWER SUPPLY CIRCUIT-VII 1. 2. 3. Disconnect ECM harness connector. Disconnect IPDM E/R harness connector. Check harness continuity between ECM terminal 111 and IPDM E/R terminal 29. Refer to Wiring Diagram. Continuity should exist. 4. Also check harness for short to ground and short to power. OK or NG OK >> GO TO 12. NG >> Repair open circuit or short to ground or short to power in harness or connectors. EC-546 POWER SUPPLY AND GROUND CIRCUIT [CR (WITHOUT EURO-OBD)] 12. CHECK 20A FUSE A 1. Disconnect 20A fuse from IPDM E/R. 2. Check 20A fuse. OK or NG OK >> GO TO 16. NG >> Replace 20A fuse. EC C 13. CHECK GROUND CONNECTIONS-II 1. Loosen and retighten ground screws on the body. Refer to EC-548, "Ground Inspection" . D E F G MBIB1502E 1. Body ground E44 2. Body ground E45 3. Body ground E28 OK or NG OK >> GO TO 14. NG >> Repair or replace ground connections. 14. CHECK ECM GROUND CIRCUIT FOR OPEN AND SHORT-II 1. 2. Disconnect ECM harness connector. Check harness continuity between ECM terminals 1, 115, 116 and ground. Refer to Wiring Diagram. H I J K Continuity should exist. 3. Also check harness for short to power. OK or NG OK >> GO TO 16. NG >> GO TO 15. L 15. DETECT MALFUNCTIONING PART M Check the following. ● Harness connectors F1, E48 ● Harness for open or short between ECM and ground >> Repair open circuit or short to power in harness or connectors. 16. CHECK INTERMITTENT INCIDENT Refer to EC-542, "TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT" . OK or NG OK >> Replace IPDM E/R. PG-18, "IPDM E/R (INTELLIGENT POWER DISTRIBUTION MODULE ENGINE ROOM)" . NG >> Repair open circuit or short to power in harness or connectors. EC-547 POWER SUPPLY AND GROUND CIRCUIT [CR (WITHOUT EURO-OBD)] Ground Inspection BBS0035V Ground connections are very important to the proper operation of electrical and electronic circuits. Ground connections are often exposed to moisture, dirt and other corrosive elements. The corrosion (rust) can become an unwanted resistance. This unwanted resistance can change the way a circuit works. Electronically controlled circuits are very sensitive to proper grounding. A loose or corroded ground can drastically affect an electronically controlled circuit. A poor or corroded ground can easily affect the circuit. Even when the ground connection looks clean, there can be a thin film of rust on the surface. When inspecting a ground connection follow these rules: ● Remove the ground bolt or screw. ● Inspect all mating surfaces for tarnish, dirt, rust, etc. ● Clean as required to assure good contact. ● Reinstall bolt or screw securely. ● Inspect for “add-on” accessories which may be interfering with the ground circuit. ● If several wires are crimped into one ground eyelet terminal, check for proper crimps. Make sure all of the wires are clean, securely fastened and providing a good ground path. If multiple wires are cased in one eyelet make sure no ground wires have excess wire insulation. For detailed ground distribution information, refer to PG-38, "Ground Distribution" . PBIB1870E EC-548 DTC U1001 CAN COMMUNICATION LINE [CR (WITHOUT EURO-OBD)] DTC U1001 CAN COMMUNICATION LINE Description PFP:23710 A BBS0035W CAN (Controller Area Network) is a serial communication line for real time application. It is an on-vehicle multiplex communication line with high data communication speed and excellent error detection ability. Many elec- EC tronic control units are equipped onto a vehicle, and each control unit shares information and links with other control units during operation (not independent). In CAN communication, control units are connected with 2 communication lines (CAN H line, CAN L line) allowing a high rate of information transmission with less wiring. C Each control unit transmits/receives data but selectively reads required data only. On Board Diagnosis Logic BBS0035X D The MI will not light up for these self-diagnoses. DTC No. Trouble diagnosis name DTC detecting condition ● U1001 1001 CAN communication line ● ECM cannot communicate to other control units. ECM cannot communicate for more than the specified time. DTC Confirmation Procedure 1. 2. 3. Possible cause ● Harness or connectors (CAN communication line is open or shorted.) E F BBS0035Y Turn ignition switch ON and wait at least 3 seconds. Select “DATA MONITOR” mode with CONSULT-II. If 1st trip DTC is detected, go to EC-551, "Diagnostic Procedure" . G H I J K L M EC-549 DTC U1001 CAN COMMUNICATION LINE [CR (WITHOUT EURO-OBD)] Wiring Diagram BBS0035Z MBWA1503E EC-550 DTC U1001 CAN COMMUNICATION LINE [CR (WITHOUT EURO-OBD)] Diagnostic Procedure BBS00360 Go to LAN-3, "Precautions When Using CONSULT-II" . A EC C D E F G H I J K L M EC-551 DTC U1010 CAN COMMUNICATION [CR (WITHOUT EURO-OBD)] DTC U1010 CAN COMMUNICATION Description PFP:23710 BBS003ZM CAN (Controller Area Network) is a serial communication line for real time application. It is an on-vehicle multiplex communication line with high data communication speed and excellent error detection ability. Many electronic control units are equipped onto a vehicle, and each control unit shares information and links with other control units during operation (not independent). In CAN communication, control units are connected with 2 communication lines (CAN H line, CAN L line) allowing a high rate of information transmission with less wiring. Each control unit transmits/receives data but selectively reads required data only. On Board Diagnosis Logic BBS003ZN The MI will not light up for this diagnosis. DTC No. U1010 1010 Trouble diagnosis name CAN communication bus DTC detecting condition Initializing CAN communication bus is malfunctioning. DTC Confirmation Procedure Possible cause ● ECM BBS003ZO WITH CONSULT-II 1. 2. 3. Turn ignition switch ON. Select “DATA MONITOR” mode with CONSULT-II. If 1st trip DTC is detected, go to EC-553, "Diagnostic Procedure" . SEF058Y WITHOUT CONSULT-II 1. 2. 3. 4. Turn ignition switch ON. Turn ignition switch OFF, wait at least 10 seconds and then turn ON. Perform Diagnostic Test Mode II (Self-diagnostic results) with ECM. If 1st trip DTC is detected, go to EC-553, "Diagnostic Procedure" . EC-552 DTC U1010 CAN COMMUNICATION [CR (WITHOUT EURO-OBD)] Diagnostic Procedure BBS003ZP 1. INSPECTION START 1. 2. 3. 4. 5. A With CONSULT-II Turn ignition switch ON. Select “SELF-DIAG RESULTS” mode with CONSULT-II. Touch “ERASE”. Perform DTC Confirmation Procedure. See EC-552, "DTC Confirmation Procedure" . Is the DTC U1010 displayed again? Without CONSULT-II 1. Turn ignition switch ON. 2. Erase the Diagnostic Test Mode II (Self-diagnostic results) memory. Refer to EC-481, "DIAGNOSTIC TEST MODE II — SELF-DIAGNOSTIC RESULTS" . 3. Perform DTC Confirmation Procedure. See EC-552, "DTC Confirmation Procedure" . 4. Is the DTC 1010 displayed again? Yes or No Yes >> GO TO 2. No >> INSPECTION END 2. REPLACE ECM 1. 2. 3. 4. 5. EC C D E F G H Replace ECM. Perform initialization of NATS system and registration of all NATS ignition key IDs. Refer to BL-218, "ECM Re-communicating Function" . Perform EC-486, "Accelerator Pedal Released Position Learning" . Perform EC-486, "Throttle Valve Closed Position Learning" . Perform EC-486, "Idle Air Volume Learning" . >> INSPECTION END I J K L M EC-553 DTC P0011 IVT CONTROL [CR (WITHOUT EURO-OBD)] DTC P0011 IVT CONTROL Description PFP:23796 BBS00361 SYSTEM DESCRIPTION Sensor Crankshaft position sensor (POS) Input Signal to ECM ECM Function Actuator Engine speed and piston position Camshaft position sensor (PHASE) Engine coolant temperature sensor Engine coolant temperature Wheel sensor Vehicle speed* Intake valve timing control Intake valve timing control solenoid valve *: This signal is sent to the ECM through CAN communication line. PBIB0540E This mechanism hydraulically controls cam phases continuously with the fixed operating angle of the intake valve. The ECM receives signals such as crankshaft position, camshaft position, engine speed, and engine coolant temperature. Then, the ECM sends ON/OFF pulse duty signals to the intake valve timing control solenoid valve depending on driving status. This makes it possible to control the shut/open timing of the intake valve to increase engine torque in low/mid speed range and output in high-speed range. CONSULT-II Reference Value in Data Monitor Mode BBS00362 Specification data are reference values. MONITOR ITEM CONDITION ● Engine: After warming up ● Shift lever: Neutral ● Air conditioner switch: OFF ● No load ● Engine: After warming up ● Shift lever: Neutral ● Air conditioner switch: OFF ● No load INT/V TIM (B1) INT/V SOL (B1) SPECIFICATION Idle −5° - 5°CA 2,000 rpm Approx. 0° - 20°CA Idle 0% - 2% 2,000 rpm Approx. 0% - 50% EC-554 DTC P0011 IVT CONTROL [CR (WITHOUT EURO-OBD)] On Board Diagnosis Logic BBS00363 A The MI will not light up for this self-diagnosis. DTC No. P0011 0011 Trouble diagnosis name Detecting condition Intake valve timing control performance There is a gap between angle of target and phase-control angle degree. Possible cause EC ● Crankshaft position sensor (POS) ● Camshaft position sensor (PHASE) ● Intake valve control solenoid valve ● Accumulation of debris to the signal pickup portion of the camshaft ● Timing chain installation ● Foreign matter caught in the oil groove for intake valve timing control C D E FAIL-SAFE MODE When the malfunction is detected, the ECM enters fail-safe mode. Detected items Engine operating condition in fail-safe mode Intake valve timing control The signal is not energized to the solenoid valve and the valve control does not function DTC Confirmation Procedure F BBS00364 CAUTION: Always drive at a safe speed. NOTE: ● If DTC P0011 is displayed with DTC P1111, first perform trouble diagnosis for DTC P1111. See EC630 . ● If DTC Confirmation Procedure has been previously conducted, always turn ignition switch OFF and wait at least 10 seconds before conducting the next test. TESTING CONDITION: Before performing the following procedure, confirm that battery voltage is between 10V and 16V at idle. G H I J WITH CONSULT-II 1. 2. 3. Turn ignition switch ON and select “DATA MONITOR” mode with CONSULT-II. Start engine and warm it up to the normal operating temperature. Maintain the following conditions from at least 6 consecutive seconds Hold the accelerator pedal as steady as possible ENG SPEED 1,200 - 2,000 rpm (A constant rotation is maintained.) COOLAN TEMP/S 60 - 120°C (140 - 248°F) B/FUEL SCHDL More than 3 msec Shift lever Neutral position 4. 5. 6. K L M PBIB0164E Let engine idle for 10 seconds. If the 1st trip DTC is detected, go to EC-556, "Diagnostic Procedure" . If the 1st trip DTC is not detected, go to next step. Maintain the following conditions for at least 20 consecutive seconds. ENG SPEED 1,700 - 3,175 rpm (A constant rotation is maintained.) COOLAN TEMP/S 70 - 105°C (176 - 194°F) Shift lever 1st or 2nd position Driving location uphill Driving vehicle uphill (Increased engine load will help maintain the driving conditions required for this test.) EC-555 DTC P0011 IVT CONTROL [CR (WITHOUT EURO-OBD)] 7. If 1st trip DTC is detected, go to EC-556, "Diagnostic Procedure" . Overall Function Check BBS00365 Use this procedure to check the overall function of the intake valve timing control system. During this check, a 1st trip DTC might not be confirmed. WITHOUT CONSULT-II 1. 2. 3. 4. 5. 6. Start engine and warm it up to normal operating temperature. Turn ignition switch OFF and wait at least 10 seconds. Turn ignition switch ON. Set the tester probe between ECM terminal 62 (IVT control solenoid valve signal) and ground. Start engine and let it idle. Check the voltage under the following conditions. Verify that the oscilloscope screen shows the signal wave as shown below. Conditions Voltage BATTERY VOLTAGE (11 - 14V) At idle Approximately 4V - BATTERY VOLTAGE(11 - 14V) 2,000 rpm SEF955V PBIB1790E : Average voltage for pulse signal (Actual pulse signal can be confirmed by oscilloscope.) 7. If NG, go to EC-556, "Diagnostic Procedure" . Diagnostic Procedure BBS00366 1. CHECK OIL PRESSURE WARNING LAMP 1. 2. Start engine. Check oil pressure warning lamp and confirm it is not illuminated. OK or NG OK >> GO TO 2. KG >> Go to LU-6, "OIL PRESSURE CHECK" . PBIA8559J 2. CHECK INTAKE VALVE TIMING CONTROL SOLENOID VALVE Refer to EC-557, "Component Inspection" . OK or NG OK >> GO TO 3. NG >> Replace intake valve timing control solenoid valve. EC-556 DTC P0011 IVT CONTROL [CR (WITHOUT EURO-OBD)] 3. CHECK CRANKSHAFT POSITION SENSOR (POS) A Refer to EC-615, "Component Inspection" . OK or NG OK >> GO TO 4. NG >> Replace crankshaft position sensor (POS). EC 4. CHECK CAMSHAFT POSITION SENSOR (PHASE) C Refer to EC-622, "Component Inspection" . OK or NG OK >> GO TO 5. NG >> Replace camshaft position sensor (PHASE). D 5. CHECK CAMSHAFT (INTAKE) E Check the following. ● Accumulation of debris to the signal plate of camshaft rear end ● Chipping signal plate of camshaft rear end OK or NG OK >> GO TO 6. NG >> Remove debris and clean the signal plate of camshaft rear end or replace camshaft. F G H PBIB0565E I 6. CHECK TIMING CHAIN INSTALLATION J Check service records for any recent repairs that may cause timing chain misaligned. Are there any service records that may cause timing chain misaligned? Yes or No Yes >> Check timing chain installation. Refer to EM-50, "TIMING CHAIN" . No >> GO TO 7. K 7. CHECK LUBRICATION CIRCUIT L Refer to EM-47, "Inspection of Camshaft Sprocket (INT) Oil Groove" . OK or NG OK >> GO TO 8. NG >> Clean lubrication line. M 8. CHECK INTERMITTENT INCIDENT Refer to EC-542, "TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT" . For Wiring Diagram, refer to EC-611 for CKP sensor (POS), EC-618 for CMP sensor (PHASE). >> INSPECTION END Component Inspection BBS00367 INTAKE VALVE TIMING CONTROL SOLENOID VALVE 1. Disconnect intake valve timing control solenoid valve harness connector. EC-557 DTC P0011 IVT CONTROL [CR (WITHOUT EURO-OBD)] 2. 3. 4. Check resistance between intake valve timing control solenoid valve as follows. Terminal Resistance 1 and 2 6.7 - 7.7Ω at 20°C (68°F) 1 or 2 and ground ∞Ω (Continuity should not exist.) If NG, replace intake valve timing control solenoid valve. If OK, go to next step. Remove intake valve timing control solenoid valve. MBIB0027E Provide 12V DC between intake valve timing control solenoid valve terminals and then interrupt it. Make sure that the plunger moves as shown in the figure. CAUTION: Do not apply 12V DC continuously for 5 seconds or more. Doing so may result in damage to the coil in intake valve timing control solenoid valve. If NG, replace intake valve timing control solenoid valve. NOTE: Always replace O-ring when intake valve timing control solenoid valve is removed. PBIB2388E Removal and Installation BBS00368 INTAKE VALVE TIMING CONTROL SOLENOID VALVE Refer to EM-35, "ROCKER COVER" . EC-558 DTC P0107, P0108 MANIFOLD ABSOLUTE PRESSURE SENSOR [CR (WITHOUT EURO-OBD)] DTC P0107, P0108 MANIFOLD ABSOLUTE PRESSURE SENSOR Component Description PFP:22365 A BBS00369 The manifold absolute pressure (MAP) sensor is placed intake manifold corrector. It detects intake manifold pressure and sends the voltage signal to the ECM, ECM uses the signal to compute intake air volume value. The sensor uses a silicon diaphragm which is sensitive to the change in pressure. As the pressure increase, the voltage rises. EC C D MBIB0278E E On Board Diagnosis Logic BBS0036A If DTC P0107 or P0108 is displayed with DTC P1229, first perform the trouble diagnosis for DTC P1229. Refer to EC-680, "DTC P1229 SENSOR POWER SUPPLY" . DTC No. Trouble diagnosis name DTC detecting condition Manifold absolute pressure sensor circuit low input An excessively low voltage from the sensor is sent to ECM. ● P0107 0107 P0108 0108 Manifold absolute pressure sensor circuit high input An excessively high voltage from the sensor is sent to ECM. F Possible cause Harness or connectors (The sensor circuit is open or shorted.) ● Manifold absolute pressure sensor ● Harness or connectors (The sensor circuit is open or shorted) ● Manifold absolute pressure sensor ● Intake air leaks G H I FAIL-SAFE MODE When the malfunction is detected, the ECM enters fail-safe mode. Detected items Manifold absolute pressure sensor circuit J Engine operating condition in fail-safe mode Engine speed will not rise more than 2,500 rpm due to the fuel cut. DTC Confirmation Procedure BBS0036B K NOTE: If DTC Confirmation Procedure has been previously conducted, always turn ignition switch OFF and wait at least 10 seconds before conducting the next test. L WITH CONSULT-II 1. 2. 3. 4. Turn ignition switch ON. Select “DATA MONITOR” mode with CONSULT-II. Wait at least 5 seconds. If 1st trip DTC is detected, go to EC-561, "Diagnostic Procedure" . M SEF058Y WITHOUT CONSULT-II 1. 2. 3. 4. Turn ignition switch ON and wait at least 5 seconds. Turn ignition switch OFF, wait at least 10 seconds and then turn ON. Perform Diagnostic Test Mode II (Self-diagnostic results) with ECM. If 1st trip DTC is detected, go to EC-561, "Diagnostic Procedure" . EC-559 DTC P0107, P0108 MANIFOLD ABSOLUTE PRESSURE SENSOR [CR (WITHOUT EURO-OBD)] Wiring Diagram BBS0036C MBWA1506E EC-560 DTC P0107, P0108 MANIFOLD ABSOLUTE PRESSURE SENSOR [CR (WITHOUT EURO-OBD)] Specification data are reference values and are measured between each terminal and ground. CAUTION: Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM's transistor. Use a ground other than ECM terminals, such as the ground. TERMINAL NO. 45 WIRE COLOR L A EC ITEM Sensor power supply CONDITION [Ignition switch: ON] DATA (DC Voltage) Approximately 5V C [Engine is running] 51 56 W B Manifold absolute pressure sensor Sensor ground (Manifold absolute pressure sensor) ● Warm-up condition ● Idle speed Approximately 1.5V D [Engine is running] ● Warm-up condition ● Engine speed: 2,000 rpm Approximately 1.2V E [Engine is running] ● Warm-up condition ● Idle speed Diagnostic Procedure Approximately 0V F BBS0036D 1. INSPECTION START G Which malfunction (P0107 or P0108) is duplicated? P0107 or P0108 P0107 >> GO TO 3. P0108 >> GO TO 2. H I 2. CHECK INTAKE SYSTEM Check the following for connection. ● Air duct ● Vacuum hoses ● Intake air passage between air duct and intake manifold OK or NG OK >> GO TO 3. NG >> Reconnect the parts. J K L M EC-561 DTC P0107, P0108 MANIFOLD ABSOLUTE PRESSURE SENSOR [CR (WITHOUT EURO-OBD)] 3. CHECK GROUND CONNECTIONS 1. 2. Turn ignition switch OFF. Loosen and retighten ground screws on the body. Refer to EC-548, "Ground Inspection" . MBIB1502E 1. Body ground E44 2. Body ground E45 3. Body ground E28 OK or NG OK >> GO TO 4. NG >> Repair or replace ground connections. 4. CHECK MAP SENSOR POWER SUPPLY CIRCUIT 1. 2. Disconnect manifold absolute pressure (MAP) sensor harness connector. Turn ignition switch ON. MBIB0276E 3. Check voltage between MAP sensor terminal 2 and ground with CONSULT-II or tester. Voltage: Approximately 5V OK or NG OK >> GO TO 5. NG >> Repair harness or connectors. MBIB0602E EC-562 DTC P0107, P0108 MANIFOLD ABSOLUTE PRESSURE SENSOR [CR (WITHOUT EURO-OBD)] 5. CHECK MAP SENSOR GROUND CIRCUIT FOR OPEN AND SHORT 1. 2. 3. A Turn ignition switch OFF. Disconnect ECM harness connector. Check harness continuity between MAP sensor terminal 4 and ECM terminal 56 Refer to Wiring Diagram. EC Continuity should exist. C 4. Also check harness for short to ground and short to power. OK or NG OK >> GO TO 6. NG >> Repair open circuit or short to ground or short to power in harness or connectors. D 6. CHECK MAP SENSOR INPUT SIGNAL CIRCUIT FOR OPEN AND SHORT 1. E Check harness continuity between MAP sensor terminal 1 and ECM terminal 51. Refer to Wiring Diagram F Continuity should exist. 2. Also check harness for short to ground and short to power. OK or NG OK >> GO TO 7. NG >> Repair open circuit or short to ground or short to power in harness or connectors. G H 7. CHECK MAP SENSOR Refer to EC-563, "Component Inspection" . OK or NG OK >> GO TO 8. NG >> Replace manifold absolute pressure sensor. I J 8. CHECK INTERMITTENT INCIDENT Refer to EC-542, "TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT" . K >> INSPECTION END L Component Inspection BBS0036E MANIFOLD ABSOLUTE PRESSURE SENSOR 1. 2. 3. 4. 5. Reconnect all harness connectors disconnected. Start engine and warm it up to normal operating temperature. Turn ignition switch OFF, wait at least 5 seconds and then turn ON. Check voltage between ECM terminal 51 (manifold absolute pressure sensor signal) and ground. NOTE: ● To avoid the affection of intake manifold vacuum, check the voltage 1 or more minutes past after engine is stopped. ● Because the sensor is absolute pressure sensor, output value may differ depends on atmospheric pressure and altitude. Measure the atmospheric pressure. NOTE: As atmospheric pressure describe on synoptic chart is value at sea level, please compensate the actual pressure with the following chart. EC-563 M SEF006P DTC P0107, P0108 MANIFOLD ABSOLUTE PRESSURE SENSOR [CR (WITHOUT EURO-OBD)] 6. Altitude Compensated pressure 0m 0hPa 200m -24hPa 400m -47hPa 600m -70hPa 800m -92hPa 1,000m -114hPa 1,500m -168hPa 2,000m -218hPa Check the manifold absolute pressure sensor value corresponds to the atmospheric pressure. Atmospheric pressure Voltage 800hPa 3.2 - 3.6V 850hPa 3.4 - 3.8V 900hPa 3.7 - 4.1V 960hPa 3.9 - 4.3V 1,000hPa 4.1 - 4.5V 1,050hPa 4.3 - 4.7V 7. Start engine and let it idle. 8. Check the voltage between ECM terminal 51 and ground at idling and confirm the voltage difference between engine is stopped and at idling is within following chart. MBIB0655E Intake manifold vacuum Voltage difference -40kPa (-300mmHg) 1.6 - 2.0V -53.3kPa (-400mmHg) 2.2 - 2.6V -66.7kPa (-500mm) 2.8 - 3.2V -80kPa (-600mmHg) 3.4 - 3.8V SEF487R Removal and Installation BBS0036F MANIFOLD ABSOLUTE PRESSURE SENSOR Refer to EM-18, "AIR CLEANER AND AIR DUCT" . EC-564 DTC P0117, P0118 ECT SENSOR [CR (WITHOUT EURO-OBD)] DTC P0117, P0118 ECT SENSOR Component Description PFP:22630 A BBS0036G The engine coolant temperature sensor is used to detect the engine coolant temperature. The sensor modifies a voltage signal from the ECM. The modified signal returns to the ECM as the engine coolant temperature input. The sensor uses a thermistor which is sensitive to the change in temperature. The electrical resistance of the thermistor decreases as temperature increases. EC C D SEF594K E Engine coolant temperature °C (°F) Voltage* V −10 (14) 4.4 Resistance F kΩ 7.0 - 11.4 20 (68) 3.5 2.1 - 2.9 50 (122) 2.2 0.68 - 1.00 90 (194) 0.9 0.236 - 0.260 G H *: This data is reference value and is measured between ECM terminal 72 (Engine coolant temperature sensor) and ground. SEF012P CAUTION: Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM's transistor. Use a ground other than ECM terminals, such as the ground. On Board Diagnosis Logic DTC No. BBS0036H Trouble Diagnosis Name DTC Detecting Condition I J Possible Cause P0117 0117 Engine coolant temperature sensor circuit low input An excessively low voltage from the sensor is sent to ECM. ● Harness or connectors (The sensor circuit is open or shorted.) P0118 0118 Engine coolant temperature sensor circuit high input An excessively high voltage from the sensor is sent to ECM. ● Engine coolant temperature sensor K L FAIL-SAFE MODE When the malfunction is detected, the ECM enters fail-safe mode. Detected items Engine operating condition in fail-safe mode Engine coolant temperature will be determined by ECM based on the time after turning ignition switch ON or START. CONSULT-II displays the engine coolant temperature decided by ECM. Engine coolant temperature decided (CONSULT-II display) Condition Engine coolant temperature sensor circuit Just as ignition switch is turned ON or START 40°C (104°F) More than approx. 4 minutes after ignition ON or START 80°C (176°F) 40 - 80°C (104 - 176°F) (Depends on the time) Except as shown above When the fail-safe system for engine coolant temperature sensor is activated, the cooling fan operates while engine is running. EC-565 M DTC P0117, P0118 ECT SENSOR [CR (WITHOUT EURO-OBD)] DTC Confirmation Procedure BBS0036I NOTE: If DTC Confirmation Procedure has been previously conducted, always turn ignition switch OFF and wait at least 10 seconds before conducting the next test. WITH CONSULT-II 1. 2. 3. 4. Turn ignition switch ON. Select “DATA MONITOR” mode with CONSULT-II. Wait at least 5 seconds. If 1st trip DTC is detected, go to EC-568, "Diagnostic Procedure" . SEF058Y WITHOUT CONSULT-II 1. 2. 3. 4. Turn ignition switch ON and wait at least 5 seconds. Turn ignition switch OFF, wait at least 10 seconds and then turn ON. Perform Diagnostic Test Mode II (Self-diagnostic results) with ECM. If 1st trip DTC is detected, go to EC-568, "Diagnostic Procedure" . EC-566 DTC P0117, P0118 ECT SENSOR [CR (WITHOUT EURO-OBD)] Wiring Diagram BBS0036J A EC C D E F G H I J K L M MBWA1508E EC-567 DTC P0117, P0118 ECT SENSOR [CR (WITHOUT EURO-OBD)] Diagnostic Procedure BBS0036K 1. CHECK GROUND CONNECTIONS 1. 2. Turn ignition switch OFF. Loosen and retighten ground screws on the body. Refer to EC-548, "Ground Inspection" . MBIB1502E 1. Body ground E44 2. Body ground E45 3. Body ground E28 OK or NG OK >> GO TO 2. NG >> Repair or replace ground connections. 2. CHECK ECT SENSOR POWER SUPPLY CIRCUIT 1. 2. Disconnect engine coolant temperature (ECT) sensor harness connector. Turn ignition switch ON. MBIB0279E 3. Check voltage between ECT sensor terminal 1 and ground with CONSULT-II or tester. Voltage: Approximately 5V OK or NG OK >> GO TO 3. NG >> Repair open circuit or short to ground or short to power in harness or connectors. PBIB0080E EC-568 DTC P0117, P0118 ECT SENSOR [CR (WITHOUT EURO-OBD)] 3. CHECK ECT SENSOR GROUND CIRCUIT FOR OPEN AND SHORT 1. 2. 3. A Turn ignition switch OFF. Disconnect ECM harness connector. Check harness continuity between ECT sensor terminal 2 and ECM terminal 73. Refer to Wiring Diagram. EC Continuity should exist. C 4. Also check harness for short to ground and short to power. OK or NG OK >> GO TO 4. NG >> Repair open circuit or short to ground or short to power in harness or connectors. D 4. CHECK ENGINE COOLANT TEMPERATURE SENSOR E Refer to EC-569, "Component Inspection" . OK or NG OK >> GO TO 5. NG >> Replace engine coolant temperature sensor. F 5. CHECK INTERMITTENT INCIDENT G Refer to EC-542, "TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT" . H >> INSPECTION END Component Inspection BBS0036L ENGINE COOLANT TEMPERATURE SENSOR 1. I Check resistance between engine coolant temperature sensor terminals 1 and 2 as shown in the figure. J K L PBIB2005E M Engine coolant temperature 2. °C (°F) Resistance kΩ 20 (68) 2.1 - 2.9 50 (122) 0.68 - 1.00 90 (194) 0.236 - 0.260 If NG, replace engine coolant temperature sensor. SEF012P Removal and Installation BBS0036M ENGINE COOLANT TEMPERATURE SENSOR Refer to CO-19, "THERMOSTAT" . EC-569 DTC P0122, P0123 TP SENSOR [CR (WITHOUT EURO-OBD)] DTC P0122, P0123 TP SENSOR Component Description PFP:16119 BBS0036N Electric throttle control actuator consists of throttle control motor, throttle position sensor, etc. The throttle position sensor responds to the throttle valve movement. The throttle position sensor has the two sensors. These sensors are a kind of potentiometers which transform the throttle valve position into output voltage, and emit the voltage signal to the ECM. In addition, these sensors detect the opening and closing speed of the throttle valve and feed the voltage signals to the ECM. The ECM judges the current opening angle of the throttle valve from these signals and the ECM controls the throttle control motor to make the throttle valve opening angle properly in response to driving condition. PBIB0145E CONSULT-II Reference Value in Data Monitor Mode BBS0036O Specification data are reference values. MONITOR ITEM CONDITION SPECIFICATION ● Ignition switch: ON (Engine stopped) Accelerator pedal: Fully released More than 0.36V ● Shift lever: 1st Accelerator pedal: Fully depressed Less than 4.75V THRTL SEN 1 THRTL SEN 2* *: Throttle position sensor 2 signal is converted by ECM internally. Thus, it differs from ECM terminal voltage signal. On Board Diagnosis Logic BBS0036P These self-diagnoses have the one trip detection logic. DTC No. Trouble diagnosis name DTC detecting condition Possible cause P0122 0122 Throttle position sensor 2 circuit low input An excessively low voltage from the TP sensor 2 is sent to ECM. ● Harness or connectors (TP sensor 2 circuit is open or shorted.) (APP sensor 2 circuit is shorted.) P0123 0123 Throttle position sensor 2 circuit high input An excessively high voltage from the TP sensor 2 is sent to ECM. ● Electric throttle control actuator (TP sensor 2) ● Accelerator pedal position sensor (APP sensor 2) FAIL-SAFE MODE When the malfunction is detected, the ECM enters fail-safe mode and the MI lights up. Engine operation condition in fail-safe mode The ECM controls the electric throttle control actuator in regulating the throttle opening in order for the idle position to be within +10 degrees. The ECM regulates the opening speed of the throttle valve to be slower than the normal condition. So, the acceleration will be poor. EC-570 DTC P0122, P0123 TP SENSOR [CR (WITHOUT EURO-OBD)] DTC Confirmation Procedure BBS0036Q A NOTE: If DTC Confirmation Procedure has been previously conducted, always turn ignition switch OFF and wait at least 10 seconds before conducting the next test. EC TESTING CONDITION: Before performing the following procedure, confirm that battery voltage is more than 10V at idle. WITH CONSULT-II 1. 2. 3. 4. C Turn ignition switch ON. Select “DATA MONITOR” mode with CONSULT-II. Start engine and let it idle for 1 second. If DTC is detected, go to EC-573, "Diagnostic Procedure" . D E F SEF058Y WITHOUT CONSULT-II 1. 2. 3. 4. G Start engine and let it idle for 1 second. Turn ignition switch OFF, wait at least 10 seconds and then turn ON. Perform Diagnostic Test Mode II (Self-diagnostic results) with ECM. If DTC is detected, go to EC-573, "Diagnostic Procedure" . H I J K L M EC-571 DTC P0122, P0123 TP SENSOR [CR (WITHOUT EURO-OBD)] Wiring Diagram BBS0036R MBWA1509E EC-572 DTC P0122, P0123 TP SENSOR [CR (WITHOUT EURO-OBD)] Specification data are reference values and are measured between each terminal and ground. CAUTION: Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM's transistor. Use a ground other than ECM terminals, such as the ground. TERMINAL NO. 47 WIRE COLOR L ITEM CONDITION Sensor power supply (Throttle position sensor) EC DATA (DC Voltage) [Ignition switch: ON] A Approximately 5V C [Ignition switch: ON] 49 Y ● Engine stopped ● Shift lever position: 1st ● Accelerator pedal: Fully released Throttle position sensor 1 More than 0.36V D [Ignition switch: ON] ● E Engine stopped ● Shift lever position: 1st ● Accelerator pedal: Fully depressed Less than 4.75V F [Engine is running] 66 B Sensor ground (Throttle position sensor) ● Warm-up condition ● Idle speed Approximately 0V G [Ignition switch: ON] 68 R Throttle position sensor 2 ● Engine stopped ● Shift lever position: 1st ● Accelerator pedal: Fully released BR Sensor power supply (APP sensor 2) H [Ignition switch: ON] ● 91 Less than 4.75V I Engine stopped ● Shift lever position: 1st ● Accelerator pedal: Fully depressed More than 0.36V J [Ignition switch: ON] Approximately 5V Diagnostic Procedure BBS0036S 1. CHECK GROUND CONNECTIONS 1. 2. Turn ignition switch OFF. Loosen and retighten ground screws on the body. Refer to EC-548, "Ground Inspection" . K L M MBIB1502E 1. Body ground E44 2. Body ground E45 OK or NG OK >> GO TO 2. NG >> Repair or replace ground connections. EC-573 3. Body ground E28 DTC P0122, P0123 TP SENSOR [CR (WITHOUT EURO-OBD)] 2. CHECK THROTTLE POSITION SENSOR 2 POWER SUPPLY CIRCUIT-I 1. 2. Disconnect electric throttle control actuator harness connector. Turn ignition switch ON. MBIB0308E 3. Check voltage between electric throttle control actuator terminal 1 and ground with CONSULT-II or tester. Voltage: Approximately 5V OK or NG OK >> GO TO 7. NG >> GO TO 3. PBIB0082E 3. CHECK THROTTLE POSITION SENSOR 2 POWER SUPPLY CIRCUIT-II 1. 2. 3. Turn ignition switch OFF. Disconnect ECM harness connector. Check harness continuity between electric throttle control actuator terminal 1 and ECM terminal 47. Refer to Wiring Diagram. Continuity should exist. OK or NG OK >> GO TO 4. NG >> Repair open circuit. 4. CHECK THROTTLE POSITION SENSOR 2 POWER SUPPLY CIRCUIT-III Check harness for short to power and short to ground, between the following terminals. ECM terminal Sensor terminal Reference Wiring Diagram 47 Electric throttle control actuator terminal 1 EC-572 91 APP sensor terminal 5 EC-710 OK or NG OK >> GO TO 5. NG >> Repair short to ground or short to power in harness or connectors. 5. CHECK APP SENSOR Refer to EC-716, "Component Inspection" . OK or NG OK >> GO TO 11 NG >> GO TO 6. EC-574 DTC P0122, P0123 TP SENSOR [CR (WITHOUT EURO-OBD)] 6. REPLACE ACCELERATOR PEDAL ASSEMBLY 1. 2. 3. 4. Replace accelerator pedal assembly. Perform EC-486, "Accelerator Pedal Released Position Learning" . Perform EC-486, "Throttle Valve Closed Position Learning" . Perform EC-486, "Idle Air Volume Learning" . 7. CHECK THROTTLE POSITION SENSOR 2 GROUND CIRCUIT FOR OPEN AND SHORT Turn ignition switch OFF. Disconnect ECM harness connector. Check harness continuity between ECM terminal 66 and electric throttle control actuator terminal 5. Refer to Wiring Diagram. Continuity should exist. 8. CHECK THROTTLE POSITION SENSOR 2 INPUT SIGNAL CIRCUIT FOR OPEN AND SHORT E G H Check harness continuity between ECM terminal 68 and electric throttle control actuator terminal 2. Refer to Wiring Diagram. I Continuity should exist. 2. Also check harness for short to ground and short to power. OK or NG OK >> GO TO 9. NG >> Repair open circuit or short to ground or short to power in harness or connectors. J K 9. CHECK THROTTLE POSITION SENSOR Refer to EC-576, "Component Inspection" . OK or NG OK >> GO TO 11. NG >> GO TO 10. L 10. REPLACE ELECTRIC THROTTLE CONTROL ACTUATOR 1. 2. 3. D F 4. Also check harness for short to ground and short to power. OK or NG OK >> GO TO 8. NG >> Repair open circuit or short to ground or short to power in harness or connectors. 1. EC C >> INSPECTION END 1. 2. 3. A Replace the electric throttle control actuator. Perform EC-486, "Throttle Valve Closed Position Learning" . Perform EC-486, "Idle Air Volume Learning" . >> INSPECTION END 11. CHECK INTERMITTENT INCIDENT Refer to EC-542, "TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT" . >> INSPECTION END EC-575 M DTC P0122, P0123 TP SENSOR [CR (WITHOUT EURO-OBD)] Component Inspection BBS0036T THROTTLE POSITION SENSOR 1. 2. 3. 4. 5. Reconnect all harness connectors disconnected. Perform EC-486, "Throttle Valve Closed Position Learning" . Turn ignition switch ON. Set shift lever to 1st position. Check voltage between ECM terminals 49 (TP sensor 1 signal), 68 (TP sensor 2 signal) and ground under the following conditions. Terminal Accelerator pedal Voltage 49 (Throttle position sensor 1) Fully released More than 0.36V Fully depressed Less than 4.75V Fully released Less than 4.75V Fully depressed More than 0.36V 68 (Throttle position sensor 2) 6. 7. 8. If NG, replace electric throttle control actuator and go to the next step. Perform EC-486, "Throttle Valve Closed Position Learning" . Perform EC-486, "Idle Air Volume Learning" . Removal and Installation MBIB1443E BBS0036U ELECTRIC THROTTLE CONTROL ACTUATOR Refer to EM-18, "AIR CLEANER AND AIR DUCT" . EC-576 DTC P0132 HO2S1 [CR (WITHOUT EURO-OBD)] DTC P0132 HO2S1 Component Description PFP:22690 A BBS0036V The heated oxygen sensor 1 is placed into the exhaust manifold. It detects the amount of oxygen in the exhaust gas compared to the outside air. The heated oxygen sensor 1 has a closed-end tube made of ceramic zirconia. The zirconia generates voltage from approximately 1V in richer conditions to 0V in leaner conditions. The heated oxygen sensor 1 signal is sent to the ECM. The ECM adjusts the injection pulse duration to achieve the ideal air-fuel ratio. The ideal air-fuel ratio occurs near the radical change from 1V to 0V. EC C D SEF463R E F G H SEF288D CONSULT-II Reference Value in Data Monitor Mode BBS0036W I Specification data are reference values. MONITOR ITEM CONDITION SPECIFICATION J 0 - 0.3V ←→ Approx. 0.6 - 1.0V HO2S1 (B1) ● HO2S1 MNTR (B1) Engine: After warming up Maintaining engine speed at 2,000 rpm LEAN ←→ RICH Changes more than 5 times during 10 seconds. On Board Diagnosis Logic K BBS0036X L To judge the malfunction, the diagnosis checks that the heated oxygen sensor 1 output is not inordinately high. M SEF301UA DTC No. P0132 0132 Trouble diagnosis name Heated oxygen sensor 1 circuit high voltage DTC detecting condition Possible cause ● Harness or connectors (The sensor circuit is open or shorted.) ● Heated oxygen sensor 1 An excessively high voltage from the sensor is sent to ECM. EC-577 DTC P0132 HO2S1 [CR (WITHOUT EURO-OBD)] DTC Confirmation Procedure BBS0036Y NOTE: If DTC Confirmation Procedure has been previously conducted, always turn ignition switch OFF and wait at least 10 seconds before conducting the next test. WITH CONSULT-II 1. 2. 3. 4. 5. 6. Start engine and warm it up to normal operating temperature. Turn ignition switch OFF and wait at least 10 seconds. Turn ignition switch ON. Select “DATA MONITOR” mode with CONSULT-II. Restart engine and let it idle for 2 minutes. If 1st trip DTC is detected, go to EC-580, "Diagnostic Procedure" . SEF174Y WITHOUT CONSULT-II 1. 2. 3. 4. 5. 6. Start engine and warm it up to normal operating temperature. Turn ignition switch OFF and wait at least 10 seconds. Restart engine and let it idle for 2 minutes. Turn ignition switch OFF and wait at least 10 seconds. Perform Diagnostic Test Mode II (Self-diagnostic results) with ECM. If 1st trip DTC is detected, go to EC-580, "Diagnostic Procedure" . EC-578 DTC P0132 HO2S1 [CR (WITHOUT EURO-OBD)] Wiring Diagram BBS0036Z A EC C D E F G H I J K L M MBWA1510E EC-579 DTC P0132 HO2S1 [CR (WITHOUT EURO-OBD)] Specification data are reference values and are measured between each terminal and ground. Pulse signal is measured by CONSULT-II. CAUTION: Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM's transistor. Use a ground other than ECM terminals, such as the ground. TERMINAL NO. WIRE COLOR ITEM CONDITION DATA (DC Voltage) Approximately 7.0V [Engine is running] 24 Y Heated oxygen sensor 1 heater ● Warm-up condition ● Engine speed: Below 3,600 rpm PBIB0519E [Engine is running] ● BATTERY VOLTAGE (11 - 14V) Engine speed: Above 3,600 rpm [Engine is running] 35 BR Heated oxygen sensor 1 ● Warm-up condition ● Engine speed: 2,000 rpm 0 - Approximately 1.0V (Periodically change) [Engine is running] 74 B Sensor ground (Heated oxygen sensor) ● Warm-up condition ● Idle speed Approximately 0V : Average voltage for pulse signal (Actual pulse signal can be confirmed by oscilloscope.) Diagnostic Procedure BBS00370 1. CHECK GROUND CONNECTIONS 1. 2. Turn ignition switch OFF. Loosen and retighten ground screws on the body. Refer to EC-548, "Ground Inspection" . MBIB1502E 1. Body ground E44 2. Body ground E45 OK or NG OK >> GO TO 2. NG >> Repair or replace ground connections. EC-580 3. Body ground E28 DTC P0132 HO2S1 [CR (WITHOUT EURO-OBD)] 2. RETIGHTEN HEATED OXYGEN SENSOR 1 A Loosen and retighten heated oxygen sensor 1 (2). ● ● : Vehicle front Exhaust manifold cover (1) EC Tightening torque: 50 N·m (5.1 kg-m, 37 ft-lb) C >> GO TO 3. D E MBIB1493E 3. CHECK HO2S1 GROUND CIRCUIT FOR OPEN AND SHORT F 1. 2. 3. Disconnect heated oxygen sensor 1 harness connector (1). Disconnect ECM harness connector. Check harness continuity between ECM terminal 74 and HO2S1 terminal 1. Refer to Wiring Diagram. G H Continuity should exist. 4. Also check harness for short to ground and short to power. OK or NG OK >> GO TO 4. NG >> Repair open circuit or short to ground or short to power in harness or connectors. I MBIB1494E J 4. CHECK HO2S1 INPUT SIGNAL CIRCUIT FOR OPEN AND SHORT 1. Check harness continuity between ECM terminal 35 and HO2S1 terminal 4. Refer to Wiring Diagram. K Continuity should exist. 2. Check harness continuity between ECM terminal 35 or HO2S1 terminal 4 and ground. Refer to Wiring Diagram. Continuity should not exist. L M 3. Also check harness for short to power. OK or NG OK >> GO TO 5. NG >> Repair open circuit or short to ground or short to power in harness or connectors. 5. CHECK HO2S1 CONNECTOR FOR WATER Check connectors for water Water should not exist. OK or NG OK >> GO TO 6. NG >> Repair or replace harness or connectors. EC-581 DTC P0132 HO2S1 [CR (WITHOUT EURO-OBD)] 6. CHECK HEATED OXYGEN SENSOR 1 Refer to EC-582, "Component Inspection" . OK or NG OK >> GO TO 7. NG >> Replace heated oxygen sensor 1. 7. CHECK INTERMITTENT INCIDENT Refer to EC-542, "TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT" . >> INSPECTION END Component Inspection BBS00371 HEATED OXYGEN SENSOR 1 With CONSULT-II 1. 2. 3. 4. 5. Start engine and warm it up to normal operating temperature. Select “MANU TRIG” and adjust “TRIGGER POINT” to 100% in “DATA MONITOR” mode with CONSULTII. Select “HO2S1 (B1)” and “HO2S1 MNTR (B1)”. Hold engine speed at 2,000 rpm under no load during the following steps. Touch “RECORD” on CONSULT-II screen. MBIB0301E 6. Check the following. ● “HO2S1 MNTR (B1)” in “DATA MONITOR” mode changes from “RICH” to “LEAN” to “RICH” more than 5 times in 10 seconds. 5 times (cycles) are counted as shown in the figure. ● “HO2S1 (B1)” voltage goes above 0.6V at least once. ● “HO2S1 (B1)” voltage goes below 0.3V at least once. ● “HO2S1 (B1)” voltage never exceeds 1.0V. SEF217YA SEF648Y CAUTION: Discard any heated oxygen sensor which has been dropped from a height of more than 0.5 m (19.7 in) onto a hard surface such as a concrete floor; use a new one. ● EC-582 DTC P0132 HO2S1 [CR (WITHOUT EURO-OBD)] ● Before installing new oxygen sensor, clean exhaust system threads using Oxygen Sensor Thread Cleaner and approved anti-seize lubricant. A Without CONSULT-II 1. 2. 3. Start engine and warm it up to normal operating temperature. EC Set voltmeter probes between ECM terminal 35 (HO2S1 signal) and ground. Check the following with engine speed held at 2,000 rpm constant under no load. C ● The voltage fluctuates between 0 to 0.3V and 0.6 to 1.0V more than 5 times within 10 seconds. ● The maximum voltage is over 0.6V at least one time. D ● The minimum voltage is below 0.3V at least one time. ● The voltage never exceeds 1.0V. 1 time: 0 - 0.3V → 0.6 - 1.0V → 0 - 0.3V E 2 times: 0 - 0.3V → 0.6 - 1.0V → 0 - 0.3V → 0.6 - 1.0V → 0 0.3V MBIB0018E CAUTION: ● Discard any heated oxygen sensor which has been dropped from a height of more than 0.5 m (19.7 F in) onto a hard surface such as a concrete floor; use a new one. ● Before installing new oxygen sensor, clean exhaust system threads using Oxygen Sensor Thread G Cleaner and approved anti-seize lubricant. Removal and Installation BBS00372 HEATED OXYGEN SENSOR 1 H Refer to EM-24, "EXHAUST MANIFOLD AND THREE WAY CATALYST" . I J K L M EC-583 DTC P0134 HO2S1 [CR (WITHOUT EURO-OBD)] DTC P0134 HO2S1 Component Description PFP:22690 BBS00373 The heated oxygen sensor 1 is placed into the exhaust manifold. It detects the amount of oxygen in the exhaust gas compared to the outside air. The heated oxygen sensor 1 has a closed-end tube made of ceramic zirconia. The zirconia generates voltage from approximately 1V in richer conditions to 0V in leaner conditions. The heated oxygen sensor 1 signal is sent to the ECM. The ECM adjusts the injection pulse duration to achieve the ideal air-fuel ratio. The ideal air-fuel ratio occurs near the radical change from 1V to 0V. SEF463R SEF288D CONSULT-II Reference Value in Data Monitor Mode BBS00374 Specification data are reference values. MONITOR ITEM CONDITION SPECIFICATION 0 - 0.3V ←→ Approx. 0.6 - 1.0V HO2S1 (B1) ● HO2S1 MNTR (B1) Engine: After warming up Maintaining engine speed at 2,000 rpm LEAN ←→ RICH Changes more than 5 times during 10 seconds. On Board Diagnosis Logic BBS00375 Under the condition in which the heated oxygen sensor 1 signal is not input, the ECM circuits will read a continuous approximately 0.3V. Therefore, for this diagnosis, the time that output voltage is within 200 to 400 mV range is monitored, and the diagnosis checks that this time is not inordinately long. SEF237U DTC No. P0134 0134 Trouble diagnosis name Heated oxygen sensor 1 circuit no activity detected DTC detecting condition Possible cause ● Harness or connectors (The sensor circuit is open or shorted.) ● Heated oxygen sensor 1 The voltage from the sensor is constantly approx. 0.3V. EC-584 DTC P0134 HO2S1 [CR (WITHOUT EURO-OBD)] Overall Function Check BBS00376 Use this procedure to check the overall function of the heated oxygen sensor 1 circuit. During this check, a 1st trip DTC might not be confirmed. WITH CONSULT-II 1. 2. 3. 4. 5. A EC Start engine and warm it up to normal operating temperature. Select “MANU TRIG” in “DATA MONITOR” mode with CONSULT-II, and select “HO2S1 (B1)”. Hold engine speed at 2,000 rpm under no load. Make sure that the indications do not remain in the range between 0.2V to 0.4V. If NG, go to EC-587, "Diagnostic Procedure" . C D E SEF646Y F WITHOUT CONSULT-II 1. 2. 3. ● 4. Start engine and warm it up to normal operating temperature. Set voltmeter probes between ECM terminal 35 (HO2S1 signal) and ground. Check the following with engine speed held at 2,000 rpm constant under no load. The voltage does not remain in the range of 0.2 - 0.4V. If NG, go to EC-587, "Diagnostic Procedure" . G H I J MBIB0018E K L M EC-585 DTC P0134 HO2S1 [CR (WITHOUT EURO-OBD)] Wiring Diagram BBS00377 MBWA1510E EC-586 DTC P0134 HO2S1 [CR (WITHOUT EURO-OBD)] Specification data are reference values and are measured between each terminal and ground. Pulse signal is measured by CONSULT-II. A CAUTION: Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM's transistor. Use a ground other than ECM terminals, such as the ground. EC TERMINAL NO. WIRE COLOR ITEM CONDITION DATA (DC Voltage) C Approximately 7.0V [Engine is running] 24 Y Heated oxygen sensor 1 heater ● Warm-up condition ● Engine speed: Below 3,600 rpm D E PBIB0519E [Engine is running] ● BATTERY VOLTAGE (11 - 14V) Engine speed Above 3,600 rpm F [Engine is running] 35 BR Heated oxygen sensor 1 ● Warm-up condition ● Engine speed: 2,000 rpm 0 - Approximately 1.0V (Periodically change) G [Engine is running] 74 B Sensor ground (Heated oxygen sensor) ● Warm-up condition ● Idle speed Approximately 0V H : Average voltage for pulse signal (Actual pulse signal can be confirmed by oscilloscope.) I Diagnostic Procedure BBS00378 1. CHECK GROUND CONNECTIONS 1. 2. J Turn ignition switch OFF. Loosen and retighten ground screws on the body. Refer to EC-548, "Ground Inspection" . K L M MBIB1502E 1. Body ground E44 2. Body ground E45 OK or NG OK >> GO TO 2. NG >> Repair or replace ground connections. EC-587 3. Body ground E28 DTC P0134 HO2S1 [CR (WITHOUT EURO-OBD)] 2. CHECK HO2S1 GROUND CIRCUIT FOR OPEN AND SHORT 1. 2. 3. Disconnect heated oxygen sensor 1 harness connector (1). Disconnect ECM harness connector. Check harness continuity between ECM terminal 74 and HO2S1 terminal 1. Refer to Wiring Diagram. Continuity should exist. 4. Also check harness for short to ground and short to power. OK or NG OK >> GO TO 3. NG >> Repair open circuit or short to ground or short to power in harness or connectors. 3. CHECK HO2S1 INPUT SIGNAL CIRCUIT FOR OPEN AND SHORT 1. Check harness continuity between ECM terminal 35 and HO2S1 terminal 4. Refer to Wiring Diagram. Continuity should exist. 2. Check harness continuity between ECM terminal 35 or HO2S1 terminal 4 and ground. Refer to Wiring Diagram. Continuity should not exist. 3. Also check harness for short to power. OK or NG OK >> GO TO 4. NG >> Repair open circuit or short to ground or short to power in harness or connectors. 4. CHECK HEATED OXYGEN SENSOR 1 Refer to EC-589, "Component Inspection" . OK or NG OK >> GO TO 5. NG >> Replace heated oxygen sensor 1. 5. CHECK INTERMITTENT INCIDENT Refer to EC-542, "TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT" . >> INSPECTION END EC-588 MBIB1494E DTC P0134 HO2S1 [CR (WITHOUT EURO-OBD)] Component Inspection BBS00379 A HEATED OXYGEN SENSOR 1 With CONSULT-II 1. 2. 3. 4. 5. Start engine and warm it up to normal operating temperature. Select “MANU TRIG” and adjust “TRIGGER POINT” to 100% in “DATA MONITOR” mode with CONSULT- EC II. Select “HO2S1 (B1)” and “HO2S1 MNTR (B1)”. C Hold engine speed at 2,000 rpm under no load during the following steps. Touch “RECORD” on CONSULT-II screen. D E MBIB0301E F 6. Check the following. ● “HO2S1 MNTR (B1)” in “DATA MONITOR” mode changes from “RICH” to “LEAN” to “RICH” more than 5 times in 10 seconds. 5 times (cycles) are counted as shown in the figure. ● “HO2S1 (B1)” voltage goes above 0.6V at least once. ● “HO2S1 (B1)” voltage goes below 0.3V at least once. ● “HO2S1 (B1)” voltage never exceeds 1.0V. G H I SEF217YA J K L SEF648Y CAUTION: Discard any heated oxygen sensor which has been dropped from a height of more than 0.5 m (19.7 in) onto a hard surface such as a concrete floor; use a new one. ● Before installing new oxygen sensor, clean exhaust system threads using Oxygen Sensor Thread Cleaner and approved anti-seize lubricant. ● Without CONSULT-II 1. 2. Start engine and warm it up to normal operating temperature. Set voltmeter probes between ECM terminal 35 (HO2S1 signal) and ground. EC-589 M DTC P0134 HO2S1 [CR (WITHOUT EURO-OBD)] 3. Check the following with engine speed held at 2,000 rpm constant under no load. ● The voltage fluctuates between 0 to 0.3V and 0.6 to 1.0V more than 5 times within 10 seconds. ● The maximum voltage is over 0.6V at least one time. ● The minimum voltage is below 0.3V at least one time. ● The voltage never exceeds 1.0V. 1 time: 0 - 0.3V → 0.6 - 1.0V → 0 - 0.3V 2 times: 0 - 0.3V → 0.6 - 1.0V → 0 - 0.3V → 0.6 - 1.0V → 0 0.3V MBIB0018E CAUTION: ● Discard any heated oxygen sensor which has been dropped from a height of more than 0.5 m (19.7 in) onto a hard surface such as a concrete floor; use a new one. ● Before installing new oxygen sensor, clean exhaust system threads using Oxygen Sensor Thread Cleaner and approved anti-seize lubricant. Removal and Installation BBS0037A HEATED OXYGEN SENSOR 1 Refer to EM-24, "EXHAUST MANIFOLD AND THREE WAY CATALYST" . EC-590 DTC P0138 HO2S2 [CR (WITHOUT EURO-OBD)] DTC P0138 HO2S2 Component Description PFP:226A0 A BBS0037B The heated oxygen sensor 2, after three way catalyst (manifold), monitors the oxygen level in the exhaust gas. Even if switching characteristics of the heated oxygen sensor 1 are shifted, the air-fuel ratio is controlled to stoichiometric, by the signal from the heated oxygen sensor 2. This sensor is made of ceramic zirconia. The zirconia generates voltage from approximately 1V in richer conditions to 0V in leaner conditions. Under normal conditions the heated oxygen sensor 2 is not used for engine control operation. EC C D SEF327R E CONSULT-II Reference Value in Data Monitor Mode BBS0037C Specification data are reference values. MONITOR ITEM HO2S2 (B1) HO2S2 MNTR (B1) F CONDITION SPECIFICATION ● Revving engine from idle to 3,000 rpm quickly after the following conditions are met. 0 - 0.3V ←→ Approx. 0.6 - 1.0V – Engine: After warning up – Keeping the engine speed between 3,500 and 4,000 rpm for 1 minute and at idle for 1 minute under no load. G LEAN ←→ RICH H On Board Diagnosis Logic BBS0037D The heated oxygen sensor 2 has a much longer switching time between rich and lean than the heated oxygen sensor 1. The oxygen storage capacity before the three way catalyst (manifold) causes the longer switching time. To judge the malfunctions of heated oxygen sensor 2, ECM monitors whether the voltage is unusually high during the various driving condition such as fuel-cut. I J K SEF305UA L DTC No. P0138 0138 Trouble diagnosis name Heated oxygen sensor 2 circuit high voltage DTC detecting condition Possible cause ● Harness or connectors (The sensor circuit is open or shorted.) ● Heated oxygen sensor 2 An excessively high voltage from the sensor is sent to ECM. DTC Confirmation Procedure BBS0037E NOTE: If DTC Confirmation Procedure has been previously conducted, always turn ignition switch OFF and wait at least 10 seconds before conducting the next test. EC-591 M DTC P0138 HO2S2 [CR (WITHOUT EURO-OBD)] WITH CONSULT-II 1. 2. 3. 4. 5. 6. Turn ignition switch ON and select “DATA MONITOR” mode with CONSULT-II. Start engine and warm it up to the normal operating temperature. Turn ignition switch OFF and wait at least 10 seconds. Start engine and keep the engine speed between 3,500 and 4,000 rpm for at least 1 minute under no load. Let engine idle for 2 minutes. If 1st trip DTC is detected, go to EC-594, "Diagnostic Procedure" . SEF189Y WITHOUT CONSULT-II 1. 2. 3. 4. 5. 6. 7. Start engine and warm it up to the normal operating temperature. Turn ignition switch OFF and wait at least 10 seconds. Start engine and keep the engine speed between 3,500 and 4,000 rpm for at least 1 minute under no load. Let engine idle for 2 minutes. Turn ignition switch OFF and wait at least 10 seconds and then turn ON. Perform Diagnostic Test Mode II (Self-diagnostic results) with ECM. If 1st trip DTC is detected, go to EC-594, "Diagnostic Procedure" . EC-592 DTC P0138 HO2S2 [CR (WITHOUT EURO-OBD)] Wiring Diagram BBS0037F A EC C D E F G H I J K L M MBWA1511E EC-593 DTC P0138 HO2S2 [CR (WITHOUT EURO-OBD)] Specification data are reference values and are measured between each terminal and ground. CAUTION: Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM's transistor. Use a ground other than ECM terminals, such as the ground. TERMINAL NO. WIRE COLOR ITEM CONDITION DATA (DC Voltage) [Engine is running] 2 GR ● Engine speed: Below 3,800 rpm after the following conditions are met. – Engine: After warming up – Keeping the engine speed between 3,500 and 4,000 rpm for 1 minute and at idle for 1 minute under no load. Heated oxygen sensor 2 heater 0 - 1.0V [Ignition switch ON] ● Engine stopped BATTERY VOLTAGE (11 - 14V) [Engine is running] ● Engine speed: Above 3,800 rpm [Engine is running] 16 LG Heated oxygen sensor 2 ● Revving engine from idle to 3,000rpm quickly after the following conditions are met. – Engine: After warming up – Keeping the engine speed between 3,500 and 4,000 rpm for 1 minute and at idle for 1 minute under no load. 0 - Approximately 1.0V [Engine is running] 74 B Sensor ground (Heated oxygen sensor) ● Warm-up condition ● Idle speed Approximately 0V Diagnostic Procedure BBS0037G 1. CHECK GROUND CONNECTIONS 1. 2. Turn ignition switch OFF. Loosen and retighten ground screws on the body. Refer to EC-548, "Ground Inspection" . MBIB1502E 1. Body ground E44 2. Body ground E45 OK or NG OK >> GO TO 2. NG >> Repair or replace ground connections. EC-594 3. Body ground E28 DTC P0138 HO2S2 [CR (WITHOUT EURO-OBD)] 2. CHECK HO2S2 GROUND CIRCUIT FOR OPEN AND SHORT 1. Disconnect heated oxygen sensor 2 harness connector (1). – : Vehicle front Heated oxygen sensor 2 (2) Oil pan (3) Disconnect ECM harness connector. Check harness continuity between ECM terminal 74 and HO2S2 terminal 4. Refer to Wiring Diagram. – – 2. 3. Continuity should exist. EC C D MBIB1459E 4. Also check harness for short to ground and short to power. OK or NG OK >> GO TO 3. NG >> Repair open circuit or short to ground or short to power in harness or connectors. 3. CHECK HO2S2 INPUT SIGNAL CIRCUIT FOR OPEN AND SHORT 1. A Check harness continuity between ECM terminal 16 and HO2S2 terminal 1. Refer to Wiring Diagram. E F G Continuity should exist. 2. Check harness continuity between ECM terminal 16 or HO2S2 terminal 1 and ground. Refer to Wiring Diagram. Continuity should not exist. H I 3. Also check harness for short to power. OK or NG OK >> GO TO 4. NG >> Repair open circuit or short to ground or short to power in harness or connectors. 4. CHECK HO2S2 CONNECTOR FOR WATER J K Check connectors for water. Water should not exist. L OK or NG OK >> GO TO 5. NG >> Repair or replace harness or connectors. 5. CHECK HEATED OXYGEN SENSOR 2 Refer to EC-596, "Component Inspection" . OK or NG OK >> GO TO 6. NG >> Replace heated oxygen sensor 2. 6. CHECK INTERMITTENT INCIDENT Refer to EC-542, "TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT" . >> INSPECTION END EC-595 M DTC P0138 HO2S2 [CR (WITHOUT EURO-OBD)] Component Inspection BBS0037H HEATED OXYGEN SENSOR 2 With CONSULT-II 1. 2. 3. 4. 5. Turn ignition switch ON and select “DATA MONITOR” mode with CONSULT-II. Start engine and warm it up to the normal operating temperature. Turn ignition switch OFF and wait at least 10 seconds. Start engine and keep the engine speed between 3,500 and 4,000 rpm for at least 1 minute under no load. Let engine idle for 1 minute. SEF174Y 6. Select “FUEL INJECTION” in “ACTIVE TEST” mode, and select “HO2S2(B1)” as the monitor item with CONSULT-II. SEF662Y 7. Check “HO2S2 (B1)” at idle speed when adjusting “FUEL INJECTION” to ±25%. MBIB1402E “HO2S2 (B1)” should be above 0.61V at least once when the “FUEL INJECTION” is +25%. “HO2S2 (B1)” should be below 0.52V at least once when the “FUEL INJECTION” is −25%. CAUTION: ● Discard any heated oxygen sensor which has been dropped from a height of more than 0.5 m (19.7 in) onto a hard surface such as a concrete floor; use a new one. ● Before installing new oxygen sensor, clean exhaust system threads using Oxygen Sensor Thread Cleaner and approved anti-seize lubricant. Without CONSULT-II 1. 2. 3. 4. 5. Start engine and warm it up to the normal operating temperature. Turn ignition switch OFF and wait at least 10 seconds. Start engine and keep the engine speed between 3,500 and 4,000 rpm for at least 1 minute under no load. Let engine idle for 1 minute. Set voltmeter probes between ECM terminal 16 (HO2S2 signal) and ground. EC-596 DTC P0138 HO2S2 [CR (WITHOUT EURO-OBD)] 6. Check the voltage when revving up to 4,000 rpm under no load at least 10 times. A (Depress and release accelerator pedal as soon as possible.) The voltage should be above 0.61V at least once during this procedure. EC If the voltage is above 0.61V at step 6, step 7 is not necessary. 7. Keep vehicle idling for 10 minutes, then check voltage. Or check C the voltage when coasting from 80 km/h (50 MPH) in 3rd gear position. The voltage should be below 0.52V at least once during this MBIB0020E procedure. D 8. If NG, replace heated oxygen sensor 2. CAUTION: ● Discard any heated oxygen sensor which has been dropped from a height of more than 0.5 m (19.7 E in) onto a hard surface such as a concrete floor; use a new one. ● Before installing new oxygen sensor, clean exhaust system threads using Oxygen Sensor Thread Cleaner and approved anti-seize lubricant. F Removal and Installation BBS0037I HEATED OXYGEN SENSOR 2 G Refer to EX-3, "EXHAUST SYSTEM" . H I J K L M EC-597 DTC P0222, P0223 TP SENSOR [CR (WITHOUT EURO-OBD)] DTC P0222, P0223 TP SENSOR Component Description PFP:16119 BBS0037J Electric throttle control actuator consists of throttle control motor, throttle position sensor, etc. the throttle position sensor responds to the throttle valve movement. The throttle position sensor has the two sensors. These sensors are a kind of potentiometers which transform the throttle valve position into output voltage, and emit the voltage signal to the ECM. In addition, these sensors detect the opening and closing speed of the throttle valve and feed the voltage signals to the ECM. The ECM judges the current opening angle of the throttle valve from these signals and the ECM controls the throttle control motor to make the throttle valve opening angle properly in response to driving condition. PBIB0145E CONSULT-II Reference Value in Data Monitor Mode BBS0037K Specification data are reference values. MONITOR ITEM CONDITION SPECIFICATION ● Ignition switch: ON (Engine stopped) Accelerator pedal: Fully released More than 0.36V ● Shift lever: 1st Accelerator pedal: Fully depressed Less than 4.75V THRTL SEN 1 THRTL SEN 2* *: Throttle position sensor 2 signal is converted by ECM internally. Thus, it differs from ECM terminal voltage signal. On Board Diagnosis Logic BBS0037L These self-diagnoses have the one trip detection logic. DTC No. Trouble diagnosis name DTC detecting condition P0222 0222 Throttle position sensor 1 circuit low input An excessively low voltage from the TP sensor 1 is sent to ECM. P0223 0223 Throttle position sensor 1 circuit high input An excessively high voltage from the TP sensor 1 is sent to ECM. Possible cause ● Harness or connectors (TP sensor 1 circuit is open or shorted.) (APP sensor 2 circuit is shorted.) ● Electric throttle control actuator (TP sensor 1) ● Accelerator pedal position sensor (APP sensor 2) FAIL-SAFE MODE When the malfunction is detected, the ECM enters fail-safe mode and the MI lights up. Engine operation condition in fail-safe mode The ECM controls the electric throttle control actuator in regulating the throttle opening in order for the idle position to be within +10 degrees. The ECM regulates the opening speed of the throttle valve to be slower than the normal condition. So, the acceleration will be poor. DTC Confirmation Procedure BBS0037M NOTE: If DTC Confirmation Procedure has been previously conducted, always turn ignition switch OFF and wait at least 10 seconds before conducting the next test. TESTING CONDITION: Before performing the following procedure, confirm that battery voltage is more than 10V at idle. EC-598 DTC P0222, P0223 TP SENSOR [CR (WITHOUT EURO-OBD)] WITH CONSULT-II 1. 2. 3. 4. A Turn ignition switch ON. Select “DATA MONITOR” mode with CONSULT-II. Start engine and let it idle for 1 second. If DTC is detected, go to EC-601, "Diagnostic Procedure" . EC C D SEF058Y WITHOUT CONSULT-II 1. 2. 3. 4. Start engine and let it idle for 1 second. Turn ignition switch OFF, wait at least 10 seconds and then turn ON. Perform Diagnostic Test Mode II (Self-diagnostic results) with ECM. If DTC is detected, go to EC-601, "Diagnostic Procedure" . E F G H I J K L M EC-599 DTC P0222, P0223 TP SENSOR [CR (WITHOUT EURO-OBD)] Wiring Diagram BBS0037N MBWA1513E EC-600 DTC P0222, P0223 TP SENSOR [CR (WITHOUT EURO-OBD)] Specification data are reference values and are measured between each terminal and ground. CAUTION: Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM's transistor. Use a ground other than ECM terminals, such as the ground. TERMINAL NO. 47 EC WIRE COLOR L A ITEM CONDITION Sensor power supply (Throttle position sensor) DATA (DC Voltage) [Ignition switch: ON] C Approximately 5V [Ignition switch: ON] 49 Y ● Engine stopped ● Shift lever position: 1st ● Accelerator pedal: Fully released Throttle position sensor 1 D More than 0.36V E [Ignition switch: ON] ● Engine stopped ● Shift lever position: 1st ● Accelerator pedal: Fully depressed Less than 4.75V F [Engine is running] 66 B Sensor ground (Throttle position sensor) ● Warm-up condition ● Idle speed Approximately 0V G [Ignition switch: ON] 68 91 R BR Throttle position sensor 2 Sensor power supply (APP sensor 2) ● Engine stopped ● Shift lever position: 1st ● Accelerator pedal: Fully released H Less than 4.75V I [Ignition switch: ON] ● Engine stopped ● Shift lever position: 1st ● Accelerator pedal: Fully depressed More than 0.36V J [Ignition switch ON] Approximately 5V K Diagnostic Procedure BBS0037O 1. RETIGHTEN GROUND CONNECTIONS 1. 2. L Turn ignition switch OFF. Loosen and retighten ground screws on the body. Refer to EC-548, "Ground Inspection" . M MBIB1502E 1. Body ground E44 2. Body ground E45 OK or NG OK >> GO TO 2. NG >> Repair or replace ground connections. EC-601 3. Body ground E28 DTC P0222, P0223 TP SENSOR [CR (WITHOUT EURO-OBD)] 2. CHECK THROTTLE POSITION SENSOR 1 POWER SUPPLY CIRCUIT-I 1. 2. Disconnect electric throttle control actuator harness connector. Turn ignition switch ON. MBIB0308E 3. Check voltage between electric throttle control actuator terminal 1 and ground with CONSULT-II or tester. Voltage: Approximately 5V OK or NG OK >> GO TO 7. NG >> GO TO 3. PBIB0082E 3. CHECK THROTTLE POSITION SENSOR 1 POWER SUPPLY CIRCUIT-II 1. 2. 3. Turn ignition switch OFF. Disconnect ECM harness connector. Check harness continuity between electric throttle control actuator terminal 1 and ECM terminal 47. Refer to Wiring Diagram. Continuity should exist. OK or NG OK >> GO TO 4. NG >> Repair open circuit. 4. CHECK THROTTLE POSITION SENSOR 1 POWER SUPPLY CIRCUIT-III Check harness for short to power and short to ground, between the following terminals. ECM terminal Sensor terminal Reference Wiring Diagram 47 Electric throttle control actuator terminal 1 EC-600 91 APP sensor terminal 5 EC-710 OK or NG OK >> GO TO 5. NG >> Repair short to ground or short to power in harness or connectors. 5. CHECK APP SENSOR Refer to EC-716, "Component Inspection" . OK or NG OK >> GO TO 11. NG >> GO TO 6. EC-602 DTC P0222, P0223 TP SENSOR [CR (WITHOUT EURO-OBD)] 6. REPLACE ACCELERATOR PEDAL ASSEMBLY 1. 2. 3. 4. Replace accelerator pedal assembly. Perform EC-486, "Accelerator Pedal Released Position Learning" . Perform EC-486, "Throttle Valve Closed Position Learning" . Perform EC-486, "Idle Air Volume Learning" . 7. CHECK THROTTLE POSITION SENSOR 1 GROUND CIRCUIT FOR OPEN AND SHORT Turn ignition switch OFF. Disconnect ECM harness connector. Check harness continuity between ECM terminal 66 and electric throttle control actuator terminal 5. Refer to Wiring Diagram. Continuity should exist. 8. CHECK THROTTLE POSITION SENSOR 1 INPUT SIGNAL CIRCUIT FOR OPEN AND SHORT E G H Check harness continuity between ECM terminal 49 and electric throttle control actuator terminal 4. Refer to Wiring Diagram. I Continuity should exist. 2. Also check harness for short to ground and short to power. OK or NG OK >> GO TO 9. NG >> Repair open circuit or short to ground or short to power in harness or connectors. J K 9. CHECK THROTTLE POSITION SENSOR Refer to EC-604, "Component Inspection" . OK or NG OK >> GO TO 11. NG >> GO TO 10. L 10. REPLACE ELECTRIC THROTTLE CONTROL ACTUATOR 1. 2. 3. D F 4. Also check harness for short to ground and short to power. OK or NG OK >> GO TO 8. NG >> Repair open circuit or short to ground or short to power in harness or connectors. 1. EC C >> INSPECTION END 1. 2. 3. A Replace the electric throttle control actuator. Perform EC-486, "Throttle Valve Closed Position Learning" . Perform EC-486, "Idle Air Volume Learning" . >> INSPECTION END 11. CHECK INTERMITTENT INCIDENT Refer to EC-542, "TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT" . >> INSPECTION END EC-603 M DTC P0222, P0223 TP SENSOR [CR (WITHOUT EURO-OBD)] Component Inspection BBS0037P THROTTLE POSITION SENSOR 1. 2. 3. 4. 5. Reconnect all harness connectors disconnected. Perform EC-486, "Throttle Valve Closed Position Learning" . Turn ignition switch ON. Set shift lever to 1st position. Check voltage between ECM terminals 49 (TP sensor 1 signal), 68 (TP sensor 2 signal) and ground under the following conditions. Terminal Accelerator pedal Voltage 49 (Throttle position sensor 1) Fully released More than 0.36V Fully depressed Less than 4.75V Fully released Less than 4.75V Fully depressed More than 0.36V 68 (Throttle position sensor 2) 6. 7. 8. If NG, replace electric throttle control actuator and go to the next step. Perform EC-486, "Throttle Valve Closed Position Learning" . Perform EC-486, "Idle Air Volume Learning" . Removal and Installation MBIB1443E BBS0037Q ELECTRIC THROTTLE CONTROL ACTUATOR Refer to EM-18, "AIR CLEANER AND AIR DUCT" . EC-604 DTC P0327, P0328 KS [CR (WITHOUT EURO-OBD)] DTC P0327, P0328 KS Component Description PFP:22060 A BBS0037R The knock sensor is attached to the cylinder block. It senses engine knocking using a piezoelectric element. A knocking vibration from the cylinder block is sensed as vibrational pressure. This pressure is converted into a voltage signal and sent to the ECM. EC C D MBIB0306E E On Board Diagnosis Logic BBS0037S The MI will not light up for these self-diagnoses. DTC No. Trouble Diagnosis Name DTC Detected Condition F Possible Cause P0327 0327 Knock sensor circuit low input An excessively low voltage from the sensor is sent to ECM. ● Harness or connectors (The sensor circuit is open or shorted.) P0328 0328 Knock sensor circuit high input An excessively high voltage from the sensor is sent to ECM. ● Knock sensor DTC Confirmation Procedure BBS0037T NOTE: If DTC Confirmation Procedure has been previously conducted, always turn ignition switch OFF and wait at least 10 seconds before conducting the next test. TESTING CONDITION: Before performing the following procedure, confirm that battery voltage is more than 10V at idle. WITH CONSULT-II 1. 2. 3. G H I J Turn ignition switch ON and select “DATA MONITOR” mode with CONSULT-II. Start engine and run it for at least 5 seconds at idle speed. If 1st trip DTC is detected, go to EC-607, "Diagnostic Procedure" . K L M SEF058Y WITHOUT CONSULT-II 1. 2. 3. 4. Start engine and run it for at least 5 seconds at idle speed. Turn ignition switch OFF, wait at least 10 seconds and then turn ON. Perform Diagnostic Test Mode II (Self-diagnostic results) with ECM. If 1st trip DTC is detected, go to EC-607, "Diagnostic Procedure" . EC-605 DTC P0327, P0328 KS [CR (WITHOUT EURO-OBD)] Wiring Diagram BBS0037U MBWA0571E EC-606 DTC P0327, P0328 KS [CR (WITHOUT EURO-OBD)] Specification data are reference values and are measured between each terminal and ground. CAUTION: Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM's transistor. Use a ground other than ECM terminals, such as the ground. TERMINAL NO. 15 WIRE COLOR W A EC ITEM Knock sensor CONDITION [Engine is running] ● Idle speed DATA (DC Voltage) C Approximately 2.5V [Engine is running] 54 — Sensor ground (Knock sensor) ● Warm-up condition ● Idle speed D Approximately 0V Diagnostic Procedure BBS0037V 1. CHECK KNOCK SENSOR INPUT SIGNAL CIRCUIT-I 1. 2. 3. Turn ignition switch OFF. Disconnect ECM harness connector. Check resistance between ECM terminal 15 and ground. Refer to Wiring Diagram. NOTE: It is necessary to use an ohmmeter which can measure more than 10 MΩ. E F G Resistance: Approximately 530 - 590kΩ [at 20°C (68°F)] H 4. Also check harness for short to ground and short to power. OK or NG OK >> GO TO 4. NG >> GO TO 2. I 2. CHECK KNOCK SENSOR INPUT SIGNAL CIRCUIT-II 1. 2. J Disconnect knock sensor harness connector. Check harness continuity between ECM terminal 15 and knock sensor terminal 2. Refer to Wiring Diagram. K Continuity should exist. 3. Also check harness for short to ground and short to power. OK or NG OK >> GO TO 3. NG >> Repair open circuit or short to ground or short to power in harness or connectors. 3. CHECK KNOCK SENSOR Refer to EC-608, "Component Inspection" . OK or NG OK >> GO TO 6. NG >> Replace knock sensor. EC-607 L M MBIB0306E DTC P0327, P0328 KS [CR (WITHOUT EURO-OBD)] 4. CHECK GROUND CONNECTIONS 1. Loosen and retighten ground screws on the body. Refer to EC-548, "Ground Inspection" . MBIB1502E 1. Body ground E44 2. Body ground E45 3. Body ground E28 OK or NG OK >> GO TO 5. NG >> Repair or replace ground connections. 5. CHECK KNOCK SENSOR SHIELD CIRCUIT FOR OPEN AND SHORT 1. Check harness continuity between ECM terminal 54 and knock sensor terminal 1. Refer to Wiring Diagram. Continuity should exist 2. Also check harness for short to ground and short to power. OK or NG OK >> GO TO 6. NG >> Repair open circuit or short to ground or short to power in harness or connectors. 6. CHECK INTERMITTENT INCIDENT Refer to EC-542, "TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT" . >> INSPECTION END Component Inspection BBS0037W KNOCK SENSOR Check resistance between knock sensor terminal 2 and ground. NOTE: It is necessary to use an ohmmeter which can measure more than 10 MΩ. Resistance: Approximately 530 - 590kΩ [at 20°C (68°F)] CAUTION: Do not use any knock sensors that have been dropped or physically damaged. Use only new ones. PBIB0253E Removal and Installation BBS0037X KNOCK SENSOR Refer to EM-74, "CYLINDER BLOCK" . EC-608 DTC P0335 CKP SENSOR (POS) [CR (WITHOUT EURO-OBD)] DTC P0335 CKP SENSOR (POS) Component Description PFP:23731 A BBS0037Y The crankshaft position sensor (POS) is located on the cylinder block rear housing facing the gear teeth (cogs) of the signal plate at the end of the crankshaft. It detects the fluctuation of the engine revolution. The sensor consists of a permanent magnet and Hall IC. When the engine is running, the high and low parts of the teeth cause the gap with the sensor to change. The changing gap causes the magnetic field near the sensor to change. Due to the changing magnetic field, the voltage from the sensor changes. The ECM receives the voltage signal and detects the fluctuation of the engine revolution. ECM receives the signals as shown in the figure. EC C D PBIB0562E E F G H PBIB2382E I CONSULT-II Reference Value in Data Monitor Mode BBS0037Z Specification data are reference values. MONITOR ITEM ENG SPEED CONDITION ● J SPECIFICATION Run engine and compare CONSULT-II value with the tachometer indication. Almost the same speed as the tachometer indication. K On Board Diagnosis Logic DTC No. Trouble diagnosis name DTC detecting condition ● P0335 0335 Crankshaft position sensor (POS) circuit BBS00380 ● ● The crankshaft position sensor (POS) signal is not detected by the ECM during the first few seconds of engine cranking. The proper pulse signal from the crankshaft position sensor (POS) is not sent to ECM while the engine is running. The crankshaft position sensor (POS) signal is not in the normal pattern during engine running. DTC Confirmation Procedure Possible cause ● L Harness or connectors (The sensor circuit is open or shorted.) M ● Crankshaft position sensor (POS) ● Signal plate BBS00381 NOTE: If DTC Confirmation Procedure has been previously conducted, always turn ignition switch OFF and wait at least 10 seconds before conducting the next test. TESTING CONDITION: Before performing the following procedure, confirm that battery voltage is more than 10.5V with ignition switch ON. EC-609 DTC P0335 CKP SENSOR (POS) [CR (WITHOUT EURO-OBD)] WITH CONSULT-II 1. 2. 3. Turn ignition switch ON and select “DATA MONITOR” mode with CONSULT-II. Crank engine for at least 2 seconds and run it for at least 5 seconds at idle speed. If 1st trip DTC is detected, go to EC-613, "Diagnostic Procedure" . SEF058Y WITHOUT CONSULT-II 1. 2. 3. 4. Crank engine for at least 2 seconds and run it for at least 5 seconds at idle speed. Turn ignition switch OFF, wait at least 10 seconds and then turn ON. Perform Diagnostic Test Mode II (Self-diagnostic results) with ECM. If 1st trip DTC is detected, go to EC-613, "Diagnostic Procedure" . EC-610 DTC P0335 CKP SENSOR (POS) [CR (WITHOUT EURO-OBD)] Wiring Diagram BBS00382 A EC C D E F G H I J K L M MBWA1515E EC-611 DTC P0335 CKP SENSOR (POS) [CR (WITHOUT EURO-OBD)] Specification data are reference values and are measured between each terminal and ground. Pulse signal is measured by CONSULT-II. CAUTION: Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM's transistor. Use a ground other than ECM terminals, such as the ground. TERMINAL NO. WIRE COLOR ITEM CONDITION [Engine is running] ● Warm-up condition ● Idle speed DATA (DC Voltage) Approximately 3.0V NOTE: The pulse cycle changes depending on rpm at idle. 13 Y PBIB0527E Crankshaft position sensor (POS) Approximately 3.0V [Engine is running] ● Engine speed: 2,000 rpm PBIB0528E 30 L Sensor ground (Crankshaft position sensor) [Engine is running] ● Warm-up condition ● Idle speed [Engine is running] [Ignition switch: OFF] ● 111 P ECM relay (Self shut-off) For a few seconds after turning ignition switch OFF [Ignition switch: OFF] ● 119 120 G G Power supply for ECM More than a few seconds passed after turning ignition switch OFF [Ignition switch: ON] : Average voltage for pulse signal (Actual pulse signal can be confirmed by oscilloscope.) EC-612 Approximately 0V 0 - 1.0V BATTERY VOLTAGE (11 - 14V) BATTERY VOLTAGE (11 - 14V) DTC P0335 CKP SENSOR (POS) [CR (WITHOUT EURO-OBD)] Diagnostic Procedure BBS00383 1. CHECK GROUND CONNECTIONS 1. 2. A Turn ignition switch OFF. Loosen and retighten ground screws on the body. Refer to EC-548, "Ground Inspection" . EC C D E MBIB1502E 1. Body ground E44 2. Body ground E45 3. F Body ground E28 OK or NG OK >> GO TO 2. NG >> Repair or replace ground connections. G 2. CHECK CRANKSHAFT POSITION (CKP) SENSOR (POS) POWER SUPPLY CIRCUIT 1. 2. H Disconnect crankshaft position (CKP) sensor (POS) harness connector. Turn ignition switch ON. I J K MBIB1078E 3. L Check voltage between CKP sensor (POS) terminal 3 and ground with CONSULT-II or tester. Voltage: Battery voltage M OK or NG OK >> GO TO 4. NG >> GO TO 3. SEF479Y 3. DETECT MALFUNCTIONING PART Check the following. ● Harness connectors F1, E48 ● Harness for open or short between crankshaft position sensor (POS) and ECM ● Harness for open or short between crankshaft position sensor (POS) and IPDM E/R >> Repair open circuit or short to ground or short to power in harness or connectors. EC-613 DTC P0335 CKP SENSOR (POS) [CR (WITHOUT EURO-OBD)] 4. CHECK CKP SENSOR (POS) GROUND CIRCUIT FOR OPEN AND SHORT 1. 2. 3. Turn ignition switch OFF. Disconnect ECM harness connector. Check harness continuity between ECM terminal 30 and CKP sensor (POS) terminal 1. Refer to Wiring Diagram. Continuity should exist. 4. Also check harness for short to ground and short to power. OK or NG OK >> GO TO 5. NG >> Repair open circuit or short to ground or short to power in harness or connectors. 5. CHECK CKP SENSOR (POS) INPUT SIGNAL CIRCUIT FOR OPEN AND SHORT 1. Check harness continuity between ECM terminal 13 and CKP sensor (POS) terminal 2. Refer to Wiring Diagram. Continuity should exist. 2. Also check harness for short to ground and short to power. OK or NG OK >> GO TO 6. NG >> Repair open circuit or short to ground or short to power in harness or connectors. 6. CHECK CRANKSHAFT POSITION SENSOR (POS) Refer to EC-615, "Component Inspection" . OK or NG OK >> GO TO 7. NG >> Replace crankshaft position sensor (POS). 7. CHECK GEAR TOOTH Visually check for chipping signal plate gear tooth. OK or NG OK >> GO TO 8. NG >> Replace the signal plate. 8. CHECK INTERMITTENT INCIDENT Refer to EC-542, "TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT" . >> INSPECTION END EC-614 DTC P0335 CKP SENSOR (POS) [CR (WITHOUT EURO-OBD)] Component Inspection BBS00384 A CRANKSHAFT POSITION SENSOR (POS) 1. 2. 3. 4. Loosen the fixing bolt of the sensor. Disconnect crankshaft position sensor (POS) harness connector. Remove the sensor. Visually check the sensor for chipping. EC C D E PBIB0563E 5. F Check resistance as shown in the figure. Terminal No. (Polarity) Resistance Ω [at 25°C (77°F)] 3 (+) - 1 (-) 3 (+) - 2 (-) G Except 0 or ∞ 2 (+) - 1 (-) 6. H If NG, replace crankshaft position sensor (POS). MBIB0024E Removal and Installation I BBS00385 CRANKSHAFT POSITION SENSOR (POS) J Refer to EM-74, "CYLINDER BLOCK" . K L M EC-615 DTC P0340 CMP SENSOR (PHASE) [CR (WITHOUT EURO-OBD)] DTC P0340 CMP SENSOR (PHASE) Component Description PFP:23731 BBS00386 The camshaft position sensor (PHASE) senses the retraction with camshaft (intake) to identify a particular cylinder. The camshaft position sensor (PHASE) senses the piston position. When the crankshaft position sensor (POS) system becomes inoperative, the camshaft position sensor (PHASE) provides various controls of engine parts instead, utilizing timing of cylinder identification signals. The sensor consists of a permanent magnet and Hall IC. When engine is running, the high and low parts of the teeth cause the gap with the sensor to change. The changing gap causes the magnetic field near the sensor to change. Due to the changing magnetic field, the voltage from the sensor changes. ECM receives the signals as shown in the figure. PBIB0562E PBIB2382E On Board Diagnosis Logic DTC No. Trouble diagnosis name DTC detecting condition ● P0340 0340 Camshaft position sensor (PHASE) circuit BBS00387 The cylinder No. signal is not sent to ECM for the first few seconds during engine cranking. Possible cause ● Harness or connectors (The sensor circuit is open or shorted.) ● Camshaft position sensor (PHASE) Camshaft (Intake) ● The cylinder No. signal is not set to ECM during engine running. ● ● Starter motor (Refer to SC-45 .) ● The cylinder No. signal is not in the normal pattern during engine running. ● Starting system circuit (Refer to SC-45 .) ● Dead (Weak) battery DTC Confirmation Procedure BBS00388 NOTE: If DTC Confirmation Procedure has been previously conducted, always turn ignition switch OFF and wait at least 10 seconds before conducting the next test. TESTING CONDITION: Before performing the following procedure, confirm that battery voltage is more than 10.5V with ignition switch ON. WITH CONSULT-II 1. Turn ignition switch ON. EC-616 DTC P0340 CMP SENSOR (PHASE) [CR (WITHOUT EURO-OBD)] 2. 3. 4. 5. 6. Select “DATA MONITOR” mode with CONSULT-II. Crank engine for at least 2 seconds and run it for at least 5 seconds at idle speed. If 1st trip DTC is detected, go to EC-619, "Diagnostic Procedure" . If 1st trip DTC is not detected, go to next step. Maintain engine speed at more than 800 rpm for at least 5 seconds. If 1st trip DTC is detected, go to EC-619, "Diagnostic Procedure" . 5. 6. 7. 8. 9. EC C SEF058Y D WITHOUT CONSULT-II 1. 2. 3. 4. A Crank engine for at least 2 seconds and run it for at least 5 seconds at idle speed. Turn ignition switch OFF, wait at least 10 seconds and then turn ON. Perform Diagnostic Test Mode II (Self-diagnostic results) with ECM. If 1st trip DTC is detected, go to EC-619, "Diagnostic Procedure" . If 1st trip DTC is not detected, go to next step. Turn ignition switch OFF and wait at least 10 seconds. Start engine and maintain engine speed at more than 800 rpm for at least 5 seconds. Turn ignition switch OFF, wait at least 10 seconds and then turn ON. Perform Diagnostic Test Mode II (Self-diagnostic results) with ECM. If 1st trip DTC is detected, go to EC-619, "Diagnostic Procedure" . E F G H I J K L M EC-617 DTC P0340 CMP SENSOR (PHASE) [CR (WITHOUT EURO-OBD)] Wiring Diagram BBS00389 MBWA1516E EC-618 DTC P0340 CMP SENSOR (PHASE) [CR (WITHOUT EURO-OBD)] Specification data are reference values and are measured between each terminal and ground. Pulse signal is measured by CONSULT-II. A CAUTION: Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM's transistor. Use a ground other than ECM terminals, such as the ground. EC TERMINAL NO. WIRE COLOR ITEM CONDITION DATA (DC Voltage) C [Engine is running] ● Warm-up condition ● Idle speed 1.0 - 4.0V D NOTE: The pulse cycle changes depending on rpm at idle. 14 R E PBIB0525E Camshaft position sensor (PHASE) 1.0 - 4.0V F [Engine is running] ● Engine speed: 2,000 rpm G PBIB0526E 29 B Sensor ground (Camshaft position sensor) ● Warm-up condition ● Idle speed ● P ECM relay (Self shut-off) For a few seconds after turning ignition switch OFF [Ignition switch: OFF] ● 119 120 G G Power supply for ECM Approximately 0V I [Engine is running] [Ignition switch: OFF] 111 H [Engine is running] More than a few seconds passed after turning ignition switch OFF [Ignition switch: ON] 0 - 1.0V J BATTERY VOLTAGE (11 - 14V) K BATTERY VOLTAGE (11 - 14V) L : Average voltage for pulse signal (Actual pulse signal can be confirmed by oscilloscope.) Diagnostic Procedure BBS0038A M 1. CHECK STARTING SYSTEM Turn ignition switch to START position. Does the engine turn over? Does the starter motor operate? Yes or No Yes >> GO TO 2. No >> Check starting system. (Refer to SC-45, "STARTING SYSTEM" .) EC-619 DTC P0340 CMP SENSOR (PHASE) [CR (WITHOUT EURO-OBD)] 2. CHECK GROUND CONNECTIONS 1. 2. Turn ignition switch OFF. Loosen and retighten ground screws on the body. Refer to EC-548, "Ground Inspection" . MBIB1502E 1. Body ground E44 2. Body ground E45 3. Body ground E28 OK or NG OK >> GO TO 3. NG >> Repair or replace ground connections. 3. CHECK CAMSHAFT POSITION (CMP) SENSOR (PHASE) POWER SUPPLY CIRCUIT 1. 2. Disconnect camshaft position (CMP) sensor (PHASE) harness connector. Turn ignition switch ON. MBIB0279E 3. Check voltage between CMP sensor (PHASE) terminal 3 and ground with CONSULT-II or tester. Voltage: Battery voltage OK or NG OK >> GO TO 5. NG >> GO TO 4. SEF479Y 4. DETECT MALFUNCTIONING PART Check the following. Harness connectors F1, E48 ● Harness for open or short between camshaft position sensor (PHASE) and ECM ● Harness for open or short between camshaft position sensor (PHASE) and IPDM E/R ● >> Repair open circuit or short to ground or short to power in harness or connectors. EC-620 DTC P0340 CMP SENSOR (PHASE) [CR (WITHOUT EURO-OBD)] 5. CHECK CMP SENSOR (PHASE) GROUND CIRCUIT FOR OPEN AND SHORT 1. 2. 3. A Turn ignition switch OFF. Disconnect ECM harness connector. Check harness continuity between ECM terminal 29 and CMP sensor (PHASE) terminal 1. Refer to Wiring Diagram. EC Continuity should exist. C 4. Also check harness for short to ground and short to power. OK or NG OK >> GO TO 6. NG >> Repair open circuit or short to ground or short to power in harness or connectors. D 6. CHECK CMP SENSOR (PHASE) INPUT SIGNAL CIRCUIT FOR OPEN AND SHORT 1. E Check harness continuity between ECM terminal 14 and CMP sensor (PHASE) terminal 2. Refer to Wiring Diagram. F Continuity should exist. 2. Also check harness for short to ground and short to power. OK or NG OK >> GO TO 7. NG >> Repair open circuit or short to ground or short to power in harness or connectors. G H 7. CHECK CAMSHAFT POSITION SENSOR (PHASE) Refer to EC-622, "Component Inspection" . OK or NG OK >> GO TO 8. NG >> Replace camshaft position sensor (PHASE). I J 8. CHECK CAMSHAFT (INTAKE) Check the following. ● Accumulation of debris to the signal plate of camshaft rear end ● Chipping signal plate of camshaft rear end OK or NG OK >> GO TO 9. NG >> Remove debris and clean the signal plate of camshaft rear end or replace camshaft. K L M PBIB0565E 9. CHECK INTERMITTENT INCIDENT Refer to EC-542, "TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT" . >> INSPECTION END EC-621 DTC P0340 CMP SENSOR (PHASE) [CR (WITHOUT EURO-OBD)] Component Inspection BBS0038B CAMSHAFT POSITION SENSOR (PHASE) 1. 2. 3. 4. Loosen the fixing bolt of the sensor. Disconnect camshaft position sensor (PHASE) harness connector. Remove the sensor. Visually check the sensor for chipping. PBIB0563E 5. Check resistance as shown in the figure. Terminal No. (Polarity) Resistance Ω [at 25°C (77°F)] 3 (+) - 1 (-) 3 (+) - 2 (-) Except 0 or ∞ 2 (+) - 1 (-) MBIB0024E Removal and Installation BBS0038C CAMSHAFT POSITION SENSOR (PHASE) Refer to EM-38, "CAMSHAFT" . EC-622 DTC P0605 ECM [CR (WITHOUT EURO-OBD)] DTC P0605 ECM Component Description PFP:23710 A BBS0038D The ECM consists of a microcomputer and connectors for signal input and output and for power supply. The ECM controls the engine. EC C D PBIB1164E E On Board Diagnosis Logic BBS0038E This self-diagnosis has one or two trip detection logic. DTC No. P0605 0605 Trouble diagnosis name Engine control module DTC detecting condition A) ECM calculation function is malfunctioning. B) ECM EEP-ROM system is malfunctioning. C) ECM self shut-off function is malfunctioning. F Possible cause ● ECM G FAIL-SAFE MODE H ECM enters fail-safe mode when malfunction A is detected. Detected items Malfunction A Engine operation condition in fail-safe mode ECM stops the electric throttle control actuator control, throttle valve is maintained at a fixed opening (approx. 5 degrees) by the return spring. DTC Confirmation Procedure BBS0038F Perform PROCEDURE FOR MALFUNCTION A first. If the DTC cannot be confirmed, perform PROCEDURE FOR MALFUNCTION B. If there is no malfunction on PROCEDURE FOR MALFUNCTION B, perform PROCEDURE FOR MALFUNCTION C. NOTE: If DTC Confirmation Procedure has been previously conducted, always turn ignition switch OFF and wait at least 10 seconds before conducting the next test. PROCEDURE FOR MALFUNCTION A With CONSULT-II 1. 2. 3. Without CONSULT-II Turn ignition switch ON. Turn ignition switch OFF, wait at least 10 seconds and then turn ON. Perform Diagnostic Test Mode II (Self-diagnostic results) with ECM. EC-623 J K L M Turn ignition switch ON. Select “DATA MONITOR” mode with CONSULT-II. If 1st DTC is detected, go to EC-625, "Diagnostic Procedure" . SEF058Y 1. 2. 3. I DTC P0605 ECM [CR (WITHOUT EURO-OBD)] 4. If DTC is detected, go to EC-625, "Diagnostic Procedure" . PROCEDURE FOR MALFUNCTION B With CONSULT-II 1. 2. 3. 4. Turn ignition switch ON and wait at least 1 second. Select “DATA MONITOR” mode with CONSULT-II. Turn ignition switch OFF, wait at least 10 seconds, and then turn ON. If 1st trip DTC is detected, go to EC-625, "Diagnostic Procedure" . SEF058Y Without CONSULT-II 1. 2. 3. 4. Turn ignition switch ON and wait at least 1 second. Turn ignition switch OFF, wait at least 10 seconds and then turn ON. Perform Diagnostic Test Mode II (Self-diagnostic results) with ECM. If 1st trip DTC is detected, go to EC-625, "Diagnostic Procedure" . PROCEDURE FOR MALFUNCTION C With CONSULT-II 1. 2. 3. 4. 5. Turn ignition switch ON and wait at least 1 second. Select “DATA MONITOR” mode with CONSULT-II. Turn ignition switch OFF, wait at least 10 seconds, and then turn ON. Repeat step 3 for 32 times. If 1st trip DTC is detected, go to EC-625, "Diagnostic Procedure" . SEF058Y Without CONSULT-II 1. 2. 3. 4. 5. Turn ignition switch ON and wait at least 1 second. Turn ignition switch OFF, wait at least 10 seconds and then turn ON. Repeat step 2 for 32 times. Perform Diagnostic Test Mode II (Self-diagnostic results) with ECM. If 1st trip DTC is detected, go to EC-625, "Diagnostic Procedure" . EC-624 DTC P0605 ECM [CR (WITHOUT EURO-OBD)] Diagnostic Procedure BBS0038G 1. INSPECTION START 1. 2. 3. 4. 5. A With CONSULT-II Turn ignition switch ON. Select “SELF DIAG RESULTS” mode with CONSULT-II. Touch “ERASE”. Perform DTC Confirmation Procedure. See EC-623, "DTC Confirmation Procedure" . Is the 1st trip DTC P0605 displayed again? Without CONSULT-II 1. Turn ignition switch ON. 2. Erase the Diagnostic Test Mode II (Self-diagnostic results) memory. Refer to EC-478, "HOW TO ERASE EMISSION-RELATED DIAGNOSTIC INFORMATION" . 3. Perform DTC Confirmation Procedure. See EC-623, "DTC Confirmation Procedure" . 4. Is the 1st trip DTC 0605 displayed again? Yes or No Yes >> GO TO 2. No >> INSPECTION END 2. REPLACE ECM 1. 2. 3. 4. 5. EC C D E F G H Replace ECM. Perform initialization of NATS system and registration of all NATS ignition key IDs. Refer to BL-218, "ECM Re-communicating Function" . Perform EC-486, "Accelerator Pedal Released Position Learning" . Perform EC-486, "Throttle Valve Closed Position Learning" . Perform EC-486, "Idle Air Volume Learning" . >> INSPECTION END I J K L M EC-625 DTC P1065 ECM POWER SUPPLY [CR (WITHOUT EURO-OBD)] DTC P1065 ECM POWER SUPPLY Component Description PFP:23710 BBS0038H Battery voltage is supplied to the ECM even when the ignition switch is turned OFF for the ECM memory function of the DTC memory, the air-fuel ratio feedback compensation value memory, the idle air volume learning value memory, etc. PBIB1164E On Board Diagnosis Logic DTC No. P1065 1065 Trouble diagnosis name ECM power supply circuit BBS0038I DTC detecting condition Possible cause ● Harness or connectors [ECM power supply (back-up) circuit is open or shorted.] ● ECM ECM back-up RAM system does not function properly. DTC Confirmation Procedure BBS0038J NOTE: If DTC Confirmation Procedure has been previously conducted, always turn ignition switch OFF and wait at least 10 seconds before conducting the next test. WITH CONSULT-II 1. 2. 3. 4. 5. 6. Turn ignition switch ON and wait at least 1 second. Select “DATA MONITOR” mode with CONSULT-II. Start engine and let it idle for 1 second. Turn ignition switch OFF, wait at least 10 seconds and then turn ON. Repeat steps 3 and 4 for 4 times. If 1st trip DTC is detected, go to EC-628, "Diagnostic Procedure" . SEF058Y WITHOUT CONSULT-II 1. 2. 3. 4. 5. 6. 7. Turn ignition switch ON and wait at least 1 second. Start engine and let it idle for 1 second. Turn ignition switch OFF, wait at least 10 seconds and then turn ON. Repeat steps 2 and 3 for 4 times. Turn ignition switch OFF, wait at least 10 seconds and then turn ON. Perform Diagnostic Test Mode II (Self-diagnostic results) with ECM. If 1st trip DTC is detected, go to EC-628, "Diagnostic Procedure" . EC-626 DTC P1065 ECM POWER SUPPLY [CR (WITHOUT EURO-OBD)] Wiring Diagram BBS0038K A EC C D E F G H I J K L M MBWA1518E EC-627 DTC P1065 ECM POWER SUPPLY [CR (WITHOUT EURO-OBD)] Specification data are reference values and are measured between each terminal and ground. CAUTION: Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM's transistor. Use a ground other than ECM terminals, such as the ground. TERMINAL NO. 121 WIRE COLOR BR ITEM Power supply for ECM (Back-up) CONDITION [Ignition switch: OFF] Diagnostic Procedure DATA (DC Voltage) BATTERY VOLTAGE (11 - 14V) BBS0038L 1. CHECK ECM POWER SUPPLY 1. 2. 3. Turn ignition switch OFF. Disconnect ECM harness connector. Check voltage between ECM terminal 121 and ground with CONSULT-II or tester. Voltage: Battery voltage OK or NG OK >> GO TO 3. NG >> GO TO 2. MBIB0026E 2. DETECT MALFUNCTIONING PART Check the following. ● 20A fuse ● IPDM E/R harness connector E7 ● Harness for open or short between ECM and IPDM E/R >> Repair or replace harness or connectors. 3. CHECK INTERMITTENT INCIDENT Refer to EC-542, "TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT" . OK or NG OK >> GO TO 4. NG >> Repair or replace harness or connectors. EC-628 DTC P1065 ECM POWER SUPPLY [CR (WITHOUT EURO-OBD)] 4. PERFORM DTC CONFIRMATION PROCEDURE With CONSULT-II Turn ignition switch ON. Select “SELF DIAG RESULTS” mode with CONSULT-II. Touch “ERASE”. Perform DTC Confirmation Procedure. See EC-626, "DTC Confirmation Procedure" . 5. Is the 1st trip DTC P1065 displayed again? 1. 2. 3. 4. Without CONSULT-II Turn ignition switch ON. Erase the Diagnostic Test Mode II (Self-diagnostic results) memory. Refer to EC-478, "HOW TO ERASE EMISSION-RELATED DIAGNOSTIC INFORMATION" . 3. Perform DTC Confirmation Procedure. See EC-626, "DTC Confirmation Procedure" . 4. Is the 1st trip DTC 1065 displayed again? Yes or No Yes >> GO TO 5. No >> INSPECTION END A EC C D 1. 2. E F G 5. REPLACE ECM 1. 2. 3. 4. 5. Replace ECM. Perform initialization of NATS system and registration of all NATS ignition key IDs. Refer to EC-473, "Description" . Perform EC-486, "Accelerator Pedal Released Position Learning" . Perform EC-486, "Throttle Valve Closed Position Learning" . Perform EC-486, "Idle Air Volume Learning" . H I J >> INSPECTION END K L M EC-629 DTC P1111 IVT CONTROL SOLENOID VALVE [CR (WITHOUT EURO-OBD)] DTC P1111 IVT CONTROL SOLENOID VALVE Component Description PFP:23796 BBS0038M Intake valve timing control solenoid valve is activated by ON/OFF pulse duty (ratio) signals from the ECM. The intake valve timing control solenoid valve changes the oil amount and direction of flow through intake valve timing control unit or stops oil flow. The longer pulse width advances valve angle. The shorter pulse width retards valve angle. When ON and OFF pulse widths become equal, the solenoid valve stops oil pressure flow to fix the intake valve angle at the control position. PBIB1842E CONSULT-II Reference Value in Data Monitor Mode BBS0038N Specification data are reference values. MONITOR ITEM CONDITION ● Engine: After warming up ● Shift lever: Neutral ● Air conditioner switch: OFF ● No load INT/V SOL (B1) SPECIFICATION Idle 0% - 2% 2,000 rpm Approx. 0% - 50% On Board Diagnosis Logic DTC No. P1111 1111 Trouble diagnosis name Intake valve timing control solenoid valve circuit BBS0038O DTC detecting condition Possible cause ● Harness or connectors (Intake valve timing control solenoid valve circuit is open or shorted.) ● Intake valve timing control solenoid valve An improper voltage is sent to the ECM through intake valve timing control solenoid valve. DTC Confirmation Procedure BBS0038P NOTE: If DTC Confirmation Procedure has been previously conducted, always turn ignition switch OFF and wait at least 10 seconds before conducting the next test. WITH CONSULT-II 1. 2. 3. 4. Turn ignition switch ON. Select “DATA MONITOR” mode with CONSULT-II. Start engine and let it idle for 5 seconds. If 1st trip DTC is detected, go to EC-633, "Diagnostic Procedure" . SEF058Y WITHOUT CONSULT-II 1. 2. 3. 4. Start engine and let it idle for 5 seconds. Turn ignition switch OFF and wait at least 10 seconds and then turn ON. Perform Diagnostic Test Mode II (Self-diagnostic results) with ECM. If 1st trip DTC is detected, go to EC-633, "Diagnostic Procedure" . EC-630 DTC P1111 IVT CONTROL SOLENOID VALVE [CR (WITHOUT EURO-OBD)] Wiring Diagram BBS0038Q A EC C D E F G H I J K L M MBWA1519E EC-631 DTC P1111 IVT CONTROL SOLENOID VALVE [CR (WITHOUT EURO-OBD)] Specification data are reference values and are measured between each terminal and ground. CAUTION: Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM's transistor. Use a ground other than ECM terminals, such as the ground. TERMINAL NO. WIRE COLOR ITEM CONDITION DATA (DC Voltage) [Engine is running] ● Warm-up condition ● Idle speed BATTERY VOLTAGE (11 - 14V) Approximately 4V - BATTERY 62 LG Intake valve timing control solenoid valve VOLTAGE (11 - 14V) [Engine is running] ● Warm-up condition ● Engine speed: 2,000 rpm PBIB1790E [Engine is running] [Ignition switch: OFF] ● 111 P ECM relay (Self shut-off) For a few seconds after turning ignition switch OFF [Ignition switch: OFF] ● 119 120 G G Power supply for ECM More than a few seconds passed after turning ignition switch OFF [Ignition switch: ON] : Average voltage for pulse signal (Actual pulse signal can be confirmed by oscilloscope.) EC-632 0 - 1.0V BATTERY VOLTAGE (11 - 14V) BATTERY VOLTAGE (11 - 14V) DTC P1111 IVT CONTROL SOLENOID VALVE [CR (WITHOUT EURO-OBD)] Diagnostic Procedure BBS0038R 1. CHECK INTAKE VALVE TIMING CONTROL SOLENOID VALVE POWER SUPPLY CIRCUIT 1. 2. 3. A Turn ignition switch OFF. Disconnect intake valve timing control solenoid valve harness connector. Turn ignition switch ON. EC C D MBIB0284E 4. Check voltage between intake valve timing control solenoid valve terminal 1 and ground with CONSULT-II or tester. E F Voltage: Battery voltage OK or NG OK >> GO TO 3. NG >> GO TO 2. G H PBIB0285E 2. DETECT MALFUNCTION PART Check the following. ● Harness connectors E48, F1 ● Harness for open or short between intake valve timing control solenoid valve and IPDM E/R I J K >> Repair or replace harness or connectors. 3. CHECK INTAKE VALVE TIMING CONTROL SOLENOID VALVE OUTPUT SIGNAL CIRCUIT FOR L OPEN AND SHORT 1. 2. 3. Turn ignition switch OFF. Disconnect ECM harness connector. Check harness continuity between ECM terminal 62 and intake valve timing control solenoid valve terminal 2. Refer to Wiring Diagram. Continuity should exist. 4. Also check harness for short to ground and short to power. OK or NG OK >> GO TO 4. NG >> Repair open circuit or short to ground or short to power in harness or connectors. 4. CHECK INTAKE VALVE TIMING CONTROL SOLENOID VALVE Refer to EC-634, "Component Inspection" . OK or NG OK >> GO TO 5. NG >> Replace intake valve timing control solenoid valve. EC-633 M DTC P1111 IVT CONTROL SOLENOID VALVE [CR (WITHOUT EURO-OBD)] 5. CHECK INTERMITTENT INCIDENT Refer to EC-542, "TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT" . >> INSPECTION END Component Inspection BBS0038S INTAKE VALVE TIMING CONTROL SOLENOID VALVE 1. 2. 3. 4. Disconnect intake valve timing control solenoid valve harness connector. Check resistance between intake valve timing control solenoid valve as follows. Terminal Resistance 1 and 2 6.7 - 7.7Ω at 20°C (68°F) 1 or 2 and ground ∞Ω (Continuity should not exist.) If NG, replace intake valve timing control solenoid valve. If OK, go to next step. Remove intake valve timing control solenoid valve. MBIB0027E Provide 12V DC between intake valve timing control solenoid valve terminals and then interrupt it. Make sure that the plunger moves as shown in the figure. CAUTION: Do not apply 12V DC continuously for 5 seconds or more. Doing so may result in damage to the coil in intake valve timing control solenoid valve. If NG, replace intake valve timing control solenoid valve. NOTE: Always replace O-ring when intake valve timing control solenoid valve is removed. PBIB2388E Removal and Installation BBS0038T INTAKE VALVE TIMING CONTROL SOLENOID VALVE Refer to EM-35, "ROCKER COVER" . EC-634 DTC P1121 ELECTRIC THROTTLE CONTROL ACTUATOR [CR (WITHOUT EURO-OBD)] DTC P1121 ELECTRIC THROTTLE CONTROL ACTUATOR Component Description PFP:16119 A BBS0038U Electric throttle control actuator consists of throttle control motor, throttle position sensor, etc. The throttle control motor is operated by the ECM and it opens and closes the throttle valve. EC The throttle position sensor detects the throttle valve position, and the opening and closing speed of the throttle valve and feeds the voltage signals to the ECM. The ECM judges the current opening angle of the throttle valve from these signals and the ECM controls the throttle control motor to make the throttle valve opening C angle properly in response to driving condition. On Board Diagnosis Logic BBS0038V D This self-diagnosis has the one trip detection logic. DTC No. P1121 1121 Trouble diagnosis name Electric throttle control actuator DTC detecting condition A) Electric throttle control actuator does not function properly due to the return spring malfunction. B) Throttle valve opening angle in fail-safe mode is not in specified range. C) ECM detect the throttle valve is stuck open. Possible cause E ● Electric throttle control actuator F FAIL-SAFE MODE G When the malfunction is detected, the ECM enters fail-safe mode and the MI lights up. Detected items Engine operating condition in fail-safe mode Malfunction A The ECM controls the electric throttle actuator by regulating the throttle opening around the idle position. The engine speed will not rise more than 2,000 rpm. Malfunction B ECM controls the electric throttle control actuator by regulating the throttle opening to 20 degrees or less. Malfunction C While the vehicle is driving, it slows down gradually by fuel cut. After the vehicle stops, the engine stalls. The engine can restart in Neutral position, and engine speed will not exceed 1,000 rpm or more. DTC Confirmation Procedure H I BBS0038W J NOTE: ● Perform PROCEDURE FOR MALFUNCTION A AND B first. If the DTC cannot be confirmed, perform PROCEDURE FOR MALFUNCTION C. ● If DTC Confirmation Procedure has been previously conducted, always turn ignition switch OFF and wait at least 10 seconds before conducting the next test. K L PROCEDURE FOR MALFUNCTION A AND B With CONSULT-II 1. 2. 3. 4. 5. 6. 7. 8. 9. Turn ignition witch ON and wait at least 1 second. Select “DATA MONITOR” mode with CONSULT-II. Set shift lever to 1st position and wait at least 2 seconds. Set shift lever to Neutral position. Turn ignition switch OFF and wait at least 10 seconds. Turn ignition witch ON and wait at least 1 second. Set shift lever to 1st position and wait at least 2 seconds. Set shift lever to Neutral position. Turn ignition switch OFF, wait at least 10 seconds, and then turn ON. 10. If DTC is detected, go to EC-636, "Diagnostic Procedure" . Without CONSULT-II 1. 2. 3. Turn ignition switch ON and wait at least 1 second. Set shift lever to 1st position and wait at least 2 seconds. Set shift lever to Neutral position. EC-635 M SEF058Y DTC P1121 ELECTRIC THROTTLE CONTROL ACTUATOR [CR (WITHOUT EURO-OBD)] 4. 5. 6. 7. 8. 9. 10. Turn ignition switch OFF and wait at least 10 seconds. Turn ignition witch ON and wait at least 1 second. Set shift lever to 1st position and wait at least 2 seconds. Set shift lever to Neutral position. Turn ignition switch OFF, wait at least 10 seconds and then turn ON. Perform Diagnostic Test Mode II (Self-diagnostic results) with ECM. If DTC is detected, go to EC-636, "Diagnostic Procedure" . PROCEDURE FOR MALFUNCTION C With CONSULT-II 1. 2. 3. 4. 5. 6. Turn ignition switch ON and wait at least 1 second. Select “DATA MONITOR” mode with CONSULT-II. Set shift lever to 1st position and wait at least 2 seconds. Set shift lever to Neutral position. Start engine and let it idle for 3 seconds. If DTC is detected, go to EC-636, "Diagnostic Procedure" . SEF058Y Without CONSULT-II 1. 2. 3. 4. 5. 6. 7. Turn ignition switch ON and wait at least 1 second. Set shift lever to 1st position and wait at least 2 seconds. Set shift lever to Neutral position. Start engine and let it idle for the 3 seconds. Turn ignition switch OFF, wait at least 10 seconds and then turn ON. Perform Diagnostic Test Mode II (Self-diagnostic results) with ECM. If DTC is detected, go to EC-636, "Diagnostic Procedure" . Diagnostic Procedure BBS0038X 1. CHECK ELECTRIC THROTTLE CONTROL ACTUATOR VISUALLY 1. 2. Remove the intake air duct. Check if a foreign matter is caught between the throttle valve and the housing. OK or NG OK >> GO TO 2. NG >> Remove the foreign matter and clean the electric throttle control actuator inside. MBIB0307E 2. REPLACE ELECTRIC THROTTLE CONTROL ACTUATOR 1. 2. 3. Replace the electric throttle control actuator. Perform EC-486, "Throttle Valve Closed Position Learning" . Perform EC-486, "Idle Air Volume Learning" . >> INSPECTION END EC-636 DTC P1122 ELECTRIC THROTTLE CONTROL FUNCTION [CR (WITHOUT EURO-OBD)] DTC P1122 ELECTRIC THROTTLE CONTROL FUNCTION Description PFP:16119 A BBS0038Y NOTE: If DTC P1122 is displayed with DTC P1121 or P1126, first perform the trouble diagnosis for DTC P1121 EC or P1126. Refer to EC-635 or EC-643 . Electric throttle control actuator consists of throttle control motor, throttle position sensor, etc. The throttle control motor is operated by the ECM and it opens and closes the throttle valve. The current opening angle of the throttle valve is detected by the throttle position sensor and it provides feed- C back to the ECM to control the throttle control motor to make the throttle valve opening angle properly in response to driving condition. D On Board Diagnosis Logic BBS0038Z This self-diagnosis has the one trip detection logic. DTC No. Trouble diagnosis name P1122 1122 Electric throttle control performance DTC detecting condition E Possible cause ● Electric throttle control function does not operate properly. ● Harness or connectors (Throttle control motor circuit is open or shorted.) F Electric throttle control actuator G FAIL-SAFE MODE When the malfunction is detected, the ECM enters fail-safe mode and the MI lights up. Engine operating condition in fail-safe mode H ECM stops the electric throttle control actuator control, throttle valve is maintained at a fixed opening (approx. 5 degrees) by the return spring. DTC Confirmation Procedure BBS00390 NOTE: If DTC Confirmation Procedure has been previously conducted, always turn ignition switch OFF and wait at least 10 seconds before conducting the next test. TESTING CONDITION: Before performing the following procedure, confirm that battery voltage is more than 11V when engine is running. I J K WITH CONSULT-II 1. 2. 3. 4. Turn ignition switch ON and wait at least 2 seconds. Select “DATA MONITOR” mode with CONSULT-II. Start engine and let it idle for 5 seconds. If DTC is detected, go to EC-639, "Diagnostic Procedure" . L M SEF058Y WITHOUT CONSULT-II 1. 2. 3. 4. 5. Turn ignition switch ON and wait at least 2 seconds. Start engine and let it idle for 5 seconds. Turn ignition switch OFF, wait at least 10 seconds and then turn ON. Perform Diagnostic Test Mode II (Self-diagnostic results) with ECM. If DTC is detected, go to EC-639, "Diagnostic Procedure" . EC-637 DTC P1122 ELECTRIC THROTTLE CONTROL FUNCTION [CR (WITHOUT EURO-OBD)] Wiring Diagram BBS00391 MBWA1520E EC-638 DTC P1122 ELECTRIC THROTTLE CONTROL FUNCTION [CR (WITHOUT EURO-OBD)] Specification data are reference values and are measured between each terminal and ground. Pulse signal is measured by CONSULT-II. A CAUTION: Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM's transistor. Use a ground other than ECM terminals, such as the ground. EC TERMINAL NO. 3 WIRE COLOR ITEM CONDITION DATA (DC Voltage) C LG Throttle control motor relay power supply BATTERY VOLTAGE (11 - 14V) [Ignition switch: ON] 0 - 14V D [Ignition switch: ON] 4 L Throttle control motor (Close) ● Engine stopped ● Shift lever position: 1st ● Accelerator pedal: Fully released E PBIB0534E F 0 - 14V [Ignition switch: ON] 5 P Throttle control motor (Open) ● Engine stopped ● Shift lever position: 1st ● Accelerator pedal: Fully depressed G H PBIB0533E 104 G Throttle control motor relay [Ignition switch: OFF] BATTERY VOLTAGE (11 - 14V) [Ignition switch: ON] 0 - 1.0V I : Average voltage for pulse signal (Actual pulse signal can be confirmed by oscilloscope.) J Diagnostic Procedure BBS00392 1. CHECK GROUND CONNECTIONS 1. 2. K Turn ignition switch OFF. Loosen and retighten ground screws on the body. Refer to EC-548, "Ground Inspection" . L M MBIB1502E 1. Body ground E44 2. Body ground E45 OK or NG OK >> GO TO 2. NG >> Repair or replace ground connections. EC-639 3. Body ground E28 DTC P1122 ELECTRIC THROTTLE CONTROL FUNCTION [CR (WITHOUT EURO-OBD)] 2. CHECK THROTTLE CONTROL MOTOR RELAY SIGNAL CIRCUIT-I Check voltage between ECM terminal 3 and ground under the following conditions with CONSULT-II or tester. Ignition switch Voltage OFF Approximately 0V ON Battery voltage (11 - 14V) OK or NG OK >> GO TO 9. NG >> GO TO 3. MBIB0028E 3. CHECK THROTTLE CONTROL MOTOR RELAY POWER SUPPLY CIRCUIT-I 1. 2. Turn ignition switch OFF. Check voltage between ECM terminal 104 and ground with CONSULT-II or tester. Voltage: Battery voltage OK or NG OK >> GO TO 6. NG >> GO TO 4. PBIB1171E 4. CHECK THROTTLE CONTROL MOTOR RELAY POWER SUPPLY CIRCUIT-II 1. 2. 3. Disconnect ECM harness connector. Disconnect IPDM E/R harness connector E5. Check continuity between ECM terminal 104 and IPDM E/R terminal 70. Refer to Wiring Diagram. Continuity should exist. 4. Also check harness for short to ground and short to power. OK or NG OK >> GO TO 5. NG >> Repair open circuit or short to ground or short to power in harness or connectors. 5. CHECK FUSE 1. Disconnect 20A fuse. 2. Check 20A fuse for blown. OK or NG OK >> GO TO 8. NG >> Replace 20A fuse. EC-640 DTC P1122 ELECTRIC THROTTLE CONTROL FUNCTION [CR (WITHOUT EURO-OBD)] 6. CHECK THROTTLE CONTROL MOTOR RELAY INPUT SIGNAL CIRCUIT-II 1. 2. 3. A Disconnect ECM harness connector. Disconnect IPDM E/R harness connector E7. Check harness continuity between ECM terminal 3 and IPDM E/R terminal 28. Refer to Wiring Diagram. EC Continuity should exist. C 4. Also check harness for short to ground and short to power. OK or NG OK >> GO TO 8. NG >> GO TO 7. D 7. DETECT MALFUNCTIONING PART E Check the following. ● Harness connectors E48, F1 ● Harness for open or short between ECM and IPDM E/R F >> Repair open circuit or short to ground or short to power in harness or connectors. G 8. CHECK INTERMITTENT INCIDENT Refer to EC-542, "TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT" . OK or NG OK >> Replace IPDM E/R. Refer to PG-18, "IPDM E/R (INTELLIGENT POWER DISTRIBUTION MODULE ENGINE ROOM)" . NG >> Repair or replace harness or connectors. 9. CHECK THROTTLE CONTROL MOTOR OUTPUT SIGNAL CIRCUIT FOR OPEN OR SHORT 1. 2. 3. 4. 3 6 ECM terminal I J Turn ignition switch OFF. Disconnect electric throttle control actuator harness connector. Disconnect ECM harness connector. Check harness continuity between the following terminals. Refer to Wiring Diagram. Electric throttle control actuator terminal H K L Continuity 5 Should not exist 4 Should exist 5 Should exist 4 Should not exist 5. Also check harness for short to ground and short to power. OK or NG OK >> GO TO 10. NG >> Repair or replace. EC-641 M MBIB0308E DTC P1122 ELECTRIC THROTTLE CONTROL FUNCTION [CR (WITHOUT EURO-OBD)] 10. CHECK ELECTRIC THROTTLE CONTROL ACTUATOR VISUALLY 1. 2. Remove the intake air duct. Check if foreign matter is caught between the throttle valve and the housing. OK or NG OK >> GO TO 11. NG >> Remove the foreign matter and clean the electric throttle control actuator inside. MBIB0307E 11. CHECK THROTTLE CONTROL MOTOR Refer to EC-642, "Component Inspection" . OK or NG OK >> GO TO 12. NG >> GO TO 13. 12. CHECK INTERMITTENT INCIDENT Refer to EC-542, "TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT" . OK or NG OK >> GO TO 13. NG >> Repair or replace harness or connectors. 13. REPLACE ELECTRIC THROTTLE CONTROL ACTUATOR 1. 2. 3. Replace the electric throttle control actuator. Perform EC-486, "Throttle Valve Closed Position Learning" . Perform EC-486, "Idle Air Volume Learning" . >> INSPECTION END Component Inspection BBS00393 THROTTLE CONTROL MOTOR 1. 2. Disconnect electric throttle control actuator harness connector. Check resistance between terminals 3 and 6. Resistance: Approximately 1 - 15 Ω [at 25 °C (77°F)] 3. 4. 5. If NG, replace electric throttle control actuator and go to next step. Perform EC-486, "Throttle Valve Closed Position Learning" . Perform EC-486, "Idle Air Volume Learning" . PBIB0095E Removal and Installation BBS00394 ELECTRIC THROTTLE CONTROL ACTUATOR Refer to EM-18, "AIR CLEANER AND AIR DUCT" . EC-642 DTC P1124, P1126 THROTTLE CONTROL MOTOR RELAY [CR (WITHOUT EURO-OBD)] DTC P1124, P1126 THROTTLE CONTROL MOTOR RELAY Component Description PFP:16119 A BBS00395 Power supply for the throttle control motor is provided to the ECM via throttle control motor relay. The throttle control motor relay is ON/OFF controlled by the ECM. When the ignition switch is turned ON, the ECM sends EC an ON signal to throttle control motor relay and battery voltage is provided to the ECM. When the ignition switch is turned OFF, the ECM sends an OFF signal to throttle control motor relay and battery voltage is not provided to the ECM. C CONSULT-II Reference Value in Data Monitor Mode BBS00396 Specification data are reference values. MONITOR ITEM THRTL RELAY CONDITION ● D SPECIFICATION Ignition switch: ON ON On Board Diagnosis Logic BBS00397 E These self-diagnoses have the one trip detection logic. DTC No. P1124 1124 P1126 1126 Trouble diagnosis name Throttle control motor relay circuit short Throttle control motor relay circuit open DTC detecting condition F Possible cause ● Harness or connectors (Throttle control motor relay circuit is shorted.) ● Throttle control motor relay ● Harness or connectors (Throttle control motor relay circuit is open.) ● Throttle control motor relay ECM detects the throttle control motor relay is stuck ON. ECM detects a voltage of power source for throttle control motor is excessively low. G H FAIL-SAFE MODE I When the malfunction is detected, the ECM enters fail-safe mode and the MI lights up. Engine operating condition in fail-safe mode ECM stops the electric throttle control actuator control, throttle valve is maintained at a fixed opening (approx. 5 degrees) by the return spring. DTC Confirmation Procedure BBS00398 NOTE: If DTC Confirmation Procedure has been previously conducted, always turn ignition switch OFF and wait at least 10 seconds before conducting the next test. PROCEDURE FOR DTC P1124 TESTING CONDITION: Before performing the following procedure, confirm that battery voltage is more than 8V. Turn ignition switch ON and wait at least 1 second. Select “DATA MONITOR” mode with CONSULT-II. If DTC is detected, go to EC-646, "Diagnostic Procedure" . SEF058Y EC-643 K L M With CONSULT-II 1. 2. 3. J DTC P1124, P1126 THROTTLE CONTROL MOTOR RELAY [CR (WITHOUT EURO-OBD)] Without CONSULT-II 1. 2. 3. Turn ignition switch ON and wait at least 1 second. Turn ignition switch OFF, wait at least 10 seconds and then turn ON. If DTC is detected, go to EC-646, "Diagnostic Procedure" . PROCEDURE FOR DTC P1126 With CONSULT-II 1. 2. 3. 4. Turn ignition switch ON and wait at least 2 seconds. Select “DATA MONITOR” mode with CONSULT-II. Start engine and let it idle for 5 seconds. If DTC is detected, go to EC-646, "Diagnostic Procedure" . SEF058Y Without CONSULT-II 1. 2. 3. 4. 5. Turn ignition switch ON and wait at least 2 second. Start engine and let it idle for 5 seconds. Turn ignition switch OFF, wait at least 10 seconds and then turn ON. Perform Diagnostic Test Mode II (Self-diagnostic results) with ECM. If DTC is detected, go to EC-646, "Diagnostic Procedure" . EC-644 DTC P1124, P1126 THROTTLE CONTROL MOTOR RELAY [CR (WITHOUT EURO-OBD)] Wiring Diagram BBS00399 A EC C D E F G H I J K L M MBWA1521E EC-645 DTC P1124, P1126 THROTTLE CONTROL MOTOR RELAY [CR (WITHOUT EURO-OBD)] Specification data are reference values and are measured between each terminal and ground. Pulse signal is measured by CONSULT-II. CAUTION: Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM's transistor. Use a ground other than ECM terminals, such as the ground. TERMINAL NO. 3 WIRE COLOR LG ITEM Throttle control motor relay power supply CONDITION [Ignition switch: ON] DATA (DC Voltage) BATTERY VOLTAGE (11 - 14V) 0 - 14V [Ignition switch: ON] 4 L Throttle control motor (Close) ● Engine stopped ● Shift lever position: 1st ● Accelerator pedal: Fully released PBIB0534E 0 - 14V [Ignition switch: ON] 5 P Throttle control motor (Open) ● Engine stopped ● Shift lever position: 1st ● Accelerator pedal: Fully depressed PBIB0533E 104 G Throttle control motor relay [Ignition switch: OFF] BATTERY VOLTAGE (11 - 14V) [Ignition switch: ON] 0 - 1.0V : Average voltage for pulse signal (Actual pulse signal can be confirmed by oscilloscope.) Diagnostic Procedure BBS0039A 1. CHECK THROTTLE CONTROL MOTOR RELAY POWER SUPPLY CIRCUIT-I 1. 2. Turn ignition switch OFF. Check voltage between ECM terminal 104 and ground with CONSULT-II or tester. Voltage: Battery voltage. OK or NG OK >> GO TO 4. NG >> GO TO 2. PBIB1171E EC-646 DTC P1124, P1126 THROTTLE CONTROL MOTOR RELAY [CR (WITHOUT EURO-OBD)] 2. CHECK THROTTLE CONTROL MOTOR RELAY POWER SUPPLY CIRCUIT-II 1. 2. 3. A Disconnect ECM harness connector. Disconnect IPDM E/R harness connector E5. Check continuity between ECM terminal 104 and IPDM E/R terminal 70. EC Continuity should exist. C 4. Also check harness for short to ground and short to power. OK or NG OK >> GO TO 3. NG >> Repair open circuit or short to ground or short to power in harness or connectors. D 3. CHECK FUSE E 1. Disconnect 20A fuse. 2. Check 20A fuse for blown. OK or NG OK >> GO TO 7. NG >> Replace 20A fuse. F 4. CHECK THROTTLE CONTROL MOTOR RELAY INPUT SIGNAL CIRCUIT-I 1. 2. G Reconnect all disconnected connectors. Check voltage between ECM terminal 3 and ground under the following conditions with CONSULT-II or tester. Ignition switch Voltage OFF Approximately 0V ON Battery voltage (11 - 14V) OK or NG OK >> GO TO 7. NG >> GO TO 5. H I J MBIB0028E K 5. CHECK THROTTLE CONTROL MOTOR RELAY INPUT SIGNAL CIRCUIT-II 1. 2. 3. 4. Turn ignition switch OFF. Disconnect ECM harness connector. Disconnect IPDM E/R harness connector E7. Check continuity between ECM terminal 3 and IPDM E/R terminal 28. Refer to Wiring Diagram. Continuity should exist. 5. Also check harness for short to ground and short to power. OK or NG OK >> GO TO 7. NG >> GO TO 6. 6. DETECT MALFUNCTIONING PART Check the following. ● Harness connectors E48, F1 ● Harness for open or short between ECM and IPDM E/R >> Repair open circuit or short to ground or short to power in harness or connectors. EC-647 L M DTC P1124, P1126 THROTTLE CONTROL MOTOR RELAY [CR (WITHOUT EURO-OBD)] 7. CHECK INTERMITTENT INCIDENT Refer to EC-542, "TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT" . OK or NG OK >> Replace IPDM E/R. Refer to PG-18, "IPDM E/R (INTELLIGENT POWER DISTRIBUTION MODULE ENGINE ROOM)" . NG >> Repair or replace harness or connectors. EC-648 DTC P1128 THROTTLE CONTROL MOTOR [CR (WITHOUT EURO-OBD)] DTC P1128 THROTTLE CONTROL MOTOR Component Description PFP:16119 A BBS0039B The throttle control motor is operated by the ECM and it opens and closes the throttle valve. The current opening angle of the throttle valve is detected by the throttle position sensor and it provides feed- EC back to the ECM to control the throttle control motor to make the throttle valve opening angle properly in response to driving condition. On Board Diagnosis Logic BBS0039C C This self-diagnosis has the one trip detection logic. DTC No. P1128 1128 Trouble diagnosis name Throttle control motor circuit short DTC detecting condition ECM detects short in both circuits between ECM and throttle control motor. Possible cause D ● Harness or connectors (Throttle control motor circuit is shorted.) ● Electric throttle control actuator (Throttle control motor) E FAIL-SAFE MODE F When the malfunction is detected, the ECM enters fail-safe mode and the MI lights up. Engine operating condition in fail-safe mode ECM stops the electric throttle control actuator control, throttle valve is maintained at a fixed opening (approx. 5 degrees) by the return spring. DTC Confirmation Procedure BBS0039D NOTE: If DTC Confirmation Procedure has been previously conducted, always turn ignition switch OFF and wait at least 10 seconds before conducting the next test. G H I WITH CONSULT-II 1. 2. 3. 4. Turn ignition switch ON and wait at least 2 seconds. Select “DATA MONITOR” mode with CONSULT-II. Start engine and let it idle for 5 seconds. If DTC is detected, go to EC-651, "Diagnostic Procedure" . J K L SEF058Y WITHOUT CONSULT-II 1. 2. 3. 4. 5. Turn ignition switch ON and wait at least 2 second. Start engine and let it idle for 5 seconds. Turn ignition switch OFF, wait at least 10 seconds and then turn ON. Perform Diagnostic Test Mode II (Self-diagnostic results) with ECM. If DTC is detected, go to EC-651, "Diagnostic Procedure" . EC-649 M DTC P1128 THROTTLE CONTROL MOTOR [CR (WITHOUT EURO-OBD)] Wiring Diagram BBS0039E MBWA1522E EC-650 DTC P1128 THROTTLE CONTROL MOTOR [CR (WITHOUT EURO-OBD)] Specification data are reference values and are measured between each terminal and ground. Pulse signal is measured by CONSULT-II. A CAUTION: Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM's transistor. Use a ground other than ECM terminals, such as the ground. EC TERMINAL NO. 3 WIRE COLOR ITEM CONDITION DATA (DC Voltage) C LG Throttle control motor relay power supply BATTERY VOLTAGE (11 - 14V) [Ignition switch: ON] 0 - 14V D [Ignition switch: ON] 4 L Throttle control motor (Close) ● Engine stopped ● Shift lever position: 1st ● Accelerator pedal: Fully released E PBIB0534E F 0 - 14V [Ignition switch: ON] 5 P Throttle control motor (Open) ● Engine stopped ● Shift lever position: 1st ● Accelerator pedal: Fully depressed G H PBIB0533E 104 G Throttle control motor relay [Ignition switch: OFF] BATTERY VOLTAGE (11 - 14V) [Ignition switch: ON] 0 - 1.0V I : Average voltage for pulse signal (Actual pulse signal can be confirmed by oscilloscope.) J Diagnostic Procedure BBS0039F 1. CHECK GROUND CONNECTIONS 1. 2. K Turn ignition switch OFF. Loosen and retighten ground screws on the body. Refer to EC-548, "Ground Inspection" . L M MBIB1502E 1. Body ground E44 2. Body ground E45 OK or NG OK >> GO TO 2. NG >> Repair or replace ground connections. EC-651 3. Body ground E28 DTC P1128 THROTTLE CONTROL MOTOR [CR (WITHOUT EURO-OBD)] 2. CHECK THROTTLE CONTROL MOTOR OUTPUT SIGNAL CIRCUIT FOR OPEN OR SHORT 1. 2. 3. Disconnect electric throttle control actuator harness connector. Disconnect ECM harness connector. Check harness continuity between the following terminals. Refer to Wiring Diagram. Electric throttle control actuator terminal ECM terminal 3 6 Continuity 4 Should exist 5 Should not exist 4 Should not exist 5 Should exist MBIB0308E 4. Also check harness for short to ground and short to power. OK or NG OK >> GO TO 3. NG >> Repair or replace. 3. CHECK THROTTLE CONTROL MOTOR Refer to EC-652, "Component Inspection" . OK or NG OK >> GO TO 4. NG >> GO TO 5. 4. CHECK INTERMITTENT INCIDENT Refer to EC-542, "TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT" . OK or NG OK >> GO TO 5. NG >> Repair or replace harness or connectors. 5. REPLACE ELECTRIC THROTTLE CONTROL ACTUATOR 1. 2. 3. Replace the electric throttle control actuator. Perform EC-486, "Throttle Valve Closed Position Learning" . Perform EC-486, "Idle Air Volume Learning" . >> INSPECTION END Component Inspection BBS0039G THROTTLE CONTROL MOTOR 1. 2. Disconnect electric throttle control actuator harness connector. Check resistance between terminals 3 and 6. Resistance: Approximately 1 - 15 Ω [at 25 °C (77°F)] 3. 4. 5. If NG, replace electric throttle control actuator and go to next step. Perform EC-486, "Throttle Valve Closed Position Learning" . Perform EC-486, "Idle Air Volume Learning" . PBIB0095E EC-652 DTC P1128 THROTTLE CONTROL MOTOR [CR (WITHOUT EURO-OBD)] Removal and Installation BBS0039H ELECTRIC THROTTLE CONTROL ACTUATOR A Refer to EM-18, "AIR CLEANER AND AIR DUCT" . EC C D E F G H I J K L M EC-653 DTC P1171 INTAKE ERROR [CR (WITHOUT EURO-OBD)] DTC P1171 INTAKE ERROR On Board Diagnosis Logic PFP:22365 BBS0039I NOTE: ● If DTC P1171 is displayed with DTC P0108, first perform the trouble diagnosis for DTC P0108. Refer to EC-559, "DTC P0107, P0108 MANIFOLD ABSOLUTE PRESSURE SENSOR" . ● If DTC P1171 is displayed with DTC P1229, first perform the trouble diagnosis for DTC P1229. Refer to EC-680, "DTC P1229 SENSOR POWER SUPPLY" . ECM computes two intake air volume values. 1: Computed from manifold absolute pressure signal and intake air temperature signal. 2: Computed from engine revolution signal and throttle position signal. In normal condition, value 1 is used for engine control. If intake air leak occurred between throttle valve and intake air port, manifold absolute pressure sensor signal might increase, and then ECM increases amount of fuel injected. In this case, ECM uses value 2 for engine control instead of value1. ECM monitors the difference between value 1 and value 2. If the difference is extremely large, ECM judges intake air leak occurs and light up the MI This diagnosis has one trip detection logic. DTC No. P1171 1171 Trouble diagnosis name Intake error DTC detecting condition A high voltage from the sensor is sent to ECM under light load driving condition. Possible cause ● Harness or connectors (The manifold absolute pressure sensor circuit is open or shorted.) ● Manifold absolute pressure ● Intake air leaks ● Vacuum hoses FAIL-SAFE MODE When the malfunction is detected, the ECM enters fail-safe mode and MI lights up. Detected items Intake air system Engine operating condition in fail-safe mode When accelerator pedal is depressed, engine speed will not rise more than 2,500 rpm due to fuel cut. DTC Confirmation Procedure BBS0039J NOTE: If DTC Confirmation Procedure has been previously conducted, always turn ignition switch OFF and wait at least 10 seconds before conducting the next test. WITH CONSULT-II 1. 2. 3. 4. Turn ignition switch ON. Select “DATA MONITOR” mode with CONSULT-II. Start engine and wait at least 5 seconds. If DTC is detected, go to EC-657, "Diagnostic Procedure" . SEF058Y EC-654 DTC P1171 INTAKE ERROR [CR (WITHOUT EURO-OBD)] WITHOUT CONSULT-II 1. 2. 3. 4. Turn ignition switch ON and wait at least 5 seconds. Turn ignition switch OFF, wait at least 10 seconds and then turn ON. Perform Diagnostic Test Mode II (Self-diagnostic results) with ECM. If DTC is detected, go to EC-657, "Diagnostic Procedure" . A EC C D E F G H I J K L M EC-655 DTC P1171 INTAKE ERROR [CR (WITHOUT EURO-OBD)] Wiring Diagram BBS0039K MBWA1506E EC-656 DTC P1171 INTAKE ERROR [CR (WITHOUT EURO-OBD)] Specification data are reference values and are measured between each terminal and ground. CAUTION: Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM's transistor. Use a ground other than ECM terminals, such as the ground. TERMINAL NO. 45 WIRE COLOR L EC ITEM Sensor power supply (Manifold absolute pressure sensor) CONDITION DATA (DC Voltage) C [Ignition switch: ON] Approximately 5V [Engine is running] 51 56 W B A Manifold absolute pressure sensor Sensor ground (Manifold absolute pressure sensor) ● Warm-up condition ● Idle speed D Approximately 1.5V [Engine is running] ● Warm-up condition ● Engine speed: 2,000 rpm E Approximately 1.2V F [Engine is running] ● Warm-up condition ● Idle speed Approximately 0V G Diagnostic Procedure BBS0039L 1. CHECK INTAKE AIR LEAK Listen for an intake air leak after the air cleaner element. OK or NG OK >> GO TO 2. NG >> Repair or replace. 2. CHECK VACUUM HOSE H I J Check intake manifold vacuum hoses for clogging or disconnection. Refer to EC-509, "Vacuum Hose Drawing" . OK or NG OK >> GO TO 3. NG >> Repair or replace. 1. K L M EC-657 DTC P1171 INTAKE ERROR [CR (WITHOUT EURO-OBD)] 3. CHECK GROUND CONNECTIONS 1. 2. Turn ignition switch OFF. Loosen and retighten ground screws on the body. Refer to EC-548, "Ground Inspection" . MBIB1502E 1. Body ground E44 2. Body ground E45 3. Body ground E28 OK or NG OK >> GO TO 4. NG >> Repair or replace ground connections. 4. CHECK MAP SENSOR POWER SUPPLY CIRCUIT 1. 2. Disconnect manifold absolute pressure sensor harness connector. Turn ignition switch ON. MBIB0276E 3. Check voltage between manifold absolute pressure sensor terminal 2 and ground with CONSULT-II or tester. Voltage: Approximately 5V OK or NG OK >> GO TO 5. NG >> Repair harness or connectors. MBIB0602E EC-658 DTC P1171 INTAKE ERROR [CR (WITHOUT EURO-OBD)] 5. CHECK MAP SENSOR GROUND CIRCUIT FOR OPEN AND SHORT 1. 2. 3. Turn ignition switch OFF. Disconnect ECM harness connector. Check harness continuity between manifold absolute pressure sensor terminal 4 and ECM terminal 56. Refer to Wiring Diagram. Continuity should exist. EC C 4. Also check harness for short to ground and short to power. OK or NG OK >> GO TO 6. NG >> Repair open circuit or short to ground or short to power in harness or connectors. 6. CHECK MAP SENSOR INPUT SIGNAL CIRCUIT FOR OPEN AND SHORT 1. A D E Check harness continuity between manifold absolute pressure sensor terminal 1 and ECM terminal 51. Refer to Wiring Diagram. F Continuity should exist. 2. Also check harness for short to ground and short to power. OK or NG OK >> GO TO 7. NG >> Repair open circuit or short to ground or short to power in harness or connectors. G H 7. CHECK MAP SENSOR Refer to EC-563, "Component Inspection" . OK or NG OK >> GO TO 8. NG >> Replace manifold absolute pressure sensor. I J 8. CHECK INTERMITTENT INCIDENT Refer to EC-542, "TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT" . K >> INSPECTION END L M EC-659 DTC P1211 TCS CONTROL UNIT [CR (WITHOUT EURO-OBD)] DTC P1211 TCS CONTROL UNIT Description PFP:47850 BBS003ZQ The malfunction information related to TCS is transferred through the CAN communication line from “ABS actuator and electric unit (control unit)” to ECM. Be sure to erase the malfunction information such as DTC not only for “ABS actuator and electric unit (control unit)” but also for ECM after TCS related repair. On Board Diagnosis Logic BBS003ZR Freeze frame data is not stored in the ECM for this self-diagnosis. The MI will not light up for this selfdiagnosis. DTC No. P1211 1211 Trouble diagnosis name TCS control unit DTC detecting condition Possible cause ● ABS actuator and electric unit (control unit) ● TCS related parts ECM receives a malfunction information from “ABS actuator and electric unit (Control unit)”. DTC Confirmation Procedure BBS003ZS TESTING CONDITION: Before performing the following procedure, confirm that battery voltage is more than 10.5V at idle. WITH CONSULT-II 1. 2. 3. 4. Turn ignition switch ON. Select “DATA MONITOR” mode with CONSULT-II. Start engine and let it idle for at least 60 seconds. If 1st trip DTC is detected, go to EC-660, "Diagnostic Procedure" . SEF058Y WITHOUT CONSULT-II 1. 2. 3. 4. Start engine and let it idle for at least 60 seconds. Turn ignition switch OFF, wait at least 10 seconds and turn ON. Perform Diagnostic Test Mode II (Self-diagnostic results) with ECM. If 1st trip DTC is detected, go to EC-660, "Diagnostic Procedure" . Diagnostic Procedure BBS003ZT Go to BRC-49, "TROUBLE DIAGNOSIS" . EC-660 DTC P1212 TCS COMMUNICATION LINE [CR (WITHOUT EURO-OBD)] DTC P1212 TCS COMMUNICATION LINE Description PFP:47850 A BBS0039M NOTE: ● If DTC P1212 is displayed with DTC U1001, first perform the trouble diagnosis for DTC U1001. EC Refer to EC-549, "DTC U1001 CAN COMMUNICATION LINE" . ● If DTC P1212 is displayed with DTC U1010, first perform the trouble diagnosis for DTC U1010. Refer to EC-552, "DTC U1010 CAN COMMUNICATION" . C This CAN communication line is used to control the smooth engine operation during the TCS operation. Pulse signals are exchanged between ECM and “ABS actuator and electric unit (control unit)”. Be sure to erase the malfunction information such as DTC not only for “ABS actuator and electric unit D (control unit)” but also for ECM after TCS related repair. On Board Diagnosis Logic BBS0039N E The MI will not light up for this self-diagnosis. Freeze frame data is not stored in the ECM for this self-diagnosis. DTC No. P1212 1212 Trouble diagnosis name TCS communication line DTC detecting condition ECM can not receive the information from “ABS actuator and electric unit (control unit)” continuously. Possible cause F ● Harness or connectors (The CAN communication line is open or shorted.) ● ABS actuator and electric unit (control unit). ● Dead (Weak) battery DTC Confirmation Procedure BBS0039O G H TESTING CONDITION: Before performing the following procedure, confirm that battery voltage is more than 10.5V at idle. I WITH CONSULT-II 1. 2. 3. 4. Turn ignition switch ON. Select “DATA MONITOR” mode with CONSULT-II. Start engine and let it idle for at least 10 seconds. If 1st trip DTC is detected, go to EC-661, "Diagnostic Procedure" . J K L SEF058Y WITHOUT CONSULT-II 1. 2. 3. 4. Start engine and let it idle for at least 10 seconds. Turn ignition switch OFF, wait at least 10 seconds and then turn ON. Perform Diagnostic Test Mode II (Self-diagnostic results) with ECM. If 1st trip DTC is detected, go to EC-661, "Diagnostic Procedure" . Diagnostic Procedure BBS0039P Refer to BRC-49, "TROUBLE DIAGNOSIS" . EC-661 M DTC P1217 ENGINE OVER TEMPERATURE [CR (WITHOUT EURO-OBD)] DTC P1217 ENGINE OVER TEMPERATURE System Description PFP:00000 BBS0047Z NOTE: ● If DTC P1217 is displayed with DTC U1001, first perform the trouble diagnosis for DTC U1001. Refer to EC-549, "DTC U1001 CAN COMMUNICATION LINE" . ● If DTC P1217 is displayed with DTC U1010, first perform the trouble diagnosis for DTC U1010. Refer to EC-552, "DTC U1010 CAN COMMUNICATION" . COOLING FAN CONTROL Sensor Input Signal to ECM Crankshaft position sensor (POS) Camshaft position sensor (PHASE) Engine speed*1 Battery Battery voltage*1 Wheel sensor Vehicle speed*2 Engine coolant temperature sensor Engine coolant temperature Air conditioner switch*3 Air conditioner ON signal*2 Refrigerant pressure sensor*3 Refrigerant pressure ECM Function Cooling fan control Actuator IPDM E/R (Cooling fan relay) *1: ECM determines the start signal status by the signals of engine speed and battery voltage. *2: This signal is sent to ECM through CAN communication line. *3: Models with air conditioner. The ECM controls the cooling fan corresponding to the vehicle speed, engine coolant temperature, refrigerant pressure, and air conditioner ON signal. The control system has 3-step control [HIGH/LOW/OFF] (models with A/C) or 2 step control [ON/OFF] (models without A/C). The ECM controls cooling fan relays through CAN communication line. OPERATION Models with A/C MBIB0650E EC-662 DTC P1217 ENGINE OVER TEMPERATURE [CR (WITHOUT EURO-OBD)] Models without A/C A EC C MBIB0656E CONSULT-II Reference Value in Data Monitor Mode BBS00480 Specification data are reference values. E MONITOR ITEM AIR COND SIG CONDITION ● ● COOLING FAN ● Engine: After warming up, idle the engine Engine: After warming up, idle the engine Air conditioner switch: OFF SPECIFICATION Air conditioner switch: OFF OFF Air conditioner switch: ON (Compressor operates.) ON Engine coolant temperature: 94°C (201°F) or less OFF Engine coolant temperature: Between 95°C (203°F) and 104°C (210°F) LOW* Engine coolant temperature: 105°C (212°F) or more HI* F G H *: Models without air conditioner, cooling fan operates only ON and OFF operation, but CONSULT-II display will change OFF, LOW and HI depends on engine coolant temperature. On Board Diagnosis Logic Trouble diagnosis name DTC detecting condition ● P1217 1217 Engine over temperature (Overheat) Harness or connectors (The cooling fan circuit is open or shorted.) ● Cooling fan Cooling fan does not operate properly (Overheat). ● IPDM E/R (Cooling fan relay) ● Radiator hose Cooling fan system does not operate properly (Overheat). ● Radiator ● Reservoir tank cap (Models with A/C) ● Radiator cap (Models without A/C) ● Water pump ● Thermostat ● Engine coolant was not added to the system using the proper filling method. ● Engine coolant is not within the specified range. For more information, refer to EC-674, "Main 12 Causes of Overheating" . CAUTION: When a malfunction is indicated, be sure to replace the coolant. Refer to CO-9, "Changing Engine coolant" . Also, replace the engine oil. Refer to LU-7, "Changing Engine Oil" . 1. Fill radiator with coolant up to specified level with a filling speed of 2 liters per minute. Be sure to use coolant with the proper mixture ratio. Refer to MA-26, "Engine Coolant Mixture Ratio" . EC-663 J K Possible cause ● ● I BBS00481 If the cooling fan or another component in the cooling system malfunctions, engine coolant temperature will rise. When the engine coolant temperature reaches an abnormally high temperature condition, a malfunction is indicated. This self-diagnosis has the one trip detection logic. DTC No. D L M DTC P1217 ENGINE OVER TEMPERATURE [CR (WITHOUT EURO-OBD)] 2. After refilling coolant, run engine to ensure that no water-flow noise is emitted. Overall Function Check BBS00482 Use this procedure to check the overall function of the cooling fan. During this check, a DTC might not be confirmed. WARNING: Never remove the radiator cap (Models without A/C) or reservoir tank cap (Models with A/C) when the engine is hot. Serious burns could be caused by high pressure fluid escaping from the radiator (Models without A/C) or reservoir tank (Models with A/C). Wrap a thick cloth around cap. Carefully remove the cap by turning it a quarter turn to allow built-up pressure to escape. Then turn the cap all the way off. WITH CONSULT-II 1. 2. 3. Check the coolant level in the reservoir tank and radiator. Allow engine to cool before checking coolant level. If the coolant level in the reservoir tank and/or radiator is below the proper range, skip the following steps and go to EC-668, "Diagnostic Procedure" . Confirm whether customer filled the coolant or not. If customer filled the coolant, skip the following steps and go to EC-668, "Diagnostic Procedure" . Turn ignition switch ON. SEF621W 4. 5. Perform “COOLING FAN” in “ACTIVE TEST” mode with CONSULT-II. If the results are NG, go to EC-668, "Diagnostic Procedure" . SEF784Z WITHOUT CONSULT-II Models with Air Conditioner 1. 2. 3. 4. 5. 6. 7. Check the coolant level in the reservoir tank and radiator. Allow engine to cool before checking coolant level. If the coolant level in the reservoir tank and/or radiator is below the proper range, skip the following steps and go to EC-668, "Diagnostic Procedure" . Confirm whether customer filled the coolant or not. If customer filled the coolant, skip the following steps and go to EC-668, "Diagnostic Procedure" . Start engine. CAUTION: Be careful not to overheat engine. Set temperature control lever to full cold position. Turn air conditioner switch ON. Turn blower fan switch ON. Run engine at idle for a few minutes with air conditioner operating. CAUTION: Be careful not to overheat engine. EC-664 SEF621W DTC P1217 ENGINE OVER TEMPERATURE [CR (WITHOUT EURO-OBD)] 8. Make sure that cooling fans operates at low speed. If NG, go to EC-668, "Diagnostic Procedure" . If OK, go to the following step. 9. Turn ignition switch OFF. 10. Turn air conditioner switch and blower fan switch OFF. 11. Disconnect engine coolant temperature sensor harness connector. 12. Connect 150Ω resistor to engine coolant temperature sensor harness connector. A EC C MBIB0651E D 13. Restart engine and make sure that cooling fan operates at higher speed than low speed. CAUTION: Be careful not to overheat engine. 14. If NG, go to EC-668, "Diagnostic Procedure" . E F G SEF023R Models without Air Conditioner 1. 2. 3. 4. 5. 6. Check the coolant level in the reservoir tank and radiator. Allow engine to cool before checking coolant level. If the coolant level in the reservoir tank and/or radiator is below the proper range, skip the following steps and go to EC-668, "Diagnostic Procedure" . Confirm whether customer filled the coolant or not. If customer filled the coolant, skip the following steps and go to EC-668, "Diagnostic Procedure" . Disconnect engine coolant temperature sensor harness connector. Connect 150Ω resistor to engine coolant temperature sensor harness connector. Start engine and make that cooling fan operates. Be careful not to overheat engine. If NG, go to EC-668, "Diagnostic Procedure" . H I J K SEF621W L M SEF023R EC-665 DTC P1217 ENGINE OVER TEMPERATURE [CR (WITHOUT EURO-OBD)] Wiring Diagram BBS00483 MODELS WITH AIR CONDITIONER MBWA1523E EC-666 DTC P1217 ENGINE OVER TEMPERATURE [CR (WITHOUT EURO-OBD)] MODELS WITHOUT AIR CONDITIONER A EC C D E F G H I J K L M MBWA1524E EC-667 DTC P1217 ENGINE OVER TEMPERATURE [CR (WITHOUT EURO-OBD)] Diagnostic Procedure BBS00484 PROCEDURE FOR MODELS WITH AIR CONDITIONER 1. INSPECTION START Do you have CONSULT-II? Yes or No Yes >> GO TO 2. No >> GO TO 4. 2. CHECK COOLING FAN LOW SPEED OPERATION With CONSULT-II Turn ignition switch ON. Perform “COOLING FAN” in “ACTIVE TEST” mode with CONSULT-II and touch “LOW” on the CONSULT-II screen. 3. Make sure that cooling fan operates at low speed. OK or NG OK >> GO TO 3. NG >> Check cooling fan low speed control circuit. (Go to EC670, "Procedure A" .) 1. 2. SEF784Z 3. CHECK COOLING FAN HIGH SPEED OPERATION With CONSULT-II 1. Touch “HIGH” on the CONSULT-II screen. 2. Make sure that cooling fan operate at higher speed than low speed. OK or NG OK >> GO TO 6. NG >> Check cooling fan high speed control circuit. (Go to EC671, "Procedure B" .) SEF785Z 4. CHECK COOLING FAN LOW SPEED OPERATION Without CONSULT-II 1. Start engine and let it idle. 2. Turn air conditioner switch ON. 3. Turn blower fan switch ON. 4. Make sure that cooling fan operates at low speed. OK or NG OK >> GO TO 5. NG >> Check cooling fan low speed control circuit. (Go to EC670, "Procedure A" .) MBIB0651E EC-668 DTC P1217 ENGINE OVER TEMPERATURE [CR (WITHOUT EURO-OBD)] 5. CHECK COOLING FAN HIGH SPEED OPERATION A Without CONSULT-II Turn ignition switch OFF. Turn air conditioner switch and blower fan switch OFF. Disconnect engine coolant temperature sensor harness connector. Connect 150Ω resistor to engine coolant temperature sensor harness connector. Restart engine and make sure that cooling fan operate at higher speed than low speed. OK or NG OK >> GO TO 6. NG >> Check cooling fan high speed control circuit. (Go to EC671, "Procedure B" .) 1. 2. 3. 4. 5. EC C D E F SEF023R 6. CHECK COOLING SYSTEM FOR LEAK G Refer to CO-8, "ENGINE COOLANT" . OK or NG OK >> GO TO 8. NG >> GO TO 7. H 7. DETECT MALFUNCTIONING PART I Check the following for leak. ● Hose ● Radiator ● Water pump (Refer to CO-17, "WATER PUMP" .) J K >> Repair or replace. 8. CHECK RESERVOIR TANK CAP L Refer to CO-16, "Checking Reservoir Tank Cap (Models with A/C)" . OK or NG OK >> GO TO 9. NG >> Replace reservoir tank cap. 9. CHECK COMPONENT PARTS Check the following. ● Thermostat. Refer to CO-19, "THERMOSTAT" . ● Engine coolant temperature sensor. Refer to EC-569, "Component Inspection" . OK or NG OK >> GO TO 10. NG >> Replace malfunctioning component. 10. CHECK MAIN 12 CAUSES If the cause cannot be isolated, go to EC-674, "Main 12 Causes of Overheating" . >> INSPECTION END EC-669 M DTC P1217 ENGINE OVER TEMPERATURE [CR (WITHOUT EURO-OBD)] Procedure A 1. CHECK POWER SUPPLY CIRCUIT 1. 2. 3. Turn ignition switch OFF. Disconnect IPDM E/R harness connector E6. Check voltage between IPDM E/R terminal 14 and ground with CONSULT-II or tester. Voltage: Battery voltage OK or NG OK >> GO TO 3. NG >> GO TO 2. MBIB1307E 2. DETECT MALFUNCTIONING PART Check the following. ● 40A fusible link ● Harness for open or short between IPDM E/R and battery >> Repair open circuit or short to ground or short to power in harness or connectors. 3. CHECK COOLING FAN MOTORS CIRCUIT 1. 2. Disconnect cooling fan motor harness connector. Check harness continuity between cooling fan motor terminal 1 and IPDM E/R terminal 10, cooling fan motor terminal 2 and ground. Refer to Wiring Diagram. Continuity should exist. 3. Also check harness for short to ground and short to power. OK or NG OK >> GO TO 5. NG >> GO TO 4. 4. DETECT MALFUNCTIONING PART Check the following. ● Harness for open or short between cooling fan motor and IPDM E/R ● Harness for open or short between cooling fan motor and ground ● Harness for open or short between resistor and IPDM E/R ● Harness for open or short between resistor and cooling fan motor ● Resistor E62 >> Repair open circuit or short to ground or short to power in harness or connectors. 5. CHECK COOLING FAN MOTOR Refer to EC-675, "Component Inspection" . OK or NG OK >> GO TO 6. NG >> Replace cooling fan motor. EC-670 MBIB1074E DTC P1217 ENGINE OVER TEMPERATURE [CR (WITHOUT EURO-OBD)] 6. CHECK INTERMITTENT INCIDENT A Perform EC-542, "TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT" . OK or NG OK >> Replace IPDM E/R. Refer to PG-18, "IPDM E/R (INTELLIGENT POWER DISTRIBUTION MOD- EC ULE ENGINE ROOM)" . NG >> Repair or replace harness or connector. C Procedure B 1. CHECK COOLING FAN MOTORS CIRCUIT 1. 2. 3. 4. D Turn ignition switch OFF. Disconnect IPDM E/R harness connector E6. Disconnect cooling fan motor harness connector. Check harness continuity between IPDM E/R terminal 12 and cooling fan motor terminal 1, cooling fan motor terminal 2 and ground. Refer to Wiring Diagram. E F Continuity should exist. 5. Also check harness for short to ground and short to power. OK or NG OK >> GO TO 3. NG >> GO TO 2. G MBIB1074E H 2. DETECT MALFUNCTIONING PART Check the following. ● Harness for open or short between cooling fan motor and IPDM E/R ● Harness for open or short between cooling fan motor and ground I J >> Repair open circuit or short to ground or short to power in harness or connectors. 3. CHECK COOLING FAN MOTOR K Refer to EC-675, "Component Inspection" . OK or NG OK >> GO TO 4. NG >> Replace cooling fan motor. L M 4. CHECK INTERMITTENT INCIDENT Perform EC-542, "TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT" . OK or NG OK >> Replace IPDM E/R. Refer to PG-18, "IPDM E/R (INTELLIGENT POWER DISTRIBUTION MODULE ENGINE ROOM)" . NG >> Repair or replace harness or connector. EC-671 DTC P1217 ENGINE OVER TEMPERATURE [CR (WITHOUT EURO-OBD)] PROCEDURE FOR MODELS WITHOUT AIR CONDITIONER 1. INSPECTION START Do you have CONSULT-II? Yes or No Yes >> GO TO 2. No >> GO TO 3. 2. CHECK COOLING FAN OPERATION With CONSULT-II 1. Turn ignition switch ON. 2. Perform “COOLING FAN” in “ACTIVE TEST” mode with CONSULT-II and touch “LOW” on the CONSULT-II screen. 3. Make sure that cooling fan operates. OK or NG OK >> GO TO4. NG >> Check cooling fan control circuit. (Go to EC-673, "Procedure A" .) SEF784Z 3. CHECK COOLING FAN OPERATION Without CONSULT-II 1. Turn ignition switch OFF. 2. Disconnect engine coolant temperature sensor harness connector. 3. Connect 150Ω resistor to engine coolant temperature sensor harness connector. 4. Restart engine and make sure that cooling fan operates. OK or NG OK >> GO TO 4. NG >> Check cooling fan control circuit. (Go to EC-673, "Procedure A" .) SEF023R 4. CHECK COOLING SYSTEM FOR LEAK Refer to CO-8, "ENGINE COOLANT" . OK or NG OK >> GO TO 6. NG >> GO TO 5. EC-672 DTC P1217 ENGINE OVER TEMPERATURE [CR (WITHOUT EURO-OBD)] 5. DETECT MALFUNCTIONING PART A Check the following for leak. ● Hose ● Radiator ● Water pump (Refer to CO-17, "WATER PUMP" .) EC C >> Repair or replace. 6. CHECK RADIATOR CAP D Refer to CO-15, "Checking Radiator Cap (Models without A/C)" . OK or NG OK >> GO TO 7. NG >> Replace radiator cap. E 7. CHECK THERMOSTAT F Check the following. ● Thermostat. Refer to CO-19, "THERMOSTAT" . ● Engine coolant temperature sensor. Refer to EC-569, "Component Inspection" . OK or NG OK >> GO TO 8. NG >> Replace malfunctioning component. G H 8. CHECK MAIN 12 CAUSES I If the cause cannot be isolated, go to EC-674, "Main 12 Causes of Overheating" . J >> INSPECTION END Procedure A 1. CHECK POWER SUPPLY CIRCUIT K 1. 2. 3. L Turn ignition switch OFF. Disconnect IPDM E/R harness connector E6. Check voltage between IPDM E/R terminal 14 and ground with CONSULT-II or tester. M Voltage: Battery voltage OK or NG OK >> GO TO 3. NG >> GO TO 2. MBIB1307E 2. DETECT MALFUNCTIONING PART Check the following. ● 40A fusible link ● Harness for open or short between IPDM E/R and battery >> Repair open circuit or short to ground or short to power in harness or connectors. EC-673 DTC P1217 ENGINE OVER TEMPERATURE [CR (WITHOUT EURO-OBD)] 3. CHECK COOLING FAN MOTORS CIRCUIT 1. 2. Disconnect cooling fan motor harness connector. Check harness continuity between cooling fan motor terminal 1 and IPDM E/R terminal 10, cooling fan motor terminal 2 and ground. Refer to wiring diagram. Continuity should exist. 3. Also check harness for short to ground and short to power. OK or NG OK >> GO TO 5. NG >> GO TO 4. MBIB1074E 4. DETECT MALFUNCTIONING PART Check the following. ● Harness for open or short between cooling fan motor and IPDM E/R ● Harness for open or short between cooling fan motor and ground >> Repair open circuit or short to ground or short to power in harness or connectors. 5. CHECK COOLING FAN MOTOR Refer to EC-675, "Component Inspection" . OK or NG OK >> GO TO 6. NG >> Replace cooling fan motor. 6. CHECK INTERMITTENT INCIDENT Perform EC-542, "TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT" . OK or NG OK >> Replace IPDM E/R. Refer to PG-18, "IPDM E/R (INTELLIGENT POWER DISTRIBUTION MODULE ENGINE ROOM)" . NG >> Repair or replace harness or connector. Main 12 Causes of Overheating Engine Step OFF 1 Inspection item ● Blocked radiator ● Blocked condenser ● Blocked radiator grille ● Blocked bumper 2 ● 3 4*5 BBS00485 Equipment Standard Visual No blocking Coolant mixture ● Coolant tester 50 - 50% coolant mixture See MA-26, "Engine Coolant Mixture Ratio" . ● Coolant level ● Visual Coolant up to MAX level in reservoir tank and radiator filler neck See CO-8, "LEVEL CHECK" . ● Radiator cap ● Pressure tester 59 - 98 kPa (0.59 - 0.98 bar, 0.6 - 1.0 See CO-15, "Checking Radiator Cap (Models without A/C)" . kg/cm2 , 9 - 14 psi) (Limit) 4*6 Reference page ● ● Reservoir tank cap ● Pressure tester EC-674 88 kPa (0.88 bar, 0.90 kg/ 2 cm , 12.8psi) — See CO-16, "Checking Reservoir Tank Cap (Models with A/C)" . DTC P1217 ENGINE OVER TEMPERATURE [CR (WITHOUT EURO-OBD)] Engine Step Inspection item Equipment Standard Reference page ON*2 5 ● Coolant leaks ● Visual No leaks See CO-8, "LEAK CHECK" . ON*2 6 ● Thermostat ● Touch the upper and lower radiator hoses Both hoses should be hot See CO-19, "THERMOSTAT" , and CO-12, "RADIATOR" . ON*1 7 ● Cooling fan ● CONSULT-II Operating See trouble diagnosis for DTC P1217 (EC-662 ). OFF 8 ● Combustion gas leak ● Color checker chemical tester 4 Gas analyzer Negative — ON*3 9 ● Coolant temperature gauge ● Visual Gauge less than 3/4 when driving — ● Coolant overflow to reservoir tank ● Visual No overflow during driving and idling See CO-9, "Changing Engine coolant" . A C D OFF*4 10 ● Coolant return from reservoir tank to radiator ● Visual Should be initial level in reservoir tank See CO-8, "LEVEL CHECK" . OFF 11 ● Cylinder head ● Straight gauge feeler gauge 0.1 mm (0.004 in) Maximum distortion (warping) See EM-60, "CYLINDER HEAD" . 12 ● Cylinder block and pistons ● Visual No scuffing on cylinder walls or piston See EM-74, "CYLINDER BLOCK" . E F *1: Turn the ignition switch ON. *2: Engine running at 3,000 rpm for 10 minutes. *3: Drive at 90 km/h (55 MPH) for 30 minutes and then let idle for 10 minutes. *4: After 60 minutes of cool down time. *5: Models without A/C. *6: Models with A/C. For more information, refer to CO-5, "OVERHEATING CAUSE ANALYSIS" . Component Inspection G H I BBS00486 COOLING FAN MOTOR 1. 2. EC Disconnect cooling fan motor harness connector. Supply cooling fan motor terminals with battery voltage and check operation. J K Terminals Cooling fan motor (+) (-) 1 2 L M MBIB0607E EC-675 DTC P1225 TP SENSOR [CR (WITHOUT EURO-OBD)] DTC P1225 TP SENSOR Component Description PFP:16119 BBS0039Y Electric throttle control actuator consists of throttle control motor, throttle position sensor, etc. The throttle position sensor responds to the throttle valve movement. The throttle position sensor has the two sensors. These sensors are a kind of potentiometers which transform the throttle valve position into output voltage, and emit the voltage signal to the ECM. In addition, these sensors detect the opening and closing speed of the throttle valve and feed the voltage signals to the ECM. The ECM judges the current opening angle of the throttle valve from these signals and the ECM controls the throttle control motor to make the throttle valve opening angle properly in response to driving condition. PBIB0145E On Board Diagnosis Logic BBS0039Z The MI will not light up for this self-diagnosis. DTC No. P1225 1225 Trouble diagnosis name Closed throttle position learning performance DTC detecting condition Closed throttle position learning value is excessively low. DTC Confirmation Procedure Possible cause ● Electric throttle control actuator (TP sensor 1 and 2) BBS003A0 NOTE: If DTC Confirmation Procedure has been previously conducted, always turn ignition switch OFF and wait at least 10 seconds before conducting the next test. TESTING CONDITION: Before performing the following procedure, confirm that battery voltage is more than 10V at idle. WITH CONSULT-II 1. 2. 3. 4. 5. Turn ignition switch ON. Select “DATA MONITOR” mode with CONSULT-II. Turn ignition switch OFF and wait at least 10 seconds. Turn ignition switch ON. If 1st trip DTC is detected, go to EC-677, "Diagnostic Procedure" . SEF058Y WITHOUT CONSULT-II 1. 2. 3. 4. Turn ignition switch ON. Turn ignition switch OFF, wait at least 10 seconds and then turn ON. Perform Diagnostic Test Mode II (Self-diagnostic results) with ECM. If 1st trip DTC is detected, go to EC-677, "Diagnostic Procedure" . EC-676 DTC P1225 TP SENSOR [CR (WITHOUT EURO-OBD)] Diagnostic Procedure BBS003A1 1. CHECK ELECTRIC THROTTLE CONTROL ACTUATOR VISUALLY A 1. 2. 3. Turn ignition switch OFF. Remove the intake air duct. Check if foreign matter is caught between the throttle valve and the housing. OK or NG OK >> GO TO 2. NG >> Remove the foreign matter and clean the electric throttle control actuator inside. EC C D E MBIB0307E 2. REPLACE ELECTRIC THROTTLE CONTROL ACTUATOR F 1. 2. 3. G Replace the electric throttle control actuator. Perform EC-486, "Throttle Valve Closed Position Learning" . Perform EC-486, "Idle Air Volume Learning" . H >> INSPECTION END Removal and Installation BBS003A2 ELECTRIC THROTTLE CONTROL ACTUATOR Refer to EM-18, "AIR CLEANER AND AIR DUCT" . I J K L M EC-677 DTC P1226 TP SENSOR [CR (WITHOUT EURO-OBD)] DTC P1226 TP SENSOR Component Description PFP:16119 BBS003A3 Electric throttle control actuator consists of throttle control motor, throttle position sensor, etc. The throttle position sensor responds to the throttle valve movement. The throttle position sensor has the two sensors. These sensors are a kind of potentiometers which transform the throttle valve position into output voltage, and emit the voltage signal to the ECM. In addition, these sensors detect the opening and closing speed of the throttle valve and feed the voltage signals to the ECM. The ECM judges the current opening angle of the throttle valve from these signals and the ECM controls the throttle control motor to make the throttle valve opening angle properly in response to driving condition. PBIB0145E On Board Diagnosis Logic BBS003A4 The MI will not light up for this self-diagnosis. DTC No. P1226 1226 Trouble diagnosis name Closed throttle position learning performance DTC detecting condition Closed throttle position learning is not performed successfully, repeatedly. DTC Confirmation Procedure Possible cause ● Electric throttle control actuator (TP sensor 1 and 2) BBS003A5 NOTE: If DTC Confirmation Procedure has been previously conducted, always turn ignition switch OFF and wait at least 10 seconds before conducting the next test. TESTING CONDITION: Before performing the following procedure, confirm that battery voltage is more than 10V at idle. WITH CONSULT-II 1. 2. 3. 4. 5. 6. Turn ignition switch ON. Select “DATA MONITOR” mode with CONSULT-II. Turn ignition switch OFF and wait at least 10 seconds. Turn ignition switch ON. Repeat steps 3 and 4 for 32 times. If 1st trip DTC is detected, go to EC-679, "Diagnostic Procedure" . SEF058Y WITHOUT CONSULT-II 1. 2. 3. 4. 5. Turn ignition switch ON. Turn ignition switch OFF, wait at least 10 seconds and then turn ON. Repeat step 2 for 32 times. Perform Diagnostic Test Mode II (Self-diagnostic results) with ECM. If 1st trip DTC is detected, go to EC-679, "Diagnostic Procedure" . EC-678 DTC P1226 TP SENSOR [CR (WITHOUT EURO-OBD)] Diagnostic Procedure BBS003A6 1. CHECK ELECTRIC THROTTLE CONTROL ACTUATOR VISUALLY A 1. 2. 3. Turn ignition switch OFF. Remove the intake air duct. Check if foreign matter is caught between the throttle valve and the housing. OK or NG OK >> GO TO 2. NG >> Remove the foreign matter and clean the electric throttle control actuator inside. EC C D E MBIB0307E 2. REPLACE ELECTRIC THROTTLE CONTROL ACTUATOR F 1. 2. 3. G Replace the electric throttle control actuator. Perform EC-486, "Throttle Valve Closed Position Learning" . Perform EC-486, "Idle Air Volume Learning" . H >> INSPECTION END Removal and Installation BBS003A7 ELECTRIC THROTTLE CONTROL ACTUATOR Refer to EM-18, "AIR CLEANER AND AIR DUCT" . I J K L M EC-679 DTC P1229 SENSOR POWER SUPPLY [CR (WITHOUT EURO-OBD)] DTC P1229 SENSOR POWER SUPPLY On Board Diagnosis Logic PFP:16119 BBS003A8 This self-diagnosis has the one trip detection logic. DTC No. P1229 1229 Trouble diagnosis name Sensor power supply circuit short DTC detecting condition Possible cause ● Harness or connectors (APP sensor 1 circuit is shorted.) (Manifold absolute pressure sensor is shorted.) (Refrigerant pressure sensor circuit is shorted.) ● Accelerator pedal position sensor (APP sensor 1) ● Manifold absolute pressure sensor ● Refrigerant pressure sensor ECM detects a voltage of power source for sensor is excessively low or high. FAIL-SAFE MODE When the malfunction is detected, the ECM enters fail-safe mode and the MI lights up. Engine operation condition in fail-safe mode ECM stops the electric throttle control actuator control, throttle valve is maintained at a fixed opening (approx. 5 degrees) by the return spring. DTC Confirmation Procedure BBS003A9 NOTE: If DTC Confirmation Procedure has been previously conducted, always turn ignition switch OFF and wait at least 10 seconds before conducting the next test. TESTING CONDITION: Before performing the following procedure, confirm that battery voltage is more than 10V at idle. WITH CONSULT-II 1. 2. 3. 4. Turn ignition switch ON. Select “DATA MONITOR” mode with CONSULT-II. Start engine and let it idle for 1 second. If DTC is detected, go to EC-685, "Diagnostic Procedure" . SEF058Y WITHOUT CONSULT-II 1. 2. 3. 4. Start engine and let it idle for 1 seconds. Turn ignition switch OFF, wait at least 10 seconds and then turn ON. Perform Diagnostic Test Mode II (Self-diagnostic results) with ECM. If DTC is detected, go to EC-685, "Diagnostic Procedure" . EC-680 DTC P1229 SENSOR POWER SUPPLY [CR (WITHOUT EURO-OBD)] Wiring Diagram BBS003AA A LHD MODELS EC C D E F G H I J K L M MBWA1525E EC-681 DTC P1229 SENSOR POWER SUPPLY [CR (WITHOUT EURO-OBD)] Specification data are reference values and are measured between each terminal and ground. CAUTION: Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM's transistor. Use a ground other than ECM terminals, such as the ground. TERMINAL NO. WIRE COLOR ITEM CONDITION DATA (DC Voltage) 45 L Sensor power supply (Manifold absolute pressure sensor) [Ignition switch: ON] Approximately 5V 46 W Sensor power supply (Refrigerant pressure sensor) [Ignition switch: ON] Approximately 5V B Sensor ground (APP sensor 1) [Engine is running] 82 ● Warm-up condition ● Idle speed Approximately 0V [Engine is running] 83 B Sensor ground (APP sensor 2) ● Warm-up condition ● Idle speed Approximately 0V 90 O Sensor power supply (APP sensor 1) [Ignition switch: ON] Approximately 5V 91 BR Sensor power supply (APP sensor 2) [Ignition switch: ON] Approximately 5V [Ignition switch: ON] 98 G Accelerator pedal position sensor 2 ● Engine stopped ● Accelerator pedal: Fully released 0.3 - 0.6V [Ignition switch: ON] ● Engine stopped ● Accelerator pedal: Fully depressed 1.95 - 2.4V [Ignition switch: ON] 106 W Accelerator pedal position sensor 1 ● Engine stopped ● Accelerator pedal: Fully released 0.6 - 0.9V [Ignition switch: ON] ● Engine stopped ● Accelerator pedal: Fully depressed EC-682 3.9 - 4.7V DTC P1229 SENSOR POWER SUPPLY [CR (WITHOUT EURO-OBD)] RHD MODELS A EC C D E F G H I J K L M MBWA1526E EC-683 DTC P1229 SENSOR POWER SUPPLY [CR (WITHOUT EURO-OBD)] Specification data are reference values and are measured between each terminal and ground. CAUTION: Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM's transistor. Use a ground other than ECM terminals, such as the ground. TERMINAL NO. WIRE COLOR ITEM CONDITION DATA (DC Voltage) 45 L Sensor power supply (Manifold absolute pressure sensor) [Ignition switch: ON] Approximately 5V 46 W Sensor power supply (Refrigerant pressure sensor) [Ignition switch: ON] Approximately 5V B Sensor ground (APP sensor 1) [Engine is running] 82 ● Warm-up condition ● Idle speed Approximately 0V [Engine is running] 83 B Sensor ground (APP sensor 2) ● Warm-up condition ● Idle speed Approximately 0V 90 O Sensor power supply (APP sensor 1) [Ignition switch: ON] Approximately 5V 91 BR Sensor power supply (APP sensor 2) [Ignition switch: ON] Approximately 5V [Ignition switch: ON] 98 G Accelerator pedal position sensor 2 ● Engine stopped ● Accelerator pedal: Fully released 0.3 - 0.6V [Ignition switch: ON] ● Engine stopped ● Accelerator pedal: Fully depressed 1.95 - 2.4V [Ignition switch: ON] 106 W Accelerator pedal position sensor 1 ● Engine stopped ● Accelerator pedal: Fully released 0.6 - 0.9V [Ignition switch: ON] ● Engine stopped ● Accelerator pedal: Fully depressed EC-684 3.9 - 4.7V DTC P1229 SENSOR POWER SUPPLY [CR (WITHOUT EURO-OBD)] Diagnostic Procedure BBS003AB 1. CHECK GROUND CONNECTIONS 1. 2. A Turn ignition switch OFF. Loosen and retighten ground screws on the body. Refer to EC-548, "Ground Inspection" . EC C D E MBIB1502E 1. Body ground E44 2. Body ground E45 3. F Body ground E28 OK or NG OK >> GO TO 2. NG >> Repair or replace ground connections. G 2. CHECK ACCELERATOR PEDAL POSITION SENSOR 1 POWER SUPPLY CIRCUIT-I 1. 2. H Disconnect accelerator pedal position sensor (APP) sensor harness connector. Turn ignition switch ON. I J K MBIB0285E 3. L Check voltage between APP sensor terminal 4 and ground with CONSULT-II or tester. Voltage: Approximately 5V M OK or NG OK >> GO TO 7. NG >> GO TO 3. MBIB0304E EC-685 DTC P1229 SENSOR POWER SUPPLY [CR (WITHOUT EURO-OBD)] 3. CHECK ACCELERATOR PEDAL POSITION SENSOR 1 POWER SUPPLY CIRCUIT-II 1. 2. 3. Turn ignition switch OFF. Disconnect ECM harness connector. Check harness continuity between APP sensor terminal 4 and ECM terminal 90. Refer to Wiring Diagram. Continuity should exist. OK or NG OK >> GO TO 5. NG (LHD models)>>Repair open circuit. NG (RHD models)>>GO TO 4. 4. DETECT MALFUNCTIONING PART Check the following. ● Harness connectors M201, M8 ● Harness connectors M1, E101 ● Harness for open or short between APP sensor and ECM >> Repair open circuit. 5. CHECK SENSOR POWER SUPPLY CIRCUIT Check harness for short to power and short to ground, between the following terminals ECM terminal Sensor terminal Reference Wiring Diagram 90 APP sensor terminal 4 EC-681 45 Manifold absolute pressure sensor terminal 2 EC-560 46 Refrigerant pressure sensor terminal 3 EC-795 OK or NG OK >> GO TO 6. NG >> Repair short to ground or short to power in harness or connectors. 6. CHECK COMPONENTS Check the following. ● Manifold absolute pressure sensor (Refer to EC-563, "Component Inspection" .) ● Refrigerant pressure sensor (Refer to ATC-85, "COMPONENT INSPECTION" or MTC-51, "COMPONENT INSPECTION" .) OK or NG OK >> GO TO 9. NG >> Replace malfunctioning component. 7. CHECK APP SENSOR Refer to EC-716, "Component Inspection" . OK or NG OK >> GO TO 9. NG >> GO TO 8. EC-686 DTC P1229 SENSOR POWER SUPPLY [CR (WITHOUT EURO-OBD)] 8. REPLACE ACCELERATOR PEDAL ASSEMBLY 1. 2. 3. 4. Replace accelerator pedal assembly. Perform EC-486, "Accelerator Pedal Released Position Learning" . Perform EC-486, "Throttle Valve Closed Position Learning" . Perform EC-486, "Idle Air Volume Learning" . A EC C >> INSPECTION END 9. CHECK INTERMITTENT INCIDENT D Refer to EC-542, "TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT" . E >> INSPECTION END F G H I J K L M EC-687 DTC P1706 PNP SWITCH [CR (WITHOUT EURO-OBD)] DTC P1706 PNP SWITCH Component Description PFP:32006 BBS003AC When the shift lever position is Neutral, park/neutral position (PNP) switch is ON. ECM detects the position because the continuity of the line (the ON signal) exists. CONSULT-II Reference Value in Data Monitor Mode BBS003AD Specification data are reference values. MONITOR ITEM P/N POSI SW CONDITION ● Ignition switch: ON SPECIFICATION Shift lever: Neutral ON Shift lever: Except above OFF On Board Diagnosis Logic DTC No. P1706 1706 BBS003AE Trouble diagnosis name DTC detecting condition Park/neutral position switch The signal of the park/neutral position (PNP) switch is not changed in the process of engine starting and driving. Overall Function Check Possible cause ● Harness or connectors [The park/neutral position (PNP) switch circuit is open or shorted.] ● Park/neutral position (PNP) switch BBS003AF Use this procedure to check the overall function of the park/neutral position (PNP) switch circuit. During this check, a 1st trip DTC might not be confirmed. WITH CONSULT-II 1. 2. Turn ignition switch ON. Select “P/N POSI SW” in “DATA MONITOR” mode with CONSULT-II. Then check the “P/N POSI SW” signal under the following conditions. Position (Shift lever) Known-good signal Neutral position ON Except the above position OFF If NG, go to EC-690, "Diagnostic Procedure" . SEF212Y WITHOUT CONSULT-II 1. 2. Turn ignition switch ON. Check voltage between ECM terminal 102 (PNP switch signal) and ground under the following conditions. Condition (Gear position) Neutral position Except the above position 3. Voltage V (Known-good data) Approx. 0 BATTERY VOLTAGE (11 - 14V) If NG, go to EC-690, "Diagnostic Procedure" . MBIB0043E EC-688 DTC P1706 PNP SWITCH [CR (WITHOUT EURO-OBD)] Wiring Diagram BBS003AG A EC C D E F G H I J K L M MBWA1527E EC-689 DTC P1706 PNP SWITCH [CR (WITHOUT EURO-OBD)] Specification data are reference values and are measured between each terminal and ground. CAUTION: Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM's transistor. Use a ground other than ECM terminals, such as the ground. TERMINAL NO. WIRE COLOR ITEM CONDITION [Ignition switch: ON] ● 102 GR PNP switch Shift lever position: Neutral [Ignition switch: ON] ● Except the above gear position Diagnostic Procedure DATA (DC Voltage) Approximately 0V BATTERY VOLTAGE (11 - 14V) BBS003AH 1. CHECK PNP SWITCH CIRCUIT 1. 2. Turn ignition switch ON. Check voltage between IPDM E/R terminal 31 and ground under following condition. Shift lever position Voltage Neutral Battery voltage (11- 14V) Except above position Approximately 0V OK or NG OK >> GO TO 8. NG >> GO TO 2. MBIB0652E 2. CHECK PNP SWITCH POWER SUPPLY CIRCUIT 1. 2. 3. 4. Turn ignition switch OFF. Disconnect PNP switch harness connector. Turn ignition switch ON. Check voltage between PNP switch terminal 2 and ground with CONSULT-II or tester. Voltage: Battery voltage OK or NG OK >> GO TO 4. NG >> GO TO 3. MBIB1444E 3. DETECT MALFUNCTIONING PARTS Check the following. ● 10A fuse ● Harness connectors E48, F1 ● IPDM E/R connector E7 ● Harness for short or open between PNP switch and fuse >> Repair or replace harness or connectors. EC-690 DTC P1706 PNP SWITCH [CR (WITHOUT EURO-OBD)] 4. CHECK HARNESS CONTINUTY BETWEEN PNP SWITCH AND IPDM E/R 1. 2. 3. Turn ignition switch OFF. Disconnect IPDM E/R harness connector E7. Check harness continuity between IPDM E/R terminal 31 and PNP switch terminal 3. Refer to Wiring Diagram. Continuity should exist. A EC C 4. Also check harness for short to ground and short to power. OK or NG OK >> GO TO 6. NG >> GO TO 5. 5. DETECT MALFUNCTIONING PARTS D E Check the following. ● Harness connectors E48, F1 ● Harness for short or open between PNP switch and IPDM E/R >> Repair open circuit or short to ground or short to power in harness or connectors. F G 6. CHECK PNP SWITCH H Refer to MT-16, "Park/Neutral Position Switch" . OK or NG OK >> GO TO 7. NG >> Replace PNP switch. I 7. CHECK INTERMITTENT INCIDENT Refer to EC-542, "TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT" . >> INSPECTION END J K 8. CHECK PNP SWITCH GROUND CIRCUIT FOR OPEN AND SHORT 1. 2. 3. Turn ignition switch OFF. Disconnect IPDM E/R harness connectors E11 and E12. Check harness continuity between IPDM E/R terminal 3, 54 and ground. Refer to Wiring Diagram. Continuity should exist. 4. Also check harness for short to power. OK or NG OK >> GO TO 9. NG >> Repair open circuit or short to power in harness or connectors. EC-691 L M DTC P1706 PNP SWITCH [CR (WITHOUT EURO-OBD)] 9. CHECK PNP SWITCH INPUT SIGNAL CIRCUIT FOR OPEN AND SHORT 1. 2. 3. Disconnect IPDM E/R harness connector E5 Disconnect ECM harness connector. Check harness continuity between ECM terminal 102 and IPDM E/R terminal 64. Refer to Wiring Diagram. Continuity should exist. 4. Also check harness for short to ground and short to power. OK or NG OK >> GO TO 10. NG >> Repair open circuit or short to ground or short to power in harness or connectors. 10. CHECK INTERMITTENT INCIDENT Refer to EC-542, "TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT" . OK or NG OK >> Replace IPDM E/R. Refer to PG-18, "IPDM E/R (INTELLIGENT POWER DISTRIBUTION MODULE ENGINE ROOM)" . NG >> Repair or replace. EC-692 DTC P1805 BRAKE SWITCH [CR (WITHOUT EURO-OBD)] DTC P1805 BRAKE SWITCH Description PFP:25320 A BBS003AI Brake switch signal is applied to the ECM through the stop lamp switch when the brake pedal is depressed. This signal is used mainly to decrease the engine speed when the vehicle is driving. EC C D MBIB0286E E CONSULT-II Reference Value in Data Monitor Mode BBS003AJ Specification data are reference values. MONITOR ITEM BRAKE SW CONDITION ● Ignition switch: ON F SPECIFICATION Brake pedal: Fully released OFF Brake pedal: Slightly depressed ON On Board Diagnosis Logic G BBS003AK This self-diagnosis has the one trip detection logic. DTC No. Trouble diagnosis name P1805 1805 Brake switch H DTC detecting condition A brake switch signal is not sent to ECM for extremely long time while the vehicle is driving. Possible cause ● Harness or connectors (Stop lamp switch circuit is open or shorted.) ● Stop lamp switch FAIL-SAFE MODE I J When the malfunction is detected, the ECM enters fail-safe mode and the MI light up. Engine operating condition in fail-safe mode K ECM controls the electric throttle control actuator by regulating the throttle opening to a small range. Therefore, acceleration will be poor. Vehicle condition Driving condition When engine is idling Normal When accelerating Poor acceleration DTC Confirmation Procedure L BBS003AM WITH CONSULT-II 1. 2. 3. 4. 5. Turn ignition switch ON. Fully depress the brake pedal for at least 5 seconds. Erase the DTC with CONSULT-II. Select “DATA MONITOR” mode with CONSULT-II. If DTC is detected, go to EC-696, "Diagnostic Procedure" . SEF058Y EC-693 M DTC P1805 BRAKE SWITCH [CR (WITHOUT EURO-OBD)] WITHOUT CONSULT-II 1. 2. 3. 4. 5. 6. Turn ignition switch ON. Fully depress the brake pedal at least 5 seconds. Erase the Diagnostic Test Mode II (Self-diagnostic results) memory. Refer to EC-478 . Turn ignition switch OFF, wait at least 10 seconds and then turn ON. Perform Diagnostic Test Mode II (Self-diagnostic results) with ECM. If DTC is detected, go to EC-696, "Diagnostic Procedure" . EC-694 DTC P1805 BRAKE SWITCH [CR (WITHOUT EURO-OBD)] Wiring Diagram BBS003AN A EC C D E F G H I J K L M MBWA1528E EC-695 DTC P1805 BRAKE SWITCH [CR (WITHOUT EURO-OBD)] Specification data are reference values and are measured between each terminal and ground. CAUTION: Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM's transistor. Use a ground other than ECM terminals, such as the ground. TERMINAL NO. WIRE COLOR ITEM CONDITION [Ignition switch: OFF] ● 101 R Stop lamp switch Brake pedal: Fully released [Ignition switch: OFF] ● Brake pedal: Slightly depressed Diagnostic Procedure DATA (DC Voltage) Approximately 0V BATTERY VOLTAGE (11 - 14V) BBS003AO 1. CHECK STOP LAMP SWITCH CIRCUIT 1. 2. Turn ignition switch OFF. Check the stop lamp when depressing and releasing the brake pedal. Brake pedal Stop lamp Fully released Not illuminated Slightly depressed Illuminated OK or NG OK >> GO TO 4. NG >> GO TO 2. 2. CHECK STOP LAMP SWITCH POWER SUPPLY CIRCUIT 1. Disconnect stop lamp switch harness connector. MBIB0286E 2. Check voltage between stop lamp switch terminal 1 and ground with CONSULT-II or tester. Voltage: Battery voltage OK or NG OK >> GO TO 4. NG >> GO TO 3. PBIB0117E EC-696 DTC P1805 BRAKE SWITCH [CR (WITHOUT EURO-OBD)] 3. DETECT MALFUNCTIONING PART A Check the following. ● 10A fuse ● Fuse block (J/B) connector M7 ● Harness connectors M1, E101 (LHD models) ● Harness connectors M8, M201 (RHD models) ● Harness for open and short between stop lamp switch and battery >> Repair open circuit or short to ground or short to power in harness or connectors. EC C D 4. CHECK STOP LAMP SWITCH INPUT SIGNAL CIRCUIT FOR OPEN AND SHORT 1. 2. 3. Disconnect ECM harness connector. Disconnect stop lamp switch harness connector. Check harness continuity between ECM terminal 101 and stop lamp switch terminal 2. Refer to Wiring Diagram. E F Continuity should exist. 4. Also check harness for short to ground and short to power. OK or NG OK >> GO TO 6. NG (LHD models)>>Repair open circuit or short to ground or short to power in harness or connectors. NG (RHD models)>>GO TO 5. 5. DETECT MALFUNCTIONING PART G H I Check the following. ● Harness connectors M8, M201 ● Harness connectors M1, E101 ● Harness for open or short between ECM and stop lamp switch >> Repair open circuit or short to ground or short to power in harness or connectors. 6. CHECK STOP LAMP SWITCH J K L Refer to EC-698, "Component Inspection" . OK or NG OK >> GO TO 7. NG >> Replace stop lamp switch. M 7. CHECK INTERMITTENT INCIDENT Refer to EC-542, "TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT" . >> INSPECTION END EC-697 DTC P1805 BRAKE SWITCH [CR (WITHOUT EURO-OBD)] Component Inspection BBS003AP STOP LAMP SWITCH 1. Disconnect stop lamp switch harness connector. MBIB0286E 2. Check continuity between stop lamp switch terminals 1 and 2 under the following conditions. Conditions Brake pedal: Fully released Brake pedal: Slightly depressed Continuity Should not exist. Should exist. If NG, adjust brake pedal installation, refer to BR-6, "BRAKE PEDAL" , and perform step 2 again. PBIB0118E EC-698 DTC P2122, P2123 APP SENSOR [CR (WITHOUT EURO-OBD)] DTC P2122, P2123 APP SENSOR Component Description PFP:18002 A BBS003AQ The accelerator pedal position sensor is installed on the upper end of the accelerator pedal assembly. The sensor detects the acceleraEC tor position and sends a signal to the ECM. Accelerator pedal position sensor has two sensors. These sensors are a kind of potentiometers which transform the accelerator pedal C position into output voltage, and emit the voltage signal to the ECM. In addition, these sensors detect the opening and closing speed of the accelerator pedal and feed the voltage signals to the ECM. The ECM judges the current opening angle of the accelerator pedal from D these signals and controls the throttle control motor based on these signals. PBIB1741E Idle position of the accelerator pedal is determined by the ECM E receiving the signal from the accelerator pedal position sensor. The ECM uses this signal for the engine operation such as fuel cut. CONSULT-II Reference Value in Data Monitor Mode BBS003AR F Specification data are reference values. MONITOR ITEM ACCEL SEN 1 ACCEL SEN 2* CLSD THL POS CONDITION ● ● ● SPECIFICATION Ignition switch: ON (Engine stopped) Accelerator pedal: Fully released 0.6 - 0.9V Accelerator pedal: Fully depressed 4.0 - 4.8V Ignition switch: ON (Engine stopped) Accelerator pedal: Fully released 0.6 - 0.9V Accelerator pedal: Fully depressed 3.9 - 4.8V Ignition switch: ON (Engine stopped) Accelerator pedal: Fully released ON Accelerator pedal: Slightly depressed OFF G H I *: Accelerator pedal position sensor 2 signal is converted by ECM internally. Thus, it differs from ECM terminal voltage. On Board Diagnosis Logic BBS003AS These self-diagnoses have the one trip detection logic. NOTE: If DTC P2122 or P2123 is displayed with DTC P1229, first perform the trouble diagnosis for DTC P1229. Refer to EC-680, "DTC P1229 SENSOR POWER SUPPLY" . DTC No. Trouble diagnosis name DTC detecting condition P2122 2122 Accelerator pedal position sensor 1 circuit low input An excessively low voltage from the APP sensor 1 is sent to ECM. P2123 2123 Accelerator pedal position sensor 1 circuit high input An excessively high voltage from the APP sensor 1 is sent to ECM. Possible cause Harness or connectors (APP sensor 1 circuit is open or shorted.) ● Accelerator pedal position sensor (APP sensor 1) When the malfunction is detected, the ECM enters fail-safe mode and the MI lights up. Engine operating condition in fail-safe mode The ECM controls the electric throttle control actuator in regulating the throttle opening in order for the idle position to be within +10 degrees. The ECM regulates the opening speed of the throttle valve to be slower than the normal condition. So, the acceleration will be poor. BBS003AT NOTE: If DTC Confirmation Procedure has been previously conducted, always turn ignition switch OFF and wait at least 10 seconds before conducting the next test. TESTING CONDITION: EC-699 K L ● FAIL-SAFE MODE DTC Confirmation Procedure J M DTC P2122, P2123 APP SENSOR [CR (WITHOUT EURO-OBD)] Before performing the following procedure, confirm that battery voltage is more than 10V at idle. WITH CONSULT-II 1. 2. 3. 4. Turn ignition switch ON. Select “DATA MONITOR” mode with CONSULT-II. Start engine and let it idle for 1 second. If DTC is detected, go to EC-704, "Diagnostic Procedure" . SEF058Y WITHOUT CONSULT-II 1. 2. 3. 4. Start engine and let it idle for 1 second. Turn ignition switch OFF, wait at least 10 seconds and then turn ON. Perform Diagnostic Test Mode II (Self-diagnostic results) with ECM. If DTC is detected, go to EC-704, "Diagnostic Procedure" . EC-700 DTC P2122, P2123 APP SENSOR [CR (WITHOUT EURO-OBD)] Wiring Diagram BBS003AU A LHD MODELS EC C D E F G H I J K L M MBWA1529E EC-701 DTC P2122, P2123 APP SENSOR [CR (WITHOUT EURO-OBD)] Specification data are reference values and are measured between each terminal and ground. CAUTION: Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM's transistor. Use a ground other than ECM terminals, such as the ground. TERMINAL NO. WIRE COLOR ITEM CONDITION DATA (DC Voltage) [Engine is running] 82 B Sensor ground (APP sensor 1) ● Warm-up condition ● Idle speed Approximately 0V [Ignition switch: ON] 83 B Sensor ground (APP sensor 2) ● Warm-up condition ● Idle speed Approximately 0V 90 O Sensor power supply (APP sensor 1) [Ignition switch: ON] Approximately 5V 91 BR Sensor power supply (APP sensor 2) [Ignition switch: ON] Approximately 5V [Ignition switch: ON] 98 G Accelerator pedal position sensor 2 ● Engine stopped ● Accelerator pedal: Fully released 0.3 - 0.6V [Ignition switch: ON] ● Engine stopped ● Accelerator pedal: Fully depressed 1.95 - 2.4V [Ignition switch: ON] 106 W Accelerator pedal position sensor 1 ● Engine stopped ● Accelerator pedal: Fully released 0.6 - 0.9V [Ignition switch: ON] ● Engine stopped ● Accelerator pedal: Fully depressed EC-702 3.9 - 4.7V DTC P2122, P2123 APP SENSOR [CR (WITHOUT EURO-OBD)] RHD MODELS A EC C D E F G H I J K L M MBWA1530E EC-703 DTC P2122, P2123 APP SENSOR [CR (WITHOUT EURO-OBD)] Specification data are reference values and are measured between each terminal and ground. CAUTION: Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM's transistor. Use a ground other than ECM terminals, such as the ground. TERMINAL NO. WIRE COLOR ITEM CONDITION DATA (DC Voltage) [Engine is running] 82 B Sensor ground (APP sensor 1) ● Warm-up condition ● Idle speed Approximately 0V [Ignition switch: ON] 83 B Sensor ground (APP sensor 2) ● Warm-up condition ● Idle speed Approximately 0V 90 O Sensor power supply (APP sensor 1) [Ignition switch: ON] Approximately 5V 91 BR Sensor power supply (APP sensor 2) [Ignition switch: ON] Approximately 5V [Ignition switch: ON] 98 G Accelerator pedal position sensor 2 ● Engine stopped ● Accelerator pedal: Fully released 0.3 - 0.6V [Ignition switch: ON] ● Engine stopped ● Accelerator pedal: Fully depressed 1.95 - 2.4V [Ignition switch: ON] 106 W Accelerator pedal position sensor 1 ● Engine stopped ● Accelerator pedal: Fully released 0.6 - 0.9V [Ignition switch: ON] ● Engine stopped ● Accelerator pedal: Fully depressed 3.9 - 4.7V Diagnostic Procedure BBS003AV 1. CHECK GROUND CONNECTIONS 1. 2. Turn ignition switch OFF. Loosen and retighten ground screws on the body. Refer to EC-548, "Ground Inspection" . MBIB1502E 1. Body ground E44 2. Body ground E45 OK or NG OK >> GO TO 2. NG >> Repair or replace ground connections. EC-704 3. Body ground E28 DTC P2122, P2123 APP SENSOR [CR (WITHOUT EURO-OBD)] 2. CHECK APP SENSOR 1 POWER SUPPLY CIRCUIT 1. 2. A Disconnect accelerator pedal position (APP) sensor harness connector. Turn ignition switch ON. EC C D MBIB0285E 3. Check voltage between APP sensor terminal 4 and ground with CONSULT-II or tester. E Voltage: Approximately 5V F G MBIB0304E H OK or NG OK >> GO TO 4. NG (LHD models)>>Repair open circuit or short to ground or short to power in harness or connectors. NG (RHD models)>>GO TO 3. I 3. DETECT MALFUNCTIONING PART J Check the following. ● Harness connectors M1, E101 ● Harness connectors M8, M201 ● Harness for open or short between ECM and accelerator pedal position sensor K L >> Repair open circuit or short to ground or short to power in harness or connectors. 4. CHECK APP SENSOR 1 GROUND CIRCUIT FOR OPEN AND SHORT 1. 2. 3. Turn ignition switch OFF. Disconnect ECM harness connector. Check harness continuity between ECM terminal 82 and APP sensor terminal 2. Refer to Wiring Diagram. Continuity should exist. 4. Also check harness for short to ground and short to power. OK or NG OK >> GO TO 6. NG (LHD models)>>Repair open circuit or short to ground or short to power in harness or connectors. NG (RHD models)>>GO TO 5. EC-705 M DTC P2122, P2123 APP SENSOR [CR (WITHOUT EURO-OBD)] 5. DETECT MALFUNCTIONING PART Check the following. ● Harness connectors M1, E101 ● Harness connectors M8, M201 ● Harness for open or short between ECM and accelerator pedal position sensor >> Repair open circuit or short to ground or short to power in harness or connectors. 6. CHECK APP SENSOR 1 INPUT SIGNAL CIRCUIT FOR OPEN AND SHORT 1. Check harness continuity between ECM terminal 106 and APP sensor terminal 3. Refer to Wiring Diagram. Continuity should exist. 2. Also check harness for short to ground and short to power. OK or NG OK >> GO TO 8. NG (LHD models)>>Repair open circuit or short to ground or short to power in harness or connectors. NG (RHD models)>>GO TO 7. 7. DETECT MALFUNCTIONING PART Check the following. Harness connectors M1, E101 ● Harness connectors M8, M201 ● Harness for open or short between ECM and accelerator pedal position sensor ● >> Repair open circuit or short to ground or short to power in harness or connectors. 8. CHECK APP SENSOR Refer to EC-706, "Component Inspection" . OK or NG OK >> GO TO 10. NG >> GO TO 9. 9. REPLACE ACCELERATOR PEDAL ASSEMBLY 1. 2. 3. 4. Replace the accelerator pedal assembly. Perform EC-486, "Accelerator Pedal Released Position Learning" . Perform EC-486, "Throttle Valve Closed Position Learning" . Perform EC-486, "Idle Air Volume Learning" . >> INSPECTION END 10. CHECK INTERMITTENT INCIDENT Refer to EC-542, "TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT" . >> INSPECTION END Component Inspection BBS003AW ACCELERATOR PEDAL POSITION SENSOR 1. 2. Reconnect all harness connectors disconnected. Turn ignition switch ON. EC-706 DTC P2122, P2123 APP SENSOR [CR (WITHOUT EURO-OBD)] 3. Check voltage between ECM terminals 106 (APP sensor 1 signal), 98 (APP sensor 2 signal) and ground under the following conditions. Terminal Accelerator pedal Voltage 106 (Accelerator pedal position sensor 1) Fully released 0.6 - 0.9V Fully depressed 3.9 - 4.7V Fully released 0.3 - 0.6V Fully depressed 1.95 - 2.4V 98 (Accelerator pedal position sensor 2) 4. 5. 6. 7. A EC C MBIB0023E D If NG, replace accelerator pedal assembly and go to the next step. Perform EC-486, "Accelerator Pedal Released Position Learning" . Perform EC-486, "Throttle Valve Closed Position Learning" . Perform EC-486, "Idle Air Volume Learning" . Removal and Installation E BBS003AX ACCELERATOR PEDAL F Refer to ACC-2, "ACCELERATOR CONTROL SYSTEM" . G H I J K L M EC-707 DTC P2127, P2128 APP SENSOR [CR (WITHOUT EURO-OBD)] DTC P2127, P2128 APP SENSOR Component Description PFP:18002 BBS003AY The accelerator pedal position sensor is installed on the upper end of the accelerator pedal assembly. The sensor detects the accelerator position and sends a signal to the ECM. Accelerator pedal position sensor has two sensors. These sensors are a kind of potentiometers which transform the accelerator pedal position into output voltage, and emit the voltage signal to the ECM. In addition, these sensors detect the opening and closing speed of the accelerator pedal and feed the voltage signals to the ECM. The ECM judges the current opening angle of the accelerator pedal from these signals and controls the throttle control motor based on these signals. PBIB1741E Idle position of the accelerator pedal is determined by the ECM receiving the signal from the accelerator pedal position sensor. The ECM uses this signal for the engine operation such as fuel cut. CONSULT-II Reference Value in Data Monitor Mode BBS003AZ Specification data are reference values. MONITOR ITEM ACCEL SEN 1 ACCEL SEN 2* CLSD THL POS CONDITION ● ● ● SPECIFICATION Ignition switch: ON (Engine stopped) Accelerator pedal: Fully released 0.6 - 0.9V Accelerator pedal: Fully depressed 4.0 - 4.8V Ignition switch: ON (Engine stopped) Accelerator pedal: Fully released 0.6 - 0.9V Accelerator pedal: Fully depressed 3.9 - 4.8V Ignition switch: ON (Engine stopped) Accelerator pedal: Fully released ON Accelerator pedal: Slightly depressed OFF *: Accelerator pedal position sensor 2 signal is converted by ECM internally. Thus, it differ from ECM terminal voltage signal. On Board Diagnosis Logic BBS003B0 These self-diagnoses have the one trip detection logic. DTC No. Trouble diagnosis name DTC detecting condition Possible cause P2127 2127 Accelerator pedal position sensor 2 circuit low input An excessively low voltage from the APP sensor 2 is sent to ECM. ● Harness or connectors (APP sensor 2 circuit is open or shorted.) (TP sensor circuit is shorted.) P2128 2128 Accelerator pedal position sensor 2 circuit high input An excessively high voltage from the APP sensor 2 is sent to ECM. ● Accelerator pedal position sensor (APP sensor 2) ● Electric throttle control actuator (TP sensor 1 and 2) FAIL-SAFE MODE When the malfunction is detected, the ECM enters fail-safe mode and the MI lights up. Engine operating condition in fail-safe mode The ECM controls the electric throttle control actuator in regulating the throttle opening in order for the idle position to be within +10 degrees. The ECM regulates the opening speed of throttle valve to be slower than the normal condition. So, the acceleration will be poor. DTC Confirmation Procedure BBS003B1 NOTE: If DTC Confirmation Procedure has been previously conducted, always turn ignition switch OFF and wait at least 10 seconds before conducting the next test. TESTING CONDITION: Before performing the following procedure, confirm that battery voltage is more than 10V at idle. EC-708 DTC P2127, P2128 APP SENSOR [CR (WITHOUT EURO-OBD)] WITH CONSULT-II 1. 2. 3. 4. A Turn ignition switch ON. Select “DATA MONITOR” mode with CONSULT-II. Start engine and let it idle for 1 second. If DTC is detected, go to EC-713, "Diagnostic Procedure" . EC C D SEF058Y WITHOUT CONSULT-II 1. 2. 3. 4. Start engine and let it idle for 1 seconds. Turn ignition switch OFF, wait at least 10 seconds and then turn ON. Perform Diagnostic Test Mode II (Self-diagnostic results) with ECM. If DTC is detected, go to EC-713, "Diagnostic Procedure" . E F G H I J K L M EC-709 DTC P2127, P2128 APP SENSOR [CR (WITHOUT EURO-OBD)] Wiring Diagram BBS003B2 LHD MODELS MBWA1531E EC-710 DTC P2127, P2128 APP SENSOR [CR (WITHOUT EURO-OBD)] Specification data are reference values and are measured between each terminal and ground. CAUTION: Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM's transistor. Use a ground other than ECM terminals, such as the ground. TERMINAL NO. WIRE COLOR A EC ITEM 47 G Sensor power supply (Throttle position sensor) 82 B Sensor ground (APP sensor 1) CONDITION [Ignition switch: ON] DATA (DC Voltage) Approximately 5V C Approximately 0V D Approximately 0V E F [Engine is running] ● Warm-up condition ● Idle speed [Ignition switch: ON] 83 B Sensor ground (APP sensor 2) ● Warm-up condition ● Idle speed 90 O Sensor power supply (APP sensor 1) [Ignition switch: ON] Approximately 5V 91 BR Sensor power supply (APP sensor 2) [Ignition switch: ON] Approximately 5V G [Ignition switch: ON] 98 G Accelerator pedal position sensor 2 ● Engine stopped ● Accelerator pedal: Fully released 0.3 - 0.6V H [Ignition switch: ON] ● Engine stopped ● Accelerator pedal: Fully depressed 1.95 - 2.4V I [Ignition switch: ON] 106 W Accelerator pedal position sensor 1 ● Engine stopped ● Accelerator pedal: Fully released 0.6 - 0.9V J [Ignition switch: ON] ● Engine stopped ● Accelerator pedal: Fully depressed 3.9 - 4.7V K L M EC-711 DTC P2127, P2128 APP SENSOR [CR (WITHOUT EURO-OBD)] RHD MODELS MBWA1532E EC-712 DTC P2127, P2128 APP SENSOR [CR (WITHOUT EURO-OBD)] Specification data are reference values and are measured between each terminal and ground. CAUTION: Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM's transistor. Use a ground other than ECM terminals, such as the ground. TERMINAL NO. A EC WIRE COLOR ITEM CONDITION 47 G Sensor power supply (Throttle position sensor) 82 B Sensor ground (APP sensor 1) DATA (DC Voltage) [Ignition switch: ON] Approximately 5V C Approximately 0V D Approximately 0V E F [Engine is running] ● Warm-up condition ● Idle speed [Ignition switch: ON] 83 B Sensor ground (APP sensor 2) ● Warm-up condition ● Idle speed 90 O Sensor power supply (APP sensor 1) [Ignition switch: ON] Approximately 5V 91 BR Sensor power supply (APP sensor 2) [Ignition switch: ON] Approximately 5V G [Ignition switch: ON] 98 G Accelerator pedal position sensor 2 ● Engine stopped ● Accelerator pedal: Fully released 0.3 - 0.6V H [Ignition switch: ON] ● Engine stopped ● Accelerator pedal: Fully depressed 1.95 - 2.4V I [Ignition switch: ON] 106 W Accelerator pedal position sensor 1 ● Engine stopped ● Accelerator pedal: Fully released 0.6 - 0.9V J [Ignition switch: ON] ● Engine stopped ● Accelerator pedal: Fully depressed 3.9 - 4.7V K Diagnostic Procedure BBS003B3 1. CHECK GROUND CONNECTIONS 1. 2. L Turn ignition switch OFF. Loosen and retighten ground screws on the body. Refer to EC-548, "Ground Inspection" . M MBIB1502E 1. Body ground E44 2. Body ground E45 OK or NG OK >> GO TO 2. NG >> Repair or replace ground connections. EC-713 3. Body ground E28 DTC P2127, P2128 APP SENSOR [CR (WITHOUT EURO-OBD)] 2. CHECK APP SENSOR 2 POWER SUPPLY CIRCUIT-I 1. 2. Disconnect accelerator pedal position (APP) sensor harness connector. Turn ignition switch ON. MBIB0285E 3. Check voltage between APP sensor terminal 5 and ground with CONSULT-II or tester. Voltage: Approximately 5V OK or NG OK >> GO TO 8. NG >> GO TO 3. MBIB0309E 3. CHECK APP SENSOR 2 POWER SUPPLY CIRCUIT-II 1. 2. 3. Turn ignition switch OFF. Disconnect ECM harness connector. Check harness continuity between APP sensor terminal 5 and ECM terminal 91. Refer to Wiring Diagram. Continuity should exist. OK or NG OK >> GO TO 5. NG (LHD models)>>Repair open circuit. NG (RHD models)>>GO TO 4. 4. DETECT MALFUNCTIONING PART Check the following. ● Harness connectors M201, M8 ● Harness connectors M1, E101 ● Harness for open or short between accelerator pedal position sensor and ECM >> Repair open circuit. EC-714 DTC P2127, P2128 APP SENSOR [CR (WITHOUT EURO-OBD)] 5. CHECK APP SENSOR 2 POWER SUPPLY CIRCUIT-III A Check harness for short to power and short to ground, between the following terminals. ECM terminal Sensor terminal Reference Wiring Diagram 91 APP sensor terminal 5 EC-710 47 Electric throttle control actuator terminal 1 EC-720 OK or NG OK >> GO TO 6. NG >> Repair short to ground or short to power in harness or connectors. EC C D 6. CHECK THROTTLE POSITION SENSOR Refer to EC-724, "Component Inspection" . OK or NG OK >> GO TO 14. NG >> GO TO 7. E F 7. REPLACE ELECTRIC THROTTLE CONTROL ACTUATOR 1. 2. 3. Replace the electric throttle control actuator. Perform EC-486, "Throttle Valve Closed Position Learning" . Perform EC-486, "Idle Air Volume Learning" . G H >> INSPECTION END 8. CHECK APP SENSOR 2 GROUND CIRCUIT FOR OPEN AND SHORT I 1. 2. 3. J Turn ignition switch OFF. Disconnect ECM harness connector. Check harness continuity between ECM terminal 83 and APP sensor terminal 1. Refer to Wiring Diagram. K Continuity should exist. 4. Also check harness for short to ground and short to power. OK or NG OK >> GO TO 10. NG (LHD models)>>Repair open circuit or short to ground or short to power in harness or connectors. NG (RHD models)>>GO TO 9. 9. DETECT MALFUNCTIONING PART Check the following. ● Harness connectors M8, M201 ● Harness connectors M1, E101 ● Harness for open or short between accelerator pedal position sensor and ECM >> Repair open circuit or short to ground or short to power in harness or connectors. EC-715 L M DTC P2127, P2128 APP SENSOR [CR (WITHOUT EURO-OBD)] 10. CHECK APP SENSOR 2 INPUT SIGNAL CIRCUIT FOR OPEN AND SHORT 1. Check harness continuity between ECM terminal 98 and APP sensor terminal 6. Refer to Wiring Diagram. Continuity should exist. 2. Also check harness for short to ground and short to power. OK or NG OK >> GO TO 12. NG (LHD models)>>Repair open circuit or short to ground or short to power in harness or connectors. NG (RHD models)>>GO TO 11. 11. DETECT MALFUNCTIONING PART Check the following. Harness connectors M8, M201 ● Harness connectors M1, E101 ● Harness for open or short between ECM and accelerator pedal position sensor ● >> Repair open circuit or short to ground or short to power in harness or connectors. 12. CHECK APP SENSOR Refer to EC-716, "Component Inspection" . OK or NG OK >> GO TO 14. NG >> GO TO 13. 13. REPLACE ACCELERATOR PEDAL ASSEMBLY 1. 2. 3. 4. Replace the accelerator pedal assembly. Perform EC-486, "Accelerator Pedal Released Position Learning" . Perform EC-486, "Throttle Valve Closed Position Learning" . Perform EC-486, "Idle Air Volume Learning" . >> INSPECTION END 14. CHECK INTERMITTENT INCIDENT Refer to EC-542, "TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT" . >> INSPECTION END Component Inspection BBS003B4 ACCELERATOR PEDAL POSITION SENSOR 1. 2. Reconnect all harness connectors disconnected. Turn ignition switch ON. EC-716 DTC P2127, P2128 APP SENSOR [CR (WITHOUT EURO-OBD)] 3. Check voltage between ECM terminals 106 (APP sensor 1 signal), 98 (APP sensor 2 signal) and ground under the following conditions. Terminal Accelerator pedal Voltage 106 (Accelerator pedal position sensor 1) Fully released 0.6 - 0.9V Fully depressed 3.9 - 4.7V Fully released 0.3 - 0.6V Fully depressed 1.95 - 2.4V 98 (Accelerator pedal position sensor 2) 4. 5. 6. 7. A EC C MBIB0023E D If NG, replace accelerator pedal assembly and go to the next step. Perform EC-486, "Accelerator Pedal Released Position Learning" . Perform EC-486, "Throttle Valve Closed Position Learning" . Perform EC-486, "Idle Air Volume Learning" . Removal and Installation E BBS003B5 ACCELERATOR PEDAL F Refer to ACC-2, "ACCELERATOR CONTROL SYSTEM" . G H I J K L M EC-717 DTC P2135 TP SENSOR [CR (WITHOUT EURO-OBD)] DTC P2135 TP SENSOR Component Description PFP:16119 BBS003B6 Electric throttle control actuator consists of throttle control motor, throttle position sensor, etc. The throttle position sensor responds to the throttle valve movement. The throttle position sensor has the two sensors. These sensors are a kind of potentiometers which transform the throttle valve position into output voltage, and emit the voltage signal to the ECM. In addition, these sensors detect the opening and closing speed of the throttle valve and feed the voltage signals to the ECM. The ECM judges the current opening angle of the throttle valve from these signals and the ECM controls the throttle control motor to make the throttle valve opening angle properly in response to driving condition. PBIB0145E CONSULT-II Reference Value in Data Monitor Mode BBS003B7 Specification data are reference values. MONITOR ITEM CONDITION SPECIFICATION ● Ignition switch: ON (Engine stopped) Accelerator pedal: Fully released More than 0.36V ● Shift lever: 1st Accelerator pedal: Fully depressed Less than 4.75V THRTL SEN 1 THRTL SEN 2* *: Throttle position sensor 2 signal is converted by ECM internally. Thus, it differs from ECM terminal voltage signal. On Board Diagnosis Logic BBS003B8 This self-diagnosis has the one trip detection logic. DTC No. P2135 2135 Trouble diagnosis name Throttle position sensor circuit range/performance DTC detecting condition Rationally incorrect voltage is sent to ECM compared with the signals from TP sensor 1 and TP sensor 2. Possible cause ● Harness or connector (TP sensor 1 and 2 circuit is open or shorted.) (APP sensor 2 circuit is shorted.) ● Electric throttle control actuator (TP sensor 1 and 2) ● Accelerator pedal position sensor (APP sensor 2) FAIL-SAFE MODE When the malfunction is detected, the ECM enters fail-safe mode and the MI lights up. Engine operation condition in fail-safe mode The ECM controls the electric throttle control actuator in regulating the throttle opening in order for the idle position to be within +10 degrees. The ECM regulates the opening speed of the throttle valve to be slower than the normal condition. So, the acceleration will be poor. DTC Confirmation Procedure BBS003B9 NOTE: If DTC Confirmation Procedure has been previously conducted, always turn ignition switch OFF and wait at least 10 seconds before conducting the next test. TESTING CONDITION: Before performing the following procedure, confirm that battery voltage is more than 10V at idle. EC-718 DTC P2135 TP SENSOR [CR (WITHOUT EURO-OBD)] WITH CONSULT-II 1. 2. 3. 4. A Turn ignition switch ON. Select “DATA MONITOR” mode with CONSULT-II. Start engine and let it idle for 1 second. If DTC is detected, go to EC-721, "Diagnostic Procedure" . EC C D SEF058Y WITHOUT CONSULT-II 1. 2. 3. 4. Start engine and let it idle for 1 second. Turn ignition switch OFF, wait at least 10 seconds and then turn ON. Perform Diagnostic Test Mode II (Self-diagnostic results) with ECM. If DTC is detected, go to EC-721, "Diagnostic Procedure" . E F G H I J K L M EC-719 DTC P2135 TP SENSOR [CR (WITHOUT EURO-OBD)] Wiring Diagram BBS003BA MBWA1533E EC-720 DTC P2135 TP SENSOR [CR (WITHOUT EURO-OBD)] Specification data are reference values and are measured between each terminal and ground. CAUTION: Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM's transistor. Use a ground other than ECM terminals, such as the ground. TERMINAL NO. 47 WIRE COLOR L ITEM CONDITION Sensor power supply (Throttle position sensor) EC DATA (DC Voltage) [Ignition switch: ON] A Approximately 5V C [Ignition switch: ON] 49 Y ● Engine stopped ● Shift lever position: 1st ● Accelerator pedal: Fully released Throttle position sensor 1 More than 0.36V D [Ignition switch: ON] ● E Engine stopped ● Shift lever position: 1st ● Accelerator pedal: Fully depressed Less than 4.75V F [Engine is running] 66 B Sensor ground (Throttle position sensor) ● Warm-up condition ● Idle speed Approximately 0V G [Ignition switch: ON] 68 R Throttle position sensor 2 ● Engine stopped ● Shift lever position: 1st ● Accelerator pedal: Fully released BR Sensor power supply (APP sensor 2) H [Ignition switch: ON] ● 91 Less than 4.75V I Engine stopped ● Shift lever position: 1st ● Accelerator pedal: Fully depressed More than 0.36V J [Ignition switch: ON] Approximately 5V Diagnostic Procedure BBS003BB 1. CHECK GROUND CONNECTIONS 1. 2. Turn ignition switch OFF. Loosen and retighten ground screws on the body. Refer to EC-548, "Ground Inspection" . K L M MBIB1502E 1. Body ground E44 2. Body ground E45 OK or NG OK >> GO TO 2. NG >> Repair or replace ground connections. EC-721 3. Body ground E28 DTC P2135 TP SENSOR [CR (WITHOUT EURO-OBD)] 2. CHECK THROTTLE POSITION SENSOR POWER SUPPLY CIRCUIT 1. 2. Disconnect electric throttle control actuator harness connector. Turn ignition switch ON. MBIB0308E 3. Check voltage between electric throttle control actuator terminal 1 and ground with CONSULT-II or tester. Voltage: Approximately 5V OK or NG OK >> GO TO 7. NG >> GO TO 3. PBIB0082E 3. CHECK THROTTLE POSITION SENSOR POWER SUPPLY CIRCUIT-II 1. 2. 3. Turn ignition switch OFF. Disconnect ECM harness connector. Check harness continuity between electric throttle control actuator terminal 1 and ECM terminal 47. Refer to Wiring Diagram. Continuity should exist. OK or NG OK >> GO TO 4. NG >> Repair open circuit. 4. CHECK THROTTLE POSITION SENSOR POWER SUPPLY CIRCUIT-III Check harness for short to power and short to ground, between the following terminals. ECM terminal Sensor terminal Reference Wiring Diagram 47 Electric throttle control actuator terminal 1 EC-720 91 APP sensor terminal 5 EC-710 OK or NG OK >> GO TO 5. NG >> Repair short to ground or short to power in harness or connectors. 5. CHECK APP SENSOR Refer to EC-716, "Component Inspection" . OK or NG OK >> GO TO 11 NG >> GO TO 6. EC-722 DTC P2135 TP SENSOR [CR (WITHOUT EURO-OBD)] 6. REPLACE ACCELERATOR PEDAL ASSEMBLY 1. 2. 3. 4. Replace accelerator pedal assembly. Perform EC-486, "Accelerator Pedal Released Position Learning" . Perform EC-486, "Throttle Valve Closed Position Learning" . Perform EC-486, "Idle Air Volume Learning" . 7. CHECK THROTTLE POSITION SENSOR GROUND CIRCUIT FOR OPEN AND SHORT Turn ignition switch OFF. Disconnect ECM harness connector. Check harness continuity between ECM terminal 66 and electric throttle control actuator terminal 5. Refer to Wiring Diagram. Continuity should exist. D E F 4. Also check harness for short to ground and short to power. OK or NG OK >> GO TO 8. NG >> Repair open circuit or short to ground or short to power in harness or connectors. 8. CHECK THROTTLE POSITION SENSOR INPUT SIGNAL CIRCUIT FOR OPEN AND SHORT 1. EC C >> INSPECTION END 1. 2. 3. A Check harness continuity between ECM terminal 49 and electric throttle control actuator terminal 4, ECM terminal 68 and electric throttle control actuator terminal 2. Refer to Wiring Diagram. G H I Continuity should exist. 2. Also check harness for short to ground and short to power. OK or NG OK >> GO TO 9. NG >> Repair open circuit or short to ground or short to power in harness or connectors. J K 9. CHECK THROTTLE POSITION SENSOR L Refer to EC-724, "Component Inspection" . OK or NG OK >> GO TO 11. NG >> GO TO 10. M 10. REPLACE ELECTRIC THROTTLE CONTROL ACTUATOR 1. 2. 3. Replace the electric throttle control actuator. Perform EC-486, "Throttle Valve Closed Position Learning" . Perform EC-486, "Idle Air Volume Learning" . >> INSPECTION END 11. CHECK INTERMITTENT INCIDENT Refer to EC-542, "TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT" . >> INSPECTION END EC-723 DTC P2135 TP SENSOR [CR (WITHOUT EURO-OBD)] Component Inspection BBS003BC THROTTLE POSITION SENSOR 1. 2. 3. 4. 5. Reconnect all harness connectors disconnected. Perform EC-486, "Throttle Valve Closed Position Learning" . Turn ignition switch ON. Set shift lever to 1st position. Check voltage between ECM terminals 49 (TP sensor 1 signal), 68 (TP sensor 2 signal) and ground under the following conditions. Terminal Accelerator pedal Voltage 49 (Throttle position sensor 1) Fully released More than 0.36V Fully depressed Less than 4.75V Fully released Less than 4.75V Fully depressed More than 0.36V 68 (Throttle position sensor 2) 6. 7. 8. If NG, replace electric throttle control actuator and go to the next step. Perform EC-486, "Throttle Valve Closed Position Learning" . Perform EC-486, "Idle Air Volume Learning" . Removal and Installation MBIB1443E BBS003BD ELECTRIC THROTTLE CONTROL ACTUATOR Refer to EM-18, "AIR CLEANER AND AIR DUCT" . EC-724 DTC P2138 APP SENSOR [CR (WITHOUT EURO-OBD)] DTC P2138 APP SENSOR Component Description PFP:18002 A BBS003BE The accelerator pedal position sensor is installed on the upper end of the accelerator pedal assembly. The sensor detects the acceleraEC tor position and sends a signal to the ECM. Accelerator pedal position sensor has two sensors. These sensors are a kind of potentiometers which transform the accelerator pedal C position into output voltage, and emit the voltage signal to the ECM. In addition, these sensors detect the opening and closing speed of the accelerator pedal and feed the voltage signals to the ECM. The ECM judges the current opening angle of the accelerator pedal from D these signals and controls the throttle control motor based on these signals. PBIB1741E Idle position of the accelerator pedal is determined by the ECM E receiving the signal from the accelerator pedal position sensor. The ECM uses this signal for the engine operation such as fuel cut. CONSULT-II Reference Value in Data Monitor Mode BBS003BF F Specification data are reference values. MONITOR ITEM ACCEL SEN 1 ACCEL SEN 2* CLSD THL POS CONDITION ● ● ● SPECIFICATION Ignition switch: ON (Engine stopped) Accelerator pedal: Fully released 0.6 - 0.9V Accelerator pedal: Fully depressed 4.0 - 4.8V Ignition switch: ON (Engine stopped) Accelerator pedal: Fully released 0.6 - 0.9V Accelerator pedal: Fully depressed 3.9 - 4.8V Ignition switch: ON (Engine stopped) Accelerator pedal: Fully released ON Accelerator pedal: Slightly depressed OFF G H I *: Accelerator pedal position sensor 2 signal is converted by ECM internally. Thus, it differs from ECM terminal voltage. On Board Diagnosis Logic BBS003BG This self-diagnosis has the one trip detection logic. NOTE: If DTC P2138 is displayed with DTC P1229, first perform trouble diagnosis for DTC P1229. Refer to EC680, "DTC P1229 SENSOR POWER SUPPLY" . DTC No. Trouble diagnosis name DTC detecting condition Possible cause ● P2138 2138 Accelerator pedal position sensor circuit range/performance Rationally incorrect voltage is sent to ECM compared with the signals from APP sensor 1 and APP sensor 2. Harness or connector (APP sensor 1 and 2 circuit is open or shorted.) (TP sensor circuit is shorted.) ● Accelerator pedal position sensor (APP sensor 1 and 2) ● Electric throttle control actuator (TP sensor 1 and 2) FAIL-SAFE MODE When the malfunction is detected, the ECM enters fail-safe mode and the MI lights up. Engine operating condition in fail-safe mode The ECM controls the electric throttle control actuator in regulating the throttle opening in order for the idle position to be within +10 degrees. The ECM regulates the opening speed of the throttle valve to be slower than the normal condition. So, the acceleration will be poor. EC-725 J K L M DTC P2138 APP SENSOR [CR (WITHOUT EURO-OBD)] DTC Confirmation Procedure BBS003BH NOTE: If DTC Confirmation Procedure has been previously conducted, always turn ignition switch OFF and wait at least 10 seconds before conducting the next test. TESTING CONDITION: Before performing the following procedure, confirm that battery voltage is more than 10V at idle. WITH CONSULT-II 1. 2. 3. 4. Turn ignition switch ON. Select “DATA MONITOR” mode with CONSULT-II. Start engine and let it idle for 1 second. If DTC is detected, go to EC-730, "Diagnostic Procedure" . SEF058Y WITHOUT CONSULT-II 1. 2. 3. 4. Start engine and let it idle for 1 second. Turn ignition switch OFF, wait at least 10 seconds and then turn ON. Perform Diagnostic Test Mode II (Self-diagnostic results) with ECM. If DTC is detected, go to EC-730, "Diagnostic Procedure" . EC-726 DTC P2138 APP SENSOR [CR (WITHOUT EURO-OBD)] Wiring Diagram BBS003BI A LHD MODELS EC C D E F G H I J K L M MBWA1534E EC-727 DTC P2138 APP SENSOR [CR (WITHOUT EURO-OBD)] Specification data are reference values and are measured between each terminal and ground. CAUTION: Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM's transistor. Use a ground other than ECM terminals, such as the ground. TERMINAL NO. WIRE COLOR ITEM CONDITION 47 G Sensor power supply (Throttle position sensor) [Ignition switch: ON] 82 B Sensor ground (APP sensor 1) ● Warm-up condition ● Idle speed DATA (DC Voltage) Approximately 5V [Engine is running] Approximately 0V [Ignition switch: ON] 83 B Sensor ground (APP sensor 2) ● Warm-up condition ● Idle speed Approximately 0V 90 O Sensor power supply (APP sensor 1) [Ignition switch: ON] Approximately 5V 91 BR Sensor power supply (APP sensor 2) [Ignition switch: ON] Approximately 5V [Ignition switch: ON] 98 G Accelerator pedal position sensor 2 ● Engine stopped ● Accelerator pedal: Fully released 0.3 - 0.6V [Ignition switch: ON] ● Engine stopped ● Accelerator pedal: Fully depressed 1.95 - 2.4V [Ignition switch: ON] 106 W Accelerator pedal position sensor 1 ● Engine stopped ● Accelerator pedal: Fully released 0.6 - 0.9V [Ignition switch: ON] ● Engine stopped ● Accelerator pedal: Fully depressed EC-728 3.9 - 4.7V DTC P2138 APP SENSOR [CR (WITHOUT EURO-OBD)] RHD MODELS A EC C D E F G H I J K L M MBWA1535E EC-729 DTC P2138 APP SENSOR [CR (WITHOUT EURO-OBD)] Specification data are reference values and are measured between each terminal and ground. CAUTION: Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM's transistor. Use a ground other than ECM terminals, such as the ground. TERMINAL NO. WIRE COLOR ITEM CONDITION 47 G Sensor power supply (Throttle position sensor) [Ignition switch: ON] 82 B Sensor ground (APP sensor 1) ● Warm-up condition ● Idle speed DATA (DC Voltage) Approximately 5V [Engine is running] Approximately 0V [Ignition switch: ON] 83 B Sensor ground (APP sensor 2) ● Warm-up condition ● Idle speed Approximately 0V 90 O Sensor power supply (APP sensor 1) [Ignition switch: ON] Approximately 5V 91 BR Sensor power supply (APP sensor 2) [Ignition switch: ON] Approximately 5V [Ignition switch: ON] 98 G Accelerator pedal position sensor 2 ● Engine stopped ● Accelerator pedal: Fully released 0.3 - 0.6V [Ignition switch: ON] ● Engine stopped ● Accelerator pedal: Fully depressed 1.95 - 2.4V [Ignition switch: ON] 106 W Accelerator pedal position sensor 1 ● Engine stopped ● Accelerator pedal: Fully released 0.6 - 0.9V [Ignition switch: ON] ● Engine stopped ● Accelerator pedal: Fully depressed 3.9 - 4.7V Diagnostic Procedure BBS003BJ 1. CHECK GROUND CONNECTIONS 1. 2. Turn ignition switch OFF. Loosen and retighten ground screws on the body. Refer to EC-548, "Ground Inspection" . MBIB1502E 1. Body ground E44 2. Body ground E45 OK or NG OK >> GO TO 2. NG >> Repair or replace ground connections. EC-730 3. Body ground E28 DTC P2138 APP SENSOR [CR (WITHOUT EURO-OBD)] 2. CHECK APP SENSOR 1 POWER SUPPLY CIRCUIT 1. 2. A Disconnect accelerator pedal position (APP) sensor harness connector. Turn ignition switch ON. EC C D MBIB0285E 3. Check voltage between APP sensor terminal 4 and ground with CONSULT-II or tester. E Voltage: Approximately 5V F G MBIB0304E H OK or NG OK >> GO TO 4. NG (LHD models)>>Repair open circuit or short to ground or short to power in harness or connectors. NG (RHD models)>>GO TO 3. I 3. DETECT MALFUNCTIONING PART J Check the following. ● Harness connectors M1, E101 ● Harness connectors M8, M201 ● Harness for open or short between ECM and accelerator pedal position sensor K L >> Repair open circuit or short to ground or short to power in harness or connectors. 4. CHECK APP SENSOR 2 POWER SUPPLY CIRCUIT-I M Check voltage between APP sensor terminal 5 and ground with CONSULT-II or tester. Voltage: Approximately 5V OK or NG OK >> GO TO 10. NG >> GO TO 5. MBIB0309E EC-731 DTC P2138 APP SENSOR [CR (WITHOUT EURO-OBD)] 5. CHECK APP SENSOR 2 POWER SUPPLY CIRCUIT-II 1. 2. 3. Turn ignition switch OFF. Disconnect ECM harness connector. Check harness continuity between APP sensor terminal 5 and ECM terminal 91. Refer to Wiring Diagram. Continuity should exist. OK or NG OK >> GO TO 7. NG (LHD models)>>Repair open circuit. NG (RHD models)>>GO TO 6. 6. DETECT MALFUNCTIONING PART Check the following. ● Harness connectors M1, E101 ● Harness connectors M8, M201 ● Harness for open or short between accelerator pedal position sensor and ECM >> Repair open circuit. 7. CHECK APP SENSOR 2 POWER SUPPLY CIRCUIT-III Check harness for short to power and short to ground, between the following terminals. ECM terminal Sensor terminal Reference Wiring Diagram 91 APP sensor terminal 5 EC-727 47 Electric throttle control actuator terminal 1 EC-720 OK or NG OK >> GO TO 8. NG >> Repair short to ground or short to power in harness or connectors. 8. CHECK THROTTLE POSITION SENSOR Refer to EC-724, "Component Inspection" . OK or NG OK >> GO TO 16. NG >> GO TO 9. 9. REPLACE ELECTRIC THROTTLE CONTROL ACTUATOR 1. 2. 3. Replace the electric throttle control actuator. Perform EC-486, "Throttle Valve Closed Position Learning" . Perform EC-486, "Idle Air Volume Learning" . >> INSPECTION END EC-732 DTC P2138 APP SENSOR [CR (WITHOUT EURO-OBD)] 10. CHECK APP SENSOR GROUND CIRCUIT FOR OPEN AND SHORT 1. 2. 3. A Turn ignition switch OFF. Disconnect ECM harness connector. Check harness continuity between ECM terminal 82 and APP sensor terminal 2, ECM terminal 83 and EC APP sensor terminal 1. Refer to Wiring Diagram. C Continuity should exist. 4. Also check harness for short to ground and short to power. OK or NG OK >> GO TO 12. NG (LHD models)>>Repair open circuit or short to ground or short to power in harness or connectors. NG (RHD models)>>GO TO 11. D E 11. DETECT MALFUNCTIONING PART Check the following. ● Harness connectors M1, E101 ● Harness connectors M8, M201 ● Harness for open or short between ECM and accelerator pedal position sensor >> Repair open circuit or short to ground or short to power in harness or connectors. F G H 12. CHECK APP SENSOR INPUT SIGNAL CIRCUIT FOR OPEN AND SHORT 1. Check harness continuity between ECM terminal 106 and APP sensor terminal 3, ECM terminal 98 and APP sensor terminal 6. Refer to Wiring Diagram. I J Continuity should exist. 2. Also check harness for short to ground and short to power. OK or NG OK >> GO TO 14. NG (LHD models)>>Repair open circuit or short to ground or short to power in harness or connectors. NG (RHD models)>>GO TO 13. 13. DETECT MALFUNCTIONING PART Check the following. ● Harness connectors M1, E101 ● Harness connectors M8, M201 ● Harness for open or short between ECM and accelerator pedal position sensor >> Repair open circuit or short to ground or short to power in harness or connectors. 14. CHECK APP SENSOR Refer to EC-734, "Component Inspection" . OK or NG OK >> GO TO 16. NG >> GO TO 15. EC-733 K L M DTC P2138 APP SENSOR [CR (WITHOUT EURO-OBD)] 15. REPLACE ACCELERATOR PEDAL ASSEMBLY 1. 2. 3. 4. Replace the accelerator pedal assembly. Perform EC-486, "Accelerator Pedal Released Position Learning" . Perform EC-486, "Throttle Valve Closed Position Learning" . Perform EC-486, "Idle Air Volume Learning" . >> INSPECTION END 16. CHECK INTERMITTENT INCIDENT Refer to EC-542, "TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT" . >> INSPECTION END Component Inspection BBS003BK ACCELERATOR PEDAL POSITION SENSOR 1. 2. 3. Reconnect all harness connectors disconnected. Turn ignition switch ON. Check voltage between ECM terminals 106 (APP sensor 1 signal), 98 (APP sensor 2 signal) and ground under the following conditions. Terminal Accelerator pedal Voltage 106 (Accelerator pedal position sensor 1) Fully released 0.6 - 0.9V Fully depressed 3.9 - 4.7V Fully released 0.3 - 0.6V Fully depressed 1.95 - 2.4V 98 (Accelerator pedal position sensor 2) 4. 5. 6. 7. MBIB0023E If NG, replace accelerator pedal assembly and go to the next step. Perform EC-486, "Accelerator Pedal Released Position Learning" . Perform EC-486, "Throttle Valve Closed Position Learning" . Perform EC-486, "Idle Air Volume Learning" . Removal and Installation BBS003BL ACCELERATOR PEDAL Refer to EM-18, "AIR CLEANER AND AIR DUCT" . EC-734 ELECTRICAL LOAD SIGNAL [CR (WITHOUT EURO-OBD)] ELECTRICAL LOAD SIGNAL Description PFP:25350 A BBS003D8 The electrical load signal (Headlamp switch signal, rear window defogger switch signal, etc.) is transferred through the CAN communication line from IPDM E/R to ECM. EC CONSULT-II Reference Value in Data Monitor Mode BBS003D9 Specification data are reference values. MONITOR ITEM LOAD SIGNAL C CONDITION ● ● HEATER FAN SW Ignition switch: ON Engine: After warming up, idle the engine SPECIFICATION Rear window defogger switch is ON and/or lighting switch is 2nd. ON Rear window defogger switch is OFF and lighting switch is OFF. OFF Heater fan: Operating ON Heater fan: Not operating OFF Diagnostic Procedure D E BBS003DA F 1. CHECK LOAD SIGNAL CIRCUIT OVERALL FUNCTION-I 1. 2. 3. Turn ignition switch ON. Connect CONSULT-II and select “DATA MONITOR” mode. Select “LOAD SIGNAL” and check indication under the following conditions. Condition G H Indication Rear window defogger switch: ON ON Rear window defogger switch: OFF OFF I OK or NG OK >> GO TO 2. NG >> GO TO 4. J PBIB0103E K 2. CHECK LOAD SIGNAL CIRCUIT OVERALL FUNCTION-II Check “LOAD SIGNAL” indication under the following conditions. Condition L Indication Lighting switch: 2nd position ON Lighting switch: OFF OFF M OK or NG OK >> GO TO 3. NG >> GO TO 5. PBIB0103E EC-735 ELECTRICAL LOAD SIGNAL [CR (WITHOUT EURO-OBD)] 3. CHECK HEATER FAN SIGNAL CIRCUIT OVERALL FUNCTION With CONSULT-II Check “HEATER FAN SW” in “DATA MONITOR” mode with CONSULT-II under the following conditions. Condition HEATER FAN SW Heater fan control switch: ON ON Heater fan control switch: OFF OFF OK or NG OK >> INSPECTION END NG >> GO TO 6. PBIB1995E 4. CHECK REAR WINDOW DEFOGGER SYSTEM Refer to GW-12, "REAR WINDOW DEFOGGER" . >> INSPECTION END 5. CHECK HEADLAMP SYSTEM Refer to LT-7, "HEADLAMP -CONVENTIONAL TYPE-" or LT-35, "HEADLAMP - DAYTIME LIGHT SYSTEM ". >> INSPECTION END 6. CHECK HEATER FAN CONTROL SYSTEM Refer to ATC-26, "TROUBLE DIAGNOSIS" or MTC-23, "TROUBLE DIAGNOSIS" . >> INSPECTION END EC-736 EVAP CANISTER PURGE VOLUME CONTROL SOLENOID VALVE [CR (WITHOUT EURO-OBD)] EVAP CANISTER PURGE VOLUME CONTROL SOLENOID VALVE Description PFP:14920 A BBS003CK SYSTEM DESCRIPTION Sensor Input Signal to ECM Crankshaft position sensor (POS) Camshaft position sensor (PHASE) Engine speed*1 Manifold absolute pressure sensor Amount of intake air Engine coolant temperature sensor Engine coolant temperature Battery Battery voltage*1 Throttle position sensor Throttle position Accelerator pedal position sensor Accelerator pedal position Heated oxygen sensors 1 Density of oxygen in exhaust gas (Mixture ratio feedback signal) Wheel sensor Vehicle speed*2 ECM Function Actuator EC C EVAP canister purge flow control EVAP canister purge volume control solenoid valve D E F *1: ECM determines the start signal status by the signals of engine speed and battery voltage. *2: This signal is sent to the ECM through CAN communication line. This system controls flow rate of fuel vapor from the EVAP canister. The opening of the vapor by-pass passage in the EVAP canister purge volume control solenoid valve changes to control the flow rate. The EVAP canister purge volume control solenoid valve repeats ON/OFF operation according to the signal sent from the ECM. The opening of the valve varies for optimum engine control. The optimum value stored in the ECM is determined by considering various engine conditions. When the engine is operating, the flow rate of fuel vapor from the EVAP canister is regulated as the air flow changes. G H COMPONENT DESCRIPTION I The EVAP canister purge volume control solenoid valve uses a ON/ OFF duty to control the flow rate of fuel vapor from the EVAP canister. The EVAP canister purge volume control solenoid valve is moved by ON/OFF pulses from the ECM. The longer the ON pulse, the greater the amount of fuel vapor that will flow through the valve. J K L SEF337U CONSULT-II Reference Value in Data Monitor Mode BBS003CL M Specification data are reference values. MONITOR ITEM CONDITION ● Engine: After warming up ● Shift lever: Neutral ● Air conditioner switch: OFF ● No load PURG VOL C/V SPECIFICATION Idle 0% 2,000 rpm 20 - 30% EC-737 EVAP CANISTER PURGE VOLUME CONTROL SOLENOID VALVE [CR (WITHOUT EURO-OBD)] Wiring Diagram BBS003CM MBWA1545E EC-738 EVAP CANISTER PURGE VOLUME CONTROL SOLENOID VALVE [CR (WITHOUT EURO-OBD)] Specification data are reference values and are measured between each terminal and ground. Pulse signal is measured by CONSULT-II. A CAUTION: Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM's transistor. Use a ground other than ECM terminals, such as the ground. EC TERMINAL NO. WIRE COLOR ITEM CONDITION DATA (DC Voltage) C BATTERY VOLTAGE (11 - 14V) D [Engine is running] ● Idle speed E 19 LG EVAP canister purge volume control solenoid valve PBIB0050E F Approximately 10V [Engine is running] ● G Engine speed: About 2,000 rpm (More than 100 seconds after starting engine) PBIB0520E [Engine is running] [Ignition switch: OFF] ● 111 P ECM relay (Self shut-off) [Ignition switch: OFF] ● 119 120 G G Power supply for ECM For a few seconds after turning ignition switch OFF More than a few seconds passed after turning ignition switch OFF [Ignition switch: ON] 0 - 1.0V BATTERY VOLTAGE (11 - 14V) BATTERY VOLTAGE (11 - 14V) H I J K : Average voltage for pulse signal (Actual pulse signal can be confirmed by oscilloscope.) L M EC-739 EVAP CANISTER PURGE VOLUME CONTROL SOLENOID VALVE [CR (WITHOUT EURO-OBD)] Diagnostic Procedure BBS003CN 1. CHECK OVERALL FUNCTION 1. 2. 3. 4. With CONSULT-II Turn ignition switch OFF. Disconnect the EVAP purge hose connected to the EVAP canister. Turn ignition switch ON, and select “PURG VOL CONT/V” in “ACTIVE TEST” mode with CONSULT-II. Start engine and let it idle. PBIB0569E 5. Change the valve opening percentage with touching “Qu” or “Qd” on CONSULT-II screen, and check for vacuum existence at the EVAP purge hose (2) under the following conditions. – : Vehicle front EVAP canister (1) – Conditions (PURG VOL CONT/V value) 0% Vacuum Should not exist 100% Should exist MBIB1497E 1. 2. 3. 4. – – Without CONSULT-II Turn ignition switch OFF. Disconnect the EVAP purge hose connected to the EVAP canister. Start engine and let it idle for at least 80 seconds. Check for vacuum existence at the EVAP purge hose (2) under the following conditions. : Vehicle front EVAP canister (1) Conditions At idle Engine speed: About 2,000 rpm Vacuum Should not exist Should exist OK or NG OK >> GO TO 2. NG >> GO TO 3. MBIB1497E 2. CHECK EVAP CANISTER Refer to EC-472, "Component Inspection" . OK or NG OK >> INSPECTION END NG >> Replace EVAP canister. EC-740 EVAP CANISTER PURGE VOLUME CONTROL SOLENOID VALVE [CR (WITHOUT EURO-OBD)] 3. CHECK EVAP PURGE LINE A Check EVAP purge line (pipe, rubber tube, fuel tank and EVAP canister) for cracks or improper connection. Refer to EC-469, "EVAPORATIVE EMISSION SYSTEM" . OK or NG OK >> GO TO 4. NG >> Repair or reconnect the hose. 4. CHECK EVAP CANISTER PURGE VOLUME CONTROL SOLENOID VALVE POWER SUPPLY CIR- EC C CUIT 1. 2. 3. D Turn ignition switch OFF. Disconnect EVAP canister purge volume control solenoid valve harness connector. Turn ignition switch ON. E F G MBIB1076E 4. H Check voltage between EVAP canister purge volume control solenoid valve terminal 1 and ground with CONSULT-II or tester. Voltage: Battery voltage I OK or NG OK >> GO TO 6. NG >> GO TO 5. J K PBIB0148E 5. DETECT MALFUNCTIONING PART L Check the following. ● Harness connectors E48, F1 ● Harness for open or short between EVAP canister purge volume control solenoid valve and IPDM E/R ● Harness for open or short between EVAP canister purge volume control solenoid valve and ECM >> Repair harness or connectors. EC-741 M EVAP CANISTER PURGE VOLUME CONTROL SOLENOID VALVE [CR (WITHOUT EURO-OBD)] 6. CHECK EVAP CANISTER PURGE VOLUME CONTROL SOLENOID VALVE OUTPUT SIGNAL CIRCUIT FOR OPEN AND SHORT 1. 2. 3. Turn ignition switch OFF. Disconnect ECM harness connector. Check harness continuity between ECM terminal 19 and EVAP canister purge volume control solenoid valve terminal 2. Refer to Wiring Diagram. Continuity should exist. 4. Also check harness for short to ground and short to power. OK or NG OK (With CONSULT-II)>>GO TO 7. OK (Without CONSULT-II)>>GO TO 8. NG >> Repair open circuit or short to ground and short to power in harness or connectors. 7. CHECK EVAP CANISTER PURGE VOLUME CONTROL SOLENOID VALVE OPERATION With CONSULT-II 1. Reconnect all harness connectors disconnected. 2. Start engine. 3. Perform “PURG VOL CONT/V” in “ACTIVE TEST” mode with CONSULT-II. Check that engine speed varies according to the valve opening. OK or NG OK >> GO TO 9. NG >> GO TO 8. PBIB0569E 8. CHECK EVAP CANISTER PURGE VOLUME CONTROL SOLENOID VALVE Refer to EC-743, "Component Inspection" . OK or NG OK >> GO TO 9. NG >> Replace EVAP canister purge volume control solenoid valve. 9. CHECK INTERMITTENT INCIDENT Refer to EC-542, "TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT" . >> INSPECTION END EC-742 EVAP CANISTER PURGE VOLUME CONTROL SOLENOID VALVE [CR (WITHOUT EURO-OBD)] Component Inspection BBS003CO A EVAP CANISTER PURGE VOLUME CONTROL SOLENOID VALVE With CONSULT-II Check air passage continuity of EVAP canister purge volume control solenoid valve under the following conditions. Condition (PURG VOL CONT/V value) EC Air passage continuity between A and B 100% Yes 0% No C D PBIB0149E Without CONSULT-II Check air passage continuity of EVAP canister purge volume control solenoid valve under the following conditions. Condition Air passage continuity between A and B 12V direct current supply between terminals 1 and 2 Yes No supply No E F G H PBIB0150E Removal and Installation BBS003CP I EVAP CANISTER PURGE VOLUME CONTROL SOLENOID VALVE Refer to EM-18, "AIR CLEANER AND AIR DUCT" . J K L M EC-743 FUEL INJECTOR [CR (WITHOUT EURO-OBD)] FUEL INJECTOR Component Description PFP:16600 BBS003CS The fuel injector is a small, precise solenoid valve. When the ECM supplies a ground to the fuel injector circuit, the coil in the fuel injector is energized. The energized coil pulls the ball valve back and allows fuel to flow through the fuel injector into the intake manifold. The amount of fuel injected depends upon the injection pulse duration. Pulse duration is the length of time the fuel injector remains open. The ECM controls the injection pulse duration based on engine fuel needs. SEF375Z CONSULT-II Reference Value in Data Monitor Mode BBS003CT Specification data are reference values. MONITOR ITEM B/FUEL SCHDL CONDITION ● See EC-532, "TROUBLE DIAGNOSIS - SPECIFICATION VALUE" . ● Engine: After warming up ● Shift lever: Neutral ● Air conditioner switch: OFF ● No load INJ PULSE-B1 SPECIFICATION Idle 2.0 - 3.0 msec 2,000 rpm 1.9 - 2.9 msec EC-744 FUEL INJECTOR [CR (WITHOUT EURO-OBD)] Wiring Diagram BBS003CU A EC C D E F G H I J K L M MBWA1538E EC-745 FUEL INJECTOR [CR (WITHOUT EURO-OBD)] Specification data are reference values and are measured between each terminal and ground. Pulse signal is measured by CONSULT-II. CAUTION: Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM's transistor. Use a ground other than ECM terminals, such as the ground. TERMINAL NO. WIRE COLOR ITEM CONDITION DATA (DC Voltage) BATTERY VOLTAGE [Engine is running] 22 23 41 42 O L R GR ● Warm-up condition ● Idle speed (11 - 14V) NOTE: The pulse cycle changes depending on rpm at idle. Fuel injector No. 3 Fuel injector No. 1 Fuel injector No. 4 Fuel injector No. 2 PBIB0529E BATTERY VOLTAGE (11 - 14V) [Engine is running] ● Warm-up condition ● Engine speed: 2,000 rpm PBIB0530E : Average voltage for pulse signal (Actual pulse signal can be confirmed by oscilloscope.) Diagnostic Procedure BBS003CV 1. INSPECTION START Turn ignition switch to START. Is any cylinder ignited? Yes or No Yes >> GO TO 2. No >> GO TO 3. EC-746 FUEL INJECTOR [CR (WITHOUT EURO-OBD)] 2. CHECK OVERALL FUNCTION A With CONSULT-II Start engine. Perform “POWER BALANCE” in “ACTIVE TEST” mode with CONSULT-II. 3. Make sure that each circuit produces a momentary engine speed drop. 1. 2. EC C D E MBIB0302E Without CONSULT-II 1. Start engine. 2. Listen to each fuel injector operating sound. Clicking noise should be heard. F G H I PBIB1986E J OK or NG OK >> INSPECTION END NG >> GO TO 3. K L M EC-747 FUEL INJECTOR [CR (WITHOUT EURO-OBD)] 3. CHECK FUEL INJECTOR POWER SUPPLY CIRCUIT 1. 2. Turn ignition switch OFF. Disconnect fuel injector harness connector (1). – : Vehicle front Turn ignition switch ON. 3. MBIB1458E 4. Check voltage between fuel injector terminal 1 and ground with CONSULT-II or tester. Voltage: Battery voltage OK or NG OK >> GO TO 5. NG >> GO TO 4. PBIB0582E 4. DETECT MALFUNCTIONING PART Check the following. Harness connectors E48, F1 ● 10A fuse ● Harness for open or short between fuel injector and fuse ● >> Repair harness or connectors. 5. CHECK FUEL INJECTOR OUTPUT SIGNAL CIRCUIT FOR OPEN AND SHORT 1. 2. 3. Turn ignition switch OFF. Disconnect ECM harness connector. Check harness continuity between fuel injector terminal 2 and ECM terminals 22, 23, 41, 42. Refer to Wiring Diagram. Continuity should exist. 4. Also check harness for short to ground and short to power. OK or NG OK >> GO TO 6. NG >> Repair open circuit or short to ground or short to power in harness or connectors. 6. CHECK FUEL INJECTOR Refer to EC-749, "Component Inspection" . OK or NG OK >> GO TO 7. NG >> Replace fuel injector. EC-748 FUEL INJECTOR [CR (WITHOUT EURO-OBD)] 7. CHECK INTERMITTENT INCIDENT A Refer to EC-542, "TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT" . EC >> INSPECTION END Component Inspection BBS003CW FUEL INJECTOR 1. 2. C Disconnect fuel injector harness connector. Check resistance between terminals as shown in the figure. Resistance: 10.4 - 15.3Ω [at 10 - 60°C (50 - 140°F)] D E F PBIB1727E Removal and Installation BBS003CX G FUEL INJECTOR Refer to EM-32, "FUEL INJECTOR AND FUEL TUBE" . H I J K L M EC-749 FUEL PUMP [CR (WITHOUT EURO-OBD)] FUEL PUMP Description PFP:17042 BBS003CY SYSTEM DESCRIPTION Sensor Input Signal to ECM Crankshaft position sensor (POS) Camshaft position sensor (PHASE) Engine speed* Battery Battery voltage* ECM Function Actuator Fuel pump control Fuel pump relay *: ECM determines the start signal status by the signals of engine speed and battery voltage. The ECM activates the fuel pump for several seconds after the ignition switch is turned on to improve engine startability. If the ECM receives a engine speed signal from the crankshaft position sensor (POS) and camshaft position sensor (PHASE), it knows that the engine is rotating, and causes the pump to operate. If the engine speed signal is not received when the ignition switch is ON, the engine stalls. The ECM stops pump operation and prevents battery discharging, thereby improving safety. The ECM does not directly drive the fuel pump. It controls the ON/OFF fuel pump relay, which in turn controls the fuel pump. Condition Fuel pump operation Ignition switch is turned to ON. Operates for 1 second. Engine running and cranking Operates. When engine is stopped Stops in 1.5 seconds. Except as shown above Stops. COMPONENT DESCRIPTION A turbine type design fuel pump is used in the fuel tank. MBIB0291E CONSULT-II Reference Value in Data Monitor Mode BBS003CZ Specification data are reference values. MONITOR ITEM FUEL PUMP RLY CONDITION ● For 1 second after turning ignition switch ON ● Engine running or cranking ● Except above conditions SPECIFICATION ON OFF EC-750 FUEL PUMP [CR (WITHOUT EURO-OBD)] Wiring Diagram BBS003D0 A EC C D E F G H I J K L M MBWA1539E EC-751 FUEL PUMP [CR (WITHOUT EURO-OBD)] Specification data are reference values and are measured between each terminal and ground. CAUTION: Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM's transistor. Use a ground other than ECM terminals, such as the ground. TERMINAL NO. WIRE COLOR ITEM CONDITION DATA (DC Voltage) [Ignition switch: ON] ● 113 R Fuel pump relay For 1 second after turning ignition switch ON 0 - 1.0V [Engine is running] [Ignition switch: ON] ● More than 1 second after turning ignition switch ON Diagnostic Procedure BATTERY VOLTAGE (11 - 14V) BBS003D1 1. CHECK OVERALL FUNCTION 1. 2. Turn ignition switch ON. Pinch fuel feed hose (1) with two fingers. Fuel pressure pulsation should be felt on the fuel hose for 1 second after ignition switch is turned ON. OK or NG OK >> INSPECTION END NG >> GO TO 2. MBIB1496E 2. CHECK FUEL PUMP RELAY POWER SUPPLY CIRCUIT 1. 2. 3. 4. Turn ignition switch OFF. Disconnect ECM harness connector. Turn ignition switch ON. Check voltage between ECM terminals 113 and ground with CONSULT-II or tester. Voltage: Battery voltage OK or NG OK >> GO TO 5. NG >> GO TO 3. PBIB1187E EC-752 FUEL PUMP [CR (WITHOUT EURO-OBD)] 3. CHECK FUEL PUMP POWER SUPPLY CIRCUIT-I A Check voltage between IPDM E/R terminal 69 and ground with CONSULT-II or tester. EC Voltage: Battery voltage OK or NG OK >> GO TO 4. NG >> GO TO 11. C D MBIB1445E 4. DETECT MALFUNCTIONING PART E Check harness for open or short between IPDM E/R and ECM F >> Repair harness or connectors. 5. CHECK FUEL PUMP POWER SUPPLY CIRCUIT-I 1. 2. 3. 4. G Turn ignition switch OFF. Reconnect all harness connectors disconnected. Disconnect “fuel level sensor unit and fuel pump” harness connector. Turn ignition switch ON. H I J MBIB0288E 5. Check voltage between “Fuel level sensor unit and fuel pump” terminal 1 and ground with CONSULT-II or tester. Voltage: L Battery voltage should exist for 1 second after ignition switch is turned ON. M OK or NG OK >> GO TO 9. NG >> GO TO 6. MBIB1446E 6. CHECK 15A FUSE 1. Turn ignition switch OFF. 2. Disconnect 15A fuse. 3. Check 15A fuse. OK or NG OK >> GO TO 7. NG >> Replace fuse. EC-753 K FUEL PUMP [CR (WITHOUT EURO-OBD)] 7. CHECK FUEL PUMP POWER SUPPLY CIRCUIT-II 1. 2. Disconnect IPDM E/R harness connector E10. Check harness continuity between IPDM E/R terminal 20 and “fuel level sensor unit and fuel pump” terminal 1. Refer to Wiring Diagram. Continuity should exist. 3. Also check harness for short to ground and short to power. OK or NG OK >> GO TO 11. NG >> GO TO 8. 8. DETECT MALFUNCTIONING PART Check the following. ● Harness connectors E101, M1 ● Harness connectors M72, B21 ● Harness for open or short between “fuel level sensor unit and fuel pump” and IPDM E/R >> Repair open circuit or short to ground or short to power in harness or connectors. 9. CHECK FUEL PUMP GROUND CIRCUIT FOR OPEN AND SHORT 1. 2. Turn ignition switch OFF. Check harness continuity between “fuel level sensor unit and fuel pump” terminal 3 and ground. Refer to Wiring Diagram. Continuity should exist. 3. Also check harness for short to power. OK or NG OK >> GO TO 10. NG >> Repair open circuit or short to power in harness or connectors. 10. CHECK FUEL PUMP Refer to EC-754, "Component Inspection" . OK or NG OK >> GO TO 11. NG >> Replace “fuel level sensor unit and fuel pump”. 11. CHECK INTERMITTENT INCIDENT Refer to EC-542, "TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT" . OK or NG OK >> Replace IPDM E/R. Refer to PG-18, "IPDM E/R (INTELLIGENT POWER DISTRIBUTION MODULE ENGINE ROOM)" . NG >> Repair or replace harness or connector. >> INSPECTION END Component Inspection BBS003D2 FUEL PUMP 1. Disconnect “fuel level sensor unit and fuel pump” harness connector. EC-754 FUEL PUMP [CR (WITHOUT EURO-OBD)] 2. Check resistance between “fuel level sensor unit and fuel pump” terminals 1 and 3. A Resistance: Approximately 0.2 - 5.0Ω [at 25°C (77°F)] EC C MBIB0311E D Removal and Installation BBS003D3 FUEL PUMP Refer to FL-4, "FUEL LEVEL SENSOR UNIT, FUEL FILTER AND FUEL PUMP ASSEMBLY" . E F G H I J K L M EC-755 HO2S1 [CR (WITHOUT EURO-OBD)] HO2S1 Component Description PFP:22690 BBS003C3 The heated oxygen sensor 1 is placed into the exhaust manifold. It detects the amount of oxygen in the exhaust gas compared to the outside air. The heated oxygen sensor 1 has a closed-end tube made of ceramic zirconia. The zirconia generates voltage from approximately 1V in richer conditions to 0V in leaner conditions. The heated oxygen sensor 1 signal is sent to the ECM. The ECM adjusts the injection pulse duration to achieve the ideal air-fuel ratio. The ideal air-fuel ratio occurs near the radical change from 1V to 0V. SEF463R SEF288D CONSULT-II Reference Value in Data Monitor Mode BBS003C4 Specification data are reference values. MONITOR ITEM CONDITION 0 - 0.3V ←→ Approx. 0.6 - 1.0V HO2S1 (B1) ● HO2S1 MNTR (B1) SPECIFICATION Engine: After warming up Maintaining engine speed at 2,000 rpm EC-756 LEAN ←→ RICH Changes more than 5 times during 10 seconds. HO2S1 [CR (WITHOUT EURO-OBD)] Wiring Diagram BBS003C5 A EC C D E F G H I J K L M MBWA1542E EC-757 HO2S1 [CR (WITHOUT EURO-OBD)] Specification data are reference values and are measured between each terminal and ground. Pulse signal is measured by CONSULT-II. CAUTION: Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM's transistor. Use a ground other than ECM terminals, such as the ground. TERMINAL NO. WIRE COLOR ITEM CONDITION DATA (DC Voltage) Approximately 7.0V [Engine is running] 24 Y Heated oxygen sensor 1 heater ● Warm-up condition ● Engine speed: Below 3,600 rpm PBIB0519E [Engine is running] ● Engine speed: Above 3,600 rpm BATTERY VOLTAGE (11 - 14V) [Engine is running] 35 BR Heated oxygen sensor 1 ● Warm-up condition ● Engine speed: 2,000 rpm 0 - Approximately 1.0V (Periodically change) [Engine is running] 74 B Sensor ground (Heated oxygen sensor) ● Warm-up condition ● Idle speed : Average voltage for pulse signal (Actual pulse signal can be confirmed by oscilloscope.) EC-758 Approximately 0V HO2S1 [CR (WITHOUT EURO-OBD)] Diagnostic Procedure BBS003C6 1. CHECK OVERALL FUNCTION A With CONSULT-II 1. Start engine and warm it up to normal operating temperature. 2. Select “HO2S1 MNTR (B1)” in “DATA MONITOR” mode with CONSULT-II. 3. Keep the engine speed at 2,000 rpm under no load, and make sure that the monitors fluctuates between LEAN and RICH more than 5 times in 10 seconds. EC C 1 time: RICH → LEAN → RICH 2 times: RICH → LEAN → RICH → LEAN →RICH D E SEF820Y Without CONSULT-II 1. Start engine and warm it up to normal operating temperature. 2. Stop engine and wait at least 10 seconds. 3. Set ECM in Diagnostic test mode - II (Heated oxygen sensor 1 monitor). Refer to EC-480, "HOW TO SWITCH DIAGNOSTIC TEST MODE" . 4. Keep the engine speed at 2,000 rpm under no load, and make sure that the MI comes ON more than 5 times in 10 seconds. OK or NG OK >> INSPECTION END NG >> GO TO 2. F G H I J K SAT652J 2. CHECK GROUND CONNECTIONS 1. 2. L Turn ignition switch OFF. Loosen and retighten ground screws on the body. Refer to EC-548, "Ground Inspection" . M MBIB1502E 1. Body ground E44 2. Body ground E45 OK or NG OK >> GO TO 3. NG >> Repair or replace ground connections. EC-759 3. Body ground E28 HO2S1 [CR (WITHOUT EURO-OBD)] 3. CHECK HO2S1 GROUND CIRCUIT FOR OPEN AND SHORT 1. 2. 3. Disconnect heated oxygen sensor 1 harness connector (1). Disconnect ECM harness connector. Check harness continuity between ECM terminal 74 and HO2S1 terminal 1. Refer to Wiring Diagram. Continuity should exist. 4. Also check harness for short to ground and short to power. OK or NG OK >> GO TO 4. NG >> Repair open circuit or short to ground or short to power in harness or connectors. MBIB1494E 4. CHECK HO2S1 INPUT SIGNAL CIRCUIT FOR OPEN AND SHORT 1. Check harness continuity between ECM terminal 35 and HO2S1 terminal 4. Refer to Wiring Diagram. Continuity should exist. 2. Check harness continuity between ECM terminal 35 or HO2S1 terminal 4 and ground. Refer to Wiring Diagram. Continuity should not exist. 3. Also check harness for short to power. OK or NG OK >> GO TO 5. NG >> Repair open circuit or short to ground or short to power in harness or connectors. 5. CHECK HEATED OXYGEN SENSOR 1 Refer to EC-760, "Component Inspection" . OK or NG OK >> GO TO 6. NG >> Replace heated oxygen sensor 1. 6. CHECK INTERMITTENT INCIDENT Refer to EC-542, "TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT" . >> INSPECTION END Component Inspection BBS003C7 HEATED OXYGEN SENSOR 1 With CONSULT-II 1. 2. Start engine and warm it up to normal operating temperature. Select “MANU TRIG” and adjust “TRIGGER POINT” to 100% in “DATA MONITOR” mode with CONSULTII. EC-760 HO2S1 [CR (WITHOUT EURO-OBD)] 3. 4. 5. Select “HO2S1 (B1)” and “HO2S1 MNTR (B1)”. Hold engine speed at 2,000 rpm under no load during the following steps. Touch “RECORD” on CONSULT-II screen. A EC C MBIB0301E D 6. Check the following. ● “HO2S1 MNTR (B1)” in “DATA MONITOR” mode changes from “RICH” to “LEAN” to “RICH” more than 5 times in 10 seconds. 5 times (cycles) are counted as shown in the figure. ● “HO2S1 (B1)” voltage goes above 0.6V at least once. ● “HO2S1 (B1)” voltage goes below 0.3V at least once. ● “HO2S1 (B1)” voltage never exceeds 1.0V. E F G SEF217YA H I J SEF648Y CAUTION: ● Discard any heated oxygen sensor which has been dropped from a height of more than 0.5 m (19.7 in) onto a hard surface such as a concrete floor; use a new one. ● Before installing new oxygen sensor, clean exhaust system threads using Oxygen Sensor Thread Cleaner and approved anti-seize lubricant. K L M Without CONSULT-II 1. 2. 3. Start engine and warm it up to normal operating temperature. Set voltmeter probes between ECM terminal 35 [HO2S1 (B1) signal] and ground. Check the following with engine speed held at 2,000 rpm constant under no load. ● The voltage fluctuates between 0 to 0.3V and 0.6 to 1.0V more than 5 times within 10 seconds. ● The maximum voltage is over 0.6V at least one time. ● The minimum voltage is below 0.3V at least one time. ● The voltage never exceeds 1.0V. 1 time: 0 - 0.3V → 0.6 - 1.0V → 0 - 0.3V 2 times: 0 - 0.3V → 0.6 - 1.0V → 0 - 0.3V → 0.6 - 1.0V → 0 0.3V MBIB0018E CAUTION: ● Discard any heated oxygen sensor which has been dropped from a height of more than 0.5 m (19.7 in) onto a hard surface such as a concrete floor; use a new one. EC-761 HO2S1 [CR (WITHOUT EURO-OBD)] ● Before installing new oxygen sensor, clean exhaust system threads using Oxygen Sensor Thread Cleaner and approved anti-seize lubricant. Removal and Installation BBS003C8 HEATED OXYGEN SENSOR 1 Refer to EM-24, "EXHAUST MANIFOLD AND THREE WAY CATALYST" . EC-762 HO2S1 HEATER [CR (WITHOUT EURO-OBD)] HO2S1 HEATER Description PFP:22690 A BBS003BM SYSTEM DESCRIPTION Sensor Input Signal to ECM Camshaft position sensor (PHASE) Crankshaft position sensor (POS) Engine speed Engine coolant temperature sensor Engine coolant temperature ECM Function Actuator Heated oxygen sensor 1 heater control EC Heated oxygen sensor 1 heater The ECM performs ON/OFF duty control of the heated oxygen sensor 1 heater corresponding to the engine speed and engine coolant temperature. The duty percent varies with engine coolant temperature when engine is started. C D OPERATION Engine speed rpm Heated oxygen sensor 1 heater Above 3,600 OFF Below 3,600 after warming up ON E F CONSULT-II Reference Value in Data Monitor Mode BBS003BN Specification data are reference values. MONITOR ITEM HO2S1 HTR (B1) CONDITION ● Engine: After warming up ● Engine speed: Below 3,600 rpm ● Engine speed: Above 3,600 rpm SPECIFICATION G ON H OFF I J K L M EC-763 HO2S1 HEATER [CR (WITHOUT EURO-OBD)] Wiring Diagram BBS003BO MBWA1542E EC-764 HO2S1 HEATER [CR (WITHOUT EURO-OBD)] Specification data are reference values and are measured between each terminal and ground. Pulse signal is measured by CONSULT-II. A CAUTION: Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM's transistor. Use a ground other than ECM terminals, such as the ground. EC TERMINAL NO. WIRE COLOR ITEM CONDITION DATA (DC Voltage) C Approximately 7.0V [Engine is running] 24 Y Heated oxygen sensor 1 heater D ● Warm-up condition ● Engine speed: Below 3,600 rpm E PBIB0519E [Engine is running] ● Engine speed: Above 3,600 rpm BATTERY VOLTAGE (11 - 14V) F [Engine is running] 35 BR 74 B Heated oxygen sensor 1 Sensor ground (Heated oxygen sensor) ● Warm-up condition ● Engine speed: 2,000 rpm 0 - Approximately 1.0V (Periodically change) G [Engine is running] ● Warm-up condition ● Idle speed Approximately 0V H : Average voltage for pulse signal (Actual pulse signal can be confirmed by oscilloscope.) I Diagnostic Procedure BBS003BP 1. CHECK OVERALL FUNCTION 1. 2. 3. 4. 5. 6. J Start engine and warm it up to normal operating temperature. Turn ignition switch OFF and wait at least 10 seconds. Turn ignition switch ON. Set tester prove between ECM terminal 24 (HO2S1 heater signal) and ground. Start engine and let it idle. Check the voltage under the following conditions. Verify that the oscilloscope screen shows the signal waves as shown below. Conditions K L M Voltage Approximately 7.0V At idle MBIB0038E PBIB0519E Engine speed: Above 3,600 rpm BATTERY VOLTAGE (11 - 14V) : Average voltage for pulse signal (Actual pulse signal can be confirmed by oscilloscope.) OK or NG OK >> INSPECTION END NG >> GO TO 2. EC-765 HO2S1 HEATER [CR (WITHOUT EURO-OBD)] 2. CHECK GROUND CONNECTIONS 1. 2. Turn ignition switch OFF. Loosen and retighten ground screws on the body. Refer to EC-548, "Ground Inspection" . MBIB1502E 1. Body ground E44 2. Body ground E45 3. Body ground E28 OK or NG OK >> GO TO 3. NG >> Repair or replace ground connections. 3. CHECK HO2S1 POWER SUPPLY CIRCUIT 1. 2. Disconnect heated oxygen sensor 1 harness connector (1). Turn ignition switch ON. MBIB1494E 3. Check voltage between HO2S1 terminal 2 and ground with CONSULT-II or tester. Voltage: Battery voltage OK or NG OK >> GO TO 5. NG >> GO TO 4. PBIA9576J 4. DETECT MALFUNCTIONING PART Check the following. Harness connectors E48, F1 ● IPDM E/R connector E10 ● 10A fuse ● Harness for open or short between heated oxygen sensor 1 and fuse ● >> Repair harness or connectors. EC-766 HO2S1 HEATER [CR (WITHOUT EURO-OBD)] 5. CHECK HO2S1 OUTPUT SIGNAL CIRCUIT FOR OPEN AND SHORT 1. 2. 3. A Turn ignition switch OFF. Disconnect ECM harness connector. Check harness continuity between ECM terminal 24 and HO2S1 terminal 3. Refer to Wiring Diagram. EC Continuity should exist. C 4. Also check harness for short to ground and short to power. OK or NG OK >> GO TO 6. NG >> Repair open circuit or short to ground or short to power in harness or connectors. D 6. CHECK HEATED OXYGEN SENSOR 1 HEATER E Refer to EC-767, "Component Inspection" . OK or NG OK >> GO TO 7. NG >> Replace heated oxygen sensor 1. F 7. CHECK INTERMITTENT INCIDENT G Refer to EC-542, "TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT" . H >> INSPECTION END Component Inspection BBS003BQ HEATED OXYGEN SENSOR 1 HEATER 1. I Check resistance between HO2S1 terminals as follows. Terminal No. Resistance 2 and 3 3.3 - 4.4 Ω at 25°C (77°F) 1 and 2, 3, 4 ∞Ω (Continuity should not exist) 4 and 1, 2, 3 J K 2. If NG, replace heated oxygen sensor 1. CAUTION: ● Discard any heated oxygen sensor which has been dropped from a height of more than 0.5 m (19.7 in) onto a hard surface such as a concrete floor; use a new one. ● Before installing new oxygen sensor, clean exhaust system threads using Oxygen Sensor Thread Cleaner and approved anti-seize lubricant. L M MBIB1306E Removal and Installation BBS003BR HEATED OXYGEN SENSOR 1 Refer to EM-24, "EXHAUST MANIFOLD AND THREE WAY CATALYST" . EC-767 HO2S2 [CR (WITHOUT EURO-OBD)] HO2S2 Component Description PFP:226A0 BBS003C9 The heated oxygen sensor 2, after three way catalyst (manifold), monitors the oxygen level in the exhaust gas on each bank. Even if switching characteristics of the heated oxygen sensor 1 are shifted, the air fuel ratio is controlled to stoichiometric, by the signal from the heated oxygen sensor 2. This sensor is made of ceramic zirconia. The zirconia generates voltage from approximately 1V in richer conditions to 0V in leaner conditions. Under normal conditions the heated oxygen sensor 2 is not used for engine control operation. SEF327R CONSULT-II Reference Value in Data Monitor Mode BBS003CA Specification data are reference values. MONITOR ITEM HO2S2 (B1) HO2S2 MNTR (B1) CONDITION SPECIFICATION ● Revving engine from idle to 3,000 rpm quickly after the following conditions are met. 0 - 0.3V ←→ Approx. 0.6 - 1.0V – Engine: After warning up – Keeping the engine speed between 3,500 and 4,000 rpm for 1 minute and at idle for 1 minute under no load. EC-768 LEAN ←→ RICH HO2S2 [CR (WITHOUT EURO-OBD)] Wiring Diagram BBS003CB A EC C D E F G H I J K L M MBWA1543E EC-769 HO2S2 [CR (WITHOUT EURO-OBD)] Specification data are reference values and are measured between each terminal and ground. CAUTION: Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM's transistor. Use a ground other than ECM terminals, such as the ground. TERMINAL NO. WIRE COLOR ITEM CONDITION DATA (DC Voltage) [Engine is running] 2 GR ● Engine speed: Below 3,800 rpm after the following conditions are met. – Engine: After warming up – Keeping the engine speed between 3,500 and 4,000 rpm for 1 minute and at idle for 1 minute under no load. Heated oxygen sensor 2 heater 0 - 1.0V [Ignition switch: ON] ● Engine stopped [Engine is running] ● BATTERY VOLTAGE (11 - 14V) Engine speed: Above 3,800 rpm [Engine is running] 16 LG Heated oxygen sensor 2 ● Revving engine from idle to 3,000rpm quickly after the following conditions are met. – Engine: After warming up – Keeping the engine speed between 3,500 and 4,000 rpm for 1 minute and at idle for 1 minute under no load. 0 - Approximately 1.0V [Engine is running] 74 B Sensor ground (Heated oxygen sensor) ● Warm-up condition ● Idle speed Diagnostic Procedure Approximately 0V BBS003CC 1. CHECK OVERALL FUNCTION-I 1. 2. 3. 4. 5. 6. Start engine and warm it up to the normal operating temperature. Turn ignition switch OFF and wait at least 10 seconds. Start engine and keep the engine speed between 3,500 and 4,000 rpm for at least 1 minute under no load. Let engine idle for 1 minute. Set voltmeter probes between ECM terminal 16 (HO2S2 signal) and ground. Check the voltage while revving up to 4,000 rpm under no load at least 10 times. (Depress and release the accelerator pedal as quickly as possible.) The voltage does not remain in the range of 0.2 - 0.4V OK or NG OK >> INSPECTION END NG >> GO TO 2. MBIB0020E EC-770 HO2S2 [CR (WITHOUT EURO-OBD)] 2. CHECK OVERALL FUNCTION-II A Keep engine at idle for 10 minutes, then check the voltage between ECM terminal 16 and ground, or check voltage when coasting 80 km/h (50 MPH) in 3rd gear position. EC The voltage does not remain in the range of 0.2 - 0.4V OK or NG OK >> INSPECTION END NG >> GO TO 3. C 3. CHECK GROUND CONNECTIONS 1. 2. D Turn ignition switch OFF. Loosen and retighten ground screws on the body. Refer to EC-548, "Ground Inspection" . E F G H MBIB1502E 1. Body ground E44 2. Body ground E45 3. Body ground E28 I OK or NG OK >> GO TO 4. NG >> Repair or replace ground connections. J 4. CHECK HO2S2 GROUND CIRCUIT FOR OPEN AND SHORT 1. Disconnect heated oxygen sensor 2 harness connector (1). – : Vehicle front Heated oxygen sensor 2 (2) Oil pan (3) Disconnect ECM harness connector. Check harness continuity between ECM terminal 74 and HO2S2 terminal 4. Refer to Wiring Diagram. – – 2. 3. K L M Continuity should exist. 4. Also check harness for short to ground and short to power. OK or NG OK >> GO TO 5. NG >> Repair open circuit or short to ground or short to power in harness or connectors. EC-771 MBIB1459E HO2S2 [CR (WITHOUT EURO-OBD)] 5. CHECK HO2S2 INPUT SIGNAL CIRCUIT FOR OPEN AND SHORT 1. Check harness continuity between ECM terminal 16 and HO2S2 terminal 1. Refer to Wiring Diagram. Continuity should exist. 2. Check harness continuity between ECM terminal 16 or HO2S2 terminal 1 and ground. Refer to Wiring Diagram. Continuity should not exist. 3. Also check harness for short to power. OK or NG OK >> GO TO 6. NG >> Repair open circuit or short to ground or short to power in harness or connectors. 6. CHECK HEATED OXYGEN SENSOR 2 Refer to EC-772, "Component Inspection" . OK or NG OK >> GO TO 7. NG >> Replace heated oxygen sensor 2. 7. CHECK INTERMITTENT INCIDENT Refer to EC-542, "TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT" . >> INSPECTION END Component Inspection BBS003CD HEATED OXYGEN SENSOR 2 With CONSULT-II 1. 2. 3. 4. 5. Turn ignition switch ON and select “DATA MONITOR” mode with CONSULT-II. Start engine and warm it up to the normal operating temperature. Turn ignition switch OFF and wait at least 10 seconds. Start engine and keep the engine speed between 3,500 and 4,000 rpm for at least 1 minute under no load. Let engine idle for 1 minute. SEF174Y 6. Select “FUEL INJECTION” in “ACTIVE TEST” mode, and select “HO2S2 (B1)” as the monitor item with CONSULT-II. SEF662Y EC-772 HO2S2 [CR (WITHOUT EURO-OBD)] 7. Check “HO2S2 (B1)” at idle speed when adjusting “FUEL INJECTION” to ±25%. A EC C MBIB1402E “HO2S2 (B1)” should be above 0.61V at least once when the “FUEL INJECTION” is +25%. “HO2S2 (B1)” should be below 0.52V at least once when the “FUEL INJECTION” is −25%. CAUTION: ● Discard any heated oxygen sensor which has been dropped from a height of more than 0.5 m (19.7 in) onto a hard surface such as a concrete floor; use a new one. ● Before installing new oxygen sensor, clean exhaust system threads using Oxygen Sensor Thread Cleaner and approved anti-seize lubricant. D E F Without CONSULT-II 1. 2. 3. 4. 5. 6. Start engine and warm it up to the normal operating temperature. Turn ignition switch OFF and wait at least 10 seconds. Start engine and keep the engine speed between 3,500 and 4,000 rpm for at least 1 minute under no load. Let engine idle for 1 minute. Set voltmeter probes between ECM terminal 16 (HO2S2 signal) and ground. Check the voltage when revving up to 4,000 rpm under no load at least 10 times. (Depress and release accelerator pedal as soon as possible.) The voltage should be above 0.61V at least once during this procedure. If the voltage is above 0.61V at step 6, step 7 is not necessary. 7. Keep vehicle idling for 10 minutes, then check voltage. Or check the voltage when coasting from 80 km/h (50 MPH) in 3rd gear position. The voltage should be below 0.52V at least once during this MBIB0020E procedure. 8. If NG, replace heated oxygen sensor 2. CAUTION: ● Discard any heated oxygen sensor which has been dropped from a height of more than 0.5 m (19.7 in) onto a hard surface such as a concrete floor; use a new one. ● Before installing new oxygen sensor, clean exhaust system threads using Oxygen Sensor Thread Cleaner and approved anti-seize lubricant. Removal and Installation BBS003CE HEATED OXYGEN SENSOR 2 Refer to EX-3, "EXHAUST SYSTEM" . EC-773 G H I J K L M HO2S2 HEATER [CR (WITHOUT EURO-OBD)] HO2S2 HEATER Description PFP:226A0 BBS003BS SYSTEM DESCRIPTION Sensor Camshaft position sensor (PHASE) Input Signal to ECM ECM Function Actuator Engine speed Crankshaft position sensor (POS) Engine coolant temperature sensor Engine coolant temperature Manifold absolute pressure (MAP) sensor Amount of intake air Heated oxygen sensor 2 heater control Heated oxygen sensor 2 heater The ECM performs ON/OFF control of the heated oxygen sensor 2 heater corresponding to the engine speed, amount of intake air and engine coolant temperature. OPERATION Engine speed rpm Heated oxygen sensor 2 heater Above 3,800 OFF ● Below 3,800 rpm after the following conditions are met. ● Engine: After warming up ● Keeping the engine speed between 3,500 and 4,000 rpm for 1 minute and at idle for 1 minute under no load ON CONSULT-II Reference Value in Data Monitor Mode BBS003BT Specification data are reference values. MONITOR ITEM HO2S2 HTR (B1) CONDITION ● Engine speed: Below 3,800 rpm after the following conditions are met. – Engine: After warming up – Keeping the engine speed at between 3,500 to 4,000 rpm for 1 minute and at idle for 1 minute under no load ● Engine speed: Above 3,800 rpm SPECIFICATION ON OFF EC-774 HO2S2 HEATER [CR (WITHOUT EURO-OBD)] Wiring Diagram BBS003BU A EC C D E F G H I J K L M MBWA1543E EC-775 HO2S2 HEATER [CR (WITHOUT EURO-OBD)] Specification data are reference values and are measured between each terminal and ground. CAUTION: Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM's transistor. Use a ground other than ECM terminals, such as the ground. TERMINAL NO. WIRE COLOR ITEM CONDITION DATA (DC Voltage) [Engine is running] 2 GR ● Engine speed: Below 3,800 rpm after the following conditions are met. – Engine: After warming up – Keeping the engine speed between 3,500 and 4,000 rpm for 1 minute and at idle for 1 minute under no load. Heated oxygen sensor 2 heater 0 - 1.0V [Ignition switch: ON] ● Engine stopped [Engine is running] ● BATTERY VOLTAGE (11 - 14V) Engine speed: Above 3,800 rpm [Engine is running] 16 LG Heated oxygen sensor 2 ● Revving engine from idle to 3,000rpm quickly after the following conditions are met. – Engine: After warming up – Keeping the engine speed between 3,500 and 4,000 rpm for 1 minute and at idle for 1 minute under no load. 0 - Approximately 1.0V [Engine is running] 74 B Sensor ground (Heated oxygen sensor) ● Warm-up condition ● Idle speed Diagnostic Procedure Approximately 0V BBS003BV 1. CHECK OVERALL FUNCTION 1. 2. 3. 4. 5. 6. Start engine and warm it up to the normal operating temperature. Turn ignition switch OFF and wait at least 10 seconds. Start engine and keep the engine speed between 3,500 and 4,000 rpm for at least 1 minute under no load. Let engine idle for 1 minute. Set voltmeter proves between ECM terminal 2 (HO2S2 heater signal) and ground. Check the voltage under the following conditions. Conditions At idle Engine speed: Above 3,800 rpm Voltage 0 - 1V Battery voltage OK or NG OK >> INSPECTION END NG >> GO TO 2. PBIB0673E EC-776 HO2S2 HEATER [CR (WITHOUT EURO-OBD)] 2. CHECK GROUND CONNECTIONS 1. 2. A Turn ignition switch OFF. Loosen and retighten ground screws on the body. Refer to EC-548, "Ground Inspection" . EC C D E MBIB1502E 1. Body ground E44 2. Body ground E45 3. Body ground E28 F OK or NG OK >> GO TO 3. NG >> Repair or replace ground connections. G 3. CHECK HO2S2 POWER SUPPLY CIRCUIT 1. Disconnect heated oxygen sensor 2 harness connector (1). H – : Vehicle front Heated oxygen sensor 2 (2) Oil pan (3) Turn ignition switch ON. I – – 2. J MBIB1459E 3. Check voltage between HO2S2 terminal 2 and ground with CONSULT-II or tester. K L Voltage: Battery voltage OK or NG OK >> GO TO 5. NG >> GO TO 4. M MBIB1442E 4. DETECT MALFUNCTIONING PART Check the following. ● Harness connectors E48, F1 ● IPDM E/R connector E10 ● 10A fuse ● Harness for open or short between heated oxygen sensor 2 and fuse >> Repair harness or connectors. EC-777 HO2S2 HEATER [CR (WITHOUT EURO-OBD)] 5. CHECK HO2S2 OUTPUT SIGNAL CIRCUIT FOR OPEN AND SHORT 1. 2. 3. Turn ignition switch OFF. Disconnect ECM harness connector. Check harness continuity between ECM terminal 2 and HO2S2 terminal 3. Refer to Wiring Diagram. Continuity should exist. 4. Also check harness for short to ground and short to power. OK or NG OK >> GO TO 6. NG >> Repair open circuit or short to ground or short to power in harness or connectors. 6. CHECK HEATED OXYGEN SENSOR 2 HEATER Refer to EC-778, "Component Inspection" . OK or NG OK >> GO TO 7. NG >> Replace heated oxygen sensor 2. 7. CHECK INTERMITTENT INCIDENT Refer to EC-542, "TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT" . >> INSPECTION END Component Inspection BBS003BW HEATED OXYGEN SENSOR 2 HEATER 1. Check resistance between HO2S2 terminals as follows. Terminal No. Resistance 2 and 3 8.0 - 10.0 Ω at 25°C (77°F) 1 and 2, 3, 4 ∞Ω (Continuity should not exist) 4 and 1, 2, 3 2. If NG, replace heated oxygen sensor 2. CAUTION: ● Discard any heated oxygen sensor which has been dropped from a height of more than 0.5 m (19.7 in) onto a hard surface such as a concrete floor; use a new one. ● Before installing new oxygen sensor, clean exhaust system threads using Oxygen Sensor Thread Cleaner and approved anti-seize lubricant. SEF249Y Removal and Installation BBS003BX HEATED OXYGEN SENSOR 2 Refer to EX-3, "EXHAUST SYSTEM" . EC-778 IAT SENSOR [CR (WITHOUT EURO-OBD)] IAT SENSOR Component Description PFP:22630 A BBS003BY The intake air temperature sensor is built into manifold absolute pressure sensor. The sensor detects intake air temperature and transmits a signal to the ECM. The temperature sensing unit uses a thermistor which is sensitive to the change in temperature. Electrical resistance of the thermistor decreases in response to the temperature rise. EC C D MBIB0276E E Intake air temperature °C (°F) Voltage* V Resistance F kΩ 25 (77) 3.32 1.9 - 2.1 80 (176) 1.23 0.31 - 0.37 G *: This data is reference value and is measured between ECM terminal 34 (Intake air temperature sensor) and ground. CAUTION: Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM's transistor. Use a ground other than ECM terminals, such as the ground. H SEF012P I J K L M EC-779 IAT SENSOR [CR (WITHOUT EURO-OBD)] Wiring Diagram BBS003BZ MBWA1544E EC-780 IAT SENSOR [CR (WITHOUT EURO-OBD)] Diagnostic Procedure BBS003C0 1. CHECK OVERALL FUNCTION 1. 2. A Turn ignition switch ON. Check voltage between ECM terminal 34 and ground with CONSULT-II or tester. EC Voltage: Approximately 0 - 4.8V C OK or NG OK >> INSPECTION END NG >> GO TO 2. D MBIB0041E E 2. CHECK GROUND CONNECTIONS 1. 2. F Turn ignition switch OFF. Loosen and retighten ground screws on the body. Refer to EC-548, "Ground Inspection" . G H I J MBIB1502E 1. Body ground E44 2. Body ground E45 OK or NG OK >> GO TO 3. NG >> Repair or replace ground connections. 3. Body ground E28 K L M EC-781 IAT SENSOR [CR (WITHOUT EURO-OBD)] 3. CHECK INTAKE AIR TEMPERATURE SENSOR POWER SUPPLY CIRCUIT 1. 2. Disconnect manifold absolute pressure (MAP) sensor (with intake air temperature sensor) harness connector. Turn ignition switch ON. MBIB0276E 3. Check voltage between MAP sensor terminal 3 and ground with CONSULT-II or tester. Voltage: Approximately 5V OK or NG OK >> GO TO 4. NG >> Repair harness or connectors. MBIB0300E 4. CHECK INTAKE AIR TEMPERATURE SENSOR GROUND CIRCUIT FOR OPEN AND SHORT 1. 2. 3. Turn ignition switch OFF. Disconnect ECM harness connector. Check harness continuity between MAP sensor terminal 4 and ECM terminal 56. Refer to Wiring Diagram. Continuity should exist. 4. Also check harness for short to ground and short to power. OK or NG OK >> GO TO 5. NG >> Repair open circuit or short to ground or short to power in harness or connectors. 5. CHECK INTAKE AIR TEMPERATURE SENSOR Refer to EC-783, "Component Inspection" . OK or NG OK >> GO TO 6. NG >> Replace manifold absolute pressure sensor (with intake air temperature sensor). 6. CHECK INTERMITTENT INCIDENT Refer to EC-542, "TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT" . >> INSPECTION END EC-782 IAT SENSOR [CR (WITHOUT EURO-OBD)] Component Inspection BBS003C1 A INTAKE AIR TEMPERATURE SENSOR 1. 2. Check resistance between manifold absolute pressure sensor terminals 3 and 4 under the following conditions. Intake air temperature °C (°F) Resistance kΩ 25 (77) 1.9 - 2.1 EC If NG, replace manifold absolute pressure sensor (with intake air temperature sensor). C D MBIB0276E E F G SEF012P Removal and Installation H BBS003C2 MANIFOLD ABSOLUTE PRESSURE SENSOR Refer to EM-18, "AIR CLEANER AND AIR DUCT" . I J K L M EC-783 IGNITION SIGNAL [CR (WITHOUT EURO-OBD)] IGNITION SIGNAL Component Description PFP:22448 BBS003CF IGNITION COIL & POWER TRANSISTOR The ignition signal from the ECM is sent to and amplified by the power transistor. The power transistor turns ON and OFF the ignition coil primary circuit. This ON-OFF operation induces the proper high voltage in the coil secondary circuit. MBIB0272E EC-784 IGNITION SIGNAL [CR (WITHOUT EURO-OBD)] Wiring Diagram BBS003CG A EC C D E F G H I J K L M MBWA1536E EC-785 IGNITION SIGNAL [CR (WITHOUT EURO-OBD)] Specification data are reference values and are measured between each terminal and ground. CAUTION: Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM's transistor. Use a ground other than ECM terminals, such as the ground. TERMINAL NO. WIRE COLOR ITEM CONDITION [Engine is running] [Ignition switch: OFF] ● 111 P ECM relay (Self shut-off) [Ignition switch: OFF] ● 119 120 G G Power supply for ECM For a few seconds after turning ignition switch OFF More than a few seconds passed after turning ignition switch OFF [Ignition switch: ON] EC-786 DATA (DC Voltage) 0 - 1.0V BATTERY VOLTAGE (11 - 14V) BATTERY VOLTAGE (11 - 14V) IGNITION SIGNAL [CR (WITHOUT EURO-OBD)] A EC C D E F G H I J K L M MBWA1537E EC-787 IGNITION SIGNAL [CR (WITHOUT EURO-OBD)] Specification data are reference values and are measured between each terminal and ground. Pulse signal is measured by CONSULT-II. CAUTION: Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM's transistor. Use a ground other than ECM terminals, such as the ground. TERMINAL NO. WIRE COLOR ITEM CONDITION [Engine is running] 60 61 79 80 Y V G BR ● Warm-up condition ● Idle speed DATA (DC Voltage) 0 - 0.1V NOTE: The pulse cycle changes depending on rpm at idle. Ignition signal No. 3 Ignition signal No. 1 Ignition signal No. 4 Ignition signal No. 2 PBIB0521E 0 - 0.2V [Engine is running] ● Warm-up condition ● Engine speed: 2,000 rpm PBIB0522E : Average voltage for pulse signal (Actual pulse signal can be confirmed by oscilloscope.) Diagnostic Procedure BBS003CH 1. CHECK ENGINE START Turn ignition switch OFF and restart engine. Is engine running? Yes or No Yes (With CONSULT-II)>>GO TO 2. Yes (Without CONSULT-II)>>GO TO 3. No >> GO TO 4. 2. CHECK OVERALL FUNCTION With CONSULT-II Perform “POWER BALANCE” in “ACTIVE TEST” mode with CONSULT-II. Make sure that each circuit produces a momentary engine speed drop. OK or NG OK >> INSPECTION END NG >> GO TO 10. 1. 2. MBIB0302E EC-788 IGNITION SIGNAL [CR (WITHOUT EURO-OBD)] 3. CHECK OVERALL FUNCTION A Without CONSULT-II Let engine idle. Read the voltage signal between ECM terminals 60, 61, 79, 80 and ground with an oscilloscope. 3. Verify that the oscilloscope screen shows the signal wave as shown in the figure. NOTE: The pulse cycle changes depending on rpm at idle. 1. 2. EC C D E MBIB0033E PBIB0521E F OK or NG OK >> INSPECTION END NG >> GO TO 10. G 4. CHECK IGNITION COIL POWER SUPPLY CIRCUIT-I 1. 2. Turn ignition switch OFF, wait at least 10 seconds and then turn ON. Check voltage between ECM terminals 119, 120 and ground with CONSULT-II or tester. H Voltage: Battery voltage I OK or NG OK >> GO TO 5. NG >> Go to EC-543, "POWER SUPPLY AND GROUND CIRCUIT" . J K MBIB0034E 5. CHECK IGNITION COIL POWER SUPPLY CIRCUIT-II 1. 2. 3. 4. L Turn ignition switch OFF. Disconnect condenser harness connector. Turn ignition switch ON. Check voltage between condenser terminal 1 and ground with CONSULT-II or tester. M Voltage: Battery voltage OK or NG OK >> GO TO 8. NG >> GO TO 6. PBIB0624E EC-789 IGNITION SIGNAL [CR (WITHOUT EURO-OBD)] 6. CHECK IGNITION COIL POWER SUPPLY CIRCUIT-III 1. 2. 3. Turn ignition switch OFF. Disconnect IPDM E/R harness connector. Check harness continuity between condenser terminal 1 and IPDM terminal 33. Refer to Wiring Diagram. Continuity should exist. 4. Also check harness for short to power and short to ground. OK or NG OK >> GO TO 15. NG >> GO TO 7. 7. DETECT MALFUNCTION PART Check the following. ● Harness connectors E48, F1 ● Harness for open or short between IPDM E/R and condenser >> Repair open circuit or short to ground or short to power in harness or connectors. 8. CHECK CONDENSER GROUND CIRCUIT FOR OPEN AND SHORT 1. 2. Turn ignition switch OFF. Check harness continuity between condenser terminal 2 and ground. Refer to Wiring Diagram. Continuity should exist. 3. Also check harness for short to power. OK or NG OK >> GO TO 9. NG >> Repair open circuit or short to power in harness or connector. 9. CHECK CONDENSER Refer to EC-792, "Component Inspection" . OK or NG OK >> GO TO 10. NG >> Replace condenser. EC-790 IGNITION SIGNAL [CR (WITHOUT EURO-OBD)] 10. CHECK IGNITION COIL POWER SUPPLY CIRCUIT-V 1. 2. 3. 4. A Turn ignition switch OFF. Reconnect all harness connectors disconnected. Disconnect ignition coil harness connector. Turn ignition switch ON. EC C D MBIB0272E 5. Check voltage between ignition coil terminal 1 and ground with CONSULT-II or tester. E F Voltage: Battery voltage OK or NG OK >> GO TO 12. NG >> GO TO 11. G H SEF107S I 11. DETECT MALFUNCTIONING PART Check harness for open or short between ignition coil and harness connector F1. J >> Repair open circuit or short to ground or short to power in harness or connectors. 12. CHECK IGNITION COIL GROUND CIRCUIT FOR OPEN AND SHORT 1. 2. Turn ignition switch OFF. Check harness continuity between ignition coil terminal 2 and ground. Refer to Wiring Diagram. Continuity should exist. L M 3. Also check harness for short to power. OK or NG OK >> GO TO 13. NG >> Repair open circuit or short to power in harness or connectors. 13. CHECK IGNITION COIL OUTPUT SIGNAL CIRCUIT FOR OPEN AND SHORT 1. 2. K Disconnect ECM harness connector. Check harness continuity between ECM terminals 60, 61, 79, 80 and ignition coil terminal 3. Refer to Wiring Diagram. Continuity should exist. 3. Also check harness for short to ground and short to power. OK or NG OK >> GO TO 14. NG >> Repair open circuit or short to ground or short to power in harness or connectors. EC-791 IGNITION SIGNAL [CR (WITHOUT EURO-OBD)] 14. CHECK IGNITION COIL WITH POWER TRANSISTOR Refer to EC-792, "Component Inspection" . OK or NG OK >> GO TO 15. NG >> Replace malfunctioning ignition coil with power transistor. 15. CHECK INTERMITTENT INCIDENT Refer to EC-542, "TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT" . OK or NG OK >> Replace IPDM E/R. Refer to PG-18, "IPDM E/R (INTELLIGENT POWER DISTRIBUTION MODULE ENGINE ROOM)" . NG >> Repair or replace. Component Inspection BBS003CI IGNITION COIL WITH POWER TRANSISTOR CAUTION: Do the following procedure in the place where ventilation is good without the combustible. 1. Turn ignition switch OFF. 2. Disconnect ignition coil harness connector. 3. Check resistance between ignition coil terminals as follows. Terminal No. Resistance Ω [at 25°C (77°F)] 2 and 3 Except 0 or ∞ 1 and 2 1 and 3 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. Except 0 If NG, replace ignition coil with power transistor. If OK, go to next step. Turn ignition switch OFF. Reconnect all harness connectors disconnected. Remove fuel pump fuse in IPDM E/R to release fuel pressure. NOTE: Do not use CONSULT-II to release fuel pressure, or fuel pressure applies again during the following procedure. Start engine. After engine stalls, crank it two or three times to release all fuel pressure. Turn ignition switch OFF. Remove ignition coil harness connectors to avoid the electrical discharge from the ignition coils. Remove ignition coil and spark plug of the cylinder to be checked. Crank engine for 5 seconds or more to remove combustion gas in the cylinder. Connect spark plug and harness connector to ignition coil. EC-792 MBIB0032E MBIB0277E IGNITION SIGNAL [CR (WITHOUT EURO-OBD)] 15. Fix ignition coil using a rope etc. with gap of 13 - 17 mm between the edge of the spark plug and grounded metal portion as shown in the figure. 16. Crank engine for about 3 seconds, and check whether spark is generated between the spark plug and the grounded part. A EC Spark should be generated. CAUTION: ● Do not approach to the spark plug and the ignition coil within 50cm. Be careful not to get an electrical shock while checking, because the electrical discharge voltage PBIB2325E becomes 20kV or more. ● If might cause to damage the ignition coil if the gap of more than 17 mm is taken. NOTE: When the gap is less than 13 mm, the spark might be generated even if the coil is malfunctioning. 17. If NG, replace ignition coil with power transistor. CONDENSER 1. 2. 3. C D E F Turn ignition switch OFF. Disconnect condenser harness connector. Check resistance between condenser terminals 1 and 2. G Resistance: Above 1 MΩ at 25°C (77°F) H I MBIB0031E Removal and Installation J BBS003CJ IGNITION COIL WITH POWER TRANSISTOR Refer to EM-29, "IGNITION COIL" . K L M EC-793 REFRIGERANT PRESSURE SENSOR [CR (WITHOUT EURO-OBD)] REFRIGERANT PRESSURE SENSOR Component Description PFP:92136 BBS003D4 The refrigerant pressure sensor (1) is installed at the condenser of the air conditioner system. The sensor uses an electrostatic volume pressure transducer to convert refrigerant pressure to voltage. The voltage signal is sent to ECM, and ECM controls cooling fan system. MBIB1492E PBIB2657E EC-794 REFRIGERANT PRESSURE SENSOR [CR (WITHOUT EURO-OBD)] Wiring Diagram BBS003D5 A EC C D E F G H I J K L M MBWA1540E EC-795 REFRIGERANT PRESSURE SENSOR [CR (WITHOUT EURO-OBD)] Specification data are reference values and are measured between each terminal and ground. CAUTION: Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM's transistor. Use a ground other than ECM terminals, such as the ground. TERMINAL NO. WIRE COLOR ITEM CONDITION 46 W Sensor power supply (Refrigerant pressure sensor) 57 Y Sensor ground (Refrigerant pressure sensor) DATA (DC Voltage) [Ignition switch: ON] Approximately 5V [Engine is running] ● Warm-up condition ● Idle speed Approximately 0V [Engine is running] 69 BR ● Warm-up condition ● Both A/C switch and blower fan switch: ON. Refrigerant pressure sensor 1.0 - 4.0V (Compressor operates.) Diagnostic Procedure BBS003D6 1. CHECK REFRIGERANT PRESSURE SENSOR OVERALL FUNCTION 1. 2. 3. Start engine and warm it up to normal operating temperature. Turn A/C switch and blower fan switch ON. Check voltage between ECM terminal 69 and ground with CONSULT-II or tester. Voltage: 1.0 - 4.0V OK or NG OK >> INSPECTION END NG >> GO TO 2. MBIB0035E 2. CHECK GROUND CONNECTIONS 1. 2. 3. Turn A/C switch and blower fan switch OFF. Turn ignition switch OFF. Loosen and retighten ground screws on the body. Refer to EC-548, "Ground Inspection" . MBIB1502E 1. Body ground E44 2. Body ground E45 OK or NG OK >> GO TO 3. NG >> Repair or replace ground connections. EC-796 3. Body ground E28 REFRIGERANT PRESSURE SENSOR [CR (WITHOUT EURO-OBD)] 3. CHECK REFRIGERANT PRESSURE SENSOR POWER SUPPLY CIRCUIT 1. 2. A Disconnect refrigerant pressure sensor (1) harness connector. Turn ignition switch ON. EC C D MBIB1492E 3. E Check voltage between refrigerant pressure sensor terminal 3 and ground with CONSULT-II or tester. Voltage: Approximately 5V F OK or NG OK >> GO TO 5. NG >> GO TO 4. G SEF479Y H 4. DETECT MALFUNCTIONING PART Check the following. ● Harness connectors E48, F1 ● Harness for open or short between ECM and refrigerant pressure sensor I J >> Repair harness or connectors. 5. CHECK REFRIGERANT PRESSURE SENSOR GROUND CIRCUIT FOR OPEN AND SHORT 1. 2. 3. Turn ignition switch OFF. Disconnect ECM harness connector. Check harness continuity between ECM terminal 57 and refrigerant pressure sensor terminal 1. Refer to Wiring Diagram. Continuity should exist. 4. Also check harness for short to ground and short to power. OK or NG OK >> GO TO 7. NG >> GO TO 6. 6. DETECT MALFUNCTIONING PART Check the following. ● Harness connectors E48, F1 ● Harness for open or short between ECM and refrigerant pressure sensor >> Repair open circuit or short to ground or short to power in harness or connectors. EC-797 K L M REFRIGERANT PRESSURE SENSOR [CR (WITHOUT EURO-OBD)] 7. CHECK REFRIGERANT PRESSURE SENSOR INPUT SIGNAL CIRCUIT FOR OPEN AND SHORT 1. Check harness continuity between ECM terminal 69 and refrigerant pressure sensor terminal 2. Refer to Wiring Diagram. Continuity should exist. 2. Also check harness for short to ground and short to power. OK or NG OK >> GO TO 9. NG >> GO TO 8. 8. DETECT MALFUNCTIONING PART Check the following. Harness connectors E48, F1 ● Harness for open or short between ECM and refrigerant pressure sensor ● >> Repair open circuit or short to ground or short to power in harness or connectors. 9. CHECK INTERMITTENT INCIDENT Refer to EC-542, "TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT" . OK or NG OK >> Replace refrigerant pressure sensor. NG >> Repair or replace. Removal and Installation BBS003D7 REFRIGERANT PRESSURE SENSOR Refer to ATC-142, "Removal and Installation for Refrigerant Pressure Sensor" (Models with A/C) or MTC-88, "Removal and Installation for Refrigerant Pressure Sensor" . EC-798 VSS [CR (WITHOUT EURO-OBD)] VSS Description PFP:32702 A BBS003CQ The vehicle speed signal is sent to the combination meter from the “ABS actuator and electric unit (control unit)” through CAN communication line. The combination meter then sends a signal to the ECM through CAN EC communication line. Diagnostic Procedure BBS003CR 1. INSPECTION START C Do you have CONSULT-II? Yes or No Yes >> GO TO 2. No >> GO TO 3. D E 2. CHECK OVERRALL FUNCTION 1. 2. 3. 4. 5. Turn ignition switch OFF. Lift up the vehicle. Start engine and let it idle Select “VHCL SPEED SE” in“DATA MONITOR” mode with CONSULT-II. Select “VHCL SPEED SE” indication when rotating wheels with suitable gear position. F G H “VHCL SPEED SE” indication should exceed 10km/h (6MPH). I OK or NG OK >> INSPECTION END. NG >> GO TO 3. PBIB0164E J 3. CHECK DTC WITH “ABS ACTUATOR AND ELECTRIC UNIT (CONTROL UNIT)” Refer to BRC-8, "TROUBLE DIAGNOSIS" (models with ESP). OK or NG OK >> GO TO 4. NG >> Repair or replace. (models without ESP) or BRC-49, "TROUBLE DIAGNOSIS" K L 4. CHECK COMBINATION METER M Check combination meter function. Refer to DI-4, "COMBINATION METERS" . >> INSPECTION END EC-799 MI & DATA LINK CONNECTORS [CR (WITHOUT EURO-OBD)] MI & DATA LINK CONNECTORS Wiring Diagram PFP:24814 BBS003DB MBWA1541E EC-800 SERVICE DATA AND SPECIFICATIONS (SDS) [CR (WITHOUT EURO-OBD)] SERVICE DATA AND SPECIFICATIONS (SDS) Fuel Pressure PFP:00030 A BBS0048B Approximately 350 kPa (3.5bar, 3.57kg/cm2 , 51psi) Fuel pressure at idle EC Idle Speed BBS0048C Target idle speed No load* (in Neutral position) Air conditioner: ON In Neutral position 650 ± 50 rpm C 900 rpm or more *: Under the following conditions: ● Air conditioner switch: OFF ● Electric load: OFF (Lights, heater fan & rear window defogger) ● Steering wheel: Kept in straight-ahead position D Manifold Absolute Pressure Sensor BBS0048E Supply voltage E Approximately 5.0V Output voltage at idle F 1.4 – 1.5 V* *: Engine is warmed up to normal operating temperature and running under no load. Intake Air Temperature Sensor BBS0048F Temperature °C (°F) G Resistance kΩ 25 (77) 1.9 – 2.1 H Engine Coolant Temperature Sensor Temperature °C (°F) BBS0048G Resistance kΩ 20 (68) 2.1 – 2.9 50 (122) 0.68 – 1.00 90 (194) 0.236 – 0.260 Knock Sensor I J BBS0048H Resistance [at 20°C (68°F)] Approximately 530 – 590kΩ Crankshaft Position Sensor (POS) K BBS0048I Refer to EC-615, "Component Inspection" . L Camshaft Position Sensor (PHASE) BBS0048J Refer to EC-622, "Component Inspection" . M Heated Oxygen Sensor 1 Heater BBS0048K Resistance [at 25°C (77°F)] 3.4 – 4.4Ω Heated Oxygen Sensor 2 Heater BBS0048L Resistance [at 25°C (77°F)] 8.0 – 10.0Ω Intake Valve Timing Control Solenoid Valve Resistance [at 20°C (68°F)] BBS0048M 6.7 – 7.7Ω Throttle Control Motor BBS0048N Resistance [at 25°C (77°F)] Approximately 1 – 15Ω Fuel Injector BBS0048O Resistance [at 10 - 60°C (50 - 140°F)] 10.4 – 15.3Ω EC-801 SERVICE DATA AND SPECIFICATIONS (SDS) [CR (WITHOUT EURO-OBD)] Fuel Pump BBS0048P Resistance [at 25°C (77°F)] Approximately 0.2 – 5.0Ω EC-802 INDEX FOR DTC [HR (WITH EURO-OBD)] INDEX FOR DTC DTC No. Index [HR (WITH EURO-OBD)] PFP:00024 A BBS0048Q NOTE: ● If DTC U1000 or U1001 is displayed with other DTC, first perform the trouble diagnosis for DTC EC U1000, U1001. Refer to EC-925, "DTC U1000, U1001 CAN COMMUNICATION LINE" . ● If DTC U1010 is displayed with other DTC, first perform the trouble diagnosis for DTC U1010. Refer to EC-928, "DTC U1010 CAN COMMUNICATION" . C DTC*1 CONSULT-II Items (CONSULT-II screen terms) Reference page 2 ECM*3 U1000 1000*4 CAN COMM CIRCUIT EC-925 U1001 1001*4 CAN COMM CIRCUIT EC-925 U1010 1010 CONTROL UNIT(CAN) EC-928 P0000 Flashing*5 NO DTC IS DETECTED. FURTHER TESTING MAY BE REQUIRED. EC-844 F P0000 0000 NO DTC IS DETECTED. FURTHER TESTING MAY BE REQUIRED. — G P0011 0011 INT/V TIM CONT-B1 EC-930 P0102 0102 MAF SEN/CIRCUIT EC-935 P0103 0103 MAF SEN/CIRCUIT EC-935 P0112 0112 IAT SEN/CIRCUIT EC-942 P0113 0113 IAT SEN/CIRCUIT EC-942 P0117 0117 ECT SEN/CIRC EC-947 P0118 0118 ECT SEN/CIRC EC-947 P0122 0122 TP SEN 2/CIRC EC-953 P0123 0123 TP SEN 2/CIRC EC-953 P0132 0132 HO2S1 (B1) EC-959 P0133 0133 HO2S1 (B1) EC-967 P0134 0134 HO2S1 (B1) EC-977 P0135 0135 HO2S1 HTR (B1) EC-985 P0138 0138 HO2S2 (B1) EC-991 P0139 0139 HO2S2 (B1) EC-998 P0141 0141 HO2S2 HTR (B1) EC-1006 P0171 0171 FUEL SYS-LEAN-B1 EC-1012 GST* D P0172 0172 FUEL SYS-RICH-B1 EC-1019 P0222 0222 TP SEN 1/CIRC EC-1026 P0223 0223 TP SEN 1/CIRC EC-1026 P0300 0300 MULTI CYL MISFIRE EC-1032 P0301 0301 CYL 1 MISFIRE EC-1032 P0302 0302 CYL 2 MISFIRE EC-1032 P0303 0303 CYL 3 MISFIRE EC-1032 P0304 0304 CYL 4 MISFIRE EC-1032 P0327 0327 KNOCK SEN/CIRC-B1 EC-1038 P0328 0328 KNOCK SEN/CIRC-B1 EC-1038 P0335 0335 CKP SEN/CIRCUIT EC-1042 EC-803 E H I J K L M INDEX FOR DTC [HR (WITH EURO-OBD)] DTC*1 CONSULT-II Items (CONSULT-II screen terms) 3 Reference page 2 ECM* P0340 0340 CMP SEN/CIRC-B1 EC-1049 P0420 0420 TW CATALYST SYS-B1 EC-1056 P0444 0444 PURG VOLUME CONT/V EC-1063 P0500 0500 VEH SPEED SEN/CIRC* 6 EC-1070 P0605 0605 ECM P0705 0705 PNP SW/CIRC P0710 0710 ATF TEMP SEN/CIRC GST* EC-1072 AT-105 AT-110 6 P0720 0720 VEH SPD SEN/CIR AT* AT-115 P0725 0725 ENGINE SPEED SIG AT-121 P0731 0731 A/T 1ST GR FNCTN AT-125 P0732 0732 A/T 2ND GR FNCTN AT-129 P0733 0733 A/T 3RD GR FNCTN AT-132 P0734 0734 A/T 4TH GR FNCTN AT-136 P0740 0740 TCC SOLENOID/CIRC AT-142 P0744 0744 A/T TCC S/V FNCTN AT-147 P0745 0745 L/PRESS SOL/CIRC AT-153 P0750 0750 SFT SOL A/CIRC AT-159 P0755 0755 SFT SOL B/CIRC AT-164 *7 P1065 1065 ECM BACK UP/CIRCUIT EC-1075 P1111 1111 INT/V TIM V/CIR-B1 EC-1077 P1121 1121 ETC ACTR EC-1082 P1122 1122 ETC FUNCTION/CIRC EC-1084 P1124 1124 ETC MOT PWR EC-1090 P1126 1126 ETC MOT PWR EC-1090 P1128 1128 ETC MOT EC-1096 P1143 1143 HO2S1 (B1) EC-1101 P1144 1144 HO2S1 (B1) EC-1107 P1146 1146 HO2S2 (B1) EC-1113 P1147 1147 HO2S2 (B1) EC-1121 P1212 1212 TCS/CIRC EC-1129 P1217 1217 ENG OVER TEMP EC-1130 P1225 1225 CTP LEARNING EC-1146 P1226 1226 CTP LEARNING EC-1148 P1229 1229 SENSOR POWER/CIRC EC-1150 P1610 - P1615 1610 - 1615 P1705 NATS MALFUNCTION BL-215 1705 TP SEN/CIRC A/T AT-169 P1706 1706 P-N POS SW/CIRCUIT EC-1158 P1760 1760 O/R CLTCH SOL/CIRC AT-171 P1805 1805 BRAKE SW/CIRCUIT EC-1167 P2122 2122 APP SEN 1/CIRC EC-1172 P2123 2123 APP SEN 1/CIRC EC-1172 P2127 2127 APP SEN 2/CIRC EC-1181 EC-804 INDEX FOR DTC [HR (WITH EURO-OBD)] DTC*1 CONSULT-II 3 Items (CONSULT-II screen terms) Reference page GST*2 ECM* P2128 2128 APP SEN 2/CIRC EC-1181 P2135 2135 TP SENSOR EC-1191 P2138 2138 APP SENSOR EC-1197 *1: 1st trip DTC No. is the same as DTC No. *2: This number is prescribed by ISO 15031-5. *3: In Diagnostic Test Mode II (Self-diagnostic results), this number is controlled by NISSAN. *4: The troubleshooting for this DTC needs CONSULT-II. *5: When engine is running, MI may flash. For details, refer to EC-844, "MI Flashing Without DTC" . *6: When the fail-safe operations for both self-diagnoses occur, the MI illuminates. *7:This self-diagnosis is not for ECM power supply circuit, even though “ECM BACK UP/CIRCUIT” is displayed on CONSULT-II screen. A EC C D E F G H I J K L M EC-805 INDEX FOR DTC [HR (WITH EURO-OBD)] Alphabetical Index BBS0048R NOTE: ● If DTC U1000 or U1001 is displayed with other DTC, first perform the trouble diagnosis for DTC U1000, U1001. Refer to EC-925, "DTC U1000, U1001 CAN COMMUNICATION LINE" . ● If DTC U1010 is displayed with other DTC, first perform the trouble diagnosis for DTC U1010. Refer to EC-928, "DTC U1010 CAN COMMUNICATION" . Items (CONSULT-II screen terms) DTC*1 CONSULT-II 2 GST* Reference page ECM*3 A/T 1ST GR FNCTN P0731 0731 AT-125 A/T 2ND GR FNCTN P0732 0732 AT-129 A/T 3RD GR FNCTN P0733 0733 AT-132 A/T 4TH GR FNCTN P0734 0734 AT-136 A/T TCC S/V FNCTN P0744 0744 AT-147 APP SEN 1/CIRC P2122 2122 EC-1172 APP SEN 1/CIRC P2123 2123 EC-1172 APP SEN 2/CIRC P2127 2127 EC-1181 APP SEN 2/CIRC P2128 2128 EC-1181 APP SENSOR P2138 2138 EC-1197 ATF TEMP SEN/CIRC P0710 0710 AT-110 BRAKE SW/CIRCUIT P1805 1805 EC-1167 4 CAN COMM CIRCUIT U1000 1000* EC-925 CAN COMM CIRCUIT U1001 1001*4 EC-925 CONTROL UNIT(CAN) U1010 1010 EC-928 CKP SEN/CIRCUIT P0335 0335 EC-1042 CMP SEN/CIRC-B1 P0340 0340 EC-1049 CTP LEARNING P1225 1225 EC-1146 CTP LEARNING P1226 1226 EC-1148 CYL 1 MISFIRE P0301 0301 EC-1032 CYL 2 MISFIRE P0302 0302 EC-1032 CYL 3 MISFIRE P0303 0303 EC-1032 CYL 4 MISFIRE P0304 0304 EC-1032 ECM P0605 0605 EC-1072 ECM BACK UP/CIRCUIT*7 P1065 1065 EC-1075 ECT SEN/CIRC P0117 0117 EC-947 ECT SEN/CIRC P0118 0118 EC-947 ENG OVER TEMP P1217 1217 EC-1130 ENGINE SPEED SIG P0725 0725 AT-121 ETC ACTR P1121 1121 EC-1082 ETC FUNCTION/CIRC P1122 1122 EC-1084 ETC MOT P1128 1128 EC-1096 ETC MOT PWR P1124 1124 EC-1090 ETC MOT PWR P1126 1126 EC-1090 FUEL SYS-LEAN-B1 P0171 0171 EC-1012 FUEL SYS-RICH-B1 P0172 0172 EC-1019 EC-806 INDEX FOR DTC [HR (WITH EURO-OBD)] DTC*1 Items (CONSULT-II screen terms) CONSULT-II Reference page GST*2 ECM* HO2S1 (B1) P0132 0132 EC-959 HO2S1 (B1) P0133 0133 EC-967 HO2S1 (B1) P0134 0134 EC-977 HO2S1 (B1) P1143 1143 EC-1101 HO2S1 (B1) P1144 1144 EC-1107 HO2S1 HTR (B1) P0135 0135 EC-985 HO2S2 (B1) P0138 0138 EC-991 HO2S2 (B1) P0139 0139 EC-998 HO2S2 (B1) P1146 1146 EC-1113 HO2S2 (B1) P1147 1147 EC-1121 HO2S2 HTR (B1) P0141 0141 EC-1006 IAT SEN/CIRCUIT P0112 0112 EC-942 IAT SEN/CIRCUIT P0113 0113 EC-942 INT/V TIM CONT-B1 P0011 0011 EC-930 INT/V TIM V/CIR-B1 P1111 1111 EC-1077 KNOCK SEN/CIRC-B1 P0327 0327 EC-1038 KNOCK SEN/CIRC-B1 P0328 0328 EC-1038 L/PRESS SOL/CIRC P0745 0745 AT-153 MAF SEN/CIRCUIT P0102 0102 EC-935 MAF SEN/CIRCUIT P0103 0103 EC-935 MULTI CYL MISFIRE P0300 0300 EC-1032 P1610 - P1615 1610 - 1615 BL-215 NO DTC IS DETECTED. FURTHER TESTING MAY BE REQUIRED. No DTC Flashing*5 EC-844 NO DTC IS DETECTED. FURTHER TESTING MAY BE REQUIRED. P0000 0000 — O/R CLTCH SOL/CIRC P1760 1760 AT-171 P-N POS SW/CIRCUIT P1706 1706 EC-1158 PNP SW/CIRC P0705 0705 AT-105 PURG VOLUME CONT/V P0444 0444 EC-1063 SENSOR POWER/CIRC P1229 1229 EC-1150 SFT SOL A/CIRC P0750 0750 AT-159 SFT SOL B/CIRC P0755 0755 AT-164 TCC SOLENOID/CIRC P0740 0740 AT-142 TCS/CIRC P1212 1212 EC-1129 TP SEN 1/CIRC P0222 0222 EC-1026 TP SEN 1/CIRC P0223 0223 EC-1026 TP SEN 2/CIRC P0122 0122 EC-953 TP SEN 2/CIRC P0123 0123 EC-953 TP SENSOR P2135 2135 EC-1191 TP SEN/CIRC A/T P1705 1705 AT-169 TW CATALYST SYS-B1 P0420 0420 EC-1056 NATS MALFUNCTION A 3 EC C D E F G H I J K L EC-807 M INDEX FOR DTC [HR (WITH EURO-OBD)] DTC*1 Items (CONSULT-II screen terms) CONSULT-II 2 GST* Reference page ECM*3 VEH SPD SEN/CIR AT*6 P0720 0720 AT-115 VEH SPEED SEN/CIRC*6 P0500 0500 EC-1070 *1: 1st trip DTC No. is the same as DTC No. *2: This number is prescribed by ISO 15031-5. *3: In Diagnostic Test Mode II (Self-diagnostic results), this number is controlled by NISSAN. *4: The troubleshooting for this DTC needs CONSULT-II. *5: When engine is running, MI may flash. For details, refer to EC-844, "MI Flashing Without DTC" . *6: When the fail-safe operation for both self-diagnoses occur, the MI illuminates. *7:This self-diagnosis is not for ECM power supply circuit, even though “ECM BACK UP/CIRCUIT” is displayed on CONSULT-II screen. EC-808 PRECAUTIONS [HR (WITH EURO-OBD)] PRECAUTIONS PFP:00001 Precautions for Supplemental Restraint System (SRS) “AIR BAG” and “SEAT BELT PRE-TENSIONER” A BBS0048S The Supplemental Restraint System such as “AIR BAG” and “SEAT BELT PRE-TENSIONER”, used along EC with a front seat belt, helps to reduce the risk or severity of injury to the driver and front passenger for certain types of collision. Information necessary to service the system safely is included in the SRS and SB section of this Service Manual. C WARNING: ● To avoid rendering the SRS inoperative, which could increase the risk of personal injury or death in the event of a collision which would result in air bag inflation, all maintenance must be perD formed by an authorized NISSAN/INFINITI dealer. ● Improper maintenance, including incorrect removal and installation of the SRS, can lead to personal injury caused by unintentional activation of the system. For removal of Spiral Cable and Air E Bag Module, see the SRS section. ● Do not use electrical test equipment on any circuit related to the SRS unless instructed to in this Service Manual. SRS wiring harnesses can be identified by yellow and/or orange harnesses or harness connectors. F Maintenance Information BBS005AS If any of following part is replaced, always replace with new* one. If it's not (or fail to do so), the electrical system may not be operated properly. *: New one means a virgin control unit that has never been energized on-board. G RHD MODELS H ● ● ● ● ● ● BCM (Models without Intelligent Key system) Intelligent Key unit (Models with Intelligent Key system) ECM IPDM E/R Combination meter EPS control unit I J LHD MODELS ● ● ● BCM (Models without Intelligent Key system) Intelligent Key unit (Models with Intelligent Key system) ECM Precautions for Procedures without Cowl Top Cover K L BBS00583 When performing the procedure after removing cowl top cover, cover the lower end of windshield with urethane, etc. M PIIB3706J On Board Diagnostic (OBD) System of Engine and A/T BBS0048U The ECM has an on board diagnostic system. It will light up the malfunction indicator (MI) to warn the driver of a malfunction causing emission deterioration. CAUTION: ● Be sure to turn the ignition switch OFF and disconnect the negative battery cable before any repair or inspection work. The open/short circuit of related switches, sensors, solenoid valves, etc. will cause the MI to light up. EC-809 PRECAUTIONS [HR (WITH EURO-OBD)] ● ● ● ● ● Be sure to connect and lock the connectors securely after work. A loose (unlocked) connector will cause the MI to light up due to the open circuit. (Be sure the connector is free from water, grease, dirt, bent terminals, etc.) Certain systems and components, especially those related to OBD, may use a new style slidelocking type harness connector. For description and how to disconnect, refer to PG-88, "HARNESS CONNECTOR" . Be sure to route and secure the harnesses properly after work. The interference of the harness with a bracket, etc. may cause the MI to light up due to the short circuit. Be sure to connect rubber tubes properly after work. A misconnected or disconnected rubber tube may cause the MI to light up due to the malfunction of the fuel injection system, etc. Be sure to erase the unnecessary malfunction information (repairs completed) from the ECM and TCM (Transmission control module) before returning the vehicle to the customer. Precaution ● ● ● ● BBS0048V Always use a 12 volt battery as power source. Do not attempt to disconnect battery cables while engine is running. Before connecting or disconnecting the ECM harness connector, turn ignition switch OFF and disconnect negative battery cable. Failure to do so may damage the ECM because battery voltage is applied to ECM even if ignition switch is turned OFF. Before removing parts, turn ignition switch OFF and then disconnect negative battery cable. SEF289H ● ● ● – – – – – – ● – – Do not disassemble ECM. If a battery cable is disconnected, the memory will return to the ECM value. The ECM will now start to self-control at its initial value. Engine operation can vary slightly when the terminal is disconnected. However, this is not an indication of a malfunction. Do not replace parts because of a slight variation. If the battery is disconnected, the following emissionrelated diagnostic information will be lost within 24 hours. Diagnostic trouble codes 1st trip diagnostic trouble codes Freeze frame data 1st trip freeze frame data System readiness test (SRT) codes Test values When connecting ECM harness connector, fasten (B) it securely with a lever (1) as far as it will go as shown in the figure. ECM (2) Loosen (A) PBIA9222J PBIB2947E EC-810 PRECAUTIONS [HR (WITH EURO-OBD)] ● ● ● ● ● ● ● ● ● ● ● When connecting or disconnecting pin connectors into or from ECM, take care not to damage pin terminals (bend or break). Make sure that there are not any bends or breaks on ECM pin terminal, when connecting pin connectors. Securely connect ECM harness connectors. A poor connection can cause an extremely high (surge) voltage to develop in coil and condenser, thus resulting in damage to ICs. Keep engine control system harness at least 10 cm (4 in) away from adjacent harness, to prevent engine control system malfunctions due to receiving external noise, degraded operation of ICs, etc. Keep engine control system parts and harness dry. Before replacing ECM, perform ECM Terminals and Reference Value inspection and make sure ECM functions properly. Refer to EC-883, "ECM Terminals and Reference Value" . Handle mass air flow sensor carefully to avoid damage. Do not clean mass air flow sensor with any type of detergent. Do not disassemble electric throttle control actuator. Even a slight leak in the air intake system can cause serious incidents. Do not shock or jar the camshaft position sensor (PHASE), crankshaft position sensor (POS). After performing each TROUBLE DIAGNOSIS, perform DTC Confirmation Procedure or Overall Function Check. The DTC should not be displayed in the DTC Confirmation Procedure if the repair is completed. The Overall Function Check should be a good result if the repair is completed. A EC C PBIB0090E D E F G MEF040D H I J K SAT652J L M EC-811 PRECAUTIONS [HR (WITH EURO-OBD)] ● ● When measuring ECM signals with a circuit tester, never allow the two tester probes to contact. Accidental contact of probes will cause a short circuit and damage the ECM power transistor. Do not use ECM ground terminals when measuring input/ output voltage. Doing so may result in damage to the ECM's transistor. Use a ground other than ECM terminals, such as the ground. SEF348N ● ● Do not operate fuel pump when there is no fuel in lines. Tighten fuel hose clamps to the specified torque. MBIB0291E ● ● ● Do not depress accelerator pedal when starting. Immediately after starting, do not rev up engine unnecessarily. Do not rev up engine just prior to shutdown. SEF709Y ● – – – When installing C.B. ham radio or a mobile phone, be sure to observe the following as it may adversely affect electronic control systems depending on installation location. Keep the antenna as far as possible from the electronic control units. Keep the antenna feeder line more than 20 cm (8 in) away from the harness of electronic controls. Do not let them run parallel for a long distance. Adjust the antenna and feeder line so that the standingwave radio can be kept smaller. SEF708Y EC-812 PRECAUTIONS [HR (WITH EURO-OBD)] – Be sure to ground the radio to vehicle body. A EC C D E F G H I J K L M EC-813 PREPARATION [HR (WITH EURO-OBD)] PREPARATION Special Service Tools PFP:00002 BBS0048W Tool number Tool name Description KV10117100 Heated oxygen sensor wrench Loosening or tightening heated oxygen sensor with 22 mm (0.87 in) hexagon nut S-NT379 KV10114400 Heated oxygen sensor wrench Loosening or tightening heated oxygen sensor a: 22 mm (0.87 in) S-NT636 EG17650301 Radiator cap tester adapter Adapting radiator cap tester to radiator cap and radiator filler neck a: 28 (1.10) dia. b: 31.4 (1.236) dia. c: 41.3 (1.626) dia. Unit: mm (in) S-NT564 EG17550000 Break-out box Measuring ECM signals with a circuit tester ZZA1194D EG17680000 Y-cable adapter Measuring ECM signals with a circuit tester PBIA9379J KV10118400 Fuel tube adapter Measuring fuel pressure PBIB3043E EC-814 PREPARATION [HR (WITH EURO-OBD)] Commercial Service Tools BBS0048X A Tool name Description Quick connector release Removing fuel tube quick connectors in engine room (Available in SEC. 164 of PARTS CATALOG: Part No. 16441 6N210) EC C PBIC0198E Fuel filler cap adapter Checking fuel tank vacuum relief valve opening pressure D E S-NT653 Socket wrench Removing and installing engine coolant temperature sensor F G H S-NT705 Oxygen sensor thread cleaner Reconditioning the exhaust system threads before installing a new oxygen sensor. Use with anti-seize lubricant shown below. a: 18 mm diameter with pitch 1.5 mm for Zirconia Oxygen Sensor b: 12 mm diameter with pitch 1.25 mm for Titania Oxygen Sensor J Lubricating oxygen sensor thread cleaning tool when reconditioning exhaust system threads. K I AEM488 Anti-seize lubricant i.e.: (PermatexTM 133AR or equivalent meeting MIL specification MIL-A907) L S-NT779 M EC-815 ENGINE CONTROL SYSTEM [HR (WITH EURO-OBD)] ENGINE CONTROL SYSTEM System Diagram PFP:23710 BBS0048Y MBIB1449E EC-816 ENGINE CONTROL SYSTEM [HR (WITH EURO-OBD)] Multiport Fuel Injection (MFI) System BBS0048Z A INPUT/OUTPUT SIGNAL CHART Sensor Crankshaft position sensor (POS) Input Signal to ECM Camshaft position sensor (PHASE) Engine speed*3 Piston position Mass air flow sensor Amount of intake air Engine coolant temperature sensor Engine coolant temperature Heated oxygen sensor 1 Density of oxygen in exhaust gas Throttle position sensor Throttle position Accelerator pedal position sensor Accelerator pedal position Park/neutral position (PNP) switch Gear position Battery Battery voltage*3 Knock sensor Engine knocking condition EPS control unit Power steering operation*2 Heated oxygen sensor 2*1 Density of oxygen in exhaust gas Air conditioner switch Air conditioner operation*2 Wheel sensor Vehicle speed*2 ECM function Actuator EC C D Fuel injection & mixture ratio control Fuel injector *1: This sensor is not used to control the engine system under normal conditions. *2: This signal is sent to the ECM through CAN communication line. *3: ECM determines the start signal status by the signals of engine speed and battery voltage. E F G H SYSTEM DESCRIPTION The amount of fuel injected from the fuel injector is determined by the ECM. The ECM controls the length of time the valve remains open (injection pulse duration). The amount of fuel injected is a program value in the ECM memory. The program value is preset by engine operating conditions. These conditions are determined by input signals (for engine speed and intake air) from the crankshaft position sensor (POS), camshaft position sensor (PHASE) and the mass air flow sensor. I J VARIOUS FUEL INJECTION INCREASE/DECREASE COMPENSATION In addition, the amount of fuel injected is compensated to improve engine performance under various operating conditions as listed below. ● During warm-up ● When starting the engine ● During acceleration ● Hot-engine operation ● When shift lever is changed from N to D (A/T models) ● High-load, high-speed operation ● During deceleration ● During high engine speed operation EC-817 K L M ENGINE CONTROL SYSTEM [HR (WITH EURO-OBD)] MIXTURE RATIO FEEDBACK CONTROL (CLOSED LOOP CONTROL) PBIB2953E The mixture ratio feedback system provides the best air-fuel mixture ratio for driveability and emission control. The three way catalyst (manifold) can then better reduce CO, HC and NOx emissions. This system uses heated oxygen sensor 1 in the exhaust manifold to monitor whether the engine operation is rich or lean. The ECM adjusts the injection pulse width according to the sensor voltage signal. For more information about heated oxygen sensor 1, refer to EC-967, "DTC P0133 HO2S1" . This maintains the mixture ratio within the range of stoichiometric (ideal air-fuel mixture). This stage is referred to as the closed loop control condition. Heated oxygen sensor 2 is located downstream of the three way catalyst (manifold). Even if the switching characteristics of heated oxygen sensor 1 shift, the air-fuel ratio is controlled to stoichiometric by the signal from heated oxygen sensor 2. Open Loop Control The open loop system condition refers to when the ECM detects any of the following conditions. Feedback control stops in order to maintain stabilized fuel combustion. ● Deceleration and acceleration ● High-load, high-speed operation ● Malfunction of heated oxygen sensor 1 or its circuit ● Insufficient activation of heated oxygen sensor 1 at low engine coolant temperature ● High engine coolant temperature ● During warm-up ● After shifting from N to D (A/T models) ● When starting the engine MIXTURE RATIO SELF-LEARNING CONTROL The mixture ratio feedback control system monitors the mixture ratio signal transmitted from heated oxygen sensor 1. This feedback signal is then sent to the ECM. The ECM controls the basic mixture ratio as close to the theoretical mixture ratio as possible. However, the basic mixture ratio is not necessarily controlled as originally designed. Both manufacturing differences (i.e., mass air flow sensor hot wire) and characteristic changes during operation (i.e., fuel injector clogging) directly affect mixture ratio. Accordingly, the difference between the basic and theoretical mixture ratios is monitored in this system. This is then computed in terms of “injection pulse duration” to automatically compensate for the difference between the two ratios. “Fuel trim” refers to the feedback compensation value compared against the basic injection duration. Fuel trim includes short term fuel trim and long term fuel trim. “Short term fuel trim” is the short-term fuel compensation used to maintain the mixture ratio at its theoretical value. The signal from heated oxygen sensor 1 indicates whether the mixture ratio is RICH or LEAN compared to the theoretical value. The signal then triggers a reduction in fuel volume if the mixture ratio is rich, and an increase in fuel volume if it is lean. “Long term fuel trim” is overall fuel compensation carried out long-term to compensate for continual deviation of the short term fuel trim from the central value. Such deviation will occur due to individual engine differences, wear over time and changes in the usage environment. EC-818 ENGINE CONTROL SYSTEM [HR (WITH EURO-OBD)] FUEL INJECTION TIMING A EC C SEF337W D Two types of systems are used. Sequential Multiport Fuel Injection System Fuel is injected into each cylinder during each engine cycle according to the firing order. This system is used when the engine is running. Simultaneous Multiport Fuel Injection System Fuel is injected simultaneously into all four cylinders twice each engine cycle. In other words, pulse signals of the same width are simultaneously transmitted from the ECM. The four fuel injectors will then receive the signals two times for each engine cycle. This system is used when the engine is being started and/or if the fail-safe system (CPU) is operating. E F G FUEL SHUT-OFF Fuel to each cylinder is cut off during deceleration, operation of the engine at excessively high speeds or operation of the vehicle at excessively high speeds. Electronic Ignition (EI) System BBS00490 INPUT/OUTPUT SIGNAL CHART Sensor Crankshaft position sensor (POS) I Input Signal to ECM Camshaft position sensor (PHASE) Engine speed*2 Piston position Mass air flow sensor Amount of intake air Engine coolant temperature sensor Engine coolant temperature Throttle position sensor Throttle position Accelerator pedal position sensor Accelerator pedal position Battery Battery voltage*2 Knock sensor Engine knocking Park/neutral position (PNP) switch Gear position Wheel sensor H ECM function Actuator J K Ignition timing control Power transistor L M 1 Vehicle speed* *1: This signal is sent to the ECM through CAN communication line. *2: ECM determines the start signal status by the signals of engine speed and battery voltage. SYSTEM DESCRIPTION Firing order: 1 - 3 - 4 - 2 The ignition timing is controlled by the ECM to maintain the best air-fuel ratio for every running condition of the engine. The ignition timing data is stored in the ECM. The ECM receives information such as the injection pulse width and camshaft position sensor (PHASE) signal. Computing this information, ignition signals are transmitted to the power transistor. During the following conditions, the ignition timing is revised by the ECM according to the other data stored in the ECM. ● At starting ● During warm-up ● At idle ● At low battery voltage EC-819 ENGINE CONTROL SYSTEM [HR (WITH EURO-OBD)] ● During acceleration The knock sensor retard system is designed only for emergencies. The basic ignition timing is programmed within the anti-knocking zone, if recommended fuel is used under dry conditions. The retard system does not operate under normal driving conditions. If engine knocking occurs, the knock sensor monitors the condition. The signal is transmitted to the ECM. The ECM retards the ignition timing to eliminate the knocking condition. Fuel Cut Control (at No Load and High Engine Speed) BBS00491 INPUT/OUTPUT SIGNAL CHART Sensor Input Signal to ECM Park/neutral position (PNP) switch Neutral position Accelerator pedal position sensor Accelerator pedal position Engine coolant temperature sensor Engine coolant temperature Crankshaft position sensor (POS) Camshaft position sensor (PHASE) Engine speed Wheel sensor Vehicle speed* ECM function Fuel cut control Actuator Fuel injector *: This signal is sent to the ECM through CAN communication line. SYSTEM DESCRIPTION If the engine speed is above 2,500 rpm under no load (for example, the shift lever position is neutral and engine speed is over 2,500 rpm) fuel will be cut off after some time. The exact time when the fuel is cut off varies based on engine speed. Fuel cut will be operated until the engine speed reaches 2,000 rpm, then fuel cut will be cancelled. NOTE: This function is different from deceleration control listed under EC-817, "Multiport Fuel Injection (MFI) System" . EC-820 AIR CONDITIONING CUT CONTROL [HR (WITH EURO-OBD)] AIR CONDITIONING CUT CONTROL Input/Output Signal Chart Sensor PFP:23710 A BBS00492 Input Signal to ECM Air conditioner switch Air conditioner ON signal* Accelerator pedal position sensor Accelerator pedal position Crankshaft position sensor (POS) Camshaft position sensor (PHASE) Engine speed*2 Engine coolant temperature sensor Engine coolant temperature Battery Battery voltage*2 Refrigerant pressure sensor Refrigerant pressure EPS control unit Power steering operation*1 Wheel sensor ECM function Actuator EC 1 C Air conditioner cut control Air conditioner relay D E 1 Vehicle speed* *1: This signal is sent to the ECM through CAN communication line. *2: ECM determines the start signal status by the signals of engine speed and battery voltage. System Description F BBS00493 This system improves engine operation when the air conditioner is used. Under the following conditions, the air conditioner is turned OFF. ● When the accelerator pedal is fully depressed. ● When cranking the engine. ● At high engine speeds. ● When the engine coolant temperature becomes excessively high. ● When operating power steering during low engine speed or low vehicle speed. ● When engine speed is excessively low. ● When refrigerant pressure is excessively low or high. G H I J K L M EC-821 CAN COMMUNICATION [HR (WITH EURO-OBD)] CAN COMMUNICATION System Description PFP:23710 BBS00494 CAN (Controller Area Network) is a serial communication line for real time application. It is an on-vehicle multiplex communication line with high data communication speed and excellent error detection ability. Many electronic control units are equipped onto a vehicle, and each control unit shares information and links with other control units during operation (not independent). In CAN communication, control units are connected with 2 communication lines (CAN H line, CAN L line) allowing a high rate of information transmission with less wiring. Each control unit transmits/receives data but selectively reads required data only. Refer to LAN-21, "CAN COMMUNICATION" , about CAN communication for detail. EC-822 EVAPORATIVE EMISSION SYSTEM [HR (WITH EURO-OBD)] EVAPORATIVE EMISSION SYSTEM Description PFP:14950 A BBS00495 SYSTEM DESCRIPTION EC C D E F G PBIB3039E The evaporative emission system is used to reduce hydrocarbons emitted into the atmosphere from the fuel system. This reduction of hydrocarbons is accomplished by activated charcoals in the EVAP canister. The fuel vapor in the sealed fuel tank is led into the EVAP canister which contains activated carbon and the vapor is stored there when the engine is not operating or when refueling to the fuel tank. The vapor in the EVAP canister is purged by the air through the purge line to the intake manifold when the engine is operating. EVAP canister purge volume control solenoid valve is controlled by ECM. When the engine operates, the flow rate of vapor controlled by EVAP canister purge volume control solenoid valve is proportionally regulated as the air flow increases. EVAP canister purge volume control solenoid valve also shuts off the vapor purge line during decelerating. H I J K L M EC-823 EVAPORATIVE EMISSION SYSTEM [HR (WITH EURO-OBD)] EVAPORATIVE EMISSION LINE DRAWING PBIB2946E : Vehicle front 1. Intake manifold : From next page 2. EVAP canister purge volume control solenoid valve 3. EVAP purge resonator NOTE: Do not use soapy water or any type of solvent while installing vacuum hose or purge hoses. EC-824 EVAPORATIVE EMISSION SYSTEM [HR (WITH EURO-OBD)] A EC C D E F G H MBIB1450E : Vehicle front 1. : To previous page I EVAP canister J K L M EC-825 EVAPORATIVE EMISSION SYSTEM [HR (WITH EURO-OBD)] Component Inspection BBS00496 EVAP CANISTER Check EVAP canister as follows: 1. Block port (B). 2. Blow air into port (A) and check that it flows freely out of port (C). 3. Release blocked port (B). 4. Apply vacuum pressure to port (B) and check that vacuum pressure exists at the ports (A) and (C). 5. Block port (A) and (B). 6. Apply pressure to port (C) and check that there is no leakage. PBIB2961E FUEL TANK VACUUM RELIEF VALVE (BUILT INTO FUEL FILLER CAP) 1. Wipe clean valve housing. SEF989X 2. Check valve opening pressure and vacuum. Pressure: Vacuum: 3. 15.3 - 20.0 kPa (0.153 - 0.200 bar, 0.156 - 0.204 kg/cm2 , 2.22 - 2.90 psi) −6.0 to −3.3 kPa (−0.060 to −0.034 bar, −0.061 to −0.035 kg/cm2 , −0.87 to −0.49 psi) If out of specification, replace fuel filler cap as an assembly. SEF943S EVAP CANISTER PURGE VOLUME CONTROL SOLENOID VALVE Refer to EC-1063, "DTC P0444 EVAP CANISTER PURGE VOLUME CONTROL SOLENOID VALVE" . EC-826 NATS (NISSAN ANTI-THEFT SYSTEM) [HR (WITH EURO-OBD)] NATS (NISSAN ANTI-THEFT SYSTEM) Description ● ● ● PFP:25386 A BBS00497 If the security indicator lights up with the ignition switch in the ON position or “NATS MALFUNCTION” is displayed on EC “SELF-DIAG RESULTS” screen, perform self-diagnostic results mode with CONSULT-II using NATS program card. Refer to BL-215, "NATS (Nissan Anti-Theft System)" . C Confirm no self-diagnostic results of NATS is displayed before touching “ERASE” in “SELF-DIAG RESULTS” mode with CONSULT-II. D When replacing ECM, initialization of NATS system and registration of all NATS ignition key IDs must be carried out SEF515Y with CONSULT-II using NATS program card. Therefore, be sure to receive all keys from vehicle owner. E Regarding the procedures of NATS initialization and all NATS ignition key ID registration, refer to CONSULT-II operation manual, NATS. F G H I J K L M EC-827 POSITIVE CRANKCASE VENTILATION [HR (WITH EURO-OBD)] POSITIVE CRANKCASE VENTILATION Description PFP:11810 BBS00498 SYSTEM DESCRIPTION PBIB2962E This system returns blow-by gas to the intake manifold. The positive crankcase ventilation (PCV) valve is provided to conduct crankcase blow-by gas to the intake manifold. During partial throttle operation of the engine, the intake manifold sucks the blow-by gas through the PCV valve. Normally, the capacity of the valve is sufficient to handle any blow-by and a small amount of ventilating air. The ventilating air is then drawn from the air inlet tubes into the crankcase. In this process the air passes through the hose connecting air inlet tubes to rocker cover. Under full-throttle condition, the manifold vacuum is insufficient to draw the blow-by flow through the valve. The flow goes through the hose connection in the reverse direction. On vehicles with an excessively high blow-by, the valve does not meet the requirement. This is because some of the flow will go through the hose connection to the air inlet tubes under all conditions. PBIB1588E Component Inspection BBS00499 PCV (POSITIVE CRANKCASE VENTILATION) VALVE With engine running at idle, remove PCV valve from rocker cover. A properly working valve makes a hissing noise as air passes through it. A strong vacuum should be felt immediately when a finger is placed over valve inlet. PBIB1589E EC-828 POSITIVE CRANKCASE VENTILATION [HR (WITH EURO-OBD)] PCV VALVE VENTILATION HOSE 1. 2. A Check hoses and hose connections for leaks. Disconnect all hoses and clean with compressed air. If any hose cannot be freed of obstructions, replace. EC C S-ET277 D E F G H I J K L M EC-829 ON BOARD DIAGNOSTIC (OBD) SYSTEM [HR (WITH EURO-OBD)] ON BOARD DIAGNOSTIC (OBD) SYSTEM Introduction PFP:00028 BBS0049A The ECM has an on board diagnostic system, which detects malfunctions related to engine sensors or actuators. The ECM also records various emission-related diagnostic information including: Emission-related diagnostic information Diagnostic service Diagnostic Trouble Code (DTC) Service $03 of ISO 15031-5 Freeze Frame data Service $02 of ISO 15031-5 System Readiness Test (SRT) code Service $01 of ISO 15031-5 1st Trip Diagnostic Trouble Code (1st Trip DTC) Service $07 of ISO 15031-5 1st Trip Freeze Frame data Test values and Test limits Service $06 of ISO 15031-5 The above information can be checked using procedures listed in the table below. ×: Applicable —: Not applicable DTC 1st trip DTC Freeze Frame data 1st trip Freeze Frame data SRT code Test value CONSULT-II × × × × × — GST × × × — × × ECM × ×* — — — — *: When DTC and 1st trip DTC simultaneously appear on the display, they cannot be clearly distinguished from each other. The malfunction indicator (MI) on the instrument panel lights up when the same malfunction is detected in two consecutive trips (Two trip detection logic), or when the ECM enters fail-safe mode. (Refer to EC-870, "FailSafe Chart" .) Two Trip Detection Logic BBS0049B When a malfunction is detected for the first time, 1st trip DTC and 1st trip Freeze Frame data are stored in the ECM memory. The MI will not light up at this stage. <1st trip> If the same malfunction is detected again during the next drive, the DTC and Freeze Frame data are stored in the ECM memory, and the MI lights up. The MI lights up at the same time when the DTC is stored. <2nd trip> The “trip” in the “Two Trip Detection Logic” means a driving mode in which self-diagnosis is performed during vehicle operation. Specific on board diagnostic items will cause the ECM to light up or blink the MI, and store DTC and Freeze Frame data, even in the 1st trip, as shown below. ×: Applicable MI DTC 1st trip Items 2nd trip —: Not applicable 1st trip DTC 1st trip displaying 2nd trip displaying 1st trip displaying 2nd trip displaying — — — × — × — — × — — × — — × — — — — — × — × × — Blinking Lighting up Blinking Lighting up Misfire (Possible three way catalyst damage) — DTC: P0300 P0304 is being detected × — — Misfire (Possible three way catalyst damage) — DTC: P0300 P0304 is being detected — — One trip detection diagnoses (Refer to EC-831, "EMISSIONRELATED DIAGNOSTIC INFORMATION ITEMS" .) — Except above — When there is an open circuit on MI circuit, the ECM cannot warn the driver by lighting up MI when there is malfunction on engine control system. Therefore, when electrical controlled throttle and part of ECM related diagnoses are continuously detected as NG for 5 trips, ECM warns the driver that engine control system malfunctions and MI circuit is open by means of operating fail-safe function. EC-830 ON BOARD DIAGNOSTIC (OBD) SYSTEM [HR (WITH EURO-OBD)] The fail-safe function also operates when above diagnoses except MI circuit are detected and demands the driver to repair the malfunction. Engine operating condition in fail-safe mode Engine speed will not rise more than 2,500 rpm due to the fuel cut Emission-related Diagnostic Information BBS0049C EMISSION-RELATED DIAGNOSTIC INFORMATION ITEMS DTC* Items (CONSULT-II screen terms) CONSULT-II GST*2 1 EC ×:Applicable —: Not applicable SRT code Test value/ Test limit (GST only) Trip MI Reference page C D ECM*3 U1000 1000*4 — — 1 × EC-925 CAN COMM CIRCUIT U1001 4 1001* — — 2 — EC-925 CONTROL UNIT(CAN) U1010 1010 — — 1 (A/T) 2 (M/T) × (A/T) — (M/T) EC-928 NO DTC IS DETECTED. FURTHER TESTING MAY BE REQUIRED. P0000 0000 — — — Flashing*5 EC-844 INT/V TIM CONT-B1 P0011 0011 — — 2 — EC-930 MAF SEN/CIRCUIT P0102 0102 — — 1 × EC-935 MAF SEN/CIRCUIT P0103 0103 — — 1 × EC-935 IAT SEN/CIRCUIT P0112 0112 — — 2 × EC-942 IAT SEN/CIRCUIT P0113 0113 — — 2 × EC-942 ECT SEN/CIRC P0117 0117 — — 1 × EC-947 ECT SEN/CIRC P0118 0118 — — 1 × EC-947 TP SEN 2/CIRC P0122 0122 — — 1 × EC-953 TP SEN 2/CIRC P0123 0123 — — 1 × EC-953 HO2S1 (B1) P0132 0132 — × 2 × EC-959 HO2S1 (B1) P0133 0133 × × 2 × EC-967 HO2S1 (B1) P0134 0134 — × 2 × EC-977 HO2S1 HTR (B1) P0135 0135 × × 2 × EC-985 HO2S2 (B1) P0138 0138 — × 2 × EC-991 HO2S2 (B1) P0139 0139 × × 2 × EC-998 HO2S2 HTR (B1) P0141 0141 × × 2 × EC-1006 FUEL SYS-LEAN-B1 P0171 0171 — — 2 × EC-1012 FUEL SYS-RICH-B1 P0172 0172 — — 2 × EC-1019 TP SEN 1/CIRC P0222 0222 — — 1 × EC-1026 TP SEN 1/CIRC P0223 0223 — — 1 × EC-1026 MULTI CYL MISFIRE P0300 0300 — — 2 × EC-1032 CYL 1 MISFIRE P0301 0301 — — 2 × EC-1032 CYL 2 MISFIRE P0302 0302 — — 2 × EC-1032 CYL 3 MISFIRE P0303 0303 — — 2 × EC-1032 CAN COMM CIRCUIT A F CYL 4 MISFIRE P0304 0304 — — 2 × EC-1032 KNOCK SEN/CIRC-B1 P0327 0327 — — 2 — EC-1038 KNOCK SEN/CIRC-B1 P0328 0328 — — 2 — EC-1038 CKP SEN/CIRCUIT P0335 0335 — — 2 × EC-1042 CMP SEN/CIRC-B1 P0340 0340 — — 2 × EC-1049 TW CATALYST SYS-B1 P0420 0420 × × 2 × EC-1056 PURG VOLUME CONT/V P0444 0444 — — 2 × EC-1063 EC-831 E G H I J K L M ON BOARD DIAGNOSTIC (OBD) SYSTEM [HR (WITH EURO-OBD)] DTC*1 Items (CONSULT-II screen terms) CONSULT-II SRT code Test value/ Test limit (GST only) Trip MI Reference page 3 GST*2 ECM* VEH SPEED SEN/CIRC*6 P0500 0500 — — 2 × EC-1070 ECM P0605 0605 — — 1 or 2 × or — EC-1072 PNP SW/CIRC P0705 0705 — — 2 × AT-105 ATF TEMP SEN/CIRC P0710 0710 — — 2 × AT-110 VEH SPD SEN/CIR AT*6 P0720 0720 — — 2 × AT-115 ENGINE SPEED SIG P0725 0725 — — 2 × AT-121 A/T 1ST GR FNCTN P0731 0731 — — 2 × AT-125 A/T 2ND GR FNCTN P0732 0732 — — 2 × AT-129 A/T 3RD GR FNCTN P0733 0733 — — 2 × AT-132 A/T 4TH GR FNCTN P0734 0734 — — 2 × AT-136 TCC SOLENOID/CIRC P0740 0740 — — 2 × AT-142 A/T TCC S/V FNCTN P0744 0744 — — 2 × AT-147 L/PRESS SOL/CIRC P0745 0745 — — 2 × AT-153 SHIFT SOL A/CIRC P0750 0750 — — 1 × AT-159 SHIFT SOL B/CIRC P0755 0755 — — 1 × AT-164 ECM BACK UP/CIRCUIT*7 P1065 1065 — — 2 × EC-1075 INT/V TIM V/CIR-B1 P1111 1111 — — 2 × EC-1077 ETC ACTR P1121 1121 — — 1 × EC-1082 ETC FUNCTION/CIRC P1122 1122 — — 1 × EC-1084 ETC MOT PWR P1124 1124 — — 1 × EC-1090 ETC MOT PWR P1126 1126 — — 1 × EC-1090 ETC MOT P1128 1128 — — 1 × EC-1096 HO2S1 (B1) P1143 1143 × × 2 × EC-1101 HO2S1 (B1) P1144 1144 × × 2 × EC-1107 HO2S2 (B1) P1146 1146 × × 2 × EC-1113 HO2S2 (B1) P1147 1147 × × 2 × EC-1121 TCS/CIRC P1212 1212 — — 2 — EC-1129 ENG OVER TEMP P1217 1217 — — 1 × EC-1130 CTP LEARNING P1225 1225 — — 2 — EC-1146 CTP LEARNING P1226 1226 — — 2 — EC-1148 SENSOR POWER/CIRC P1229 1229 — — 1 × EC-1150 NATS MALFUNCTION P1610 - P1615 1610 - 1615 — — 2 — BL-215 TP SEN/CIRC A/T P1705 1705 — — 1 × AT-169 P-N POS SW/CIRCUIT P1706 1706 — — 2 × EC-1158 O/R CLTCH SOL/CIRC P1760 1760 — — 2 × AT-171 BRAKE SW/CIRCUIT P1805 1805 — — 2 — EC-1167 APP SEN 1/CIRC P2122 2122 — — 1 × EC-1172 APP SEN 1/CIRC P2123 2123 — — 1 × EC-1172 APP SEN 2/CIRC P2127 2127 — — 1 × EC-1181 APP SEN 2/CIRC P2128 2128 — — 1 × EC-1181 TP SENSOR P2135 2135 — — 1 × EC-1191 APP SENSOR P2138 2138 — — 1 × EC-1197 EC-832 ON BOARD DIAGNOSTIC (OBD) SYSTEM [HR (WITH EURO-OBD)] *1: 1st trip DTC No. is the same as DTC No. *2: This number is prescribed by ISO 15031-5. *3: In Diagnostic Test Mode II (Self-diagnostic results), this number is controlled by NISSAN. *4: The troubleshooting for this DTC needs CONSULT-II. *5: When engine is running, MI may flash. For details, refer to EC-844, "MI Flashing Without DTC" . *6: When the fail-safe operations for both self-diagnoses occur at the same time, the MI illuminates. *7:This self-diagnosis is not for ECM power supply circuit, even though “ECM BACK UP/CIRCUIT” is displayed on CONSULT-II screen. DTC AND 1ST TRIP DTC The 1st trip DTC (whose number is the same as the DTC number) is displayed for the latest self-diagnostic result obtained. If the ECM memory was cleared previously, and the 1st trip DTC did not reoccur, the 1st trip DTC will not be displayed. If a malfunction is detected during the 1st trip, the 1st trip DTC is stored in the ECM memory. The MI will not light up (two trip detection logic). If the same malfunction is not detected in the 2nd trip (meeting the required driving pattern), the 1st trip DTC is cleared from the ECM memory. If the same malfunction is detected in the 2nd trip, both the 1st trip DTC and DTC are stored in the ECM memory and the MI lights up. In other words, the DTC is stored in the ECM memory and the MI lights up when the same malfunction occurs in two consecutive trips. If a 1st trip DTC is stored and a non-diagnostic operation is performed between the 1st and 2nd trips, only the 1st trip DTC will continue to be stored. For malfunctions that blink or light up the MI during the 1st trip, the DTC and 1st trip DTC are stored in the ECM memory. Procedures for clearing the DTC and the 1st trip DTC from the ECM memory are described in EC-841, "HOW TO ERASE EMISSION-RELATED DIAGNOSTIC INFORMATION" . For malfunctions in which 1st trip DTCs are displayed, refer to EC-831, "EMISSION-RELATED DIAGNOSTIC INFORMATION ITEMS" . These items are required by legal regulations to continuously monitor the system/ component. In addition, the items monitored non-continuously are also displayed on CONSULT-II. 1st trip DTC is specified in Service $07 of ISO 15031-5. 1st trip DTC detection occurs without lighting up the MI and therefore does not warn the driver of a malfunction. However, 1st trip DTC detection will not prevent the vehicle from being tested, for example during Inspection/Maintenance (I/M) tests. When a 1st trip DTC is detected, check, print out or write down and erase (1st trip) DTC and Freeze Frame data as specified in Work Flow procedure Step 2, refer to EC-864, "WORK FLOW" . Then perform DTC Confirmation Procedure or Overall Function Check to try to duplicate the malfunction. If the malfunction is duplicated, the item requires repair. How to Read DTC and 1st Trip DTC A EC C D E F G H I J DTC and 1st trip DTC can be read by the following methods. With CONSULT-II With GST CONSULT-II or GST (Generic Scan Tool) Examples: P0340, P0740, P1217, etc. These DTCs are prescribed by ISO 15031-5. (CONSULT-II also displays the malfunctioning component or system.) No Tools The number of blinks of the MI in the Diagnostic Test Mode II (Self-Diagnostic Results) indicates the DTC. Example: 0340, 0740, 1217, etc. These DTCs are controlled by NISSAN. ● 1st trip DTC No. is the same as DTC No. ● Output of a DTC indicates a malfunction. However, GST or the Diagnostic Test Mode II do not indicate whether the malfunction is still occurring or has occurred in the past and has returned to normal. CONSULT-II can identify malfunction status as shown below. Therefore, using CONSULT-II (if available) is recommended. A sample of CONSULT-II display for DTC and 1st trip DTC is shown below. DTC or 1st trip DTC of a malfunction is displayed in SELF-DIAGNOSTIC RESULTS mode of CONSULT-II. Time data indicates how many times the vehicle was driven after the last detection of a DTC. If the DTC is being detected currently, the time data will be [0]. EC-833 K L M ON BOARD DIAGNOSTIC (OBD) SYSTEM [HR (WITH EURO-OBD)] If a 1st trip DTC is stored in the ECM, the time data will be [1t]. PBIB0911E FREEZE FRAME DATA AND 1ST TRIP FREEZE FRAME DATA The ECM records the driving conditions such as fuel system status, calculated load value, engine coolant temperature, short term fuel trim, long term fuel trim, engine speed, vehicle speed, base fuel schedule and intake air temperature at the moment a malfunction is detected. Data which are stored in the ECM memory, along with the 1st trip DTC, are called 1st trip freeze frame data. The data, stored together with the DTC data, are called freeze frame data and displayed on CONSULT-II or GST. The 1st trip freeze frame data can only be displayed on the CONSULT-II screen, not on the GST. For details, see EC-893, "Freeze Frame Data and 1st Trip Freeze Frame Data" . Only one set of freeze frame data (either 1st trip freeze frame data or freeze frame data) can be stored in the ECM. 1st trip freeze frame data is stored in the ECM memory along with the 1st trip DTC. There is no priority for 1st trip freeze frame data and it is updated each time a different 1st trip DTC is detected. However, once freeze frame data (2nd trip detection/MI on) is stored in the ECM memory, 1st trip freeze frame data is no longer stored. Remember, only one set of freeze frame data can be stored in the ECM. The ECM has the following priorities to update the data. Priority 1 2 3 Items Freeze frame data Misfire — DTC: P0300 - P0304 Fuel Injection System Function — DTC: P0171, P0172 Except the above items (Includes A/T related items) 1st trip freeze frame data For example, the EGR malfunction (Priority: 2) was detected and the freeze frame data was stored in the 2nd trip. After that when the misfire (Priority: 1) is detected in another trip, the freeze frame data will be updated from the EGR malfunction to the misfire. The 1st trip freeze frame data is updated each time a different malfunction is detected. There is no priority for 1st trip freeze frame data. However, once freeze frame data is stored in the ECM memory, 1st trip freeze data is no longer stored (because only one freeze frame data or 1st trip freeze frame data can be stored in the ECM). If freeze frame data is stored in the ECM memory and freeze frame data with the same priority occurs later, the first (original) freeze frame data remains unchanged in the ECM memory. Both 1st trip freeze frame data and freeze frame data (along with the DTCs) are cleared when the ECM memory is erased. Procedures for clearing the ECM memory are described in EC-841, "HOW TO ERASE EMISSION-RELATED DIAGNOSTIC INFORMATION" . SYSTEM READINESS TEST (SRT) CODE System Readiness Test (SRT) code is specified in Service $01 of ISO 15031-5. As part of an enhanced emissions test for Inspection & Maintenance (I/M), certain states require the status of SRT be used to indicate whether the ECM has completed self-diagnosis of major emission systems and components. Completion must be verified in order for the emissions inspection to proceed. If a vehicle is rejected for a State emissions inspection due to one or more SRT items indicating “INCMP”, use the information in this Service Manual to set the SRT to “CMPLT”. In most cases the ECM will automatically complete its self-diagnosis cycle during normal usage, and the SRT status will indicate “CMPLT” for each application system. Once set as “CMPLT”, the SRT status remains “CMPLT” until the self-diagnosis memory is erased. Occasionally, certain portions of the self-diagnostic test may not be completed as a result of the customer's normal driving pattern; the SRT will indicate “INCMP” for these items. NOTE: The SRT will also indicate “INCMP” if the self-diagnosis memory is erased for any reason or if the ECM memory power supply is interrupted for several hours. EC-834 ON BOARD DIAGNOSTIC (OBD) SYSTEM [HR (WITH EURO-OBD)] If, during the state emissions inspection, the SRT indicates “CMPLT” for all test items, the inspector will continue with the emissions test. However, if the SRT indicates “INCMP” for one or more of the SRT items the A vehicle is returned to the customer untested. NOTE: If MI is ON during the state emissions inspection, the vehicle is also returned to the customer untested even EC though the SRT indicates “CMPLT” for all test items. Therefore, it is important to check SRT (“CMPLT”) and DTC (No DTCs) before the inspection. SRT Item C The table below shows required self-diagnostic items to set the SRT to “CMPLT”. SRT item (CONSULT-II indication) Performance Priority* Required self-diagnostic items to set the SRT to “CMPLT” Corresponding DTC No. CATALYST 2 Three way catalyst function P0420 HO2S 1 Heated oxygen sensor 1 P0133 Heated oxygen sensor 1 P1143 Heated oxygen sensor 1 P1144 Heated oxygen sensor 2 P0139 Heated oxygen sensor 2 P1146 Heated oxygen sensor 2 P1147 Heated oxygen sensor 1 heater P0135 Heated oxygen sensor 2 heater P0141 HO2S HTR 1 D E F G *: If completion of several SRTs is required, perform driving patterns (DTC confirmation procedure), one by one based on the priority for models with CONSULT-II. H SRT Set Timing SRT is set as “CMPLT” after self-diagnosis has been performed one or more times. Completion of SRT is done regardless of whether the result is OK or NG. The set timing is different between OK and NG results and is shown in the table below. J Example Self-diagnosis result All OK Case 1 Case 2 NG exists Case 3 Ignition cycle ← ON → OFF ← ON → Diagnosis ← ON → P0400 OK (1) — (1) OK (2) — (2) P0402 OK (1) — (1) — (1) OK (2) P1402 OK (1) OK (2) — (2) — (2) SRT of EGR “CMPLT” “CMPLT” “CMPLT” “CMPLT” P0400 OK (1) — (1) — (1) — (1) P0402 — (0) — (0) OK (1) — (1) P1402 OK (1) OK (2) — (2) — (2) SRT of EGR “INCMP” “INCMP” “CMPLT” “CMPLT” P0400 OK OK — — P0402 — — — — P1402 NG — NG NG (Consecutive NG) (1st trip) DTC 1st trip DTC — 1st trip DTC DTC (= MI ON) SRT of EGR “INCMP” “INCMP” “INCMP” “CMPLT” OFF OFF ← ON → OK: Self-diagnosis is carried out and the result is OK. NG: Self-diagnosis is carried out and the result is NG. —: Self-diagnosis is not carried out. When all SRT related self-diagnoses showed OK results in a single cycle (Ignition OFF-ON-OFF), the SRT will indicate “CMPLT”. → Case 1 above EC-835 I K L M ON BOARD DIAGNOSTIC (OBD) SYSTEM [HR (WITH EURO-OBD)] When all SRT related self-diagnoses showed OK results through several different cycles, the SRT will indicate “CMPLT” at the time the respective self-diagnoses have at least one OK result. → Case 2 above If one or more SRT related self-diagnoses showed NG results in 2 consecutive cycles, the SRT will also indicate “CMPLT”. → Case 3 above The table above shows that the minimum number of cycles for setting SRT as “INCMP” is one (1) for each self-diagnosis (Case 1 & 2) or two (2) for one of self-diagnoses (Case 3). However, in preparation for the state emissions inspection, it is unnecessary for each self-diagnosis to be executed twice (Case 3) for the following reasons: ● The SRT will indicate “CMPLT” at the time the respective self-diagnoses have one (1) OK result. ● The emissions inspection requires “CMPLT” of the SRT only with OK self-diagnosis results. ● When, during SRT driving pattern, 1st trip DTC (NG) is detected prior to “CMPLT” of SRT, the self-diagnosis memory must be erased from ECM after repair. ● If the 1st trip DTC is erased, all the SRT will indicate “INCMP”. NOTE: SRT can be set as “CMPLT” together with the DTC(s). Therefore, DTC check must always be carried out prior to the state emission inspection even though the SRT indicates “CMPLT”. SRT Service Procedure If a vehicle has failed the state emissions inspection due to one or more SRT items indicating “INCMP”, review the flowchart diagnostic sequence on the next page. EC-836 ON BOARD DIAGNOSTIC (OBD) SYSTEM [HR (WITH EURO-OBD)] A EC C D E F G H I J K L M SEF573XB *1 EC-833, "How to Read DTC and 1st Trip DTC" *2 EC-837, "How to Display SRT Code" *3 EC-838, "How to Set SRT Code" How to Display SRT Code WITH CONSULT-II Selecting “SRT STATUS” in “DTC & SRT CONFIRMATION” mode with CONSULT-II. For items whose SRT codes are set, a “CMPLT” is displayed on the CONSULT-II screen; for items whose SRT codes are not set, “INCMP” is displayed. A sample of CONSULT-II display for SRT code is shown in the figure. “INCMP” means the self-diagnosis is incomplete and SRT is not set. “CMPLT” means the self-diagnosis is complete and SRT is set. PBIB0666E EC-837 ON BOARD DIAGNOSTIC (OBD) SYSTEM [HR (WITH EURO-OBD)] WITH GST Selecting Service $01 with GST (Generic Scan Tool) How to Set SRT Code To set all SRT codes, self-diagnosis for the items indicated above must be performed one or more times. Each diagnosis may require a long period of actual driving under various conditions. WITH CONSULT-II Perform corresponding DTC Confirmation Procedure one by one based on Performance Priority in the table on EC-835, "SRT Item" . WITHOUT CONSULT-II The most efficient driving pattern in which SRT codes can be properly set is explained on the next page. The driving pattern should be performed one or more times to set all SRT codes. EC-838 ON BOARD DIAGNOSTIC (OBD) SYSTEM [HR (WITH EURO-OBD)] Driving Pattern A EC C D E F G H I J K L M PBIB2451E EC-839 ON BOARD DIAGNOSTIC (OBD) SYSTEM [HR (WITH EURO-OBD)] The time required for each diagnosis varies with road surface conditions, weather, altitude, individual driving habits, etc. Zone A refers to the range where the time, required for the diagnosis under normal conditions*, is the shortest. Zone B refers to the range where the diagnosis can still be performed if the diagnosis is not completed within zone A. *: Normal conditions refer to the following: ● Sea level ● Flat road ● Ambient air temperature: 20 - 30°C (68 - 86°F) ● Diagnosis is performed as quickly as possible under normal conditions. Under different conditions [For example: ambient air temperature other than 20 - 30°C (68 - 86°F)], diagnosis may also be performed. Pattern 1: ● The engine is started at the engine coolant temperature of −10 to 35°C (14 to 95°F) (where the voltage between the ECM terminal 38 and ground is 3.0 - 4.3V). ● The engine must be operated at idle speed until the engine coolant temperature is greater than 70°C (158°F) (where the voltage between the ECM terminal 38 and ground is lower than 1.4V). Pattern 2: ● When steady-state driving is performed again even after it is interrupted, each diagnosis can be conducted. In this case, the time required for diagnosis may be extended. *1: Depress the accelerator pedal until vehicle speed is 90 km/h (56 MPH), then release the accelerator pedal and keep it released for more than 10 seconds. Depress the accelerator pedal until vehicle speed is 90 km/h (56 MPH) again. *2: Checking the vehicle speed with GST is advised. ● Suggested Transmission Gear Position Set the shift lever in the D position with the overdrive switch turned ON. EC-840 ON BOARD DIAGNOSTIC (OBD) SYSTEM [HR (WITH EURO-OBD)] TEST VALUE AND TEST LIMIT (GST ONLY — NOT APPLICABLE TO CONSULT-II) A The following is the information specified in Service $06 of ISO 15031-5. The test value is a parameter used to determine whether a system/circuit diagnostic test is OK or NG while being monitored by the ECM during self-diagnosis. The test limit is a reference value which is specified as the maximum or minimum value and is compared with the test value being monitored. EC These data (test value and test limit) are specified by Test ID (TID) and Component ID (CID) and can be displayed on the GST screen. SRT item CATALYST Self-diagnostic test item Three way catalyst function Heated oxygen sensor 1 HO2S Heated oxygen sensor 2 Test value (GST display) DTC C Test limit TID CID P0420 01H 01H Max. P0420 02H 81H Min. P0133 09H 04H Max. P1143 0AH 84H Min. P1144 0BH 04H Max. P0132 0CH 04H Max. P0134 0DH 04H Max. P0139 19H 86H Min. P1147 1AH 86H Min. P1146 1BH 06H Max. P0138 1CH 06H Max. 29H 08H Max. 2AH 88H Min. 2DH 0AH Max. 2EH 8AH Min. Heated oxygen sensor 1 heater P0135 Heated oxygen sensor 2 heater P0141 HO2S HTR HOW TO ERASE EMISSION-RELATED DIAGNOSTIC INFORMATION How to Erase DTC WITH CONSULT-II The emission related diagnostic information in the ECM can be erased by selecting “ERASE” in the “SELFDIAG RESULTS” mode with CONSULT-II. If DTCs are displayed for both ECM and TCM (Transmission control module), they need to be erased individually from the ECM and TCM (Transmission control module). NOTE: If the DTC is not for A/T related items (see EC-803, "INDEX FOR DTC" ), skip steps 2 through 4. 1. If the ignition switch stays ON after repair work, be sure to turn ignition switch OFF once. Wait at least 10 seconds and then turn it ON (engine stopped) again. 2. Turn CONSULT-II ON and touch “A/T”. 3. Touch “SELF-DIAG RESULTS”. 4. Touch “ERASE”. [The DTC in the TCM (Transmission control module) will be erased.] Then touch “BACK” twice. 5. Touch “ENGINE”. 6. Touch “SELF-DIAG RESULTS”. 7. Touch “ERASE”. (The DTC in the ECM will be erased.) EC-841 D E F G H I J K L M ON BOARD DIAGNOSTIC (OBD) SYSTEM [HR (WITH EURO-OBD)] SCIA5680E WITH GST The emission related diagnostic information in the ECM can be erased by selecting Service $04 with GST. NOTE: If the DTC is not for A/T related items (see EC-803, "INDEX FOR DTC" ), skip step 2. 1. If the ignition switch stays ON after repair work, be sure to turn ignition switch OFF once. Wait at least 10 seconds and then turn it ON (engine stopped) again. 2. Perform AT-98, "OBD Diagnostic Trouble Code (DTC)" . (The DTC in TCM will be erased) 3. Select Service $04 with GST (Generic Scan Tool). No Tools NOTE: If the DTC is not for AT related items (see EC-803, "INDEX FOR DTC" ), skip step 2. 1. If the ignition switch stays ON after repair work, be sure to turn ignition switch OFF once. Wait at least 10 seconds and then turn it ON (engine stopped) again. 2. Perform AT-98, "OBD Diagnostic Trouble Code (DTC)" . (The DTC in the TCM will be erased.) 3. Change the diagnostic test mode from Mode II to Mode I by depressing the accelerator pedal. Refer to EC-1269, "HOW TO SWITCH DIAGNOSTIC TEST MODE" . ● If the battery is disconnected, the emission-related diagnostic information will be lost within 24 hours. ● The following data are cleared when the ECM memory is erased. – Diagnostic trouble codes – 1st trip diagnostic trouble codes – Freeze frame data – 1st trip freeze frame data – System readiness test (SRT) codes EC-842 ON BOARD DIAGNOSTIC (OBD) SYSTEM [HR (WITH EURO-OBD)] Test values Actual work procedures are explained using a DTC as an example. Be careful so that not only the DTC, but all of the data listed above, are cleared from the ECM memory during work procedures. – Malfunction Indicator (MI) BBS0049D DESCRIPTION The MI is located on the instrument panel. 1. The MI will light up when the ignition switch is turned ON without the engine running. This is a bulb check. If the MI does not light up, check MI circuit. Refer to DI-32, "WARNING LAMPS" , or see EC-1236, "MI & DATA LINK CONNECTORS" . 2. When the engine is started, the MI should go off. If the MI remains on, the on board diagnostic system has detected an engine system malfunction. A EC C D E SAT652J ON BOARD DIAGNOSTIC SYSTEM FUNCTION F The on board diagnostic system has the following four functions. Diagnostic Test Mode KEY and ENG. Status Function Mode I Ignition switch in ON position BULB CHECK Explanation of Function G This function checks the MI bulb for damage (blown, open circuit, etc.). If the MI does not come on, check MI circuit. Engine stopped Engine running Mode II Ignition switch in ON position H I MALFUNCTION WARNING This is a usual driving condition. When a malfunction is detected twice in two consecutive driving cycles (two trip detection logic), the MI will light up to inform the driver that a malfunction has been detected. The following malfunctions will light up or blink the MI in the 1st trip. SELF-DIAGNOSTIC RESULTS ● Misfire (Possible three way catalyst damage) ● One trip detection diagnoses J K L This function allows DTCs and 1st trip DTCs to be read. M Engine stopped Engine running HEATED OXYGEN SENSOR 1 MONITOR This function allows the fuel mixture condition (lean or rich), monitored by heated oxygen sensor 1, to be read. When there is an open circuit on MI circuit, the ECM cannot warn the driver by lighting up MI when there is malfunction on engine control system. Therefore, when electrical controlled throttle and part of ECM related diagnoses are continuously detected as NG for 5 trips, ECM warns the driver that engine control system malfunctions and MI circuit is open by means of operating fail-safe function. EC-843 ON BOARD DIAGNOSTIC (OBD) SYSTEM [HR (WITH EURO-OBD)] The fail-safe function also operates when above diagnoses except MI circuit are detected and demands the driver to repair the malfunction. Engine operating condition in fail-safe mode Engine speed will not rise more than 2,500 rpm due to the fuel cut MI Flashing Without DTC If the ECM is in Diagnostic Test Mode II, MI may flash when engine is running. In this case, check ECM diagnostic test mode. How to switch the diagnostic test (function) modes, and details of the above functions are described later. Refer to EC-1269, "HOW TO SWITCH DIAGNOSTIC TEST MODE" . The following emission-related diagnostic information is cleared when the ECM memory is erased. ● Diagnostic trouble codes ● 1st trip diagnostic trouble codes ● Freeze frame data ● 1st trip freeze frame data ● System readiness test (SRT) codes ● Test values HOW TO SWITCH DIAGNOSTIC TEST MODE NOTE: ● It is better to count the time accurately with a clock. ● It is impossible to switch the diagnostic mode when an accelerator pedal position sensor circuit has a malfunction. ● Always ECM returns to Diagnostic Test Mode I after ignition switch is turned OFF. How to Set Diagnostic Test Mode II (Self-diagnostic Results) 1. 2. a. b. 3. 4. Confirm that accelerator pedal is fully released, turn ignition switch ON and wait 3 seconds. Repeat the following procedure quickly five times within 5 seconds. Fully depress the accelerator pedal. Fully release the accelerator pedal. Wait 7 seconds, fully depress the accelerator pedal and keep it for approx. 10 seconds until the MI starts blinking. Fully release the accelerator pedal. ECM has entered to Diagnostic Test Mode II (Self-diagnostic results). NOTE: Wait until the same DTC (or 1st trip DTC) appears to confirm all DTCs certainly. PBIB0092E How to Set Diagnostic Test Mode II (Heated Oxygen Sensor 1 Monitor) 1. 2. Set the ECM in Diagnostic Test Mode II (Self-diagnostic results). Refer to EC-1269, "How to Set Diagnostic Test Mode II (Self-diagnostic Results)" . Start Engine. ECM has entered to Diagnostic Test Mode II (Heated oxygen sensor 1 monitor). How to Erase Diagnostic Test Mode II (Self-diagnostic Results) 1. 2. Set ECM in Diagnostic Test Mode II (Self-diagnostic results). Refer to EC-1269, "How to Set Diagnostic Test Mode II (Self-diagnostic Results)" . Fully depress the accelerator pedal and keep it for more than 10 seconds. The emission-related diagnostic information has been erased from the backup memory in the ECM. EC-844 ON BOARD DIAGNOSTIC (OBD) SYSTEM [HR (WITH EURO-OBD)] 3. Fully release the accelerator pedal, and confirm the DTC 0000 is displayed. A DIAGNOSTIC TEST MODE I — BULB CHECK In this mode, the MI on the instrument panel should stay ON. If it remains OFF, check MI circuit. Refer to DI32, "WARNING LAMPS" or see EC-1236, "MI & DATA LINK CONNECTORS" . EC DIAGNOSTIC TEST MODE I — MALFUNCTION WARNING MI Condition ON When the malfunction is detected. OFF No malfunction. C This DTC number is clarified in Diagnostic Test Mode II (SELF-DIAGNOSTIC RESULTS) D DIAGNOSTIC TEST MODE II — SELF-DIAGNOSTIC RESULTS In this mode, the DTC and 1st trip DTC are indicated by the number of blinks of the MI as shown below. The DTC and 1st trip DTC are displayed at the same time. If the MI does not illuminate in diagnostic test mode I (Malfunction warning), all displayed items are 1st trip DTCs. If only one code is displayed when the MI illuminates in diagnostic test mode II (SELF-DIAGNOSTIC RESULTS), it is a DTC; if two or more codes are displayed, they may be either DTCs or 1st trip DTCs. DTC No. is same as that of 1st trip DTC. These unidentified codes can be identified by using the CONSULT-II or GST. A DTC will be used as an example for how to read a code. E F G H I J K L PBIA3905E A particular trouble code can be identified by the number of four-digit numeral flashes. The “zero” is indicated by the number of ten flashes. The length of time the 1,000th-digit numeral flashes on and off is 1.2 seconds consisting of an ON (0.6-second) - OFF (0.6-second) cycle. The 100th-digit numeral and lower digit numerals consist of a 0.3-second ON and 0.3-second OFF cycle. A change from one digit numeral to another occurs at an interval of 1.0-second OFF. In other words, the later numeral appears on the display 1.3 seconds after the former numeral has disappeared. A change from one trouble code to another occurs at an interval of 1.8-second OFF. In this way, all the detected malfunctions are classified by their DTC numbers. The DTC 0000 refers to no malfunction. (See EC-803, "INDEX FOR DTC" .) How to Erase Diagnostic Test Mode II (Self-diagnostic Results) The DTC can be erased from the back up memory in the ECM by depressing accelerator pedal. Refer to EC1269, "How to Erase Diagnostic Test Mode II (Self-diagnostic Results)" . ● If the battery is disconnected, the DTC will be lost from the backup memory within 24 hours. ● Be careful not to erase the stored memory before starting trouble diagnoses. DIAGNOSTIC TEST MODE II — HEATED OXYGEN SENSOR 1 MONITOR In this mode, the MI displays the condition of the fuel mixture (lean or rich) which is monitored by the heated oxygen sensor 1. EC-845 M ON BOARD DIAGNOSTIC (OBD) SYSTEM [HR (WITH EURO-OBD)] MI Fuel mixture condition in the exhaust gas ON Lean OFF Rich *Remains ON or OFF Any condition Air fuel ratio feedback control condition Closed loop system Open loop system *: Maintains conditions just before switching to open loop. To check the heated oxygen sensor 1 function, start engine in the Diagnostic Test Mode II and warm it up until engine coolant temperature indicator points to the middle of the gauge. Next run engine at about 2,000 rpm for about 2 minutes under no load conditions. Then make sure that the MI comes ON more than 5 times within 10 seconds with engine running at 2,000 rpm under no load. OBD System Operation Chart BBS0049E RELATIONSHIP BETWEEN MI, 1ST TRIP DTC, DTC, AND DETECTABLE ITEMS ● ● ● ● ● When a malfunction is detected for the first time, the 1st trip DTC and the 1st trip freeze frame data are stored in the ECM memory. When the same malfunction is detected in two consecutive trips, the DTC and the freeze frame data are stored in the ECM memory, and the MI will come on. For details, refer to EC-830, "Two Trip Detection Logic" . The MI will go off after the vehicle is driven 3 times (driving pattern B) with no malfunction. The drive is counted only when the recorded driving pattern is met (as stored in the ECM). If another malfunction occurs while counting, the counter will reset. The DTC and the freeze frame data will be stored until the vehicle is driven 40 times (driving pattern A) without the same malfunction recurring (except for Misfire and Fuel Injection System). For Misfire and Fuel Injection System, the DTC and freeze frame data will be stored until the vehicle is driven 80 times (driving pattern C) without the same malfunction recurring. The “TIME” in “SELF-DIAGNOSTIC RESULTS” mode of CONSULT-II will count the number of times the vehicle is driven. The 1st trip DTC is not displayed when the self-diagnosis results in OK for the 2nd trip. SUMMARY CHART Items Fuel Injection System Misfire Other MI (goes off) 3 (pattern B) 3 (pattern B) 3 (pattern B) DTC, Freeze Frame Data (no display) 80 (pattern C) 80 (pattern C) 40 (pattern A) 1 (pattern C), *1 1 (pattern C), *1 1 (pattern B) *1, *2 *1, *2 1 (pattern B) 1st Trip DTC (clear) 1st Trip Freeze Frame Data (clear) For details about patterns B and C under “Fuel Injection System” and “Misfire”, see EC-848, "EXPLANATION FOR DRIVING PATTERNS FOR “MISFIRE ”, “FUEL INJECTION SYSTEM”" . For details about patterns A and B under Other, see EC-850, "EXPLANATION FOR DRIVING PATTERNS EXCEPT FOR “MISFIRE ”, “FUEL INJECTION SYSTEM”" . *1: Clear timing is at the moment OK is detected. *2: Clear timing is when the same malfunction is detected in the 2nd trip. EC-846 ON BOARD DIAGNOSTIC (OBD) SYSTEM [HR (WITH EURO-OBD)] RELATIONSHIP BETWEEN MI, DTC, 1ST TRIP DTC AND DRIVING PATTERNS FOR “MISFIRE ” , “FUEL INJECTION SYSTEM” A EC C D E F G H I J K L M SEF392SA *1: When the same malfunction is detected in two consecutive trips, MI will light up. *2: MI will go off after vehicle is driven 3 times (pattern B) without any malfunctions. *3: When the same malfunction is detected in two consecutive trips, the DTC and the freeze frame data will be stored in ECM. *4: The DTC and the freeze frame data will not be displayed any longer after vehicle is driven 80 times (pattern C) without the same malfunction. (The DTC and the freeze frame data still remain in ECM.) *5: When a malfunction is detected for the first time, the 1st trip DTC and the 1st trip freeze frame data will be stored in ECM. *6: The 1st trip DTC and the 1st trip freeze frame data will be cleared at the moment OK is detected. *7: When the same malfunction is detected in the 2nd trip, the 1st trip freeze frame data will be cleared. *8: 1st trip DTC will be cleared when vehicle is driven once (pattern C) without the same malfunction after DTC is stored in ECM. EC-847 ON BOARD DIAGNOSTIC (OBD) SYSTEM [HR (WITH EURO-OBD)] EXPLANATION FOR DRIVING PATTERNS FOR “MISFIRE ”, “FUEL INJECTION SYSTEM” Driving pattern B means the vehicle operation as follows: All components and systems should be monitored at least once by the OBD system. ● The B counter will be cleared when the malfunction is detected once regardless of the driving pattern. ● The B counter will be counted up when driving pattern B is satisfied without any malfunction. ● The MI will go off when the B counter reaches 3. (*2 in “OBD SYSTEM OPERATION CHART”) Driving pattern C means the vehicle operation as follows: The following conditions should be satisfied at the same time: Engine speed: (Engine speed in the freeze frame data) ±375 rpm Calculated load value: (Calculated load value in the freeze frame data) x (1±0.1) [%] Engine coolant temperature (T) condition: ● When the freeze frame data shows lower than 70°C (158°F), T should be lower than 70°C (158°F). ● When the freeze frame data shows higher than or equal to 70°C (158°F), T should be higher than or equal to 70°C (158°F). Example: If the stored freeze frame data is as follows: Engine speed: 850 rpm, Calculated load value: 30%, Engine coolant temperature: 80°C (176°F) To be satisfied with driving pattern C, the vehicle should run under the following conditions: Engine speed: 475 - 1,225 rpm, Calculated load value: 27 - 33%, Engine coolant temperature: more than 70°C (158°F) ● The C counter will be cleared when the malfunction is detected regardless of vehicle conditions above. ● The C counter will be counted up when vehicle conditions above is satisfied without the same malfunction. ● The DTC will not be displayed after C counter reaches 80. ● The 1st trip DTC will be cleared when C counter is counted once without the same malfunction after DTC is stored in ECM. EC-848 ON BOARD DIAGNOSTIC (OBD) SYSTEM [HR (WITH EURO-OBD)] RELATIONSHIP BETWEEN MI, DTC, 1ST TRIP DTC AND DRIVING PATTERNS EXCEPT FOR “MISFIRE ”, “FUEL INJECTION SYSTEM” A EC C D E F G H I J K L M PBIB2551E *1: When the same malfunction is detected in two consecutive trips, MI will light up. *2: MI will go off after vehicle is driven 3 times (pattern B) without any malfunctions. *3: When the same malfunction is detected in two consecutive trips, the DTC and the freeze frame data will be stored in ECM. *4: The DTC and the freeze frame data will not be displayed any longer after vehicle is driven 40 times (pattern A) without the same malfunction. (The DTC and the freeze frame data still remain in ECM.) *5: When a malfunction is detected for the first time, the 1st trip DTC and the 1st trip freeze frame data will be stored in ECM. *6: 1st trip DTC will be cleared after vehicle is driven once (pattern B) without the same malfunction. *7: When the same malfunction is detected in the 2nd trip, the 1st trip freeze frame data will be cleared. EC-849 ON BOARD DIAGNOSTIC (OBD) SYSTEM [HR (WITH EURO-OBD)] EXPLANATION FOR DRIVING PATTERNS EXCEPT FOR “MISFIRE ”, “FUEL INJECTION SYSTEM” AEC574 ● ● ● The A counter will be cleared when the malfunction is detected regardless of (1) - (4). The A counter will be counted up when (1) - (4) are satisfied without the same malfunction. The DTC will not be displayed after the A counter reaches 40. Driving pattern B means the vehicle operation as follows: All components and systems should be monitored at least once by the OBD system. ● The B counter will be cleared when the malfunction is detected once regardless of the driving pattern. ● The B counter will be counted up when driving pattern B is satisfied without any malfunctions. ● The MI will go off when the B counter reaches 3 (*2 in OBD SYSTEM OPERATION CHART). EC-850 BASIC SERVICE PROCEDURE [HR (WITH EURO-OBD)] BASIC SERVICE PROCEDURE Basic Inspection PFP:00018 A BBS0049F 1. INSPECTION START 1. 2. – – – – – – 3. – – – – 4. Check service records for any recent repairs that may indicate a related malfunction, or a current need for scheduled maintenance. Open engine hood and check the following: Harness connectors for improper connections Wiring harness for improper connections, pinches and cut Vacuum hoses for splits, kinks and improper connections Hoses and ducts for leaks Air cleaner clogging Gasket Confirm that electrical or mechanical loads are not applied. Headlamp switch is OFF. SEF983U Air conditioner switch is OFF. Rear window defogger switch is OFF. Steering wheel is in the straight-ahead position, etc. Start engine and warm it up until engine coolant temperature indicator points the middle of gauge. Ensure engine stays below 1,000 rpm. EC C D E F G H I J SEF976U 5. Run engine at about 2,000 rpm for about 2 minutes under no load. 6. Make sure that no DTC is displayed with CONSULT-II or GST. OK or NG OK >> GO TO 3. NG >> GO TO 2. K L M SEF977U 2. REPAIR OR REPLACE Repair or replace components as necessary according to corresponding Diagnostic Procedure. >> GO TO 3 EC-851 BASIC SERVICE PROCEDURE [HR (WITH EURO-OBD)] 3. CHECK TARGET IDLE SPEED 1. 2. With CONSULT-II Run engine at about 2,000 rpm for about 2 minutes under no load. Rev engine (2,000 to 3,000 rpm) two or three times under no load, then run engine at idle speed for about 1 minute. PBIA8513J 3. Read idle speed in “DATA MONITOR” mode with CONSULT-II. Refer to EC-856, "IDLE SPEED" . A/T: M/T: 700 ± 50 rpm (in P or N position) 650 ± 50 rpm (in Neutral position) SEF058Y Without CONSULT-II Run engine at about 2,000 rpm for about 2 minutes under no load. Rev engine (2,000 to 3,000 rpm) two or three times under no load, then run engine at idle speed for about 1 minute. 3. Check idle speed. Refer to EC-856, "IDLE SPEED" . 1. 2. A/T: M/T: 700 ± 50 rpm (in P or N position) 650 ± 50 rpm (in Neutral position) OK or NG OK >> GO TO 10. NG >> GO TO 4. 4. PERFORM ACCELERATOR PEDAL RELEASED POSITION LEARNING 1. 2. Stop engine. Perform EC-857, "Accelerator Pedal Released Position Learning" . >> GO TO 5. 5. PERFORM THROTTLE VALVE CLOSED POSITION LEARNING Perform EC-857, "Throttle Valve Closed Position Learning" . >> GO TO 6. EC-852 BASIC SERVICE PROCEDURE [HR (WITH EURO-OBD)] 6. PERFORM IDLE AIR VOLUME LEARNING A Refer to EC-858, "Idle Air Volume Learning" . Is Idle Air Volume Learning carried out successfully? Yes or No Yes >> GO TO 7. No >> 1. Follow the instruction of Idle Air Volume Learning. 2. GO TO 4. EC C 7. CHECK TARGET IDLE SPEED AGAIN D With CONSULT-II 1. Start engine and warm it up to normal operating temperature. 2. Read idle speed in “DATA MONITOR” mode with CONSULT-II. Refer to EC-856, "IDLE SPEED" . A/T: M/T: E 700 ± 50 rpm (in P or N position) 650 ± 50 rpm (in Neutral position) F Without CONSULT-II 1. Start engine and warm it up to normal operating temperature. 2. Check idle speed. Refer to EC-856, "IDLE SPEED" . A/T: M/T: 700 ± 50 rpm (in P or N position) 650 ± 50 rpm (in Neutral position) G SEF174Y H OK or NG OK >> GO TO 10. NG >> GO TO 8. I 8. DETECT MALFUNCTIONING PART J Check the Following. ● Check camshaft position sensor (PHASE) and circuit. Refer to EC-1049, "DTC P0340 CMP SENSOR (PHASE)" . ● Check crankshaft position sensor (POS) and circuit. Refer to EC-1042, "DTC P0335 CKP SENSOR (POS)" . OK or NG OK >> GO TO 9. NG >> 1. Repair or replace. 2. GO TO 4. 9. CHECK ECM FUNCTION 1. 2. Substitute another known-good ECM to check ECM function. (ECM may be the cause of an incident, but this is a rare case.) Perform initialization of NATS system and registration of all NATS ignition key IDs. Refer to BL-218, "ECM Re-communicating Function" . >> GO TO 4. EC-853 K L M BASIC SERVICE PROCEDURE [HR (WITH EURO-OBD)] 10. CHECK IGNITION TIMING 1. 2. – Run engine at idle. Check ignition timing with a timing light. Refer to EC-856, "IGNITION TIMING" . Timing indicator (1) A/T: M/T: 6 ± 5° BTDC (in P or N position) 6 ± 5° BTDC (in Neutral position) OK or NG OK >> INSPECTION END NG >> GO TO 11. MBIB1331E 11. PERFORM ACCELERATOR PEDAL RELEASED POSITION LEARNING 1. 2. Stop engine. Perform EC-857, "Accelerator Pedal Released Position Learning" . >> GO TO 12. 12. PERFORM THROTTLE VALVE CLOSED POSITION LEARNING Perform EC-857, "Throttle Valve Closed Position Learning" . >> GO TO 13. 13. PERFORM IDLE AIR VOLUME LEARNING Refer to EC-858, "Idle Air Volume Learning" . Is Idle Air Volume Learning carried out successfully? Yes or No Yes >> GO TO 14. No >> 1. Follow the instruction of Idle Air Volume Learning. 2. GO TO 4. 14. CHECK TARGET IDLE SPEED AGAIN With CONSULT-II 1. Start engine and warm it up to normal operating temperature. 2. Read idle speed in “DATA MONITOR” mode with CONSULT-II. Refer to EC-856, "IDLE SPEED" . A/T: M/T: 700 ± 50 rpm (in P or N position) 650 ± 50 rpm (in Neutral position) Without CONSULT-II 1. Start engine and warm it up to normal operating temperature. 2. Check idle speed. Refer to EC-856, "IDLE SPEED" . A/T: M/T: 700 ± 50 rpm (in P or N position) 650 ± 50 rpm (in Neutral position) OK or NG OK >> GO TO 15. NG >> GO TO 17. EC-854 SEF174Y BASIC SERVICE PROCEDURE [HR (WITH EURO-OBD)] 15. CHECK IGNITION TIMING AGAIN 1. 2. – A Run engine at idle. Check ignition timing with a timing light. Refer to EC-856, "IGNITION TIMING" . Timing indicator (1) A/T: M/T: EC 6 ± 5° BTDC (in P or N position) 6 ± 5° BTDC (in Neutral position) C OK or NG OK >> INSPECTION END NG >> GO TO 16. D MBIB1331E E 16. CHECK TIMING CHAIN INSTALLATION Check timing chain installation. Refer to EM-142, "TIMING CHAIN" . OK or NG OK >> GO TO 17. NG >> 1. Repair the timing chain installation. 2. GO TO 4. 17. DETECT MALFUNCTIONING PART F G H Check the following. ● Check camshaft position sensor (PHASE) and circuit. Refer to EC-1049, "DTC P0340 CMP SENSOR (PHASE)" . ● Check crankshaft position sensor (POS) and circuit. Refer to EC-1042, "DTC P0335 CKP SENSOR (POS)" . OK or NG OK >> GO TO 18. NG >> 1. Repair or replace. 2. GO TO 4. I J K 18. CHECK ECM FUNCTION 1. 2. Substitute another known-good ECM to check ECM function. (ECM may be the cause of an incident, but this is a rare case.) Perform initialization of NATS system and registration of all NATS ignition key IDs. Refer to BL-218, "ECM Re-communicating Function" . >> GO TO 4. EC-855 L M BASIC SERVICE PROCEDURE [HR (WITH EURO-OBD)] Idle Speed and Ignition Timing Check BBS0049G IDLE SPEED With CONSULT-II Check idle speed in “DATA MONITOR” mode with CONSULT-II. SEF058Y With GST Check idle speed with GST. IGNITION TIMING Any of following two methods may be used. Method A 1. Attach timing light A to loop wire (1) as shown. ● : Vehicle front PBIB2955E 2. Check ignition timing. ● Timing indicator (1) MBIB1331E Method B 1. Remove ignition coil No. 4 (1). ● : Vehicle front MBIB1457E EC-856 BASIC SERVICE PROCEDURE [HR (WITH EURO-OBD)] 2. Connect ignition coil No. 4 (1) and spark plug No. 4 with suitable high-tension wire A as shown, and attach timing light clamp B to this wire. A EC C MBIB1541E D E F G SEF166Y 3. Check ignition timing. ● Timing indicator (1) H I J MBIB1331E Accelerator Pedal Released Position Learning BBS0049H DESCRIPTION Accelerator Pedal Released Position Learning is an operation to learn the fully released position of the accelerator pedal by monitoring the accelerator pedal position sensor output signal. It must be performed each time harness connector of accelerator pedal position sensor or ECM is disconnected. Make sure that accelerator pedal is fully released. Turn ignition switch ON and wait at least 2 seconds. Turn ignition switch OFF and wait at least 10 seconds. Turn ignition switch ON and wait at least 2 seconds. Turn ignition switch OFF and wait at least 10 seconds. Throttle Valve Closed Position Learning BBS0049I DESCRIPTION Throttle Valve Closed Position Learning is an operation to learn the fully closed position of the throttle valve by monitoring the throttle position sensor output signal. It must be performed each time harness connector of electric throttle control actuator or ECM is disconnected. OPERATION PROCEDURE 1. 2. 3. L M OPERATION PROCEDURE 1. 2. 3. 4. 5. K Make sure that accelerator pedal is fully released. Turn ignition switch ON. Turn ignition switch OFF and wait at least 10 seconds. EC-857 BASIC SERVICE PROCEDURE [HR (WITH EURO-OBD)] Make sure that throttle valve moves during above 10 seconds by confirming the operating sound. Idle Air Volume Learning BBS0049J DESCRIPTION Idle Air Volume Learning is an operation to learn the idle air volume that keeps each engine within the specific range. It must be performed under any of the following conditions: ● Each time electric throttle control actuator or ECM is replaced. ● Idle speed or ignition timing is out of specification. PREPARATION Before performing Idle Air Volume Learning, make sure that all of the following conditions are satisfied. Learning will be cancelled if any of the following conditions are missed for even a moment. ● Battery voltage: More than 12.9V (At idle) ● Engine coolant temperature: 70 - 95°C (158 - 203°F) ● PNP switch: ON ● Electric load switch: OFF (Air conditioner, headlamp, rear window defogger) On vehicles equipped with daytime light systems, set lighting switch to the 1st position to light only small lamps. ● Steering wheel: Neutral (Straight-ahead position) ● Vehicle speed: Stopped ● Transmission: Warmed-up – A/T models • With CONSULT-II: Drive vehicle until “FLUID TEMP SE” in “DATA MONITOR” mode of “A/T” system indicates less than 0.9V. • Without CONSULT-II: Drive vehicle for 10 minutes. – M/T models • Drive vehicle for 10 minutes. OPERATION PROCEDURE With CONSULT-II 1. 2. 3. 4. 5. Perform EC-857, "Accelerator Pedal Released Position Learning" . Perform EC-857, "Throttle Valve Closed Position Learning" . Start engine and warm it up to normal operating temperature. Check that all items listed under the topic PREPARATION (previously mentioned) are in good order. Select “IDLE AIR VOL LEARN” in “WORK SUPPORT” mode. SEF217Z EC-858 BASIC SERVICE PROCEDURE [HR (WITH EURO-OBD)] 6. Touch “START” and wait 20 seconds. A EC C SEF454Y D 7. 8. Make sure that “CMPLT” is displayed on CONSULT-II screen. If “CMPLT” is not displayed, Idle Air Volume Learning will not be carried out successfully. In this case, find the cause of the incident by referring to the DIAGNOSTIC PROCEDURE below. Rev up the engine two or three times and make sure that idle speed and ignition timing are within the specifications. ITEM SPECIFICATION Idle speed A/T: 700 ± 50 rpm (in P or N position) M/T: 650 ± 50 rpm (in Neutral position) Ignition timing A/T: 6 ± 5° BTDC (in P or N position) M/T: 6 ± 5° BTDC (in Neutral position) E F G MBIB0238E H Without CONSULT-II NOTE: ● It is better to count the time accurately with a clock. ● It is impossible to switch the diagnostic mode when an accelerator pedal position sensor circuit has a malfunction. 1. Perform EC-857, "Accelerator Pedal Released Position Learning" . 2. Perform EC-857, "Throttle Valve Closed Position Learning" . 3. Start engine and warm it up to normal operating temperature. 4. Check that all items listed under the topic PREPARATION (previously mentioned) are in good order. 5. Turn ignition switch OFF and wait at least 10 seconds. 6. Confirm that accelerator pedal is fully released, turn ignition switch ON and wait 3 seconds. 7. Repeat the following procedure quickly five times within 5 seconds. a. Fully depress the accelerator pedal. b. Fully release the accelerator pedal. 8. Wait 7 seconds, fully depress the accelerator pedal and keep it for approx. 20 seconds until the MI stops blinking and turned ON. 9. Fully release the accelerator pedal within 3 seconds after the MI turned ON. 10. Start engine and let it idle. 11. Wait 20 seconds. PBIB0665E EC-859 I J K L M BASIC SERVICE PROCEDURE [HR (WITH EURO-OBD)] 12. Rev up the engine two or three times and make sure that idle speed and ignition timing are within the specifications. ITEM SPECIFICATION Idle speed A/T: 700 ± 50 rpm (in P or N position) M/T: 650 ± 50 rpm (in Neutral position) Ignition timing A/T: 6 ± 5° BTDC (in P or N position) M/T: 6 ± 5° BTDC (in Neutral position) 13. If idle speed and ignition timing are not within the specification, Idle Air Volume Learning will not be carried out successfully. In this case, find the cause of the incident by referring to the Diagnostic Procedure below. DIAGNOSTIC PROCEDURE If idle air volume learning cannot be performed successfully, proceed as follows: 1. Check that throttle valve is fully closed. 2. Check PCV valve operation. 3. Check that downstream of throttle valve is free from air leakage. 4. When the above three items check out OK, engine component parts and their installation condition are questionable. Check and eliminate the cause of the incident. It is useful to perform EC-1237, "SERVICE DATA AND SPECIFICATIONS (SDS)" . 5. If any of the following conditions occur after the engine has started, eliminate the cause of the incident and perform Idle Air Volume Learning all over again: ● Engine stalls. ● Erroneous idle. Fuel Pressure Check BBS0049K FUEL PRESSURE RELEASE With CONSULT-II 1. 2. 3. 4. 5. Turn ignition switch ON. Perform “FUEL PRESSURE RELEASE” in “WORK SUPPORT” mode with CONSULT-II. Start engine. After engine stalls, crank it two or three times to release all fuel pressure. Turn ignition switch OFF. SEF214Y Without CONSULT-II 1. 2. 3. 4. 5. Remove fuel pump fuse located in IPDM E/R. Start engine. After engine stalls, crank it 2 or 3 times to release all fuel pressure. Turn ignition switch OFF. Reinstall fuel pump fuse after servicing fuel system. MBIB0277E FUEL PRESSURE CHECK CAUTION: ● Before disconnecting fuel line, release fuel pressure from fuel line to eliminate danger. ● The fuel hose connection method used when taking fuel pressure check must not be used for other purposes. EC-860 BASIC SERVICE PROCEDURE [HR (WITH EURO-OBD)] Be careful not to scratch or put debris around connection area when servicing, so that the quick connector maintains sealability with O-rings inside. A ● Do not perform fuel pressure check with electrical systems operating (i.e. lights, rear defogger, A/ C, etc.) Fuel pressure gauge may indicate false readings due to varying engine load and changes in manifold vacuum. EC NOTE: Prepare pans or saucers under the disconnected fuel line because the fuel may spill out. The fuel pressure cannot be completely released because E11 models do not have fuel return system. C 1. Release fuel pressure to zero. Refer to EC-860, "FUEL PRESSURE RELEASE" . 2. Prepare fuel hose for fuel pressure check B and fuel tube adapter (KV10118400) D, then connect fuel pressure gauge A. D ● : To quick connector ● : To fuel tube (engine side) C: Clamp ● Use suitable fuel hose for fuel pressure check (genuine NISSAN fuel hose without quick connector). ● To avoid unnecessary force or tension to hose, use moderately long fuel hose for fuel pressure check. ● Do not use the fuel hose for checking fuel pressure with damage or cracks on it. ● Use Pressure Gauge to check fuel pressure. Remove fuel hose. Refer to EM-120, "INTAKE MANIFOLD" . ● Do not twist or kink fuel hose because it is plastic hose. Connect fuel hose for fuel pressure check (1) to fuel tube (engine side) with clamp (2) as shown in the figure. ● No.2 spool (5) ● Wipe off oil or dirt from hose insertion part using cloth moistened with gasoline. ● Apply proper amount of gasoline between top of the fuel tube (3) and No.1 spool (4). ● Insert fuel hose for fuel pressure check until it touches the No.1 spool on fuel tube. ● Use NISSAN genuine hose clamp (part number: 16439 N4710 or 16439 40U00). ● When reconnecting fuel line, always use new clamps. ● Use a torque driver to tighten clamps. ● Install hose clamp to the position within 1 - 2 mm (0.04 - 0.08 in). ● E ● 3. 4. Tightening torque: 5. 6. 7. 8. 9. F PBIB2982E G H I J K PBIB2983E L M 1 - 1.5 N·m (0.1 - 0.15 kg-m, 9 - 13 in-lb) ● Make sure that clamp screw does not contact adjacent parts. Connect fuel tube adapter to quick connector. ● A: Fuel pressure gauge ● B: Fuel hose for fuel pressure check After connecting fuel hose for fuel pressure check, pull the hose with a force of approximately 98 N (10 kg, 22 lb) to confirm fuel tube does not come off. Turn ignition switch ON and check for fuel leakage. Start engine and check for fuel leakage. Read the indication of fuel pressure gauge. ● Do not perform fuel pressure check with system operating. Fuel pressure gauge may indicate false readings. ● During fuel pressure check, confirm for fuel leakage from fuel connection every 3 minutes. EC-861 PBIB2984E BASIC SERVICE PROCEDURE [HR (WITH EURO-OBD)] At idling: Approximately 350 kPa (3.5 bar, 3.57 kg/cm2 , 51 psi) 10. If result is unsatisfactory, go to next step. 11. Check the following. ● Fuel hoses and fuel tubes for clogging ● Fuel filter for clogging ● Fuel pump ● Fuel pressure regulator for clogging If OK, replace fuel pressure regulator. If NG, repair or replace. EC-862 TROUBLE DIAGNOSIS [HR (WITH EURO-OBD)] TROUBLE DIAGNOSIS Trouble Diagnosis Introduction PFP:00004 A BBS0049L INTRODUCTION The engine has an ECM to control major systems such as fuel control, ignition control, idle air control system, etc. The ECM accepts input signals from sensors and instantly drives actuators. It is essential that both input and output signals are proper and stable. At the same time, it is important that there are no malfunctions such as vacuum leaks, fouled spark plugs, or other malfunctions with the engine. EC C D MEF036D It is much more difficult to diagnose an incident that occurs intermittently rather than continuously. Most intermittent incidents are caused by poor electric connections or improper wiring. In this case, careful checking of suspected circuits may help prevent the replacement of good parts. E F G H SEF233G I A visual check only may not find the cause of the incidents. A road test with CONSULT-II (or GST) or a circuit tester connected should be performed. Follow the Work Flow on EC-864, "WORK FLOW" . Before undertaking actual checks, take a few minutes to talk with a customer who approaches with a driveability complaint. The customer can supply good information about such incidents, especially intermittent ones. Find out what symptoms are present and under what conditions they occur. A Diagnostic Worksheet like the example on EC-868, "Worksheet Sample" should be used. Start your diagnosis by looking for conventional malfunctions first. This will help troubleshoot driveability malfunctions on an electronically controlled engine vehicle. J K L SEF234G M EC-863 TROUBLE DIAGNOSIS [HR (WITH EURO-OBD)] WORK FLOW Overall Sequence PBIB2267E EC-864 TROUBLE DIAGNOSIS [HR (WITH EURO-OBD)] Detailed Flow A 1. GET INFORMATION FOR SYMPTOM Get the detailed information from the customer about the symptom (the condition and the environment when EC the incident/malfunction occurred) using the EC-867, "DIAGNOSTIC WORKSHEET" . >> GO TO 2. C 2. CHECK DTC*1 1. Check DTC*1 . 2. Perform the following procedure if DTC*1 is displayed. – Record DTC*1 and freeze frame data*2 . (Print them out with CONSULT-II or GST.) – D Erase DTC*1 . (Refer to EC-841, "HOW TO ERASE EMISSION-RELATED DIAGNOSTIC INFORMATION" .) Study the relationship between the cause detected by DTC*1 and the symptom described by the customer. (Symptom Matrix Chart is useful. Refer to EC-871, "Symptom Matrix Chart" .) 3. Check related service bulletins for information. Is any symptom described and any DTC detected? – Symptom is described, DTC*1 is displayed>>GO TO 3. Symptom is described, DTC*1 is not displayed>>GO TO 4. Symptom is not described, DTC*1 is displayed>>GO TO 5. E F G H 3. CONFIRM THE SYMPTOM I Try to confirm the symptom described by the customer (except MI ON). DIAGNOSIS WORK SHEET is useful to verify the incident. Connect CONSULT-II to the vehicle in “DATA MONITOR (AUTO TRIG)” mode and check real time diagnosis results. Verify relation between the symptom and the condition when the symptom is detected. J K >> GO TO 5. 4. CONFIRM THE SYMPTOM L Try to confirm the symptom described by the customer. DIAGNOSIS WORK SHEET is useful to verify the incident. Connect CONSULT-II to the vehicle in “DATA MONITOR (AUTO TRIG)” mode and check real time diagnosis results. Verify relation between the symptom and the condition when the symptom is detected. >> GO TO 6. EC-865 M TROUBLE DIAGNOSIS [HR (WITH EURO-OBD)] 5. PERFORM DTC CONFIRMATION PROCEDURE Perform DTC Confirmation Procedure for the displayed DTC*1 , and then make sure that DTC*1 is detected again. At this time, always connect CONSULT-II to the vehicle, and check diagnostic results in real time on “DATA MONITOR (AUTO TRIG)”. If two or more DTCs*1 are detected, refer to EC-869, "DTC Inspection Priority Chart" and determine trouble diagnosis order. NOTE: ● Freeze frame data*2 is useful if the DTC*1 is not detected. ● Perform Overall Function Check if DTC Confirmation Procedure is not included on Service Manual. This simplified check procedure is an effective alternative though DTC*1 cannot be detected during this check. If the result of Overall Function Check is NG, it is the same as the detection of DTC*1 by DTC Confirmation Procedure. Is DTC*1 detected? Yes >> GO TO 10. No >> Check according to EC-917, "TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT" . 6. PERFORM BASIC INSPECTION Perform EC-851, "Basic Inspection" . With CONSULT-II>>GO TO 7. Without CONSULT-II>>GO TO 9. 7. PERFORM DATA MONITOR (SPEC) MODE With CONSULT-II Make sure that “MAS A/F SE-B1”, “B/FUEL SCHDL”, and “A/F ALPHA-B1” are within the SP value using CONSULT-II “DATA MONITOR (SPEC)” mode. Refer to EC-907, "Inspection Procedure" . Are they within the SP value? Yes >> GO TO 9. No >> GO TO 8. SEF601Z 8. DETECT MALFUNCTIONING PART BY TROUBLE DIAGNOSIS - SPECIFICATION VALUE Detect malfunctioning part according to EC-908, "Diagnostic Procedure" . Is malfunctioning part detected? Yes >> GO TO 11. No >> GO TO 9. 9. DETECT MALFUNCTIONING SYSTEM BY SYMPTOM MATRIX CHART Detect malfunctioning system according to EC-871, "Symptom Matrix Chart" based on the confirmed symptom in step 4, and determine the trouble diagnosis order based on possible causes and symptom. >> GO TO 10. EC-866 TROUBLE DIAGNOSIS [HR (WITH EURO-OBD)] 10. DETECT MALFUNCTIONING PART BY DIAGNOSTIC PROCEDURE A Inspect according to Diagnostic Procedure of the system. NOTE: The Diagnostic Procedure in EC section described based on open circuit inspection. A short circuit inspection EC is also required for the circuit check in the Diagnostic Procedure. For details, refer to Circuit Inspection in GI25, "How to Perform Efficient Diagnosis for an Electrical Incident" . Is malfunctioning part detected? C Yes >> GO TO 11. No >> Monitor input data from related sensors or check voltage of related ECM terminals using CONSULT-II. Refer to EC-883, "ECM Terminals and Reference Value" , EC-902, "CONSULT-II Refer- D ence Value in Data Monitor" . 11. REPAIR OR REPLACE THE MALFUNCTIONING PART 1. 2. 3. E Repair or replace the malfunctioning part. Reconnect parts or connectors disconnected during Diagnostic Procedure again after repair and replacement. Check DTC. If DTC is displayed, erase it, refer to EC-841, "HOW TO ERASE EMISSION-RELATED DIAGNOSTIC INFORMATION" . F G >> GO TO 12. 12. FINAL CHECK H When DTC was detected in step 2, perform DTC Confirmation Procedure or Overall Function Check again, and then make sure that the malfunction have been repaired securely. When symptom was described from the customer, refer to confirmed symptom in step 3 or 4, and make sure that the symptom is not detected. OK or NG I NG (DTC*1 is detected)>>GO TO 10. NG (Symptom remains)>>GO TO 6. OK >> 1. Before returning the vehicle to the customer, make sure to erase unnecessary DTC*1 in ECM and TCM (Transmission Control Module). (Refer to EC-841, "HOW TO ERASE EMISSIONRELATED DIAGNOSTIC INFORMATION" and AT-98, "OBD Diagnostic Trouble Code (DTC)" .) 2. If the completion of SRT is needed, drive vehicle under the specific driving pattern. Refer to EC839, "Driving Pattern" . 3. INSPECTION END *1: Include 1st trip DTC. *2: Include 1st trip freeze frame data. DIAGNOSTIC WORKSHEET Description There are many operating conditions that lead to the malfunction of engine components. A good grasp of such conditions can make troubleshooting faster and more accurate. In general, each customer feels differently about a incident. It is important to fully understand the symptoms or conditions for a customer complaint. Utilize a diagnostic worksheet like the one on the next page in order to organize all the information for troubleshooting. Some conditions may cause the MI to come on steady or blink and DTC to be detected. Examples: ● Vehicle ran out of fuel, which caused the engine to misfire. EC-867 SEF907L J K L M TROUBLE DIAGNOSIS [HR (WITH EURO-OBD)] Worksheet Sample MTBL0017 EC-868 TROUBLE DIAGNOSIS [HR (WITH EURO-OBD)] DTC Inspection Priority Chart BBS0049M A If some DTCs are displayed at the same time, perform inspections one by one based on the following priority chart. NOTE: ● If DTC U1000 or U1001 is displayed with other DTC, first perform the trouble diagnosis for DTC EC U1000, U1001. Refer to EC-925, "DTC U1000, U1001 CAN COMMUNICATION LINE" . ● If DTC U1010 is displayed with other DTC, first perform the trouble diagnosis for DTC U1010. Refer C to EC-928, "DTC U1010 CAN COMMUNICATION" . Priority 1 2 3 Detected items (DTC) ● U1000 U1001 CAN communication line ● U1010 CAN communication ● P0102 P0103 Mass air flow sensor ● P0112 P0113 Intake air temperature sensor ● P0117 P0118 Engine coolant temperature sensor ● P0122 P0123 P0222 P0223 P1225 P1226 P2135 Throttle position sensor ● P0327 P0328 Knock sensor ● P0335 Crankshaft position sensor (POS) ● P0340 Camshaft position sensor (PHASE) ● P0500 Vehicle speed sensor ● P0605 ECM ● P0705 Park/Neutral position (PNP) switch ● P1229 Sensor power supply ● P1610 - P1615 NATS ● P1706 Park/Neutral position (PNP) switch ● P2122 P2123 P2127 P2128 P2138 Accelerator pedal position sensor ● P0132 P0133 P0134 P1143 P1144 Heated oxygen sensor 1 ● P0135 Heated oxygen sensor 1 heater ● P0138 P0139 P1146 P1147 Heated oxygen sensor 2 ● P0141 Heated oxygen sensor 2 heater ● P0444 EVAP canister purge volume control solenoid valve ● P0710 P0720 P0725 P0731 P0732 P0733 P0734 P0740 P0744 P0745 P0750 P0755 P1705 P1760 A/T related sensors, solenoid valves and switches ● P1065 ECM ● P1111 Intake valve timing control solenoid valve ● P1122 Electric throttle control function ● P1124 P1126 Throttle control motor relay ● P1128 Throttle control motor ● P1217 Engine over temperature (OVERHEAT) ● P1805 Brake switch ● P0011 Intake valve timing control ● P0171 P0172 Fuel injection system function ● P0300 - P0304 Misfire ● P0420 Three way catalyst function ● P1121 Electric throttle control actuator ● P1212 ESP communication line D E F G H I J K L M EC-869 TROUBLE DIAGNOSIS [HR (WITH EURO-OBD)] Fail-Safe Chart BBS0049N When the DTC listed below is detected, the ECM enters fail-safe mode and the MI lights up. DTC No. Detected items Engine operating condition in fail-safe mode P0102 P0103 Mass air flow sensor circuit Engine speed will not rise more than 2,400 rpm due to the fuel cut. P0117 P0118 Engine coolant temperature sensor circuit Engine coolant temperature will be determined by ECM based on the time after turning ignition switch ON or START. CONSULT-II displays the engine coolant temperature decided by ECM. Condition Engine coolant temperature decided (CONSULTII display) Just as ignition switch is turned ON or START 40°C (104°F) More than approx. 4 minutes after ignition ON or START 80°C (176°F) Except as shown above 40 - 80°C (104 - 176°F) (Depends on the time) When the fail-safe system for engine coolant temperature sensor is activated, the cooling fan operates while engine is running. P0122 P0123 P0222 P0223 P2135 Throttle position sensor The ECM controls the electric throttle control actuator in regulating the throttle opening in order for the idle position to be within +10 degrees. The ECM regulates the opening speed of the throttle valve to be slower than the normal condition. So, the acceleration will be poor. P1121 Electric throttle control actuator (When electric throttle control actuator does not function properly due to the return spring malfunction:) ECM controls the electric throttle actuator by regulating the throttle opening around the idle position. The engine speed will not rise more than 2,000 rpm. (When throttle valve opening angle in fail-safe mode is not in specified range:) ECM controls the electric throttle control actuator by regulating the throttle opening to 20 degrees or less. (When ECM detects the throttle valve is stuck open:) While the vehicle is driving, it slows down gradually by fuel cut. After the vehicle stops, the engine stalls. The engine can restart in N or P (A/T), Neutral (M/T) position, and engine speed will not exceed 1,000 rpm or more. ● P1122 Electric throttle control function ECM stops the electric throttle control actuator control, throttle valve is maintained at a fixed opening (approx. 5 degrees) by the return spring. P1124 P1126 Throttle control relay ECM stops the electric throttle control actuator control, throttle valve is maintained at a fixed opening (approx. 5 degrees) by the return spring. P1128 Throttle control motor ECM stops the electric throttle control actuator control, throttle valve is maintained at a fixed opening (approx. 5 degrees) by the return spring. P1229 Sensor power supply ECM stops the electric throttle control actuator control, throttle valve is maintained at a fixed opening (approx. 5 degrees) by the return spring. P2122 P2123 P2127 P2128 P2138 Accelerator pedal position sensor The ECM controls the electric throttle control actuator in regulating the throttle opening in order for the idle position to be within +10 degrees. The ECM regulates the opening speed of the throttle valve to be slower than the normal condition. So, the acceleration will be poor. When there is an open circuit on MI circuit, the ECM cannot warn the driver by lighting up MI when there is malfunction on engine control system. Therefore, when electrical controlled throttle and part of ECM related diagnoses are continuously detected as NG for 5 trips, ECM warns the driver that engine control system malfunctions and MI circuit is open by means of operating fail-safe function. The fail-safe function also operates when above diagnoses except MI circuit are detected and demands the driver to repair the malfunction. Engine operating condition in fail-safe mode Engine speed will not rise more than 2,500 rpm due to the fuel cut EC-870 TROUBLE DIAGNOSIS [HR (WITH EURO-OBD)] Symptom Matrix Chart BBS0049O A SYSTEM — BASIC ENGINE CONTROL SYSTEM 1 1 2 3 2 Fuel pressure regulator system 3 3 4 4 4 Fuel injector circuit 1 1 2 3 2 Evaporative emission system 3 3 4 4 4 Air Positive crankcase ventilation system 4 4 4 3 3 Incorrect idle speed adjustment Ignition BATTERY DEAD (UNDER CHARGE) Fuel pump circuit EXCESSIVE OIL CONSUMPTION Fuel EXCESSIVE FUEL CONSUMPTION AE OVERHEATS/WATER TEMPERATURE HIGH LACK OF POWER/POOR ACCELERATION AD SLOW/NO RETURN TO IDLE SPARK KNOCK/DETONATION AC IDLING VIBRATION HESITATION/SURGING/FLAT SPOT AB ROUGH IDLE/HUNTING ENGINE STALL AA Warranty symptom code HIGH IDLE/LOW IDLE HARD/NO START/RESTART (EXCP. HA) SYMPTOM AF AG AH AJ AK AL AM HA 2 2 4 4 2 2 4 4 4 4 4 1 2 4 EC 3 4 2 C Reference page E F EC-1215 4 EC-860 2 EC-1209 4 4 EC-823 4 4 4 1 1 1 1 2 2 2 2 1 EC-851 1 2 3 3 Incorrect ignition timing adjustment 3 3 1 1 1 1 1 1 EC-851 Ignition circuit 1 1 2 2 2 2 2 2 EC-1221 2 2 3 3 3 3 3 3 EC-918 Engine coolant temperature sensor circuit 2 2 3 3 Heated oxygen sensor 1 circuit 2 2 2 2 2 3 Knock sensor circuit 2 EC-959, EC-967 , EC-977 , EC-1101 , EC-1107 EC-953, EC-1026 , EC-1146 , EC-1148 , EC-1191 Throttle position sensor circuit Accelerator pedal position sensor circuit 2 EC-1150, EC-1172 , EC-1181 , EC-1197 1 2 3 EC-1038 Crankshaft position sensor (POS) circuit 2 2 EC-1042 Camshaft position sensor (PHASE) circuit 3 2 EC-1049 Vehicle speed signal circuit ECM 2 2 3 2 3 3 3 J K EC-947 3 2 2 I EC-935 1 1 H EC-1082, EC-1084 1 Mass air flow sensor circuit G EC-828 Electric throttle control actuator Main power supply and ground circuit D 3 EC-871 3 3 3 3 3 3 EC-1070 3 EC-1072, EC-1075 L M TROUBLE DIAGNOSIS [HR (WITH EURO-OBD)] LACK OF POWER/POOR ACCELERATION HIGH IDLE/LOW IDLE ROUGH IDLE/HUNTING IDLING VIBRATION SLOW/NO RETURN TO IDLE OVERHEATS/WATER TEMPERATURE HIGH EXCESSIVE FUEL CONSUMPTION EXCESSIVE OIL CONSUMPTION BATTERY DEAD (UNDER CHARGE) AF AG AH AJ AK AL AM HA 2 1 3 2 2 3 3 3 3 3 HESITATION/SURGING/FLAT SPOT AE ENGINE STALL AD HARD/NO START/RESTART (EXCP. HA) Warranty symptom code SPARK KNOCK/DETONATION SYMPTOM AA AB AC 3 Intake valve timing control solenoid valve circuit PNP switch circuit Refrigerant pressure sensor circuit 2 3 Electrical load signal circuit 3 3 EC-1077 3 EC-1158 4 EC-1231 3 Air conditioner circuit 2 2 ABS actuator and electric unit (control unit) 3 3 3 3 3 Reference page EC-1207 3 3 3 2 ATC-20, MTC-20 BRC-8 or BRC-49 4 1 - 6: The numbers refer to the order of inspection. (continued on next page) SYSTEM — ENGINE MECHANICAL & OTHER Fuel ENGINE STALL HESITATION/SURGING/FLAT SPOT SPARK KNOCK/DETONATION LACK OF POWER/POOR ACCELERATION HIGH IDLE/LOW IDLE ROUGH IDLE/HUNTING IDLING VIBRATION SLOW/NO RETURN TO IDLE OVERHEATS/WATER TEMPERATURE HIGH EXCESSIVE FUEL CONSUMPTION EXCESSIVE OIL CONSUMPTION BATTERY DEAD (UNDER CHARGE) Warranty symptom code HARD/NO START/RESTART (EXCP. HA) SYMPTOM AA AB AC AD AE AF AG AH AJ AK AL AM HA Fuel tank Fuel piping FL-19 5 Vapor lock 5 5 5 5 5 5 FL-14 — 5 Valve deposit Poor fuel (Heavy weight gasoline, Low octane) Reference page — 5 5 5 5 5 5 5 — EC-872 TROUBLE DIAGNOSIS [HR (WITH EURO-OBD)] SYMPTOM Air HARD/NO START/RESTART (EXCP. HA) ENGINE STALL HESITATION/SURGING/FLAT SPOT SPARK KNOCK/DETONATION LACK OF POWER/POOR ACCELERATION HIGH IDLE/LOW IDLE ROUGH IDLE/HUNTING IDLING VIBRATION SLOW/NO RETURN TO IDLE OVERHEATS/WATER TEMPERATURE HIGH EXCESSIVE FUEL CONSUMPTION EXCESSIVE OIL CONSUMPTION BATTERY DEAD (UNDER CHARGE) Warranty symptom code A AA AB AC AD AE AF AG AH AJ AK AL AM HA E Air cleaner EM-118 5 5 5 5 5 5 5 5 EM-118 5 5 EM-120 Air leakage from intake manifold/ Collector/Gasket SC-5 1 Starter circuit 3 Signal plate 6 PNP switch 4 Cylinder head 5 1 1 1 1 1 1 5 5 5 5 5 5 5 4 EM-189 J AT-105, MT-16 , MT-46 K EM-173 L 4 6 6 6 6 6 6 6 6 EM-189 Connecting rod Bearing Crankshaft Timing chain EM-142 Camshaft EM-151 5 5 5 5 5 5 5 EM-142 5 Intake valve 3 EM-173 Exhaust valve Exhaust Exhaust manifold/Tube/Muffler/ Gasket 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 Three way catalyst Lubrication Oil pan/Oil strainer/Oil pump/Oil filter/Oil gallery I 3 Piston Intake valve timing control H SC-15 Cylinder block Valve mechanism G SC-45 1 Cylinder head gasket Piston ring F EM-120 Battery Generator circuit C D EM-118 Electric throttle control actuator Engine Reference page Air duct Air leakage from air duct (Mass air flow sensor — electric throttle control actuator) Cranking EC Oil level (Low)/Filthy oil EM-124, EX-3 EM-127, LU-19 LU-16 EC-873 M TROUBLE DIAGNOSIS [HR (WITH EURO-OBD)] Cooling ENGINE STALL HESITATION/SURGING/FLAT SPOT SPARK KNOCK/DETONATION LACK OF POWER/POOR ACCELERATION HIGH IDLE/LOW IDLE ROUGH IDLE/HUNTING IDLING VIBRATION SLOW/NO RETURN TO IDLE OVERHEATS/WATER TEMPERATURE HIGH EXCESSIVE FUEL CONSUMPTION EXCESSIVE OIL CONSUMPTION BATTERY DEAD (UNDER CHARGE) Warranty symptom code HARD/NO START/RESTART (EXCP. HA) SYMPTOM AA AB AC AD AE AF AG AH AJ AK AL AM HA Radiator/Hose/Radiator filler cap CO-31 Thermostat 5 CO-38 Water pump Water gallery CO-36 5 5 5 5 5 5 5 4 Cooling fan 5 CO-26 CO-33 5 Coolant level (Low)/Contaminated coolant NATS (Nissan Anti-Theft System) Reference page CO-27 1 1 BL-215 1 - 6: The numbers refer to the order of inspection. EC-874 TROUBLE DIAGNOSIS [HR (WITH EURO-OBD)] Engine Control Component Parts Location BBS0049P A EC C D E F G H I J MBIB1542E 1. Ignition coil (with power transistor) and spark plug 2. Intake valve timing control solenoid valve 3. Refrigerant pressure sensor 4. Knock sensor 5. Fuel injector 6. Cooling fan motor 7. Camshaft position sensor (PHASE) ECM 10. Mass air flow sensor (with intake air temperature sensor) K 8. IPDM E/R 9. 11. Engine coolant temperature sensor 12. Electric throttle control actuator (with built-in throttle position sensor, throttle control motor) 13. EVAP canister purge volume control solenoid valve L M EC-875 TROUBLE DIAGNOSIS [HR (WITH EURO-OBD)] PBIB2940E : Vehicle front 1. Mass air flow sensor (with intake air temperature sensor) 2. Engine coolant temperature sensor 3. Electric throttle control actuator 4. Camshaft position sensor (PHASE) 5. Ignition coil (with power transistor) 6. Fuel injector 7. EVAP canister purge volume control solenoid valve EC-876 TROUBLE DIAGNOSIS [HR (WITH EURO-OBD)] A EC C D E F G H I J K L M MBIB1543E : Vehicle front 1. ECM harness connectors 2. ECM 3. IPDM E/R 4. Fuel pump fuse (15A) 5. Intake valve timing control solenoid valve 6. Knock sensor 7. Refrigerant pressure sensor 8. PCV valve EC-877 TROUBLE DIAGNOSIS [HR (WITH EURO-OBD)] PBIB2942E PBIB2943E : Vehicle front 1. Exhaust manifold 4. Heated oxygen sensor 2 harness connector 2. Heated oxygen sensor 1 EC-878 3. Heated oxygen sensor 2 TROUBLE DIAGNOSIS [HR (WITH EURO-OBD)] A EC C D E F G H I J K L M MBIB1544E 1. Cooling fan motor 2. Crankshaft position sensor (POS) 3. Stop lamp switch 4. Brake pedal 5. Accelerator pedal position sensor harness connector 6. Accelerator pedal position sensor 7. Accelerator pedal 8. Fuel level sensor unit and fuel pump harness connector 9. Fuel pump and fuel filter 10. Fuel pressure regulator 11. Fuel level sensor unit EC-879 TROUBLE DIAGNOSIS [HR (WITH EURO-OBD)] Vacuum Hose Drawing BBS0049Q PBIB2946E : Vehicle front 1. Intake manifold : To EVAP canister 2. EVAP canister purge volume control solenoid valve 3. EVAP purge resonator NOTE: Do not use soapy water or any type of solvent while installing vacuum hoses or purge hoses. Refer to EC-816, "System Diagram" for Vacuum Control System. EC-880 TROUBLE DIAGNOSIS [HR (WITH EURO-OBD)] Circuit Diagram BBS0049R A EC C D E F G H I J K L M MBWA1453E EC-881 TROUBLE DIAGNOSIS [HR (WITH EURO-OBD)] MBWA1454E EC-882 TROUBLE DIAGNOSIS [HR (WITH EURO-OBD)] ECM Harness Connector Terminal Layout BBS0049S A EC C PBIA9221J ECM Terminals and Reference Value BBS0049T PREPARATION 1. E ECM (1) is located in the engine room left side near battery. ● D : Vehicle front F G H PBIB2959E 2. 3. Disconnect ECM harness connector. ● When disconnecting ECM harness connector, loosen (A) it with levers (1) as far as they will go as shown in the figure. – ECM (2) – Fasten (B) Connect a break-out box (SST) and Y-cable adapter (SST) between the ECM and ECM harness connector. ● Use extreme care not to touch 2 pins at one time. ● Data is for comparison and may not be exact. I J K PBIB2947E L ECM INSPECTION TABLE Specification data are reference values and are measured between each terminal and ground. Pulse signal is measured by CONSULT-II. CAUTION: Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECMs transistor. Use a ground other than ECM terminals, such as the ground. TERMINAL NO. WIRE COLOR ITEM CONDITION DATA (DC Voltage) Approximately 3.2V [Ignition switch: ON] 1 P Throttle control motor (Open) ● Engine stopped ● Shift lever: D (A/T), 1st (M/T) ● Accelerator pedal: Fully depressed PBIA8150J 2 LG Throttle control motor power supply [Ignition switch: ON] EC-883 BATTERY VOLTAGE (11 - 14V) M TROUBLE DIAGNOSIS [HR (WITH EURO-OBD)] TERMINAL NO. WIRE COLOR ITEM CONDITION DATA (DC Voltage) Approximately 10V [Engine is running] 3 Y ● Warm-up condition ● Engine speed: Below 3,600 rpm Heated oxygen sensor 1 heater PBIA8148J [Ignition switch: ON] ● Engine stopped [Engine is running] ● BATTERY VOLTAGE (11 - 14V) Engine speed: Above 3,600 rpm Approximately 1.8V [Ignition switch: ON] 4 L Throttle control motor (Close) ● Engine stopped ● Shift lever: D (A/T), 1st (M/T) ● Accelerator pedal: Fully released PBIA8149J [Engine is running] 5 GR ● Engine speed: Below 3,600 rpm after the following conditions are met. – Engine: After warming up – Keeping the engine speed between 3,500 and 4,000 rpm for 1 minute and at idle for 1 minute under no load. Heated oxygen sensor 2 heater Approximately 10V PBIA8148J [Ignition switch: ON] ● Engine stopped [Engine is running] ● BATTERY VOLTAGE (11 - 14V) Engine speed: Above 3,600 rpm BATTERY VOLTAGE (11 - 14V) [Engine is running] ● 9 LG Idle speed EVAP canister purge volume control solenoid valve PBIB0050E Approximately 10V [Engine is running] ● Engine speed: About 2,000 rpm (More than 100 seconds after starting engine) PBIB0520E 10 11 B B/W ECM ground [Engine is running] ● Idle speed EC-884 Body ground TROUBLE DIAGNOSIS [HR (WITH EURO-OBD)] TERMINAL NO. WIRE COLOR ITEM CONDITION [Engine is running] ● Warm-up condition ● Idle speed DATA (DC Voltage) A 3 - 5V EC NOTE: The pulse cycle changes depending on rpm at idle. C PBIA8164J 13 L Tachometer signal D 3 - 5V [Engine is running] ● ● E Warm-up condition Engine speed: 2,000 rpm F PBIA8165J 15 G [Ignition switch: OFF] BATTERY VOLTAGE (11 - 14V) [Ignition switch: ON] 0 - 1.0V Throttle control motor relay [Engine is running] 17 18 21 22 V BR G Y ● Warm-up condition ● Idle speed G 0 - 0.3V H NOTE: The pulse cycle changes depending on rpm at idle. Ignition signal No. 1 Ignition signal No. 2 Ignition signal No. 4 Ignition signal No. 3 I PBIA9265J J 0.2 - 0.5V [Engine is running] ● ● K Warm-up condition Engine speed: 2,500 rpm L PBIA9266J [Ignition switch: ON] ● 23 R Fuel pump relay For 1 second after turning ignition switch ON 0 - 1.0V [Engine is running] [Ignition switch: ON] ● More than 1 second after turning ignition switch ON EC-885 BATTERY VOLTAGE (11 - 14V) M TROUBLE DIAGNOSIS [HR (WITH EURO-OBD)] TERMINAL NO. WIRE COLOR ITEM CONDITION DATA (DC Voltage) BATTERY VOLTAGE [Engine is running] 25 29 30 31 R O GR L ● Warm-up condition ● Idle speed (11 - 14V) NOTE: The pulse cycle changes depending on rpm at idle. Fuel injector No. 4 Fuel injector No. 3 Fuel injector No. 2 Fuel injector No. 1 PBIB0529E BATTERY VOLTAGE (11 - 14V) [Engine is running] ● Warm-up condition ● Engine speed: 2,000 rpm PBIA4943J [Engine is running] [Ignition switch: OFF] ● 32 P ECM relay (Self shut-off) For a few seconds after turning ignition switch OFF [Ignition switch: OFF] ● More than a few seconds after turning ignition switch OFF 0 - 1.0V BATTERY VOLTAGE (11 - 14V) [Ignition switch: ON] 33 Y ● Engine stopped ● Shift lever: D (A/T), 1st (M/T) ● Accelerator pedal: Fully released More than 0.36V Throttle position sensor 1 [Ignition switch: ON] ● Engine stopped ● Shift lever: D (A/T), 1st (M/T) ● Accelerator pedal: Fully depressed Less than 4.75V [Ignition switch: ON] 34 R ● Engine stopped ● Shift lever: D (A/T), 1st (M/T) ● Accelerator pedal: Fully released Throttle position sensor 2 Less than 4.75V [Ignition switch: ON] ● Engine stopped ● Shift lever: D (A/T), 1st (M/T) ● Accelerator pedal: Fully depressed More than 0.36V [Engine is running] 36 37 BR W Sensor ground (Throttle position sensor) Knock sensor ● Warm-up condition ● Idle speed [Engine is running] ● 38 P Engine coolant temperature sensor Idle speed [Engine is running] EC-886 Approximately 0V Approximately 2.5V Approximately 0 - 4.8V Output voltage varies with engine coolant temperature. TROUBLE DIAGNOSIS [HR (WITH EURO-OBD)] TERMINAL NO. WIRE COLOR ITEM CONDITION DATA (DC Voltage) A [Engine is running] 40 — Sensor ground (Knock sensor) ● Warm-up condition ● Idle speed Approximately 0V EC [Engine is running] ● 41 44 BR B Refrigerant pressure sensor Sensor ground (Engine coolant temperature sensor) ● C Warm-up condition Both A/C switch and blower fan switch: ON (Compressor operates.) 1.0 - 4.0V D [Engine is running] ● Warm-up condition ● Idle speed [Ignition switch: ON] ● Engine stopped Approximately 0V E Approximately 0.4V F [Engine is running] 45 G Mass air flow sensor ● Warm-up condition ● Idle speed [Engine is running] 46 V Intake air temperature sensor 48 Y Sensor ground (Refrigerant pressure sensor) ● Warm-up condition ● Engine is revving from idle to about 4,000 rpm [Engine is running] 1.0 - 1.3V G 1.0 - 1.3 to Approximately 2.4V (Check for linear voltage rise in response to engine being increased to about 4,000 rpm.) H Approximately 0 - 4.8V Output voltage varies with intake air temperature. I Approximately 0V J 0 - Approximately 1.0V (Periodically change) K [Engine is running] ● Warm-up condition ● Idle speed [Engine is running] 49 BR Heated oxygen sensor 1 ● Warm-up condition ● Engine speed: 2,000 rpm [Engine is running] 50 B Heated oxygen sensor 2 ● Revving engine from idle to 3,000 rpm quickly after the following conditions are met. – Engine: After warming up – Keeping the engine speed between 3,500 and 4,000 rpm for 1 minute and at idle for 1 minute under no load. L 0 - Approximately 1.0V [Engine is running] 52 55 LG O Sensor ground (Mass air flow sensor) Sensor ground (Intake air temperature sensor) ● Warm-up condition ● Idle speed Approximately 0V [Engine is running] ● Warm-up condition ● Idle speed Approximately 0V [Engine is running] 56 R Sensor ground (Heated oxygen sensor 1) ● Warm-up condition ● Idle speed Approximately 0V [Engine is running] 59 LG Sensor ground (Heated oxygen sensor 2) ● Warm-up condition ● Idle speed EC-887 Approximately 0V M TROUBLE DIAGNOSIS [HR (WITH EURO-OBD)] TERMINAL NO. WIRE COLOR ITEM CONDITION [Engine is running] ● Warm-up condition ● Idle speed DATA (DC Voltage) 0 - 1.0V NOTE: The pulse cycle changes depending on rpm at idle. 61 Y MBIB1453E Crankshaft position sensor (POS) 0 - 1.0V [Engine is running] ● Engine speed: 2,000 rpm MBIB1454E 62 63 W B Sensor ground [Crankshaft position sensor (POS)] [Engine is running] Sensor ground [Camshaft position sensor (PHASE)] [Engine is running] ● Warm-up condition ● Idle speed ● Warm-up condition ● Idle speed [Engine is running] ● Warm-up condition ● Idle speed Approximately 0V Approximately 0V 0 - 1.0V NOTE: The pulse cycle changes depending on rpm at idle. 65 R MBIB1455E Camshaft position sensor (PHASE) 0 - 1.0V [Engine is running] ● Engine speed: 2,000 rpm MBIB1456E [Ignition switch: ON] 70 GR Park/Neutral position (PNP) switch ● Shift lever: P or N (A/T models) ● Shift lever: Neutral (M/T models) [Ignition switch: ON] ● 72 L Sensor power supply (Throttle position sensor) Except above position [Ignition switch: ON] EC-888 Approximately 0V BATTERY VOLTAGE (11 - 14V) Approximately 5V TROUBLE DIAGNOSIS [HR (WITH EURO-OBD)] TERMINAL NO. WIRE COLOR ITEM CONDITION DATA (DC Voltage) A [Engine is running] ● Warm-up condition ● Idle speed BATTERY VOLTAGE (11 - 14V) EC 7 - 10V 73 LG Intake valve timing control solenoid valve C [Engine is running] ● Warm-up condition ● Engine speed: 2,000 rpm D PBIA4937J 74 W Sensor power supply (Refrigerant pressure sensor) 75 G Sensor power supply [Crankshaft position sensor (POS)] [Ignition switch: ON] Approximately 5V 78 O Sensor power supply [Camshaft position sensor (PHASE)] [Ignition switch: ON] Approximately 5V 83 Y CAN communication line [Ignition switch: ON] Approximately 1.7 - 2.3V 84 L CAN communication line [Ignition switch: ON] Approximately 2.6 - 3.2V 88 LG DATA link connector [Ignition switch: ON] Approximately 5V F G [Ignition switch: ON] ● 93 O CONSULT-II or GST: Disconnected. 0V [Ignition switch: ON] BATTERY VOLTAGE (11 - 14V) ● R Stop lamp switch Brake pedal: Fully released [Ignition switch: OFF] ● 102 BR Sensor power supply (Accelerator pedal position sensor 2) Approximately 2.7V [Ignition switch: OFF] Ignition switch [Ignition switch: OFF] 99 Brake pedal: Slightly depressed 104 G B Accelerator pedal position sensor 2 H I J Approximately 0V K BATTERY VOLTAGE (11 - 14V) L [Ignition switch: ON] Approximately 5V [Ignition switch: ON] 103 E ● Engine stopped ● Accelerator pedal: Fully released M 0.3 - 0.6V [Ignition switch: ON] ● Engine stopped ● Accelerator pedal: Fully depressed Sensor ground (Accelerator pedal position sensor 2) [Engine is running] ● Warm-up condition ● Idle speed 1.95 - 2.4V Approximately 0V 105 G Power supply for ECM [Ignition switch: ON] BATTERY VOLTAGE (11 - 14V) 106 O Sensor power supply (Accelerator pedal position sensor 1) [Ignition switch: ON] Approximately 5V 108 B ECM ground [Engine is running] ● Idle speed EC-889 Body ground TROUBLE DIAGNOSIS [HR (WITH EURO-OBD)] TERMINAL NO. WIRE COLOR ITEM CONDITION DATA (DC Voltage) [Ignition switch: ON] 110 111 W B Accelerator pedal position sensor 1 Sensor ground (Accelerator pedal position sensor 1) ● Engine stopped ● Accelerator pedal: Fully released 0.6 - 0.9V [Ignition switch: ON] ● Engine stopped ● Accelerator pedal: Fully depressed 3.9 - 4.7V [Engine is running] ● Warm-up condition ● Idle speed : Average voltage for pulse signal (Actual pulse signal can be confirmed by oscilloscope.) EC-890 Approximately 0V TROUBLE DIAGNOSIS [HR (WITH EURO-OBD)] CONSULT-II Function (ENGINE) BBS0049U A FUNCTION Diagnostic test mode Function Work support This mode enables a technician to adjust some devices faster and more accurately by following the indications on the CONSULT-II unit. Self-diagnostic results Self-diagnostic results such as 1st trip DTC, DTCs and 1st trip freeze frame data or freeze frame data can be read and erased quickly.* Data monitor Input/Output data in the ECM can be read. Data monitor (SPEC) Input/Output of the specification for Basic fuel schedule, AFM, A/F feedback control value and the other data monitor items can be read. CAN diagnostic support monitor The results of transmit/receive diagnosis of CAN communication can be read. Active test Diagnostic Test Mode in which CONSULT-II drives some actuators apart from the ECMs and also shifts some parameters in a specified range. Function test This mode is used to inform customers when their vehicle condition requires periodic maintenance. DTC & SRT confirmation The status of system monitoring tests and the self-diagnosis status/result can be confirmed. ECM part number ECM part number can be read. EC C D E F *: The following emission-related diagnostic information is cleared when the ECM memory is erased. ● Diagnostic trouble codes ● 1st trip diagnostic trouble codes ● Freeze frame data ● 1st trip freeze frame data ● System readiness test (SRT) codes ● Test values G H I J K L M EC-891 TROUBLE DIAGNOSIS [HR (WITH EURO-OBD)] ENGINE CONTROL COMPONENT PARTS/CONTROL SYSTEMS APPLICATION DIAGNOSTIC TEST MODE SELF-DIAGNOSTIC RESULTS Item WORK SUPPORT DTC*1 FREEZE FRAME DATA MONITOR DATA MONITOR (SPEC) INPUT OUTPUT ENGINE CONTROL COMPONENT PARTS ENGINE CONTROL COMPONENT PARTS DATA*2 DTC & SRT CONFIRMATION ACTIVE TEST SRT STATUS DTC WORK SUPPORT Crankshaft position sensor (POS) × × × × Camshaft position sensor (PHASE) × × × × Mass air flow sensor × × × Engine coolant temperature sensor × × × Heated oxygen sensor 1 × × × × × Heated oxygen sensor 2 × × × × × Wheel sensor × × × Accelerator pedal position sensor × × × Throttle position sensor × × × Intake air temperature sensor × × × Knock sensor × EPS control unit × × Refrigerant pressure sensor × × Closed throttle position switch (accelerator pedal position sensor signal) × × Air conditioner switch × × × × × × Park/neutral position (PNP) switch × × × Stop lamp switch × × × Battery voltage × × Load signal × × Fuel injector × × × Power transistor (Ignition timing) × × × × × × × × × × × × × Throttle control motor relay × Throttle control motor × EVAP canister purge volume control solenoid valve × Air conditioner relay Fuel pump relay × × × Cooling fan relay × × × Heated oxygen sensor 1 heater × × × × Heated oxygen sensor 2 heater × × × × Intake valve timing control solenoid valve × × × × × × Calculated load value × X: Applicable *1: This item includes 1st trip DTCs. *2: This mode includes 1st trip freeze frame data or freeze frame data. The items appear on CONSULT-II screen in freeze frame data mode only if a 1st trip DTC or DTC is detected. For details, refer to EC-834, "FREEZE FRAME DATA AND 1ST TRIP FREEZE FRAME DATA" . EC-892 TROUBLE DIAGNOSIS [HR (WITH EURO-OBD)] INSPECTION PROCEDURE A Refer to GI-36, "CONSULT-II Start Procedure" . WORK SUPPORT MODE Work Item EC WORK ITEM CONDITION FUEL PRESSURE RELEASE IDLE AIR VOL LEARN ● ● SELF-LEARNING CONT ● USAGE FUEL PUMP WILL STOP BY TOUCHING “START” DURING IDLING. CRANK A FEW TIMES AFTER ENGINE STALLS. When releasing fuel pressure from fuel line THE IDLE AIR VOLUME THAT KEEPS THE ENGINE WITHIN THE SPECIFIED RANGE IS MEMORIZED IN ECM. When learning the idle air volume THE COEFFICIENT OF SELF-LEARNING CONTROL MIXTURE RATIO RETURNS TO THE ORIGINAL COEFFICIENT. When clearing the coefficient of self-learning control value C D TARGET IDLE RPM ADJ* ● IDLE CONDITION When setting target idle speed TARGET IGN TIM ADJ* ● IDLE CONDITION When adjusting target ignition timing E F *: This function is not necessary in the usual service procedure. G SELF-DIAG RESULTS MODE Self Diagnostic Item Regarding items of DTC and 1st trip DTC, refer to EC-831, "EMISSION-RELATED DIAGNOSTIC INFORMATION ITEMS" . H Freeze Frame Data and 1st Trip Freeze Frame Data Freeze frame data item* DIAG TROUBLE CODE [PXXXX] Description ● The engine control component part/control system has a trouble code, it is displayed as PXXXX. (Refer to EC-803, "INDEX FOR DTC" .) ● “Fuel injection system status” at the moment a malfunction is detected is displayed. ● One mode in the following is displayed. Mode2: Open loop due to detected system malfunction Mode3: Open loop due to driving conditions (power enrichment, deceleration enleanment) Mode4: Closed loop - using oxygen sensor(s) as feedback for fuel control Mode5: Open loop - has not yet satisfied condition to go to closed loop FUEL SYS-B1 CAL/LD VALUE [%] ● The calculated load value at the moment a malfunction is detected is displayed. COOLANT TEMP [°C] or [°F] ● The engine coolant temperature at the moment a malfunction is detected is displayed. ● “Long-term fuel trim” at the moment a malfunction is detected is displayed. ● The long-term fuel trim indicates much more gradual feedback compensation to the base fuel schedule than short-term fuel trim. L-FUEL TRM-B1 [%] ● “Short-term fuel trim” at the moment a malfunction is detected is displayed. S-FUEL TRM-B1 [%] ● The short-term fuel trim indicates dynamic or instantaneous feedback compensation to the base fuel schedule. ENGINE SPEED [rpm] ● The engine speed at the moment a malfunction is detected is displayed. VEHICL SPEED [km/h] or [mph] ● The vehicle speed at the moment a malfunction is detected is displayed. B/FUEL SCHDL [msec] ● The base fuel schedule at the moment a malfunction is detected is displayed. INT/A TEMP SE [°C] or [°F] ● The intake air temperature at the moment a malfunction is detected is displayed. *: The items are the same as those of 1st trip freeze frame data. EC-893 I J K L M TROUBLE DIAGNOSIS [HR (WITH EURO-OBD)] DATA MONITOR MODE Monitored Item Monitored item [Unit] ECM INPUT SIGNALS ×: Applicable MAIN SIGNALS Description ● ENG SPEED [rpm] × × MAS A/F SE-B1 [V] × × B/FUEL SCHDL [msec] × COOLAN TEMP/S [°C] or [°F] × × HO2S1 (B1) [V] × × HO2S2 (B1) [V] × HO2S1 MNTR (B1) [RICH/LEAN] ● The signal voltage of the mass air flow sensor is displayed. ● “Base fuel schedule” indicates the fuel injection pulse width programmed into ECM, prior to any learned on board correction. × A/F ALPHA-B1 [%] × Indicates the engine speed computed from the signals of the crankshaft position sensor (POS) and camshaft position sensor (PHASE). ● The mean value of the air-fuel ratio feedback correction factor per cycle is indicated. ● The engine coolant temperature (determined by the signal voltage of the engine coolant temperature sensor) is displayed. ● The signal voltage of the heated oxygen sensor 1 is displayed. ● The signal voltage of the heated oxygen sensor 2 is displayed. ● Display of heated oxygen sensor 1 signal during air-fuel ratio feedback control: RICH: means the mixture became “rich”, and control is being affected toward a leaner mixture. LEAN: means the mixture became “lean”, and control is being affected toward a rich mixture. × ● Display of heated oxygen sensor 2 signal: RICH: means the amount of oxygen after three way catalyst is relatively small. LEAN: means the amount of oxygen after three way catalyst is relatively large. HO2S2 MNTR (B1) [RICH/LEAN] × VHCL SPEED SE [km/h] or [mph] × × ● The vehicle speed computed from the vehicle speed signal is displayed. BATTERY VOLT [V] × × ● The power supply voltage of ECM is displayed. ACCEL SEN 1 [V] × × ● The accelerator pedal position sensor signal voltage is displayed. ● The throttle position sensor signal voltage is displayed. ACCEL SEN 2 [V] × THRTL SEN 1 [V] × THRTL SEN 2 [V] × × EC-894 Remarks ● Accuracy becomes poor if engine speed drops below the idle rpm. ● If the signal is interrupted while the engine is running, an abnormal value may be indicated. ● When the engine is stopped, a certain value is indicated. ● When the engine is stopped, a certain value is indicated. ● This data also includes the data for the air-fuel ratio learning control. ● When the engine coolant temperature sensor is open or shortcircuited, ECM enters fail-safe mode. The engine coolant temperature determined by the ECM is displayed. ● After turning ON the ignition switch, “RICH” is displayed until air-fuel mixture ratio feedback control begins. ● When the air-fuel ratio feedback is clamped, the value just before the clamping is displayed continuously. ● When the engine is stopped, a certain value is indicated. ● ACCEL SEN 2 signal is converted by ECM internally. Thus, it differs from ECM terminal voltage signal. ● THRTL SEN 2 signal is converted by ECM internally. Thus, it differs from ECM terminal voltage signal. TROUBLE DIAGNOSIS [HR (WITH EURO-OBD)] ECM INPUT SIGNALS MAIN SIGNALS INT/A TEMP SE [°C] or [°F] × × START SIGNAL [ON/OFF] × × CLSD THL POS [ON/OFF] × × AIR COND SIG [ON/OFF] × × P/N POSI SW [ON/OFF] × × PW/ST SIGNAL [ON/OFF] × × Monitored item [Unit] Description ● ● ● ● Remarks The intake air temperature (determined by the signal voltage of the intake air temperature sensor) is indicated. Indicates start signal status [ON/OFF] computed by the ECM according to the signals of engine speed and battery voltage. EC ● After starting the engine, [OFF] is displayed regardless of the starter signal. D Indicates [ON/OFF] condition of the air conditioner switch as determined by the air conditioner signal. E Indicates [ON/OFF] condition from the park/ neutral position (PNP) switch signal. ● [ON/OFF] condition of the power steering system (determined by the signal sent from EPS control unit) is indicated. ● Indicates [ON/OFF] condition from the electrical load signal. ON: Rear window defogger switch is ON and/ or lighting switch is in 2nd position. OFF: Both rear window defogger switch and lighting switch are OFF. F G LOAD SIGNAL [ON/OFF] × IGNITION SW [ON/OFF] × ● Indicates [ON/OFF] condition from ignition switch. HEATER FAN SW [ON/OFF] × ● Indicates [ON/OFF] condition from the heater fan switch signal. BRAKE SW [ON/OFF] × ● Indicates [ON/OFF] condition from the stop lamp switch signal. ● Indicates the actual fuel injection pulse width compensated by ECM according to the input signals. ● When the engine is stopped, a certain computed value is indicated. ● Indicates the ignition timing computed by ECM according to the input signals. ● When the engine is stopped, a certain value is indicated. INJ PULSE-B1 [msec] × IGN TIMING [BTDC] × CAL/LD VALUE [%] MASS AIRFLOW [g·m/s] ● “Calculated load value” indicates the value of the current airflow divided by peak airflow. ● Indicates the mass airflow computed by ECM according to the signal voltage of the mass air flow sensor. ● Indicates the EVAP canister purge volume control solenoid valve control value computed by the ECM according to the input signals. ● The opening becomes larger as the value increases. ● Indicates [°CA] of intake camshaft advanced angle. ● The control value of the intake valve timing control solenoid valve (determined by ECM according to the input signal) is indicated. ● The advance angle becomes larger as the value increases PURG VOL C/V [%] INT/V TIM (B1) [°CA] INT/V SOL (B1) [%] C Indicates idle position [ON/OFF] computed by the ECM according to the accelerator pedal position sensor signal. ● × A EC-895 H I J K L M TROUBLE DIAGNOSIS [HR (WITH EURO-OBD)] Monitored item [Unit] ECM INPUT SIGNALS MAIN SIGNALS AIR COND RLY [ON/OFF] × FUEL PUMP RLY [ON/OFF] × THRTL RELAY [ON/OFF] × Description ● The air conditioner relay control condition (determined by ECM according to the input signals) is indicated. ● Indicates the fuel pump relay control condition determined by ECM according to the input signals. ● Indicates the throttle control motor relay control condition determined by the ECM according to the input signals. ● Indicates the condition of the cooling fan (determined by ECM according to the input signals). HI: High speed operation LOW: Low speed operation OFF: Stop ● Indicates [ON/OFF] condition of heated oxygen sensor 1 heater determined by ECM according to the input signals. ● Indicates [ON/OFF] condition of heated oxygen sensor 2 heater determined by ECM according to the input signals. ● Display the condition of idle air volume learning YET: Idle Air Volume Learning has not been performed yet. CMPLT: Idle Air Volume Learning has already been performed successfully. ● Distance traveled while MIL is activated. ● Indicates the heated oxygen sensor 1 heater control value computed by the ECM according to the input signals. COOLING FAN [HI/LOW/OFF] HO2S1 HTR (B1) [ON/OFF] HO2S2 HTR (B1) [ON/OFF] IDL A/V LEARN [YET/CMPLT] TRVL AFTER MIL [km] or [mile] O2SEN HTR DTY [%] I/P PULLY SPD [km/h] or [MPH] × ● Indicates the engine speed computed from the turbine revolution sensor signal. AC PRESS SEN [V] × ● The signal voltage from the refrigerant pressure sensor is displayed. Remarks Voltage [V] Frequency [msec], [Hz] or [%] DUTY-HI DUTY-LOW ● Voltage, frequency, duty cycle or pulse width measured by the probe. PLS WIDTH-HI ● Only “#” is displayed if item is unable to be measured. ● Figures with “#”s are temporary ones. They are the same figures as an actual piece of data which was just previously measured. PLS WIDTH-LOW NOTE: Any monitored item that does not match the vehicle being diagnosed is deleted from the display automatically. EC-896 TROUBLE DIAGNOSIS [HR (WITH EURO-OBD)] DATA MONITOR (SPEC) MODE Monitored Item Monitored item [Unit] ECM input signals A Main signals Description EC ● ENG SPEED [rpm] × × MAS A/F SE-B1 [V] × × B/FUEL SCHDL [msec] The signal voltage of the mass air flow sensor specification is displayed. ● “Base fuel schedule” indicates the fuel injection pulse width programmed into ECM, prior to any learned on board correction. ● × Indicates the engine speed computed from the signal of the crankshaft position sensor (POS) and camshaft position sensor (PHASE). ● × A/F ALPHA-B1 [%] Remarks The mean value of the air-fuel ratio feedback correction factor per cycle is indicated. C ● ● When engine is running specification range is indicated. When engine is running specification range is indicated. ● When engine is running specification range is indicated. ● This data also includes the data for the air-fuel ratio learning control. D E F NOTE: Any monitored item that does not match the vehicle being diagnosed is deleted from the display automatically. G ACTIVE TEST MODE Test Item H TEST ITEM CONDITION ● FUEL INJECTION IGNITION TIMING POWER BALANCE COOLING FAN*1, ● FUEL PUMP RELAY Change the amount of fuel injection using CONSULT-II. ● Engine: Return to the original trouble condition ● Timing light: Set ● Retard the ignition timing using CONSULT-II. ● Engine: After warming up, idle the engine. ● A/C switch OFF ● Shift lever: P or N (A/T), Neutral (M/T) ● Cut off each fuel injector signal one at a time using CONSULT-II. ● Ignition switch: ON ● Turn the cooling fan “LOW”, “MID”, “HI” and “OFF” with CONSULT-II. *2, *3 ENG COOLANT TEMP Engine: Return to the original trouble condition ● Engine: Return to the original trouble condition ● Change the engine coolant temperature using CONSULT-II. ● Ignition switch: ON (Engine stopped) ● Turn the fuel pump relay ON and OFF using CONSULT-II and listen to operating sound. JUDGEMENT If trouble symptom disappears, see CHECK ITEM. CHECK ITEM (REMEDY) ● Harness and connectors ● Fuel injector ● Air fuel ratio (A/F) sensor 1 I J If trouble symptom disappears, see CHECK ITEM. ● K ● Harness and connectors ● Compression ● Fuel injector ● Power transistor ● Spark plug ● Ignition coil ● Harness and connectors ● Cooling fan relay ● Cooling fan motor ● Harness and connectors ● Engine coolant temperature sensor ● Fuel injector ● Harness and connectors ● Fuel pump relay Engine runs rough or dies. Cooling fan moves and stops. If trouble symptom disappears, see CHECK ITEM. Fuel pump relay makes the operating sound. EC-897 Perform Idle Air Volume Learning. L M TROUBLE DIAGNOSIS [HR (WITH EURO-OBD)] TEST ITEM PURG VOL CONT/V CONDITION ● Engine: After warming up, run engine at 1,500 rpm. ● Change the EVAP canister purge volume control solenoid valve opening percent using CONSULT-II. ● V/T ASSIGN ANGLE ● Engine: Return to the original trouble condition Change intake valve timing using CONSULT-II. JUDGEMENT Engine speed changes according to the opening percent. If trouble symptom disappears, see CHECK ITEM. CHECK ITEM (REMEDY) ● Harness and connectors ● Solenoid valve ● Harness and connectors ● Intake valve timing control solenoid valve *1: Leaving cooling fan OFF with CONSULT-II while engine is running may cause the engine to overheat. *2: With A/C: “OFF”, “LOW”, “MID” or “HI” is displayed on CONSULT-II screen. But cooling fan operates at the same speed when “MID” or “HI” is displayed. *3:Without A/C: “OFF”, “LOW”, “MID” or “HI” is displayed on CONSULT-II screen. But cooling fan operates at the same speed when an item other than “OFF” is displayed. DTC & SRT CONFIRMATION MODE SRT STATUS Mode For details, refer to EC-834, "SYSTEM READINESS TEST (SRT) CODE" . SRT WORK SUPPORT Mode This mode enables a technician to drive a vehicle to set the SRT while monitoring the SRT status. DTC WORK SUPPORT Mode Test mode HO2S1 Test item Reference page HO2S1 (B1) P0133 EC-967, "DTC P0133 HO2S1" HO2S1 (B1) P0134 EC-977, "DTC P0134 HO2S1" HO2S1 (B1) P1143 HO2S1 (B1) P1144 HO2S2 (B1) P0139 HO2S2 Condition Refer to corresponding trouble diagnosis for DTC. EC-1101, "DTC P1143 HO2S1" EC-1107, "DTC P1144 HO2S1" EC-998, "DTC P0139 HO2S2" HO2S2 (B1) P1146 EC-1113, "DTC P1146 HO2S2" HO2S2 (B1) P1147 EC-1121, "DTC P1147 HO2S2" REAL TIME DIAGNOSIS IN DATA MONITOR MODE (RECORDING VEHICLE DATA) Description CONSULT-II has two kinds of triggers and they can be selected by touching “SETTING” in “DATA MONITOR” mode. 1. “AUTO TRIG” (Automatic trigger): ● The malfunction will be identified on the CONSULT-II screen in real time. In other words, DTC/1st trip DTC and malfunction item will be displayed if the malfunction is detected by ECM. At the moment a malfunction is detected by ECM, “MONITOR” in “DATA MONITOR” screen is changed to “Recording Data ... xx%” as shown at right, and the data after the malfunction detection is recorded. Then when the percentage reached 100%, “REAL-TIME DIAG” screen is displayed. If “STOP” is touched on the screen during “Recording Data ... PBIB1593E xx%”, “REAL-TIME DIAG” screen is also displayed. EC-898 TROUBLE DIAGNOSIS [HR (WITH EURO-OBD)] 2. The recording time after the malfunction detection and the recording speed can be changed by “TRIGGER POINT” and “Recording Speed”. Refer to CONSULT-II OPERATION MANUAL. “MANU TRIG” (Manual trigger): ● DTC/1st trip DTC and malfunction item will not be displayed automatically on CONSULT-II screen even though a malfunction is detected by ECM. DATA MONITOR can be performed continuously even though a malfunction is detected. A EC C SEF707X D Operation 1. 2. “AUTO TRIG” ● While trying to detect the DTC/1st trip DTC by performing the “DTC Confirmation Procedure”, be sure to select to “DATA MONITOR (AUTO TRIG)” mode. You can confirm the malfunction at the moment it is detected. ● While narrowing down the possible causes, CONSULT-II should be set in “DATA MONITOR (AUTO TRIG)” mode, especially in case the incident is intermittent. When you are inspecting the circuit by gently shaking (or twisting) the suspicious connectors, components and harness in the “DTC Confirmation Procedure”, the moment a malfunction is found the DTC/ 1st trip DTC will be displayed. (Refer to “INCIDENT SIMULATION TESTS” in GI-25, "How to Perform Efficient Diagnosis for an Electrical Incident" .) “MANU TRIG” ● If the malfunction is displayed as soon as “DATA MONITOR” is selected, reset CONSULT-II to “MANU TRIG”. By selecting “MANU TRIG” you can monitor and store the data. The data can be utilized for further diagnosis, such as a comparison with the value for the normal operating condition. E F G H I J K L M PBIB0197E EC-899 TROUBLE DIAGNOSIS [HR (WITH EURO-OBD)] Generic Scan Tool (GST) Function BBS0049V DESCRIPTION Generic Scan Tool (OBDII scan tool) complying with ISO 15031-4 has 8 different functions explained below. ISO9141 is used as the protocol. The name “GST” or “Generic Scan Tool” is used in this service manual. SEF139P FUNCTION Diagnostic service Function Service $01 READINESS TESTS This diagnostic service gains access to current emission-related data values, including analog inputs and outputs, digital inputs and outputs, and system status information. Service $02 (FREEZE DATA) This diagnostic service gains access to emission-related data value which were stored by ECM during the freeze frame. For details, refer to EC-834, "FREEZE FRAME DATA AND 1ST TRIP FREEZE FRAME DATA" . Service $03 DTCs This diagnostic service gains access to emission-related power train trouble codes which were stored by ECM. This diagnostic service can clear all emission-related diagnostic information. This includes: Service $04 CLEAR DIAG INFO ● Clear number of diagnostic trouble codes (Service $01) ● Clear diagnostic trouble codes (Service $03) ● Clear trouble code for freeze frame data (Service $01) ● Clear freeze frame data (Service $02) ● Reset status of system monitoring test (Service $01) ● Clear on board monitoring test results (Service $06 and $07) Service $06 (ON BOARD TESTS) This diagnostic service accesses the results of on board diagnostic monitoring tests of specific components/systems that are not continuously monitored. Service $07 (ON BOARD TESTS) This diagnostic service enables the off board test drive to obtain test results for emissionrelated powertrain components/systems that are continuously monitored during normal driving conditions. Service $08 Service $09 — (CALIBRATION ID) This diagnostic service is not applicable on this vehicle. This diagnostic service enables the off-board test device to request specific vehicle information such as Vehicle Identification Number (VIN) and Calibration IDs. INSPECTION PROCEDURE 1. 2. Turn ignition switch OFF. Connect GST to data link connector (1), which is located under LH dash panel. PBIB2951E EC-900 TROUBLE DIAGNOSIS [HR (WITH EURO-OBD)] 3. 4. Turn ignition switch ON. Enter the program according to instruction on the screen or in the operation manual. (*: Regarding GST screens in this section, sample screens are shown.) A EC C SEF398S D 5. Perform each diagnostic service according to each service procedure. For further information, see the GST Operation Manual of the tool maker. E F G SEF416S H I J K L M EC-901 TROUBLE DIAGNOSIS [HR (WITH EURO-OBD)] CONSULT-II Reference Value in Data Monitor BBS0049W Remarks: ● Specification data are reference values. ● Specification data are output/input values which are detected or supplied by the ECM at the connector. * Specification data may not be directly related to their components signals/values/operations. i.e. Adjust ignition timing with a timing light before monitoring IGN TIMING, because the monitor may show the specification data in spite of the ignition timing not being adjusted to the specification data. This IGN TIMING monitors the data calculated by the ECM according to the signals input from the camshaft position sensor and other ignition timing related sensors. MONITOR ITEM CONDITION SPECIFICATION ● ENG SPEED Run engine and compare CONSULT-II value with the tachometer indication. Almost the same speed as the tachometer indication. MAS A/F SE-B1 See EC-907, "TROUBLE DIAGNOSIS - SPECIFICATION VALUE" . B/FUEL SCHDL See EC-907, "TROUBLE DIAGNOSIS - SPECIFICATION VALUE" . A/F ALPHA-B1 See EC-907, "TROUBLE DIAGNOSIS - SPECIFICATION VALUE" . COOLAN TEMP/S ● Engine: After warming up HO2S1 (B1) ● Engine: After warming up ● Revving engine from idle to 3,000 rpm quickly after the following conditions are met. – Engine: After warming up – Keep the engine speed between 3,500 rpm and 4,000 rpm for 1 minute and idle for 1 minute under no load ● Engine: After warming up ● Revving engine from idle to 3,000 rpm quickly after the following conditions are met. – Engine: After warming up – Keep the engine speed between 3,500 rpm and 4,000 rpm for 1 minute and idle for 1 minute under no load ● Turn drive wheels and compare CONSULT-II value with the speedometer indication. Almost the same speed as the speedometer indication. ● Ignition switch: ON (Engine stopped) 11 - 14V ● Ignition switch: ON (Engine stopped) Accelerator pedal: Fully released 0.6 - 0.9V Accelerator pedal: Fully depressed 4.0 - 4.8V Ignition switch: ON (Engine stopped) Accelerator pedal: Fully released 0.6 - 0.9V Accelerator pedal: Fully depressed 3.9 - 4.8V HO2S2 (B1) HO2S1 MNTR (B1) HO2S2 MNTR (B1) VHCL SPEED SE BATTERY VOLT ACCEL SEN 1 ACCEL SEN 2*1 ● More than 70°C (158°F) Maintaining engine speed at 2,000 rpm Maintaining engine speed at 2,000 rpm 0 - 0.3V ←→ Approx. 0.6 1.0V 0 - 0.3V ←→ Approx. 0.6 1.0V LEAN ←→ RICH Changes more than 5 times during 10 seconds. LEAN ←→ RICH ● Ignition switch: ON (Engine stopped) Accelerator pedal: Fully released More than 0.36V ● Shift lever: D (A/T), 1st (M/T) Accelerator pedal: Fully depressed Less than 4.75V START SIGNAL ● Ignition switch: ON → START → ON CLSD THL POS ● Ignition switch: ON THRTL SEN 1 THRTL SEN 2* 1 AIR COND SIG P/N POSI SW PW/ST SIGNAL ● ● ● Engine: After warming up, idle the engine Ignition switch: ON Engine: After warming up, idle the engine OFF → ON → OFF Accelerator pedal: Fully released ON Accelerator pedal: Slightly depressed OFF Air conditioner switch: OFF OFF Air conditioner switch: ON (Compressor operates.) ON Shift lever: P or N (A/T), Neutral (M/T) ON Shift lever: Except above OFF Steering wheel: Not being turned. OFF Steering wheel: Being turned. ON EC-902 TROUBLE DIAGNOSIS [HR (WITH EURO-OBD)] MONITOR ITEM LOAD SIGNAL CONDITION ● Ignition switch: ON IGNITION SW ● Ignition switch: ON → OFF → ON HEATER FAN SW ● Ignition switch: ON BRAKE SW INJ PULSE-B1 IGN TIMING CAL/LD VALUE MASS AIRFLOW PURG VOL C/V INT/V TIM (B1) INT/V SOL (B1) AIR COND RLY ● Ignition switch: ON ● Engine: After warming up ● Air conditioner switch: OFF ● Shift lever: P or N (A/T), Neutral (M/T) ● No load ● Engine: After warming up ● Air conditioner switch: OFF ● Shift lever: P or N (A/T), Neutral (M/T) ● No load ● Engine: After warming up ● Air conditioner switch: OFF ● Shift lever: P or N (A/T), Neutral (M/T) ● No load ● Engine: After warming up ● Air conditioner switch: OFF ● Shift lever: P or N (A/T), Neutral (M/T) ● No load ● Engine: After warming up ● Air conditioner switch: OFF ● Shift lever: P or N (A/T), Neutral (M/T) ● No load ● Engine: After warming up ● Air conditioner switch: OFF ● Shift lever: P or N (A/T), Neutral (M/T) ● No load ● Engine: After warming up ● Air conditioner switch: OFF ● Shift lever: P or N (A/T), Neutral (M/T) ● No load ● Engine: After warming up, idle the engine SPECIFICATION A Rear window defogger switch: ON and/or Lighting switch: 2nd ON Rear window defogger switch and lighting switch: OFF OFF EC ON → OFF → ON Heater fan: Operating. ON Heater fan: Not operating OFF Brake pedal: Fully released OFF Brake pedal: Slightly depressed ON Idle 2.0 - 3.0 msec C D E 2,000 rpm 1.9 - 2.9 msec Idle 1° - 11° BTDC 2,000 rpm 25° - 45° BTDC Idle 10% - 35% 2,500 rpm 10% - 35% Idle 1.0 - 4.0 g·m/s 2,500 rpm 2.0 - 10.0 g·m/s F G H I J K Idle 0% L 2,000 rpm 0 - 50% Idle −5° - 5°CA 2,500 rpm Approx. 0° - 40°CA Idle 0% - 2% 2,500 rpm Approx. 0% - 90% Air conditioner switch: OFF OFF Air conditioner switch: ON (Compressor operates) ON M EC-903 TROUBLE DIAGNOSIS [HR (WITH EURO-OBD)] MONITOR ITEM FUEL PUMP RLY THRTL RELAY CONDITION SPECIFICATION ● For 1 second after turning ignition switch ON ● Engine running or cranking ● Except above conditions OFF ● Ignition switch: ON ON ● COOLING FAN ● Engine: After warming up, idle the engine Air conditioner switch: OFF ON Engine coolant temperature is 94°C (201°F) or less OFF Engine coolant temperature is between 95°C (203°F) and 99°C (210°F) LOW*2 Engine coolant temperature is 100°C (212°F) or more HIGH*2 ● Engine: After warming up ● Engine speed: Below 3,600 rpm ● Engine speed: Above 3,600 rpm ● Below 3,600 rpm after the following conditions are met. – Engine: After warming up – Keeping the engine speed between 3,500 and 4,000 rpm for 1 minute and at idle for 1 minute under no load ● Engine speed: Above 3,600 rpm OFF I/P PULLY SPD ● Vehicle speed: More than 20 km/h (12 MPH) Almost the same speed as the tachometer indication TRVL AFTER MIL ● Ignition switch: ON ● Engine coolant temperature when engine started: More than 80°C (176°F) ● Engine speed: below 3,600 rpm ● Engine: Idle ● Air conditioner switch: ON (Compressor operates) HO2S1 HTR (B1) HO2S2 HTR (B1) O2SEN HTR DTY AC PRESS SEN ON OFF ON Vehicle has traveled after MI has turned ON. 0 - 65,535 km (0 - 40,723 mile) Approx. 30% 1.0 - 4.0V *1: Accelerator pedal position sensor 2 signal and throttle position sensor 2 signal are converted by ECM internally. Thus, they differ from ECM terminals voltage signal. *2: Models without air conditioner, cooling fan operates only ON and OFF operation, but CONSULT-II display will change OFF, LOW and HI depends on engine coolant temperature. EC-904 TROUBLE DIAGNOSIS [HR (WITH EURO-OBD)] Major Sensor Reference Graph in Data Monitor Mode BBS0049X A The following are the major sensor reference graphs in “DATA MONITOR” mode. CLSD THL POS, ACCEL SEN 1, THRTL SEN 1 Below is the data for “CLSD THL POS”, “ACCEL SEN 1” and “THRTL SEN 1” when depressing the accelera- EC tor pedal with the ignition switch ON and with shift lever in D position (A/T), 1st position (M/T). The signal of “ACCEL SEN 1” and “THRTL SEN 1” should rise gradually without any intermittent drop or rise after “CLSD THL POS” is changed from “ON” to “OFF”. C D E F PBIB0198E ENG SPEED, MAS A/F SE-B1, THRTL SEN 1, HO2S2 (B1), INJ PULSE-B1 Below is the data for “ENG SPEED”, “MAS A/F SE-B1”, “THRTL SEN 1”, “HO2S2 (B1)” and “INJ PULSE-B1” when revving engine quickly up to 4,800 rpm under no load after warming up engine sufficiently. Each value is for reference, the exact value may vary. G H I J K L M PBIB2445E EC-905 TROUBLE DIAGNOSIS [HR (WITH EURO-OBD)] PBIB0668E EC-906 TROUBLE DIAGNOSIS - SPECIFICATION VALUE [HR (WITH EURO-OBD)] TROUBLE DIAGNOSIS - SPECIFICATION VALUE Description PFP:00031 A BBS0049Y The specification (SP) value indicates the tolerance of the value that is displayed in “DATA MONITOR (SPEC)” mode of CONSULT-II during normal operation of the Engine Control System. When the value in “DATA MONI- EC TOR (SPEC)” mode is within the SP value, the Engine Control System is confirmed OK. When the value in “DATA MONITOR (SPEC)” mode is NOT within the SP value, the Engine Control System may have one or more malfunctions. The SP value is used to detect malfunctions that may affect the Engine Control System, but will not light the C MI. The SP value will be displayed for the following three items: ● B/FUEL SCHDL (The fuel injection pulse width programmed into ECM prior to any learned on board cor- D rection) ● A/F ALPHA-B1 (The mean value of air-fuel ratio feedback correction factor per cycle) E ● MAS A/F SE-B1 (The signal voltage of the mass air flow sensor) Testing Condition ● ● ● ● ● ● – – ● – BBS0049Z Vehicle driven distance: More than 5,000 km (3,107 miles) F 2 Barometric pressure: 98.3 - 104.3 kPa (0.983 - 1.043 bar, 1.003 - 1.064 kg/cm , 14.25 - 15.12 psi) Atmospheric temperature: 20 - 30°C (68 - 86°F) Engine coolant temperature: 75 - 95°C (167 - 203°F) Engine speed: Idle Transmission: Warmed-up A/T models: After the engine is warmed up to normal operating temperature, drive vehicle until “FLUID TEMP SE” (A/T fluid temperature sensor signal) indicates more than 60°C (140°F). M/T models: After the engine is warmed up to normal operating temperature, drive vehicle for 5 minutes. Electrical load: Not applied Rear window defogger switch, air conditioner switch, lighting switch are OFF. Steering wheel is straight ahead. Inspection Procedure G H I J BBS004A0 NOTE: Perform “DATA MONITOR (SPEC)” mode in maximum scale display. 1. Perform EC-851, "Basic Inspection" . 2. Confirm that the testing conditions indicated above are met. 3. Select “B/FUEL SCHDL”, “A/F ALPHA-B1” and “MAS A/F SEB1” in “DATA MONITOR (SPEC)” mode with CONSULT-II. 4. Make sure that monitor items are within the SP value. 5. If NG, go to EC-908, "Diagnostic Procedure" . K L M SEF601Z EC-907 TROUBLE DIAGNOSIS - SPECIFICATION VALUE [HR (WITH EURO-OBD)] Diagnostic Procedure BBS004A1 OVERALL SEQUENCE PBIB2384E EC-908 TROUBLE DIAGNOSIS - SPECIFICATION VALUE [HR (WITH EURO-OBD)] A EC C D E F G H I J K L M PBIB3213E EC-909 TROUBLE DIAGNOSIS - SPECIFICATION VALUE [HR (WITH EURO-OBD)] DETAILED PROCEDURE 1. CHECK “A/F ALPHA-B1” 1. 2. 3. Start engine. Confirm that the testing conditions are met. Refer to EC-907, "Testing Condition" . Select “A/F ALPHA-B1” in “DATA MONITOR (SPEC)” mode, and make sure that the each indication is within the SP value. NOTE: Check “A/F ALPHA-B1” for approximately 1 minute because they may fluctuate. It is NG if the indication is out of the SP value even a little. OK or NG OK >> GO TO 17. NG (Less than the SP value)>>GO TO 2. NG (More than the SP value)>>GO TO 3. PBIB2369E 2. CHECK “B/FUEL SCHDL” Select “B/FUEL SCHDL” in “DATA MONITOR (SPEC)” mode, and make sure that the indication is within the SP value. OK or NG OK >> GO TO 4. NG (More than the SP value)>>GO TO 19. PBIB2332E 3. CHECK “B/FUEL SCHDL” Select “B/FUEL SCHDL” in “DATA MONITOR (SPEC)” mode, and make sure that the indication is within the SP value. OK or NG OK >> GO TO 6. NG (More than the SP value)>>GO TO 6. NG (Less than the SP value)>>GO TO 25. PBIB2332E 4. CHECK “A/F ALPHA-B1” 1. 2. 3. 4. Stop the engine. Disconnect PCV hose, and then plug it. Start engine. Select “A/F ALPHA-B1” in “DATA MONITOR (SPEC)” mode, and make sure that the each indication is within the SP value. OK or NG OK >> GO TO 5. NG >> GO TO 6. EC-910 TROUBLE DIAGNOSIS - SPECIFICATION VALUE [HR (WITH EURO-OBD)] 5. CHANGE ENGINE OIL 1. 2. A Stop the engine. Change engine oil. EC NOTE: This symptom may occur when a large amount of gasoline is mixed with engine oil because of driving conditions (such as when engine oil temperature does not rise enough since a journey distance is too short during winter). The symptom will not be detected after changing engine oil or changing driving con- C dition. >> INSPECTION END D 6. CHECK FUEL PRESSURE Check fuel pressure. (Refer to EC-860, "FUEL PRESSURE CHECK" .) OK or NG OK >> GO TO 9. NG (Fuel pressure is too high)>>Replace fuel pressure regulator, refer to EC-860, "FUEL PRESSURE CHECK" . GO TO 8. NG (Fuel pressure is too low)>>GO TO 7. E 7. DETECT MALFUNCTIONING PART G 1. – – – 2. Check the following. Clogged and bent fuel hose and fuel tube Clogged fuel filter Fuel pump and its circuit (Refer to EC-1215, "FUEL PUMP" .) If NG, repair or replace the malfunctioning part. (Refer to EC-860, "FUEL PRESSURE CHECK" .) If OK, replace fuel pressure regulator. F H I J >> GO TO 8. 8. CHECK “A/F ALPHA-B1” K 1. 2. Start engine. Select “A/F ALPHA-B1” in “DATA MONITOR (SPEC)” mode, and make sure that the each indication is within the SP value. OK or NG OK >> INSPECTION END NG >> GO TO 9. 9. PERFORM POWER BALANCE TEST 1. 2. Perform “POWER BALANCE” in “ACTIVE TEST” mode. Make sure that the each cylinder produces a momentary engine speed drop. OK or NG OK >> GO TO 12. NG >> GO TO 10. PBIB0133E EC-911 L M TROUBLE DIAGNOSIS - SPECIFICATION VALUE [HR (WITH EURO-OBD)] 10. DETECT MALFUNCTIONING PART 1. – – – – 2. Check the following. Ignition coil and its circuit (Refer to EC-1221, "IGNITION SIGNAL" .) Fuel injector and its circuit (Refer to EC-1209, "FUEL INJECTOR" .) Intake air leakage Low compression pressure (Refer to EM-173, "CHECKING COMPRESSION PRESSURE" .) If NG, repair or replace the malfunctioning part. If OK, replace fuel injector. (It may be caused by leakage from fuel injector or clogging.) >> GO TO 11. 11. CHECK “A/F ALPHA-B1” 1. 2. Start engine. Select “A/F ALPHA-B1” in “DATA MONITOR (SPEC)” mode, and make sure that the each indication is within the SP value. OK or NG OK >> INSPECTION END NG >> GO TO 12. 12. CHECK HEATED OXYGEN SENSOR 1 FUNCTION 1. 2. 3. Run engine at about 2,000 rpm for about 2 minutes under no load. Select “HO2S1 MNTR (B1)”, in “DATA MONITOR” mode. Running engine at 2,000 rpm under no load (The engine is warmed up to normal operating temperature.), check that the monitor fluctuates between LEAN and RICH more than 5 times during 10 seconds. 1 time 2 times : RICH → LEAN → RICH : RICH → LEAN → RICH → LEAN → RICH OK or NG OK >> GO TO 15. NG >> GO TO 13. SEF820Y 13. CHECK HEATED OXYGEN SENSOR 1 CIRCUIT Check heated oxygen sensor 1 and its circuit. Refer to EC-977, "DTC P0134 HO2S1" . >> GO TO 14. 14. CHECK “A/F ALPHA-B1” 1. 2. Start engine. Select “A/F ALPHA-B1” in “DATA MONITOR (SPEC)” mode, and make sure that the each indication is within the SP value. OK or NG OK >> INSPECTION END NG >> GO TO 15. EC-912 TROUBLE DIAGNOSIS - SPECIFICATION VALUE [HR (WITH EURO-OBD)] 15. DISCONNECT AND RECONNECT ECM HARNESS CONNECTOR 1. 2. A Stop the engine. Disconnect ECM harness connector. Check pin terminal and connector for damage, and then reconnect it. EC >> GO TO 16. 16. CHECK “A/F ALPHA-B1” C 1. 2. D Start engine. Select “A/F ALPHA-B1” in “DATA MONITOR (SPEC)” mode, and make sure that the each indication is within the SP value. OK or NG OK >> INSPECTION END NG >> Detect malfunctioning part according to EC-871, "Symptom Matrix Chart" . 17. CHECK “B/FUEL SCHDL” E F Select “B/FUEL SCHDL” in “DATA MONITOR (SPEC)” mode, and make sure that the indication is within the SP value. OK or NG OK >> INSPECTION END NG (More than the SP value)>>GO TO 18. NG (Less than the SP value)>>GO TO 25. G H I PBIB2332E 18. DETECT MALFUNCTIONING PART 1. – – – – – 2. – – – J Check for the cause of large engine friction. Refer to the following. Engine oil level is too high Engine oil viscosity Belt tension of power steering, alternator, A/C compressor, etc. is excessive Noise from engine Noise from transmission, etc. Check for the cause of insufficient combustion. Refer to the following. Valve clearance malfunction Intake valve timing control function malfunction Camshaft sprocket installation malfunction, etc. >> Repair or replace malfunctioning part, and then GO TO 30. 19. CHECK INTAKE SYSTEM Check for the cause of uneven air flow through mass air flow sensor. Refer to the following. ● Crushed air ducts ● Malfunctioning seal of air cleaner element ● Uneven dirt of air cleaner element ● Improper specification of intake air system OK or NG OK >> GO TO 21. NG >> Repair or replace malfunctioning part, and then GO TO 20. EC-913 K L M TROUBLE DIAGNOSIS - SPECIFICATION VALUE [HR (WITH EURO-OBD)] 20. CHECK “A/F ALPHA-B1” AND “B/FUEL SCHDL” Select “A/F ALPHA-B1” and “B/FUEL SCHDL” in “DATA MONITOR (SPEC)” mode, and make sure that the each indication is within the SP value. OK or NG OK >> INSPECTION END NG (“B/FUEL SCHDL” is more, “A/F ALPHA-B1” is less than the SP value)>>GO TO 21. 21. DISCONNECT AND RECONNECT MASS AIR FLOW SENSOR HARNESS CONNECTOR 1. 2. Stop the engine. Disconnect mass air flow sensor harness connector. Check pin terminal and connector for damage and then reconnect it again. >> GO TO 22. 22. CHECK “A/F ALPHA-B1” 1. 2. Start engine. Select “A/F ALPHA-B1” in “DATA MONITOR (SPEC)” mode, and make sure that the each indication is within the SP value. OK or NG OK >> 1. Detect malfunctioning part of mass air flow sensor circuit and repair it. Refer to EC-935, "DTC P0102, P0103 MAF SENSOR" . 2. GO TO 29. NG >> GO TO 23. 23. CHECK “MAS A/F SE-B1” Select “MAS A/F SE-B1” in “DATA MONITOR (SPEC)” mode, and make sure that the indication is within the SP value. OK or NG OK >> GO TO 24. NG (More than the SP value)>>Replace mass air flow sensor, and then GO TO 29. PBIB2370E 24. REPLACE ECM 1. 2. 3. 4. 5. Replace ECM. Perform initialization of NATS system and registration of all NATS ignition key IDs. Refer to BL-215, "NATS (Nissan Anti-Theft System)" . Perform EC-857, "Accelerator Pedal Released Position Learning" . Perform EC-857, "Throttle Valve Closed Position Learning" . Perform EC-858, "Idle Air Volume Learning" . >> GO TO 29. EC-914 TROUBLE DIAGNOSIS - SPECIFICATION VALUE [HR (WITH EURO-OBD)] 25. CHECK INTAKE SYSTEM A Check for the cause of uneven air flow through mass air flow sensor. Refer to the following. ● Crushed air ducts ● Malfunctioning seal of air cleaner element ● Uneven dirt of air cleaner element ● Improper specification of intake air system OK or NG OK >> GO TO 27. NG >> Repair or replace malfunctioning part, and then GO TO 26. EC C D 26. CHECK “B/FUEL SCHDL” Select “B/FUEL SCHDL” in “DATA MONITOR (SPEC)” mode, and make sure that the indication is within the SP value. OK or NG OK >> INSPECTION END NG (Less than the SP value)>>GO TO 27. 27. CHECK “MAS A/F SE-B1” E F G Select “MAS A/F SE-B1” in “DATA MONITOR (SPEC)” mode, and make sure that the indication is within the SP value. OK or NG OK >> GO TO 28. NG (Less than the SP value)>>Replace mass air flow sensor, and then GO TO 30. H I J PBIB2370E 28. CHECK INTAKE SYSTEM K Check for the cause of air leak after the mass air flow sensor. Refer to the following. ● Disconnection, looseness, and cracks in air duct ● Looseness of oil filler cap ● Disconnection of oil level gauge ● Open stuck, breakage, hose disconnection, or cracks of PCV valve ● Disconnection or cracks of EVAP purge hose, open stuck of EVAP canister purge volume control solenoid valve ● Malfunctioning seal of rocker cover gasket ● Disconnection, looseness, or cracks of hoses, such as vacuum hose, connecting to intake air system parts ● Malfunctioning seal of intake air system, etc. >> GO TO 30. 29. CHECK “A/F ALPHA-B1” AND “B/FUEL SCHDL” Select “A/F ALPHA-B1” and “B/FUEL SCHDL” in “DATA MONITOR (SPEC)” mode, and make sure that the each indication is within the SP value. OK or NG OK >> INSPECTION END NG >> Detect malfunctioning part according to EC-871, "Symptom Matrix Chart" . EC-915 L M TROUBLE DIAGNOSIS - SPECIFICATION VALUE [HR (WITH EURO-OBD)] 30. CHECK “B/FUEL SCHDL” Select “B/FUEL SCHDL” in “DATA MONITOR (SPEC)” mode, and then make sure that the indication is within the SP value. OK or NG OK >> INSPECTION END NG >> Detect malfunctioning part according to EC-871, "Symptom Matrix Chart" . EC-916 TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT [HR (WITH EURO-OBD)] TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT Description PFP:00006 A BBS004A2 Intermittent incidents may occur. In many cases, the malfunction resolves itself (the part or circuit function returns to normal without intervention). It is important to realize that the symptoms described in the customer's EC complaint often do not recur on (1st trip) DTC visits. Realize also that the most frequent cause of intermittent incidents occurrences is poor electrical connections. Because of this, the conditions under which the incident occurred may not be clear. Therefore, circuit checks made as part of the standard diagnostic procedure may C not indicate the specific malfunctioning area. Common Intermittent Incidents Report Situations STEP in Work Flow 2 3 or 4 Situation D The CONSULT-II is used. The SELF-DIAG RESULTS screen shows time data other than [0] or [1t]. The symptom described by the customer does not recur. 5 (1st trip) DTC does not appear during the DTC Confirmation Procedure. 10 The Diagnostic Procedure for PXXXX does not indicate the malfunctioning area. Diagnostic Procedure E BBS004A3 F 1. INSPECTION START Erase (1st trip) DTCs. Refer to EC-841, "HOW TO ERASE EMISSION-RELATED DIAGNOSTIC INFORMATION" . G H >> GO TO 2. 2. CHECK GROUND TERMINALS Check ground terminals for corroding or loose connection. Refer to EC-924, "Ground Inspection" . OK or NG OK >> GO TO 3. NG >> Repair or replace. 3. SEARCH FOR ELECTRICAL INCIDENT I J K Perform GI-25, "How to Perform Efficient Diagnosis for an Electrical Incident" , “INCIDENT SIMULATION TESTS”. OK or NG OK >> INSPECTION END NG >> Repair or replace. EC-917 L M POWER SUPPLY AND GROUND CIRCUIT [HR (WITH EURO-OBD)] POWER SUPPLY AND GROUND CIRCUIT Wiring Diagram PFP:24110 BBS004A4 MBWA1455E EC-918 POWER SUPPLY AND GROUND CIRCUIT [HR (WITH EURO-OBD)] Specification data are reference values and are measured between each terminal and ground. CAUTION: Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM's transistor. Use a ground other than ECM terminals, such as the ground. TERMINAL NO. 10 11 EC WIRE COLOR B B/W ITEM ECM ground CONDITION [Engine is running] ● Idle speed [Engine is running] [Ignition switch: OFF] ● 32 P ECM relay (Self shut-off) For a few seconds after turning ignition switch OFF [Ignition switch: OFF] ● 93 O Ignition switch 105 G Power supply for ECM 108 B ECM ground More than a few seconds after turning ignition switch OFF DATA (DC Voltage) [Ignition switch: ON] [Ignition switch: ON] BATTERY VOLTAGE (11 - 14V) Diagnostic Procedure E BATTERY VOLTAGE (11 - 14V) BATTERY VOLTAGE (11 - 14V) Idle speed D 0 - 1.0V 0V [Engine is running] C Body ground [Ignition switch: OFF] ● F G Body ground H BBS004A5 1. INSPECTION START I Start engine. Is engine running? Yes or No Yes >> GO TO 8. No >> GO TO 2. J K 2. CHECK ECM POWER SUPPLY CIRCUIT-I 1. 2. A Turn ignition switch OFF and then ON. Check voltage between ECM terminal 93 and ground with CONSULT-II or tester. L M Voltage: Battery voltage OK or NG OK >> GO TO 4. NG >> GO TO 3. PBIA9561J EC-919 POWER SUPPLY AND GROUND CIRCUIT [HR (WITH EURO-OBD)] 3. DETECT MALFUNCTIONING PART Check the following. ● Harness connectors M1, E101 ● Fuse block (J/B) connector M1. ● 10A fuse ● Harness for open or short between ECM and fuse >> Repair open circuit or short to ground or short to power in harness or connectors. 4. CHECK GROUND CONNECTIONS-1 1. 2. Turn ignition switch OFF. Loosen and retighten ground screws on the body. Refer to EC-924, "Ground Inspection" . MBIB1550E 1. IPDM E/R 2. Body ground 3. Body ground OK or NG OK >> GO TO 5. NG >> Repair or replace ground connections. 5. CHECK ECM GROUND CIRCUIT FOR OPEN AND SHORT-I 1. 2. Disconnect ECM harness connector. Check harness continuity between ECM terminals 10, 11, 108 and ground. Refer to Wiring Diagram. Continuity should exist. 3. Also check harness for short to power. OK or NG OK >> GO TO 7. NG >> GO TO 6. 6. DETECT MALFUNCTIONING PART Check the following. Harness connectors F1, E59 ● Harness for open or short between ECM and ground ● >> Repair open circuit or short to power in harness or connectors. EC-920 POWER SUPPLY AND GROUND CIRCUIT [HR (WITH EURO-OBD)] 7. CHECK ECM POWER SUPPLY CIRCUIT-II 1. 2. 3. A Reconnect ECM harness connector. Turn ignition switch ON. Check voltage between IPDM E/R terminal 33 and ground with CONSULT-II or tester. EC Voltage: Battery voltage C OK or NG OK >> Go to EC-1221, "IGNITION SIGNAL" . NG >> GO TO 8. D MBIB1353E E 8. CHECK ECM POWER SUPPLY CIRCUIT-III 1. 2. 3. F Turn ignition switch OFF and wait at least 10 seconds. Turn ignition switch ON and then OFF. Check voltage between ECM terminal 105 and ground with CONSULT-II or tester. Voltage: G After turning ignition switch OFF, battery voltage will exist for a few seconds, then drop approximately 0V. OK or NG OK >> GO TO 14. NG (Battery voltage does not exist.)>>GO TO 9. NG (Battery voltage exists for more than a few seconds.)>>GO TO 11. H I PBIB3037E J 9. CHECK ECM POWER SUPPLY CIRCUIT-IV 1. 2. K Turn ignition switch OFF and wait at least 10 seconds. Check voltage between ECM terminal 32 and ground with CONSULT-II or tester. L Voltage: Battery voltage OK or NG OK >> GO TO 10. NG >> GO TO 11. M PBIA9562J EC-921 POWER SUPPLY AND GROUND CIRCUIT [HR (WITH EURO-OBD)] 10. CHECK ECM POWER SUPPLY CIRCUIT-V 1. 2. 3. Disconnect ECM harness connector. Disconnect IPDM E/R harness connector E7. Check harness continuity between ECM terminal 105 and IPDM E/R terminal 32. Refer to Wiring Diagram. Continuity should exist. 4. Also check harness for short to ground and short to power. OK or NG OK >> GO TO 17. NG >> Repair open circuit or short to ground or short to power in harness or connectors. 11. CHECK ECM POWER SUPPLY CIRCUIT-VI 1. 2. 3. Disconnect ECM harness connector. Disconnect IPDM E/R harness connector E7. Check harness continuity between ECM terminal 32 and IPDM E/R terminal 29. Refer to Wiring Diagram. Continuity should exist. 4. Also check harness for short to ground and short to power. OK or NG OK >> GO TO 13. NG >> GO TO 12. 12. DETECT MALFUNCTIONING PART Check the following. ● Harness or connectors E59, F1 ● Harness for open or short between ECM and IPDM E/R >> Repair open circuit or short to ground or short to power in harness or connectors. 13. CHECK 20A FUSE 1. Disconnect 20A fuse from IPDM E/R. 2. Check 20A fuse. OK or NG OK >> GO TO 17. NG >> Replace 20A fuse. EC-922 POWER SUPPLY AND GROUND CIRCUIT [HR (WITH EURO-OBD)] 14. CHECK GROUND CONNECTIONS-II 1. A Loosen and retighten ground screws on the body. Refer to EC-924, "Ground Inspection" . EC C D MBIB1550E 1. IPDM E/R 2. Body ground 3. E Body ground OK or NG OK >> GO TO 15. NG >> Repair or replace ground connections. F 15. CHECK ECM GROUND CIRCUIT FOR OPEN AND SHORT-II G 1. 2. H Disconnect ECM harness connector. Check harness continuity between ECM terminals 10, 11, 108 and ground. Refer to Wiring Diagram. Continuity should exist. I 3. Also check harness for short to power. OK or NG OK >> GO TO 17. NG >> GO TO 16. J 16. DETECT MALFUNCTIONING PART K Check the following. ● Harness or connectors F1, E59 ● Harness for open or short between ECM and ground >> Repair open circuit or short to power in harness or connectors. 17. CHECK INTERMITTENT INCIDENT Refer to EC-917, "TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT" . OK or NG OK >> Replace IPDM E/R. Refer to PG-18, "IPDM E/R (INTELLIGENT POWER DISTRIBUTION MODULE ENGINE ROOM)" NG >> Repair open circuit or short to power in harness or connectors. EC-923 L M POWER SUPPLY AND GROUND CIRCUIT [HR (WITH EURO-OBD)] Ground Inspection BBS004A6 Ground connections are very important to the proper operation of electrical and electronic circuits. Ground connections are often exposed to moisture, dirt and other corrosive elements. The corrosion (rust) can become an unwanted resistance. This unwanted resistance can change the way a circuit works. Electronically controlled circuits are very sensitive to proper grounding. A loose or corroded ground can drastically affect an electronically controlled circuit. A poor or corroded ground can easily affect the circuit. Even when the ground connection looks clean, there can be a thin film of rust on the surface. When inspecting a ground connection follow these rules: ● Remove the ground bolt or screw. ● Inspect all mating surfaces for tarnish, dirt, rust, etc. ● Clean as required to assure good contact. ● Reinstall bolt or screw securely. ● Inspect for “add-on” accessories which may be interfering with the ground circuit. ● If several wires are crimped into one ground eyelet terminal, check for proper crimps. Make sure all of the wires are clean, securely fastened and providing a good ground path. If multiple wires are cased in one eyelet make sure no ground wires have excess wire insulation. For detailed ground distribution information, refer to PG-38, "Ground Distribution" . PBIB1870E EC-924 DTC U1000, U1001 CAN COMMUNICATION LINE [HR (WITH EURO-OBD)] DTC U1000, U1001 CAN COMMUNICATION LINE Description PFP:23710 A BBS004A7 CAN (Controller Area Network) is a serial communication line for real time application. It is an on-vehicle multiplex communication line with high data communication speed and excellent error detection ability. Many elec- EC tronic control units are equipped onto a vehicle, and each control unit shares information and links with other control units during operation (not independent). In CAN communication, control units are connected with 2 communication lines (CAN H line, CAN L line) allowing a high rate of information transmission with less wiring. C Each control unit transmits/receives data but selectively reads required data only. On Board Diagnosis Logic DTC No. 1000*1 U1001*2 1001*2 D Trouble diagnosis name U1000*1 DTC detecting condition ● CAN communication line BBS004A8 ● ECM cannot communicate to other control units. ECM cannot communicate for more than the specified time. Possible cause ● Harness or connectors (CAN communication line is open or shorted.) E F *1: This self-diagnosis has the one trip detection logic. *2: The MI will not light up for this self-diagnosis. G DTC Confirmation Procedure 1. 2. 3. BBS004A9 Turn ignition switch ON and wait at least 3 seconds. Select “DATA MONITOR” mode with CONSULT-II. If 1st trip DTC is detected, go to EC-927, "Diagnostic Procedure" . H I J K L M EC-925 DTC U1000, U1001 CAN COMMUNICATION LINE [HR (WITH EURO-OBD)] Wiring Diagram BBS004AA MBWA1456E EC-926 DTC U1000, U1001 CAN COMMUNICATION LINE [HR (WITH EURO-OBD)] Diagnostic Procedure BBS004AB Go to LAN-3, "Precautions When Using CONSULT-II" . A EC C D E F G H I J K L M EC-927 DTC U1010 CAN COMMUNICATION [HR (WITH EURO-OBD)] DTC U1010 CAN COMMUNICATION Description PFP:23710 BBS004AC CAN (Controller Area Network) is a serial communication line for real time application. It is an on-vehicle multiplex communication line with high data communication speed and excellent error detection ability. Many electronic control units are equipped onto a vehicle, and each control unit shares information and links with other control units during operation (not independent). In CAN communication, control units are connected with 2 communication lines (CAN H line, CAN L line) allowing a high rate of information transmission with less wiring. Each control unit transmits/receives data but selectively reads required data only. On Board Diagnosis Logic BBS004AD This self-diagnosis has the one trip detection logic (A/T). The MI will not light up for this self-diagnosis (M/T). DTC No. U1010 1010 Trouble diagnosis name CAN communication bus DTC detecting condition Initializing CAN communication bus is malfunctioning. DTC Confirmation Procedure Possible cause ● ECM BBS004AE WITH CONSULT-II 1. 2. 3. Turn ignition switch ON. Select “DATA MONITOR” mode with CONSULT-II. If 1st trip DTC is detected, go to EC-929, "Diagnostic Procedure" . SEF058Y WITH GST Follow the procedure “WITH CONSULT-II” above. EC-928 DTC U1010 CAN COMMUNICATION [HR (WITH EURO-OBD)] Diagnostic Procedure BBS004AF 1. INSPECTION START 1. 2. 3. 4. 5. A With CONSULT-II Turn ignition switch ON. Select “SELF-DIAG RESULTS” mode with CONSULT-II. Touch “ERASE”. Perform DTC Confirmation Procedure. See EC-928, "DTC Confirmation Procedure" . Is the 1st trip DTC U1010 displayed again? With GST 1. Turn ignition switch ON. 2. Select Service $04 with GST. 3. Perform DTC Confirmation Procedure. See EC-928, "DTC Confirmation Procedure" . 4. Is the 1st trip DTC U1010 displayed again? Yes or No Yes >> GO TO 2. No >> INSPECTION END EC C D E F G 2. REPLACE ECM 1. 2. 3. 4. 5. Replace ECM. Perform initialization of NATS system and registration of all NATS ignition key IDs. Refer to BL-218, "ECM Re-communicating Function" . Perform EC-857, "Accelerator Pedal Released Position Learning" . Perform EC-857, "Throttle Valve Closed Position Learning" . Perform EC-858, "Idle Air Volume Learning" . H I J >> INSPECTION END K L M EC-929 DTC P0011 IVT CONTROL [HR (WITH EURO-OBD)] DTC P0011 IVT CONTROL Description PFP:23796 BBS004AG SYSTEM DESCRIPTION Sensor Input signal to ECM Crankshaft position sensor (POS) Camshaft position sensor (PHASE) Engine speed and piston position Engine coolant temperature sensor Engine coolant temperature Wheel sensor Vehicle speed* ECM function Intake valve timing control Actuator Intake valve timing control solenoid valve *: This signal is sent to the ECM through CAN communication line. MBIB1560E This mechanism hydraulically controls cam phases continuously with the fixed operating angle of the intake valve. The ECM receives signals such as crankshaft position, camshaft position, engine speed, and engine coolant temperature. Then, the ECM sends ON/OFF pulse duty signals to the intake valve timing control solenoid valve depending on driving status. This makes it possible to control the shut/open timing of the intake valve to increase engine torque in low/mid speed range and output in high-speed range. CONSULT-II Reference Value in Data Monitor Mode BBS004AH Specification data are reference values. MONITOR ITEM INT/V TIM (B1) INT/V SOL (B1) CONDITION ● Engine: After warming up ● Air conditioner switch: OFF ● Shift lever: P or N (A/T), Neutral (M/T) ● No load ● Engine: After warming up ● Air conditioner switch: OFF ● Shift lever: P or N (A/T), Neutral (M/T) ● No load SPECIFICATION Idle −5° - 5°CA 2,500 rpm Approx. 0° - 40°CA Idle 0% - 2% 2,500 rpm Approx. 0% - 90% EC-930 DTC P0011 IVT CONTROL [HR (WITH EURO-OBD)] On Board Diagnosis Logic BBS004AI A The MI will not light up for these self-diagnoses. DTC No. P0011 0011 Trouble diagnosis name Intake valve timing control performance Detecting condition There is a gap between angle of target and phase-control angle degree. Possible cause EC ● Crankshaft position sensor (POS) ● Camshaft position sensor (PHASE) ● Intake valve timing control solenoid valve ● Accumulation of debris to the signal pick-up portion of the camshaft ● Timing chain installation ● Foreign matter caught in the oil groove for intake valve timing control C D E FAIL-SAFE MODE ECM enters in fail-safe mode when the malfunction is detected. Detected items Intake valve timing control Engine operating condition in fail-safe mode The signal is not energized to the solenoid valve and the valve control does not function DTC Confirmation Procedure F BBS004AJ CAUTION: Always drive at a safe speed. NOTE: ● If DTC P0011 is displayed with DTC P1111, first perform trouble diagnosis for DTC P1111. See EC1077, "DTC P1111 IVT CONTROL SOLENOID VALVE" . ● If DTC Confirmation Procedure has been previously conducted, always turn ignition switch OFF and wait at least 10 seconds before conducting the next test. TESTING CONDITION: Before performing the following procedure, confirm that battery voltage is between 10V and 16V at idle. G H I J WITH CONSULT-II 1. 2. 3. Turn ignition switch ON and select “DATA MONITOR” mode with CONSULT-II. Start engine and warm it up to the normal operating temperature. Maintain the following conditions for at least 6 consecutive seconds. Hold the accelerator pedal as steady as possible. ENG SPEED 1,200 - 2,000 rpm (A constant rotation is maintained.) COOLAN TEMP/S 60 - 120°C (140 - 248°F) B/FUEL SCHDL More than 3.5 msec Shift lever A/T: P or N position M/T: Neutral position 4. 5. 6. K L M SEF174Y Let engine idle for 10 seconds. If the 1st trip DTC is detected, go to EC-932, "Diagnostic Procedure" . If the 1st trip DTC is not detected, go to next step. Maintain the following conditions for at least 20 consecutive seconds. ENG SPEED 1,700 - 3,175 rpm (A constant rotation is maintained.) COOLAN TEMP/S 70 - 105°C (158 - 221°F) EC-931 DTC P0011 IVT CONTROL [HR (WITH EURO-OBD)] Shift lever 1st or 2nd position Driving location uphill Driving vehicle uphill (Increased engine load will help maintain the driving conditions required for this test.) 7. If 1st trip DTC is detected, go to EC-932, "Diagnostic Procedure" . WITH GST Follow the procedure “WITH CONSULT-II” above. Diagnostic Procedure BBS004AK 1. CHECK OIL PRESSURE WARNING LAMP 1. 2. Start engine. Check oil pressure warning lamp and confirm it is not illuminated. OK or NG OK >> GO TO 2. KG >> Go to LU-16, "OIL PRESSURE CHECK" . PBIA8559J 2. CHECK INTAKE VALVE TIMING CONTROL SOLENOID VALVE Refer to EC-933, "Component Inspection" . OK or NG OK >> GO TO 3. NG >> Replace intake valve timing control solenoid valve. 3. CHECK CRANKSHAFT POSITION SENSOR (POS) Refer to EC-1048, "Component Inspection" . OK or NG OK >> GO TO 4. NG >> Replace crankshaft position sensor (POS). 4. CHECK CAMSHAFT POSITION SENSOR (PHASE) Refer to EC-1054, "Component Inspection" . OK or NG OK >> GO TO 5. NG >> Replace camshaft position sensor (PHASE). EC-932 DTC P0011 IVT CONTROL [HR (WITH EURO-OBD)] 5. CHECK CAMSHAFT (INTAKE) A Check the following. ● Accumulation of debris to the signal plate of camshaft (1) rear end ● Chipping signal plate of camshaft rear end OK or NG OK >> GO TO 6. NG >> Remove debris and clean the signal plate of camshaft rear end or replace camshaft. EC C D PBIA9557J 6. CHECK TIMING CHAIN INSTALLATION E Check service records for any recent repairs that may cause timing chain misaligned. Are there any service records that may cause timing chain misaligned? Yes or No Yes >> Check timing chain installation. Refer to EM-142, "TIMING CHAIN" . No >> GO TO 7. F G 7. CHECK LUBRICATION CIRCUIT Refer to EM-166, "Inspection of Camshaft Sprocket (INT) Oil Groove" . OK or NG OK >> GO TO 8. NG >> Clean lubrication line. H I 8. CHECK INTERMITTENT INCIDENT Refer to EC-917, "TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT" . For Wiring Diagram, refer to EC-1044, "Wiring Diagram" for CKP sensor (POS) and EC-1051, "Wiring Diagram" for CMP sensor (PHASE). J K >> INSPECTION END Component Inspection BBS004AL INTAKE VALVE TIMING CONTROL SOLENOID VALVE 1. 2. 3. Disconnect intake valve timing control solenoid valve harness connector. Check resistance between intake valve timing control solenoid valve as follows. Terminal Resistance 1 and 2 6.7 - 7.7Ω [at 20°C (68°F)] 1 or 2 and ground ∞Ω (Continuity should not exist.) If NG, replace intake valve timing control solenoid valve. If OK, go to next step. Remove intake valve timing control solenoid valve. EC-933 L M PBIB0193E DTC P0011 IVT CONTROL [HR (WITH EURO-OBD)] 4. Provide 12V DC between intake valve timing control solenoid valve terminals and then interrupt it. Make sure that the plunger moves as shown in the figure. CAUTION: Do not apply 12V DC continuously for 5 seconds or more. Doing so may result in damage to the coil in intake valve timing control solenoid valve. If NG, replace intake valve timing control solenoid valve. NOTE: Always replace O-ring when intake valve timing control solenoid valve is removed. Removal and Installation PBIB2275E BBS004AM INTAKE VALVE TIMING CONTROL SOLENOID VALVE Refer to EM-142, "TIMING CHAIN" . EC-934 DTC P0102, P0103 MAF SENSOR [HR (WITH EURO-OBD)] DTC P0102, P0103 MAF SENSOR Component Description PFP:22680 A BBS004AN The mass air flow sensor (1) is placed in the stream of intake air. It measures the intake flow rate by measuring a part of the entire intake flow. The mass air flow sensor controls the temperature of the hot wire to a certain amount. The heat generated by the hot wire is reduced as the intake air flows around it. The more air, the greater the heat loss. Therefore, the electric current supplied to hot wire is changed to maintain the temperature of the hot wire as air flow increases. The ECM detects the air flow by means of this current change. EC C D PBIA9559J E CONSULT-II Reference Value in Data Monitor Mode BBS004AO Specification data are reference values. MONITOR ITEM MAS A/F SE-B1 CONDITION SPECIFICATION ● Engine: After warming up ● Shift lever: P or N (A/T), Neutral (M/T) ● Air conditioner switch: OFF ● No load ● Engine: After warming up ● Shift lever: P or N (A/T), Neutral (M/T) ● Air conditioner switch: OFF ● No load CAL/LD VALUE MASS AIRFLOW Idle 10% - 35% 2,500 rpm 10% - 35% G H Idle 1.0 - 4.0 g·m/s I 2,500 rpm 2.0 - 10.0 g·m/s J On Board Diagnosis Logic BBS004AP These self-diagnoses have the one trip detection logic. DTC No. P0102 0102 P0103 0103 F See EC-907, "TROUBLE DIAGNOSIS - SPECIFICATION VALUE" . Trouble diagnosis name Mass air flow sensor circuit low input Mass air flow sensor circuit high input K DTC detecting condition Possible cause An excessively low voltage from the sensor is sent to ECM. ● Harness or connectors (The sensor circuit is open or shorted.) ● Intake air leaks ● Mass air flow sensor ● Harness or connectors (The sensor circuit is open or shorted.) ● Mass air flow sensor An excessively high voltage from the sensor is sent to ECM. FAIL-SAFE MODE When the malfunction is detected, the ECM enters fail-safe mode and the MI lights up. Detected items Mass air flow sensor circuit Engine operating condition in fail-safe mode Engine speed will not rise more than 2,400 rpm due to the fuel cut. EC-935 L M DTC P0102, P0103 MAF SENSOR [HR (WITH EURO-OBD)] DTC Confirmation Procedure BBS004AQ NOTE: If DTC Confirmation Procedure has been previously conducted, always turn ignition switch OFF and wait at least 10 seconds before conducting the next test. PROCEDURE FOR DTC P0102 With CONSULT-II 1. 2. 3. 4. Turn ignition switch ON. Select “DATA MONITOR” mode with CONSULT-II. Start engine and wait at least 5 seconds. If DTC is detected, go to EC-938, "Diagnostic Procedure" . SEF058Y With GST Follow the procedure “With CONSULT-II” above. PROCEDURE FOR DTC P0103 With CONSULT-II 1. 2. 3. 4. 5. 6. Turn ignition switch ON. Select “DATA MONITOR” mode with CONSULT-II. Wait at least 5 seconds. If DTC is detected, go to EC-938, "Diagnostic Procedure" . If DTC is not detected, go to next step. Start engine and wait at least 5 seconds. If DTC is detected, go to EC-938, "Diagnostic Procedure" . SEF058Y With GST Follow the procedure “With CONSULT-II” above. EC-936 DTC P0102, P0103 MAF SENSOR [HR (WITH EURO-OBD)] Wiring Diagram BBS004AR A EC C D E F G H I J K L M MBWA1457E EC-937 DTC P0102, P0103 MAF SENSOR [HR (WITH EURO-OBD)] Specification data are reference values and are measured between each terminal and ground. CAUTION: Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM's transistor. Use a ground other than ECM terminals, such as the ground. TERMINAL NO. WIRE COLOR ITEM CONDITION [Engine is running] [Ignition switch: OFF] ● 32 P ECM relay (Self shut-off) For a few seconds after turning ignition switch OFF [Ignition switch: OFF] ● More than a few seconds after turning ignition switch OFF [Ignition switch: ON] ● Engine stopped DATA (DC Voltage) 0 - 1.0V BATTERY VOLTAGE (11 - 14V) Approximately 0.4V [Engine is running] 45 G Mass air flow sensor ● Warm-up condition ● Idle speed [Engine is running] ● Warm-up condition ● Engine is revving from idle to about 4,000 rpm 1.0 - 1.3V 1.0 - 1.3 to Approximately 2.4V (Check for linear voltage rise in response to engine being increased to about 4,000 rpm.) [Engine is running] 52 105 LG G Sensor ground (Mass air flow sensor) Power supply for ECM ● Warm-up condition ● Idle speed [Ignition switch: ON] Diagnostic Procedure Approximately 0V BATTERY VOLTAGE (11 - 14V) BBS004AS 1. INSPECTION START Which malfunction (P0102 or P0103) is duplicated? P0102 or P0103 P0102 >> GO TO 2. P0103 >> GO TO 3. 2. CHECK INTAKE SYSTEM Check the following for connection. Air duct ● Vacuum hoses ● Intake air passage between air duct to intake manifold OK or NG OK >> GO TO 3. NG >> Reconnect the parts. ● EC-938 DTC P0102, P0103 MAF SENSOR [HR (WITH EURO-OBD)] 3. CHECK GROUND CONNECTIONS 1. 2. A Turn ignition switch OFF. Loosen and retighten ground screws on the body. Refer to EC-924, "Ground Inspection" . EC C D E MBIB1550E 1. IPDM E/R 2. Body ground 3. Body ground F OK or NG OK >> GO TO 4. NG >> Repair or replace ground connections. G 4. CHECK MAF SENSOR POWER SUPPLY CIRCUIT 1. 2. H Disconnect mass air flow (MAF) sensor (1) harness connector. Turn ignition switch ON. I J PBIB2948E 3. Check voltage between MAF sensor terminal 2 and ground with CONSULT-II or tester. K L Voltage: Battery voltage OK or NG OK >> GO TO 6. NG >> GO TO 5. M PBIB1168E 5. DETECT MALFUNCTIONING PART Check the following. ● Harness connectors E59, F1 ● Harness for open or short between mass air flow sensor and ECM ● Harness for open or short between mass air flow sensor and IPDM E/R >> Repair open circuit or short to ground or short to power in harness or connectors. EC-939 DTC P0102, P0103 MAF SENSOR [HR (WITH EURO-OBD)] 6. CHECK MAF SENSOR GROUND CIRCUIT FOR OPEN AND SHORT 1. 2. 3. Turn ignition switch OFF. Disconnect ECM harness connector. Check harness continuity between MAF sensor terminal 3 and ECM terminal 52. Refer to Wiring Diagram. Continuity should exist. 4. Also check harness for short to ground and short to power. OK or NG OK >> GO TO 7. NG >> Repair open circuit or short to ground or short to power in harness or connectors. 7. CHECK MAF SENSOR INPUT SIGNAL CIRCUIT FOR OPEN AND SHORT 1. Check harness continuity between MAF sensor terminal 4 and ECM terminal 45. Refer to Wiring Diagram. Continuity should exist. 2. Also check harness for short to ground and short to power. OK or NG OK >> GO TO 8. NG >> Repair open circuit or short to ground or short to power in harness or connectors. 8. CHECK MASS AIR FLOW SENSOR Refer to EC-940, "Component Inspection" . OK or NG OK >> GO TO 9. NG >> Replace mass air flow sensor. 9. CHECK INTERMITTENT INCIDENT Refer to EC-917, "TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT" . >> INSPECTION END Component Inspection BBS004AT MASS AIR FLOW SENSOR With CONSULT-II 1. 2. 3. 4. Reconnect all harness connectors disconnected. Start engine and warm it up to normal operating temperature. Connect CONSULT-II and select “DATA MONITOR” mode. Select “MAS A/F SE-B1” and check indication under the following conditions. Condition MAS A/F SE-B1 (V) Ignition switch ON (Engine stopped.) Approx. 0.4 Idle (Engine is warmed-up to normal operating temperature.) 1.0 - 1.3 Idle to about 4,000 rpm 1.0 - 1.3 to Approx. 2.4* *: Check for linear voltage rise in response to engine being increased to about 4,000 rpm. PBIB2371E 5. a. If the voltage is out of specification, proceed the following. Check for the cause of uneven air flow through mass air flow sensor. Refer to following. EC-940 DTC P0102, P0103 MAF SENSOR [HR (WITH EURO-OBD)] Crushed air ducts Malfunctioning seal of air cleaner element ● Uneven dirt of air cleaner element ● Improper specification of intake air system parts If NG, repair or replace malfunctioning part and perform step 2 to 4 again. If OK, go to next step. Turn ignition switch OFF. Disconnect mass air flow sensor harness connector and reconnect it again. Perform step 2 to 4 again. If NG, clean or replace mass air flow sensor. ● A ● b. 6. 7. 8. 9. EC C D Without CONSULT-II 1. 2. 3. Reconnect all harness connectors disconnected. Start engine and warm it up to normal operating temperature. Check voltage between ECM terminal 45 (Mass air flow sensor signal) and ground. E F Condition Voltage V Ignition switch ON (Engine stopped.) Approx. 0.4 Idle (Engine is warmed-up to normal operating temperature.) 1.0 - 1.3 Idle to about 4,000 rpm G 1.0 - 1.3 to Approx. 2.4* H *: Check for linear voltage rise in response to engine being increased to about 4,000 rpm. PBIA9564J 4. a. b. 5. 6. 7. 8. If the voltage is out of specification, proceed the following. Check for the cause of uneven air flow through mass air flow sensor. Refer to following. ● Crushed air ducts ● Malfunctioning seal of air cleaner element ● Uneven dirt of air cleaner element ● Improper specification of intake air system parts If NG, repair or replace malfunctioning part and perform step 2 to 3 again. If OK, go to next step. Turn ignition switch OFF. Disconnect mass air flow sensor harness connector and reconnect it again. Perform step 2 and 3 again. If NG, clean or replace mass air flow sensor. Removal and Installation I J K L BBS004AU MASS AIR FLOW SENSOR Refer to EM-118, "AIR CLEANER AND AIR DUCT" . EC-941 M DTC P0112, P0113 IAT SENSOR [HR (WITH EURO-OBD)] DTC P0112, P0113 IAT SENSOR Component Description PFP:22630 BBS004AV The intake air temperature sensor is built-into mass air flow sensor (1). The sensor detects intake air temperature and transmits a signal to the ECM. The temperature sensing unit uses a thermistor which is sensitive to the change in temperature. Electrical resistance of the thermistor decreases in response to the temperature rise. PBIA9559J Intake air temperature °C (°F) Voltage* V Resistance kΩ 25 (77) 3.3 1.800 - 2.200 80 (176) 1.2 0.283 - 0.359 *: This data is reference value and is measured between ECM terminal 46 (Intake air temperature sensor) and ground. CAUTION: Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM's transistor. Use a ground other than ECM terminals, such as the ground. SEF012P On Board Diagnosis Logic DTC No. Trouble diagnosis name BBS004AW DTC detecting condition P0112 0112 Intake air temperature sensor circuit low input An excessively low voltage from the sensor is sent to ECM. P0113 0113 Intake air temperature sensor circuit high input An excessively high voltage from the sensor is sent to ECM. DTC Confirmation Procedure Possible cause ● Harness or connectors (The sensor circuit is open or shorted.) ● Intake air temperature sensor BBS004AX NOTE: If DTC Confirmation Procedure has been previously conducted, always turn ignition switch OFF and wait at least 10 seconds before conducting the next test. WITH CONSULT-II 1. 2. 3. 4. Turn ignition switch ON. Select “DATA MONITOR” mode with CONSULT-II. Wait at least 5 seconds. If 1st trip DTC is detected, go to EC-945, "Diagnostic Procedure" . SEF058Y EC-942 DTC P0112, P0113 IAT SENSOR [HR (WITH EURO-OBD)] WITH GST A Follow the procedure “WITH CONSULT-II” above. EC C D E F G H I J K L M EC-943 DTC P0112, P0113 IAT SENSOR [HR (WITH EURO-OBD)] Wiring Diagram BBS004AY MBWA1458E EC-944 DTC P0112, P0113 IAT SENSOR [HR (WITH EURO-OBD)] Diagnostic Procedure BBS004AZ 1. CHECK GROUND CONNECTIONS 1. 2. A Turn ignition switch OFF. Loosen and retighten ground screws on the body. Refer to EC-924, "Ground Inspection" . EC C D E MBIB1550E 1. IPDM E/R 2. Body ground 3. F Body ground OK or NG OK >> GO TO 2. NG >> Repair or replace ground connections. G 2. CHECK INTAKE AIR TEMPERATURE SENSOR POWER SUPPLY CIRCUIT 1. 2. H Disconnect mass air flow sensor (intake air temperature sensor is built-into) (1) harness connector. Turn ignition switch ON. I J K PBIB2948E 3. Check voltage between mass air flow sensor terminal 5 and ground with CONSULT-II or tester. L Voltage: Approximately 5V M OK or NG OK >> GO TO 3. NG >> Repair open circuit or short to ground or short to power in harness or connectors. PBIB1169E EC-945 DTC P0112, P0113 IAT SENSOR [HR (WITH EURO-OBD)] 3. CHECK INTAKE AIR TEMPERATURE SENSOR GROUND CIRCUIT FOR OPEN AND SHORT 1. 2. 3. Turn ignition switch OFF. Disconnect ECM harness connector. Check harness continuity between mass air flow sensor terminal 6 and ECM terminal 55. Refer to Wiring Diagram. Continuity should exist. 4. Also check harness for short to ground and short to power. OK or NG OK >> GO TO 4. NG >> Repair open circuit or short to ground or short to power in harness or connectors. 4. CHECK INTAKE AIR TEMPERATURE SENSOR Refer to EC-946, "Component Inspection" . OK or NG OK >> GO TO 5. NG >> Replace mass air flow sensor (with intake air temperature sensor). 5. CHECK INTERMITTENT INCIDENT Refer to EC-917, "TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT" . >> INSPECTION END Component Inspection BBS004B0 INTAKE AIR TEMPERATURE SENSOR 1. 2. Check resistance between mass air flow sensor (1) terminals 5 and 6 under the following conditions. Intake air temperature °C (°F) Resistance kΩ 25 (77) 1.800 - 2.200 If NG, replace mass air flow sensor (with intake air temperature sensor). PBIA9559J SEF012P Removal and Installation BBS004B1 MASS AIR FLOW SENSOR Refer to EM-118, "AIR CLEANER AND AIR DUCT" . EC-946 DTC P0117, P0118 ECT SENSOR [HR (WITH EURO-OBD)] DTC P0117, P0118 ECT SENSOR Component Description PFP:22630 A BBS004B2 The engine coolant temperature sensor is used to detect the engine coolant temperature. The sensor modifies a voltage signal from the ECM. The modified signal returns to the ECM as the engine coolant temperature input. The sensor uses a thermistor which is sensitive to the change in temperature. The electrical resistance of the thermistor decreases as temperature increases. EC C D SEF594K E Engine coolant temperature °C (°F) –10 (14) Voltage* V Resistance 4.4 F kΩ 7.0 - 11.4 20 (68) 3.5 2.1 - 2.9 50 (122) 2.2 0.68 - 1.00 90 (194) 0.9 0.236 - 0.260 G H *: This data is reference value and is measured between ECM terminal 38 (Engine coolant temperature sensor) and ground. SEF012P CAUTION: Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM's transistor. Use a ground other than ECM terminals, such as the ground. On Board Diagnosis Logic BBS004B3 I J These self-diagnoses have the one trip detection logic. DTC No. Trouble Diagnosis Name DTC Detecting Condition P0117 0117 Engine coolant temperature sensor circuit low input An excessively low voltage from the sensor is sent to ECM. P0118 0118 Engine coolant temperature sensor circuit high input An excessively high voltage from the sensor is sent to ECM. Possible Cause ● Harness or connectors (The sensor circuit is open or shorted.) ● Engine coolant temperature sensor When the malfunction is detected, the ECM enters fail-safe mode and the MI lights up. Engine operating condition in fail-safe mode Engine coolant temperature will be determined by ECM based on the time after turning ignition switch ON or START. CONSULT-II displays the engine coolant temperature decided by ECM. Condition Engine coolant temperature sensor circuit L M FAIL-SAFE MODE Detected items K Engine coolant temperature decided (CONSULT-II display) Just as ignition switch is turned ON or START 40°C (104°F) More than approx. 4 minutes after ignition ON or START 80°C (176°F) 40 - 80°C (104 - 176°F) (Depends on the time) Except as shown above When the fail-safe system for engine coolant temperature sensor is activated, the cooling fan operates while engine is running. EC-947 DTC P0117, P0118 ECT SENSOR [HR (WITH EURO-OBD)] DTC Confirmation Procedure BBS004B4 NOTE: If DTC Confirmation Procedure has been previously conducted, always turn ignition switch OFF and wait at least 10 seconds before conducting the next test. WITH CONSULT-II 1. 2. 3. 4. Turn ignition switch ON. Select “DATA MONITOR” mode with CONSULT-II. Wait at least 5 seconds. If DTC is detected, go to EC-950, "Diagnostic Procedure" . SEF058Y WITH GST Follow the procedure “WITH CONSULT-II” above. EC-948 DTC P0117, P0118 ECT SENSOR [HR (WITH EURO-OBD)] Wiring Diagram BBS004B5 A EC C D E F G H I J K L M MBWA1459E EC-949 DTC P0117, P0118 ECT SENSOR [HR (WITH EURO-OBD)] Diagnostic Procedure BBS004B6 1. CHECK GROUND CONNECTIONS 1. 2. Turn ignition switch OFF. Loosen and retighten ground screws on the body. Refer to EC-924, "Ground Inspection" . MBIB1550E 1. IPDM E/R 2. Body ground 3. Body ground OK or NG OK >> GO TO 2. NG >> Repair or replace ground connections. 2. CHECK ECT SENSOR POWER SUPPLY CIRCUIT 1. Disconnect engine coolant temperature (ECT) sensor (1) harness connector. – : Vehicle front Turn ignition switch ON. 2. PBIB2964E 3. Check voltage between ECT sensor terminal 1 and ground with CONSULT-II or tester. Voltage: Approximately 5V OK or NG OK >> GO TO 3. NG >> Repair open circuit or short to ground or short to power in harness or connectors. PBIB0080E EC-950 DTC P0117, P0118 ECT SENSOR [HR (WITH EURO-OBD)] 3. CHECK ECT SENSOR GROUND CIRCUIT FOR OPEN AND SHORT 1. 2. 3. 4. A Turn ignition switch OFF. Disconnect ECM harness connector. Disconnect TCM harness connector. Check harness continuity between ECM terminal 44, TCM terminal 42 and ECT sensor terminal 2. Refer to Wiring Diagram. EC C Continuity should exist. 5. Also check harness for short to ground and short to power. OK or NG OK >> GO TO 5. NG >> GO TO 4. D E 4. DETECT MALFUNCTIONING PART Check the following. ● Harness connectors E59, F1 ● Harness for open or short between ECM and ECT sensor ● Harness for open or short between TCM and ECT sensor F G >> Repair open circuit or short to ground or short to power in harness or connectors. H 5. CHECK ENGINE COOLANT TEMPERATURE SENSOR Refer to EC-951, "Component Inspection" . OK or NG OK >> GO TO 6. NG >> Replace engine coolant temperature sensor. I J 6. CHECK INTERMITTENT INCIDENT Refer to EC-917, "TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT" . K >> INSPECTION END Component Inspection BBS004B7 L ENGINE COOLANT TEMPERATURE SENSOR 1. Check resistance between engine coolant temperature sensor terminals 1 and 2 as shown in the figure. M PBIB2005E EC-951 DTC P0117, P0118 ECT SENSOR [HR (WITH EURO-OBD)] Temperature 2. °C (°F) Resistance kΩ 20 (68) 2.1 - 2.9 50 (122) 0.68 - 1.00 90 (194) 0.236 - 0.260 If NG, replace engine coolant temperature sensor. SEF012P Removal and Installation BBS004B8 ENGINE COOLANT TEMPERATURE SENSOR Refer to EM-173, "CYLINDER HEAD" . EC-952 DTC P0122, P0123 TP SENSOR [HR (WITH EURO-OBD)] DTC P0122, P0123 TP SENSOR Component Description PFP:16119 A BBS004B9 Electric throttle control actuator consists of throttle control motor, throttle position sensor, etc. The throttle position sensor responds to the throttle valve movement. The throttle position sensor has the two sensors. These sensors are a kind of potentiometers which transform the throttle valve position into output voltage, and emit the voltage signal to the ECM. In addition, these sensors detect the opening and closing speed of the throttle valve and feed the voltage signals to the ECM. The ECM judges the current opening angle of the throttle valve from these signals and the ECM controls the throttle control motor to make the throttle valve opening angle properly in response to driving condition. EC C D PBIB0145E E CONSULT-II Reference Value in Data Monitor Mode BBS004BA Specification data are reference values. MONITOR ITEM CONDITION ● Ignition switch: ON (Engine stopped) ● Shift lever: D (A/T), 1st (M/T) THRTL SEN 1 THRTL SEN 2* SPECIFICATION Accelerator pedal: Fully released More than 0.36V Accelerator pedal: Fully depressed Less than 4.75V F G *: Throttle position sensor 2 signal is converted by ECM internally. Thus, it differs from ECM terminal voltage signal. On Board Diagnosis Logic BBS004BB These self-diagnoses have the one trip detection logic. NOTE: If DTC P0122 or P0123 is displayed with DTC P1229, first perform the trouble diagnosis for DTC P1229. Refer to EC-1150, "DTC P1229 SENSOR POWER SUPPLY" . DTC No. Trouble diagnosis name DTC detecting condition Possible cause P0122 0122 Throttle position sensor 2 circuit low input An excessively low voltage from the TP sensor 2 is sent to ECM. ● Harness or connectors (TP sensor 2 circuit is open or shorted.) P0123 0123 Throttle position sensor 2 circuit high input An excessively high voltage from the TP sensor 2 is sent to ECM. ● Electric throttle control actuator (TP sensor 2) FAIL-SAFE MODE H I J K L When the malfunction is detected, ECM enters fail-safe mode and the MI lights up. Engine operation condition in fail-safe mode The ECM controls the electric throttle control actuator in regulating the throttle opening in order for the idle position to be within +10 degrees. The ECM regulates the opening speed of the throttle valve to be slower than the normal condition. So, the acceleration will be poor. EC-953 M DTC P0122, P0123 TP SENSOR [HR (WITH EURO-OBD)] DTC Confirmation Procedure BBS004BC NOTE: If DTC Confirmation Procedure has been previously conducted, always turn ignition switch OFF and wait at least 10 seconds before conducting the next test. TESTING CONDITION: Before performing the following procedure, confirm that battery voltage is more than 10V at idle. WITH CONSULT-II 1. 2. 3. 4. Turn ignition switch ON. Select “DATA MONITOR” mode with CONSULT-II. Start engine and let it idle for 1 second. If DTC is detected, go to EC-956, "Diagnostic Procedure" . SEF058Y WITH GST Follow the procedure “WITH CONSULT-II” above. EC-954 DTC P0122, P0123 TP SENSOR [HR (WITH EURO-OBD)] Wiring Diagram BBS004BD A EC C D E F G H I J K L M MBWA1460E EC-955 DTC P0122, P0123 TP SENSOR [HR (WITH EURO-OBD)] Specification data are reference values and are measured between each terminal and ground. CAUTION: Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM's transistor. Use a ground other than ECM terminals, such as the ground. TERMINAL NO. WIRE COLOR ITEM CONDITION DATA (DC Voltage) [Ignition switch: ON] 33 Y ● Engine stopped ● Shift lever: D (A/T), 1st (M/T) ● Accelerator pedal: Fully released Throttle position sensor 1 More than 0.36V [Ignition switch: ON] ● Engine stopped ● Shift lever: D (A/T), 1st (M/T) ● Accelerator pedal: Fully depressed Less than 4.75V [Ignition switch: ON] 34 R Throttle position sensor 2 ● Engine stopped ● Shift lever: D (A/T), 1st (M/T) ● Accelerator pedal: Fully released Less than 4.75V [Ignition switch: ON] ● Engine stopped ● Shift lever: D (A/T), 1st (M/T) ● Accelerator pedal: Fully depressed More than 0.36V [Engine is running] 36 72 BR L Sensor ground (Throttle position sensor) Sensor power supply (Throttle position sensor) ● Warm-up condition ● Idle speed Approximately 0V [Ignition switch: ON] Approximately 5V Diagnostic Procedure BBS004BE 1. CHECK GROUND CONNECTIONS 1. 2. Turn ignition switch OFF. Loosen and retighten ground screws on the body. Refer to EC-924, "Ground Inspection" . MBIB1550E 1. IPDM E/R 2. Body ground OK or NG OK >> GO TO 2. NG >> Repair or replace ground connections. EC-956 3. Body ground DTC P0122, P0123 TP SENSOR [HR (WITH EURO-OBD)] 2. CHECK THROTTLE POSITION SENSOR 2 POWER SUPPLY CIRCUIT 1. Disconnect electric throttle control actuator (1) harness connector. – : Vehicle front Turn ignition switch ON. 2. A EC C D PBIB2965E 3. Check voltage between electric throttle control actuator terminal 1 and ground with CONSULT-II or tester. E Voltage: Approximately 5V F OK or NG OK >> GO TO 3. NG >> Repair open circuit or short to ground or short to power in harness or connectors. G PBIA9580J H 3. CHECK THROTTLE POSITION SENSOR 2 GROUND CIRCUIT FOR OPEN AND SHORT 1. 2. 3. Turn ignition switch OFF. Disconnect ECM harness connector. Check harness continuity between electric throttle control actuator terminal 4 and ECM terminal 36. Refer to Wiring Diagram. I J Continuity should exist. 4. Also check harness for short to ground and short to power. OK or NG OK >> GO TO 4. NG >> Repair open circuit or short to ground or short to power in harness or connectors. K L 4. CHECK THROTTLE POSITION SENSOR 2 INPUT SIGNAL CIRCUIT FOR OPEN AND SHORT 1. Check harness continuity between ECM terminal 34 and electric throttle control actuator terminal 3. Refer to Wiring Diagram. Continuity should exist. 2. Also check harness for short to ground and short to power. OK or NG OK >> GO TO 5. NG >> Repair open circuit or short to ground or short to power in harness or connectors. 5. CHECK THROTTLE POSITION SENSOR Refer to EC-958, "Component Inspection" . OK or NG OK >> GO TO 7. NG >> GO TO 6. EC-957 M DTC P0122, P0123 TP SENSOR [HR (WITH EURO-OBD)] 6. REPLACE ELECTRIC THROTTLE CONTROL ACTUATOR 1. 2. 3. Replace the electric throttle control actuator. Perform EC-857, "Throttle Valve Closed Position Learning" . Perform EC-858, "Idle Air Volume Learning" . >> INSPECTION END 7. CHECK INTERMITTENT INCIDENT Refer to EC-917, "TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT" . >> INSPECTION END Component Inspection BBS004BF THROTTLE POSITION SENSOR 1. 2. 3. 4. 5. Reconnect all harness connectors disconnected. Perform EC-857, "Throttle Valve Closed Position Learning" . Turn ignition switch ON. Set shift lever to D position (A/T) or 1st position (M/T). Check voltage between ECM terminals 33 (TP sensor 1 signal), 34 (TP sensor 2 signal) and ground under the following conditions. Terminal Accelerator pedal Voltage 33 (Throttle position sensor 1) Fully released More than 0.36V Fully depressed Less than 4.75V Fully released Less than 4.75V Fully depressed More than 0.36V 34 (Throttle position sensor 2) 6. 7. 8. If NG, replace electric throttle control actuator and go to the next step. Perform EC-857, "Throttle Valve Closed Position Learning" . Perform EC-858, "Idle Air Volume Learning" . Removal and Installation PBIB3038E BBS004BG ELECTRIC THROTTLE CONTROL ACTUATOR Refer to EM-120, "INTAKE MANIFOLD" . EC-958 DTC P0132 HO2S1 [HR (WITH EURO-OBD)] DTC P0132 HO2S1 Component Description PFP:22690 A BBS004BH The heated oxygen sensor 1 is placed into the exhaust manifold. It detects the amount of oxygen in the exhaust gas compared to the outside air. The heated oxygen sensor 1 has a closed-end tube made of ceramic zirconia. The zirconia generates voltage from approximately 1V in richer conditions to 0V in leaner conditions. The heated oxygen sensor 1 signal is sent to the ECM. The ECM adjusts the injection pulse duration to achieve the ideal air-fuel ratio. The ideal air-fuel ratio occurs near the radical change from 1V to 0V. EC C D SEF463R E F G H SEF288D CONSULT-II Reference Value in Data Monitor Mode BBS004BI I Specification data are reference values. MONITOR ITEM CONDITION SPECIFICATION J 0 - 0.3V ←→ Approx. 0.6 - 1.0V HO2S1 (B1) ● HO2S1 MNTR (B1) Engine: After warming up Maintaining engine speed at 2,000 rpm. LEAN ←→ RICH Changes more than 5 times during 10 seconds. On Board Diagnosis Logic K BBS004BJ L To judge the malfunction, the diagnosis checks that the heated oxygen sensor 1 output is not inordinately high. M PBIB1848E DTC No. P0132 0132 Trouble diagnosis name Heated oxygen sensor 1 circuit high voltage DTC detecting condition Possible cause ● Harness or connectors (The sensor circuit is open or shorted.) ● Heated oxygen sensor 1 An excessively high voltage from the sensor is sent to ECM. EC-959 DTC P0132 HO2S1 [HR (WITH EURO-OBD)] DTC Confirmation Procedure BBS004BK NOTE: If DTC Confirmation Procedure has been previously conducted, always turn ignition switch OFF and wait at least 10 seconds before conducting the next test. WITH CONSULT-II 1. 2. 3. 4. 5. 6. Start engine and warm it up to normal operating temperature. Turn ignition switch OFF and wait at least 10 seconds. Turn ignition switch ON. Select “DATA MONITOR” mode with CONSULT-II. Restart engine and let it idle for 2 minutes. If 1st trip DTC is detected, go to EC-962, "Diagnostic Procedure" . SEF174Y WITH GST Follow the procedure “WITH CONSULT-II” above. EC-960 DTC P0132 HO2S1 [HR (WITH EURO-OBD)] Wiring Diagram BBS004BL A EC C D E F G H I J K L M MBWA1461E EC-961 DTC P0132 HO2S1 [HR (WITH EURO-OBD)] Specification data are reference values and are measured between each terminal and ground. Pulse signal is measured by CONSULT-II. CAUTION: Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM's transistor. Use a ground other than ECM terminals, such as the ground. TERMINAL NO. WIRE COLOR ITEM CONDITION DATA (DC Voltage) Approximately 10V [Engine is running] 3 Y ● Warm-up condition ● Engine speed: Below 3,600 rpm Heated oxygen sensor 1 heater PBIA8148J [Ignition switch: ON] ● Engine stopped BATTERY VOLTAGE (11 - 14V) [Engine is running] ● Engine speed: Above 3,600 rpm [Engine is running] 49 56 BR R Heated oxygen sensor 1 Sensor ground (Heated oxygen sensor 1) ● Warm-up condition ● Engine speed: 2,000 rpm 0 - Approximately 1.0V (Periodically change) [Engine is running] ● Approximately 0V Idle speed : Average voltage for pulse signal (Actual pulse signal can be confirmed by oscilloscope.) Diagnostic Procedure BBS004BM 1. CHECK GROUND CONNECTIONS 1. 2. Turn ignition switch OFF. Loosen and retighten ground screws on the body. Refer to EC-924, "Ground Inspection" . MBIB1550E 1. IPDM E/R 2. Body ground OK or NG OK >> GO TO 2. NG >> Repair or replace ground connections. EC-962 3. Body ground DTC P0132 HO2S1 [HR (WITH EURO-OBD)] 2. RETIGHTEN HEATED OXYGEN SENSOR 1 A Loosen and retighten heated oxygen sensor 1 (1). ● ● : Vehicle front Exhaust manifold (2) EC Tightening torque: 50 N·m (5.1 kg-m, 37 ft-lb) C >> GO TO 3. D PBIB2966E 3. CHECK HO2S1 GROUND CIRCUIT FOR OPEN AND SHORT 1. Disconnect heated oxygen sensor 1 harness connector (1). – : Vehicle front Disconnect ECM harness connector. Check harness continuity between HO2S1 terminal 1 and ECM terminal 56. Refer to Wiring Diagram. 2. 3. E F G Continuity should exist. 4. Also check harness for short to ground and short to power. OK or NG OK >> GO TO 4. NG >> Repair open circuit or short to ground or short to power in harness or connectors. 4. CHECK HO2S1 INPUT SIGNAL CIRCUIT FOR OPEN AND SHORT 1. PBIB2967E I J Check harness continuity between HO2S1 terminal 4 and ECM terminal 49. Refer to Wiring Diagram. K Continuity should exist. 2. H Check harness continuity between ECM terminal 49 or HO2S1 terminal 4 and ground. Refer to Wiring Diagram. L Continuity should not exist. 3. Also check harness for short to power. OK or NG OK >> GO TO 5. NG >> Repair open circuit or short to ground or short to power in harness or connectors. 5. CHECK HO2S1 CONNECTOR FOR WATER Check heated oxygen sensor 1 connector for water. Water should not exist. OK or NG OK >> GO TO 6. NG >> Repair or replace harness or connectors. EC-963 M DTC P0132 HO2S1 [HR (WITH EURO-OBD)] 6. CHECK HEATED OXYGEN SENSOR 1 Refer to EC-965, "Component Inspection" . OK or NG OK >> GO TO 7. NG >> Replace heated oxygen sensor 1. 7. CHECK INTERMITTENT INCIDENT Refer to EC-917, "TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT" . >> INSPECTION END EC-964 DTC P0132 HO2S1 [HR (WITH EURO-OBD)] Component Inspection BBS004BN A HEATED OXYGEN SENSOR 1 With CONSULT-II 1. 2. 3. 4. 5. Start engine and warm it up to normal operating temperature. Select “MANU TRIG” and adjust “TRIGGER POINT” to 100% in “DATA MONITOR” mode with CONSULT- EC II. Select “HO2S1 (B1)” and “HO2S1 MNTR (B1)”. C Hold engine speed at 2,000 rpm under no load during the following steps. Touch “RECORD” on CONSULT-II screen. D E SEF646Y F 6. Check the following. ● “HO2S1 MNTR (B1)” in “DATA MONITOR” mode changes from “RICH” to “LEAN” to “RICH” more than 5 times in 10 seconds. 5 times (cycles) are counted as shown in the figure. ● “HO2S1 (B1)” voltage goes above 0.6V at least once. ● “HO2S1 (B1)” voltage goes below 0.3V at least once. ● “HO2S1 (B1)” voltage never exceeds 1.0V. G H I SEF217YA J K L SEF648Y CAUTION: Discard any heated oxygen sensor which has been dropped from a height of more than 0.5 m (19.7 in) onto a hard surface such as a concrete floor; use a new one. ● Before installing new oxygen sensor, clean exhaust system threads using Oxygen Sensor Thread Cleaner tool and approved anti-seize lubricant. ● Without CONSULT-II 1. 2. Start engine and warm it up to normal operating temperature. Set voltmeter probes between ECM terminal 49 (HO2S1 signal) and ground. EC-965 M DTC P0132 HO2S1 [HR (WITH EURO-OBD)] 3. Check the following with engine speed held at 2,000 rpm constant under no load. ● The voltage fluctuates between 0 to 0.3V and 0.6 to 1.0V more than 5 times within 10 seconds. ● The maximum voltage is over 0.6V at least 1 time. ● The minimum voltage is below 0.3V at least 1 time. ● The voltage never exceeds 1.0V. 1 time: 0 - 0.3V → 0.6 - 1.0V → 0 - 0.3V 2 times: 0 - 0.3V → 0.6 - 1.0V → 0 - 0.3V → 0.6 - 1.0V → 0 - 0.3V PBIA9566J CAUTION: ● Discard any heated oxygen sensor which has been dropped from a height of more than 0.5 m (19.7 in) onto a hard surface such as a concrete floor; use a new one. ● Before installing new oxygen sensor, clean exhaust system threads using Oxygen Sensor Thread Cleaner tool and approved anti-seize lubricant. Removal and Installation BBS004BO HEATED OXYGEN SENSOR 1 Refer to EM-124, "EXHAUST MANIFOLD" . EC-966 DTC P0133 HO2S1 [HR (WITH EURO-OBD)] DTC P0133 HO2S1 Component Description PFP:22690 A BBS004BP The heated oxygen sensor 1 is placed into the exhaust manifold. It detects the amount of oxygen in the exhaust gas compared to the outside air. The heated oxygen sensor 1 has a closed-end tube made of ceramic zirconia. The zirconia generates voltage from approximately 1V in richer conditions to 0V in leaner conditions. The heated oxygen sensor 1 signal is sent to the ECM. The ECM adjusts the injection pulse duration to achieve the ideal air-fuel ratio. The ideal air-fuel ratio occurs near the radical change from 1V to 0V. EC C D SEF463R E F G H SEF288D CONSULT-II Reference Value in Data Monitor Mode BBS004BQ I Specification data are reference values. MONITOR ITEM CONDITION J 0 - 0.3V ←→ Approx. 0.6 - 1.0V HO2S1 (B1) ● HO2S1 MNTR (B1) SPECIFICATION Engine: After warming up Maintaining engine speed at 2,000 rpm. On Board Diagnosis Logic LEAN ←→ RICH Changes more than 5 times during 10 seconds. K BBS004BR L To judge the malfunction of heated oxygen sensor 1, this diagnosis measures response time of heated oxygen sensor 1 signal. The time is compensated by engine operating (speed and load), fuel feedback control constant, and heated oxygen sensor 1 temperature index. Judgment is based on whether the compensated time (heated oxygen sensor 1 cycling time index) is inordinately long or not. M PBIB2991E EC-967 DTC P0133 HO2S1 [HR (WITH EURO-OBD)] DTC No. P0133 0133 Trouble diagnosis name Heated oxygen sensor 1 circuit slow response DTC detecting condition The response of the voltage signal from the sensor takes more than the specified time. DTC Confirmation Procedure Possible cause ● Harness or connectors (The sensor circuit is open or shorted.) ● Heated oxygen sensor 1 ● Fuel pressure ● Fuel injector ● Intake air leaks ● Exhaust gas leaks ● PCV valve ● Mass air flow sensor BBS004BS CAUTION: Always drive vehicle at a safe speed. NOTE: If DTC Confirmation Procedure has been previously conducted, always turn ignition switch OFF and wait at least 10 seconds before conducting the next test. TESTING CONDITION: ● Always perform at a temperature above −10°C (14°F). ● Before performing the following procedure, confirm that battery voltage is more than 11V at idle. WITH CONSULT-II 1. 2. 3. 4. 5. Start engine and warm it up to normal operating temperature. Stop engine and wait at least 10 seconds. Turn ignition switch ON and select “HO2S1 (B1) P0133” of “HO2S1” in “DTC WORK SUPPORT” mode with CONSULT-II. Touch “START”. Start engine and let it idle for at least 3 minutes. NOTE: Never raise engine speed above 3,600 rpm after this step. If the engine speed limit is exceeded, return to step 5. SEF338Z 6. When the following conditions are met, “TESTING” will be displayed on the CONSULT-II screen. Maintain the conditions continuously until “TESTING” changes to “COMPLETED”. (It will take approximately 40 to 50 seconds.) ENG SPEED A/T: 1,900 - 3,300 rpm M/T: 2,400 - 3,950 rpm VHCL SPEED SE More than 80 km/h (50 MPH) B/FUEL SCHDL A/T: 3.5 - 11.2 msec M/T: 2.8 - 10.2 msec Shift lever Suitable position SEF339Z If “TESTING” is not displayed after 5 minutes, retry from step 2. EC-968 DTC P0133 HO2S1 [HR (WITH EURO-OBD)] 7. Make sure that “OK” is displayed after touching “SELF-DIAG RESULTS”. If “NG” is displayed, refer to EC-971, "Diagnostic Procedure" . A EC C SEF658Y D Overall Function Check BBS004BT Use this procedure to check the overall function of the heated oxygen sensor 1 circuit. During this check, a 1st trip DTC might not be confirmed. E WITH GST 1. 2. 3. ● Start engine and warm it up to normal operating temperature. Set voltmeter probes between ECM terminal 49 (HO2S1 signal) and ground. Check the following with engine speed held at 2,000 rpm constant under no load. The voltage fluctuates between 0 to 0.3V and 0.6 to 1.0V more than 5 times within 10 seconds. 1 time: 2 times: 4. F G 0 - 0.3V → 0.6 - 1.0V → 0 - 0.3V 0 - 0.3V → 0.6 - 1.0V → 0 - 0.3V → 0.6 - 1.0V → 0 - 0.3V H I If NG, go to EC-971, "Diagnostic Procedure" . PBIA9566J J K L M EC-969 DTC P0133 HO2S1 [HR (WITH EURO-OBD)] Wiring Diagram BBS004BU MBWA1461E EC-970 DTC P0133 HO2S1 [HR (WITH EURO-OBD)] Specification data are reference values and are measured between each terminal and ground. Pulse signal is measured by CONSULT-II. A CAUTION: Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM's transistor. Use a ground other than ECM terminals, such as the ground. EC TERMINAL NO. WIRE COLOR ITEM CONDITION DATA (DC Voltage) C Approximately 10V [Engine is running] 3 Y ● Warm-up condition ● Engine speed: Below 3,600 rpm D Heated oxygen sensor 1 heater E PBIA8148J [Ignition switch: ON] ● Engine stopped ● F BATTERY VOLTAGE (11 - 14V) [Engine is running] Engine speed: Above 3,600 rpm G [Engine is running] 49 BR Heated oxygen sensor 1 ● Warm-up condition ● Engine speed: 2,000 rpm 0 - Approximately 1.0V (Periodically change) H [Engine is running] 56 R Sensor ground (Heated oxygen sensor 1) ● Warm-up condition ● Idle speed Approximately 0V I : Average voltage for pulse signal (Actual pulse signal can be confirmed by oscilloscope.) Diagnostic Procedure BBS004BV 1. CHECK GROUND CONNECTIONS 1. 2. Turn ignition switch OFF. Loosen and retighten ground screws on the body. Refer to EC-924, "Ground Inspection" . J K L M MBIB1550E 1. IPDM E/R 2. Body ground OK or NG OK >> GO TO 2. NG >> Repair or replace ground connections. EC-971 3. Body ground DTC P0133 HO2S1 [HR (WITH EURO-OBD)] 2. RETIGHTEN HEATED OXYGEN SENSOR 1 Loosen and retighten heated oxygen sensor 1 (1). ● ● : Vehicle front Exhaust manifold (2) Tightening torque: 50 N·m (5.1 kg-m, 37 ft-lb) >> GO TO 3. PBIB2966E 3. CHECK FOR EXHAUST GAS LEAK 1. 2. Start engine and run it at idle. Listen for an exhaust gas leak before three way catalyst (manifold). SEC502D OK or NG OK >> GO TO 4. NG >> Repair or replace. 4. CHECK FOR INTAKE AIR LEAK Listen for an intake air leak after the mass air flow sensor. OK or NG OK >> GO TO 5. NG >> Repair or replace. EC-972 DTC P0133 HO2S1 [HR (WITH EURO-OBD)] 5. CLEAR THE SELF-LEARNING DATA 1. 2. 3. 4. A With CONSULT-II Start engine and warm it up to normal operating temperature. Select “SELF-LEARNING CONT” in “WORK SUPPORT” mode with CONSULT-II. Clear the self-learning control coefficient by touching “CLEAR”. Run engine for at least 10 minutes at idle speed. Is the 1st trip DTC P0171 or P0172 detected? Is it difficult to start engine? EC C D E SEF215Z Without CONSULT-II 1. Start engine and warm it up to normal operating temperature. 2. Turn ignition switch OFF. 3. Disconnect mass air flow sensor (1) harness connector, and restart and run engine for at least 5 seconds at idle speed. 4. Stop engine and reconnect mass air flow sensor harness connector. 5. Make sure that DTC P0102 is displayed. 6. Erase the DTC memory. Refer to EC-841, "HOW TO ERASE EMISSION-RELATED DIAGNOSTIC INFORMATION" . 7. Make sure that DTC P0000 is displayed. 8. Run engine for at least 10 minutes at idle speed. Is the 1st trip DTC P0171 or P0172 detected? PBIB2948E Is it difficult to start engine? Yes or No Yes >> Perform trouble diagnosis for DTC P0171 or DTC P0172 (Refer to EC-1012, "DTC P0171 FUEL INJECTION SYSTEM FUNCTION" or EC-1019, "DTC P0172 FUEL INJECTION SYSTEM FUNCTION" ). No >> GO TO 6. F G H I J K L 6. CHECK HO2S1 GROUND CIRCUIT FOR OPEN AND SHORT 1. 2. Turn ignition switch OFF. Disconnect heated oxygen sensor 1 harness connector (1). – : Vehicle front Disconnect ECM harness connector. Check harness continuity between HO2S1 terminal 1 and ECM terminal 56. Refer to Wiring Diagram. 3. 4. M Continuity should exist. 5. Also check harness for short to ground and short to power. OK or NG OK >> GO TO 7. NG >> Repair open circuit or short to ground or short to power in harness or connectors. EC-973 PBIB2967E DTC P0133 HO2S1 [HR (WITH EURO-OBD)] 7. CHECK HO2S1 INPUT SIGNAL CIRCUIT FOR OPEN AND SHORT 1. Check harness continuity between HO2S1 terminal 4 and ECM terminal 49. Refer to Wiring Diagram. Continuity should exist. 2. Check harness continuity between ECM terminal 49 or HO2S1 terminal 4 and ground. Refer to Wiring Diagram. Continuity should not exist. 3. Also check harness for short to power. OK or NG OK >> GO TO 8. NG >> Repair open circuit or short to ground or short to power in harness or connectors. 8. CHECK MASS AIR FLOW SENSOR Refer to EC-940, "Component Inspection" . OK or NG OK >> GO TO 9. NG >> Replace mass air flow sensor. 9. CHECK PCV VALVE Refer to EC-828, "Component Inspection" . OK or NG OK >> GO TO 10. NG >> Replace PCV valve. 10. CHECK HEATED OXYGEN SENSOR 1 Refer to EC-975, "Component Inspection" . OK or NG OK >> GO TO 11. NG >> Replace heated oxygen sensor 1. 11. CHECK INTERMITTENT INCIDENT Refer to EC-917, "TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT" . >> INSPECTION END EC-974 DTC P0133 HO2S1 [HR (WITH EURO-OBD)] Component Inspection BBS004BW A HEATED OXYGEN SENSOR 1 With CONSULT-II 1. 2. 3. 4. 5. Start engine and warm it up to normal operating temperature. Select “MANU TRIG” and adjust “TRIGGER POINT” to 100% in “DATA MONITOR” mode with CONSULT- EC II. Select “HO2S1 (B1)” and “HO2S1 MNTR (B1)”. C Hold engine speed at 2,000 rpm under no load during the following steps. Touch “RECORD” on CONSULT-II screen. D E SEF646Y F 6. Check the following. ● “HO2S1 MNTR (B1)” in “DATA MONITOR” mode changes from “RICH” to “LEAN” to “RICH” more than 5 times in 10 seconds. 5 times (cycles) are counted as shown in the figure. ● “HO2S1 (B1)” voltage goes above 0.6V at least once. ● “HO2S1 (B1)” voltage goes below 0.3V at least once. ● “HO2S1 (B1)” voltage never exceeds 1.0V. G H I SEF217YA J K L SEF648Y CAUTION: Discard any heated oxygen sensor which has been dropped from a height of more than 0.5 m (19.7 in) onto a hard surface such as a concrete floor; use a new one. ● Before installing new oxygen sensor, clean exhaust system threads using Oxygen Sensor Thread Cleaner tool and approved anti-seize lubricant. ● EC-975 M DTC P0133 HO2S1 [HR (WITH EURO-OBD)] Without CONSULT-II 1. 2. 3. Start engine and warm it up to normal operating temperature. Set voltmeter probes between ECM terminal 49 (HO2S1 signal) and ground. Check the following with engine speed held at 2,000 rpm constant under no load. ● The voltage fluctuates between 0 to 0.3V and 0.6 to 1.0V more than 5 times within 10 seconds. ● The maximum voltage is over 0.6V at least 1 time. ● The minimum voltage is below 0.3V at least 1 time. ● The voltage never exceeds 1.0V. 1 time: 0 - 0.3V → 0.6 - 1.0V → 0 - 0.3V 2 times: 0 - 0.3V → 0.6 - 1.0V → 0 - 0.3V → 0.6 - 1.0V → 0 - 0.3V PBIA9566J CAUTION: ● Discard any heated oxygen sensor which has been dropped from a height of more than 0.5 m (19.7 in) onto a hard surface such as a concrete floor; use a new one. ● Before installing new oxygen sensor, clean exhaust system threads using Oxygen Sensor Thread Cleaner tool and approved anti-seize lubricant. Removal and Installation BBS004BX HEATED OXYGEN SENSOR 1 Refer to EM-124, "EXHAUST MANIFOLD" . EC-976 DTC P0134 HO2S1 [HR (WITH EURO-OBD)] DTC P0134 HO2S1 Component Description PFP:22690 A BBS004BY The heated oxygen sensor 1 is placed into the exhaust manifold. It detects the amount of oxygen in the exhaust gas compared to the outside air. The heated oxygen sensor 1 has a closed-end tube made of ceramic zirconia. The zirconia generates voltage from approximately 1V in richer conditions to 0V in leaner conditions. The heated oxygen sensor 1 signal is sent to the ECM. The ECM adjusts the injection pulse duration to achieve the ideal air-fuel ratio. The ideal air-fuel ratio occurs near the radical change from 1V to 0V. EC C D SEF463R E F G H SEF288D CONSULT-II Reference Value in Data Monitor Mode BBS004BZ I Specification data are reference values. MONITOR ITEM CONDITION SPECIFICATION J 0 - 0.3V ←→ Approx. 0.6 - 1.0V HO2S1 (B1) ● HO2S1 MNTR (B1) Engine: After warming up Maintaining engine speed at 2,000 rpm. LEAN ←→ RICH Changes more than 5 times during 10 seconds. On Board Diagnosis Logic BBS004C0 L Under the condition in which the heated oxygen sensor 1 signal is not input, the ECM circuits will read a continuous approximately 0.3V. Therefore, for this diagnosis, the time that output voltage is within 200 to 400 mV range is monitored, and the diagnosis checks that this time is not inordinately long. M SEF237U DTC No. P0134 0134 Trouble diagnosis name Heated oxygen sensor 1 circuit no activity detected K DTC detecting condition Possible cause ● Harness or connectors (The sensor circuit is open or shorted.) ● Heated oxygen sensor 1 The voltage from the sensor is constantly approx. 0.3V. EC-977 DTC P0134 HO2S1 [HR (WITH EURO-OBD)] DTC Confirmation Procedure BBS004C1 CAUTION: Always drive vehicle at a safe speed. NOTE: If DTC Confirmation Procedure has been previously conducted, always turn ignition switch OFF and wait at least 10 seconds before conducting the next test. TESTING CONDITION: Before performing the following procedure, confirm that battery voltage is more than 11V at idle. WITH CONSULT-II 1. 2. 3. 4. Start engine and warm it up to normal operating temperature. Select “HO2S1 (B1) P0134” of “HO2S1” in “DTC WORK SUPPORT” mode with CONSULT-II. Touch “START”. Let it idle for at least 3 minutes. NOTE: Never raise engine speed above 3,600 rpm after this step. If the engine speed limit is exceeded, return to step 4. PBIB0544E 5. When the following conditions are met, “TESTING” will be displayed on the CONSULT-II screen. Maintain the conditions continuously until “TESTING” changes to “COMPLETED”. (It will take approximately 10 to 60 seconds.) ENG SPEED A/T: 1,300 - 3,500 rpm M/T: 1,800 - 4,250 rpm VHCL SPEED SE More than 64 km/h (40 MPH) B/FUEL SCHDL A/T: 2.8 - 11.2 msec M/T: 2.0 - 10.2 msec Shift lever Suitable position 6. PBIB0545E If “TESTING” is not displayed after 5 minutes, retry from step 2. Make sure that “OK” is displayed after touching “SELF-DIAG RESULTS”. If “NG” is displayed, refer to EC-981, "Diagnostic Procedure" . SEC750C EC-978 DTC P0134 HO2S1 [HR (WITH EURO-OBD)] Overall Function Check BBS004C2 Use this procedure to check the overall function of the heated oxygen sensor 1 circuit. During this check, a 1st trip DTC might not be confirmed. WITH GST 1. 2. 3. ● 4. A EC Start engine and warm it up to normal operating temperature. Set voltmeter probes between ECM terminal 49 (HO2S1 signal) and ground. Check the following with engine speed held at 2,000 rpm constant under no load. The voltage does not remain in the range of 0.2 to 0.4V. If NG, go to EC-981, "Diagnostic Procedure" . C D E PBIA9566J F G H I J K L M EC-979 DTC P0134 HO2S1 [HR (WITH EURO-OBD)] Wiring Diagram BBS004C3 MBWA1461E EC-980 DTC P0134 HO2S1 [HR (WITH EURO-OBD)] Specification data are reference values and are measured between each terminal and ground. Pulse signal is measured by CONSULT-II. A CAUTION: Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM's transistor. Use a ground other than ECM terminals, such as the ground. EC TERMINAL NO. WIRE COLOR ITEM CONDITION DATA (DC Voltage) C Approximately 10V [Engine is running] 3 Y ● Warm-up condition ● Engine speed: Below 3,600 rpm D Heated oxygen sensor 1 heater E PBIA8148J [Ignition switch: ON] ● Engine stopped ● F BATTERY VOLTAGE (11 - 14V) [Engine is running] Engine speed: Above 3,600 rpm G [Engine is running] 49 BR Heated oxygen sensor 1 ● Warm-up condition ● Engine speed: 2,000 rpm 0 - Approximately 1.0V (Periodically change) H [Engine is running] 56 R Sensor ground (Heated oxygen sensor 1) ● Warm-up condition ● Idle speed Approximately 0V I : Average voltage for pulse signal (Actual pulse signal can be confirmed by oscilloscope.) Diagnostic Procedure BBS004C4 1. CHECK GROUND CONNECTIONS 1. 2. Turn ignition switch OFF. Loosen and retighten ground screws on the body. Refer to EC-924, "Ground Inspection" . J K L M MBIB1550E 1. IPDM E/R 2. Body ground OK or NG OK >> GO TO 2. NG >> Repair or replace ground connections. EC-981 3. Body ground DTC P0134 HO2S1 [HR (WITH EURO-OBD)] 2. CHECK HO2S1 GROUND CIRCUIT FOR OPEN AND SHORT 1. Disconnect heated oxygen sensor 1 harness connector (1). – : Vehicle front Disconnect ECM harness connector. Check harness continuity between HO2S1 terminal 1 and ECM terminal 56. Refer to Wiring Diagram. 2. 3. Continuity should exist. 4. Also check harness for short to ground and short to power. OK or NG OK >> GO TO 3. NG >> Repair open circuit or short to ground or short to power in harness or connectors. 3. CHECK HO2S1 INPUT SIGNAL CIRCUIT FOR OPEN AND SHORT 1. Check harness continuity between HO2S1 terminal 4 and ECM terminal 49. Refer to Wiring Diagram. Continuity should exist. 2. Check harness continuity between ECM terminal 49 or HO2S1 terminal 4 and ground. Refer to Wiring Diagram. Continuity should not exist. 3. Also check harness for short to power. OK or NG OK >> GO TO 4. NG >> Repair open circuit or short to ground or short to power in harness or connectors. 4. CHECK HEATED OXYGEN SENSOR 1 Refer to EC-983, "Component Inspection" . OK or NG OK >> GO TO 5. NG >> Replace heated oxygen sensor 1. 5. CHECK INTERMITTENT INCIDENT Refer to EC-917, "TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT" . >> INSPECTION END EC-982 PBIB2967E DTC P0134 HO2S1 [HR (WITH EURO-OBD)] Component Inspection BBS004C5 A HEATED OXYGEN SENSOR 1 With CONSULT-II 1. 2. 3. 4. 5. Start engine and warm it up to normal operating temperature. Select “MANU TRIG” and adjust “TRIGGER POINT” to 100% in “DATA MONITOR” mode with CONSULT- EC II. Select “HO2S1 (B1)” and “HO2S1 MNTR (B1)”. C Hold engine speed at 2,000 rpm under no load during the following steps. Touch “RECORD” on CONSULT-II screen. D E SEF646Y F 6. Check the following. ● “HO2S1 MNTR (B1)” in “DATA MONITOR” mode changes from “RICH” to “LEAN” to “RICH” more than 5 times in 10 seconds. 5 times (cycles) are counted as shown in the figure. ● “HO2S1 (B1)” voltage goes above 0.6V at least once. ● “HO2S1 (B1)” voltage goes below 0.3V at least once. ● “HO2S1 (B1)” voltage never exceeds 1.0V. G H I SEF217YA J K L SEF648Y CAUTION: Discard any heated oxygen sensor which has been dropped from a height of more than 0.5 m (19.7 in) onto a hard surface such as a concrete floor; use a new one. ● Before installing new oxygen sensor, clean exhaust system threads using Oxygen Sensor Thread Cleaner tool and approved anti-seize lubricant. ● Without CONSULT-II 1. 2. Start engine and warm it up to normal operating temperature. Set voltmeter probes between ECM terminal 49 (HO2S1 signal) and ground. EC-983 M DTC P0134 HO2S1 [HR (WITH EURO-OBD)] 3. Check the following with engine speed held at 2,000 rpm constant under no load. ● The voltage fluctuates between 0 to 0.3V and 0.6 to 1.0V more than 5 times within 10 seconds. ● The maximum voltage is over 0.6V at least 1 time. ● The minimum voltage is below 0.3V at least 1 time. ● The voltage never exceeds 1.0V. 1 time: 0 - 0.3V → 0.6 - 1.0V → 0 - 0.3V 2 times: 0 - 0.3V → 0.6 - 1.0V → 0 - 0.3V → 0.6 - 1.0V → 0 - 0.3V PBIA9566J CAUTION: ● Discard any heated oxygen sensor which has been dropped from a height of more than 0.5 m (19.7 in) onto a hard surface such as a concrete floor; use a new one. ● Before installing new oxygen sensor, clean exhaust system threads using Oxygen Sensor Thread Cleaner tool and approved anti-seize lubricant. Removal and Installation BBS004C6 HEATED OXYGEN SENSOR 1 Refer to EM-124, "EXHAUST MANIFOLD" . EC-984 DTC P0135 HO2S1 HEATER [HR (WITH EURO-OBD)] DTC P0135 HO2S1 HEATER Description PFP:23710 A BBS004C7 SYSTEM DESCRIPTION Sensor Input Signal to ECM Camshaft position sensor (PHASE) Crankshaft position sensor (POS) Engine speed Engine coolant temperature sensor Engine coolant temperature ECM function Actuator Heated oxygen sensor 1 heater control EC Heated oxygen sensor 1 heater The ECM performs ON/OFF duty control of the heated oxygen sensor 1 heater corresponding to the engine speed and engine coolant temperature. The duty percent varies with engine coolant temperature when engine is started. OPERATION Heated oxygen sensor 1 heater Above 3,600 rpm OFF Below 3,600 rpm after warming up ON F CONSULT-II Reference Value in Data Monitor Mode BBS004C8 Specification data are reference values. G MONITOR ITEM CONDITION SPECIFICATION ● Engine: After warming up ● Engine speed: Below 3,600 rpm ● Engine speed: Above 3,600 rpm ● Engine coolant temperature when engine started: More than 80°C (176°F) ● Engine speed: Below 3,600 rpm O2SEN HTR DTY ON P0135 0135 Trouble diagnosis name Heated oxygen sensor 1 heater control circuit H OFF I Approx. 30% On Board Diagnosis Logic DTC No. D E Engine speed HO2S1 HTR (B1) C BBS004C9 J DTC detecting condition The current amperage in the heated oxygen sensor 1 heater circuit is out of the normal range. (An excessively low voltage signal is sent to ECM through the heated oxygen sensor 1 heater.) Possible cause ● Harness or connectors (The heated oxygen sensor 1 heater circuit is open or shorted.) ● Heated oxygen sensor 1 heater K L M EC-985 DTC P0135 HO2S1 HEATER [HR (WITH EURO-OBD)] DTC Confirmation Procedure BBS004CA NOTE: If DTC Confirmation Procedure has been previously conducted, always turn ignition switch OFF and wait at least 10 seconds before conducting the next test. TESTING CONDITION: Before performing the following procedure, confirm that battery voltage is between 11V and 16V at idle. WITH CONSULT-II 1. 2. 3. 4. Turn ignition switch ON. Select “DATA MONITOR” mode with CONSULT-II. Wait at least 5 seconds. If 1st trip DTC is detected, go to EC-988, "Diagnostic Procedure" . SEF058Y WITH GST Follow the procedure “WITH CONSULT-II” above. EC-986 DTC P0135 HO2S1 HEATER [HR (WITH EURO-OBD)] Wiring Diagram BBS004CB A EC C D E F G H I J K L M MBWA1462E EC-987 DTC P0135 HO2S1 HEATER [HR (WITH EURO-OBD)] Specification data are reference values and are measured between each terminal and ground. Pulse signal is measured by CONSULT-II. CAUTION: Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM's transistor. Use a ground other than ECM terminals, such as the ground. TERMINAL NO. WIRE COLOR ITEM CONDITION DATA (DC Voltage) Approximately 10V [Engine is running] 3 Y ● Warm-up condition ● Engine speed: Below 3,600 rpm Heated oxygen sensor 1 heater PBIA8148J [Ignition switch: ON] ● Engine stopped BATTERY VOLTAGE (11 - 14V) [Engine is running] ● Engine speed: Above 3,600 rpm [Engine is running] 49 56 BR R Heated oxygen sensor 1 Sensor ground (Heated oxygen sensor 1) ● Warm-up condition ● Engine speed: 2,000 rpm 0 - Approximately 1.0V (Periodically change) [Engine is running] ● Approximately 0V Idle speed : Average voltage for pulse signal (Actual pulse signal can be confirmed by oscilloscope.) Diagnostic Procedure BBS004CC 1. CHECK GROUND CONNECTIONS 1. 2. Turn ignition switch OFF. Loosen and retighten ground screws on the body. Refer to EC-924, "Ground Inspection" . MBIB1550E 1. IPDM E/R 2. Body ground OK or NG OK >> GO TO 2. NG >> Repair or replace ground connections. EC-988 3. Body ground DTC P0135 HO2S1 HEATER [HR (WITH EURO-OBD)] 2. CHECK HO2S1 POWER SUPPLY CIRCUIT A 1. Disconnect heated oxygen sensor 1 harness connector (1). – : Vehicle front Turn ignition switch ON. 2. EC C D PBIB2967E 3. E Check voltage between HO2S1 terminal 2 and ground with CONSULT-II or tester. Voltage: Battery voltage F OK or NG OK >> GO TO 4. NG >> GO TO 3. G PBIA9576J H 3. DETECT MALFUNCTIONING PART Check the following. ● Harness connectors E59, F1 ● IPDM E/R connector E10 ● 10A fuse ● Harness for open or short between heated oxygen sensor 1 and fuse I J K >> Repair open circuit or short to ground or short to power in harness or connectors. 4. CHECK HO2S1 OUTPUT SIGNAL CIRCUIT FOR OPEN AND SHORT L 1. 2. 3. M Turn ignition switch OFF. Disconnect ECM harness connector. Check harness continuity between ECM terminal 3 and HO2S1 terminal 3. Refer to Wiring Diagram. Continuity should exist. 4. Also check harness for short to ground and short to power. OK or NG OK >> GO TO 5. NG >> Repair open circuit or short to ground or short to power in harness or connectors. 5. CHECK HEATED OXYGEN SENSOR 1 HEATER Refer to EC-990, "Component Inspection" . OK or NG OK >> GO TO 6. NG >> Replace heated oxygen sensor 1. EC-989 DTC P0135 HO2S1 HEATER [HR (WITH EURO-OBD)] 6. CHECK INTERMITTENT INCIDENT Refer to EC-917, "TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT" . >> INSPECTION END Component Inspection BBS004CD HEATED OXYGEN SENSOR 1 HEATER 1. Check resistance between HO2S1 terminals as follows. Terminal No. Resistance 2 and 3 3.4 - 4.4 Ω [at 25°C (77°F)] 1 and 2, 3, 4 ∞Ω (Continuity should not exist) 4 and 1, 2, 3 2. If NG, replace heated oxygen sensor 1. CAUTION: ● Discard any heated oxygen sensor which has been dropped from a height of more than 0.5 m (19.7 in) onto a hard surface such as a concrete floor; use a new one. ● Before installing new oxygen sensor, clean exhaust system threads using Oxygen Sensor Thread Cleaner tool and approved anti-seize lubricant. PBIA9577J Removal and Installation BBS004CE HEATED OXYGEN SENSOR 1 Refer to EM-124, "EXHAUST MANIFOLD" . EC-990 DTC P0138 HO2S2 [HR (WITH EURO-OBD)] DTC P0138 HO2S2 Component Description PFP:226A0 A BBS004CF The heated oxygen sensor 2, after three way catalyst (manifold), monitors the oxygen level in the exhaust gas. Even if switching characteristics of the heated oxygen sensor 1 are shifted, the air-fuel ratio is controlled to stoichiometric, by the signal from the heated oxygen sensor 2. This sensor is made of ceramic zirconia. The zirconia generates voltage from approximately 1V in richer conditions to 0V in leaner conditions. Under normal conditions the heated oxygen sensor 2 is not used for engine control operation. EC C D SEF327R E CONSULT-II Reference Value in Data Monitor Mode BBS004CG Specification data are reference values. MONITOR ITEM HO2S2 (B1) HO2S2 MNTR (B1) F CONDITION SPECIFICATION ● Revving engine from idle to 3,000 rpm quickly after the following conditions are met. 0 - 0.3V ←→ Approx. 0.6 - 1.0V – Engine: After warming up – Keep the engine speed between 3,500 rpm and 4,000 rpm for 1 minute and idle for 1 minute under no load G LEAN ←→ RICH H On Board Diagnosis Logic BBS004CH The heated oxygen sensor 2 has a much longer switching time between rich and lean than the heated oxygen sensor 1. The oxygen storage capacity before the three way catalyst (manifold) causes the longer switching time. To judge the malfunctions of heated oxygen sensor 2, ECM monitors whether the voltage is unusually high during the various driving condition such as fuel-cut. I J K PBIB1848E L DTC No. P0138 0138 Trouble diagnosis name Heated oxygen sensor 2 circuit high voltage DTC detecting condition Possible cause ● Harness or connectors (The sensor circuit is open or shorted.) ● Heated oxygen sensor 2 An excessively high voltage from the sensor is sent to ECM. EC-991 M DTC P0138 HO2S2 [HR (WITH EURO-OBD)] DTC Confirmation Procedure BBS004CI CAUTION: Always drive vehicle at a safe speed. NOTE: If DTC Confirmation Procedure has been previously conducted, always turn ignition switch OFF and wait at least 10 seconds before conducting the next test. WITH CONSULT-II 1. 2. 3. 4. 5. 6. Turn ignition switch ON and select “DATA MONITOR” mode with CONSULT-II. Start engine and warm it up to the normal operating temperature. Turn ignition switch OFF and wait at least 10 seconds. Start engine and keep the engine speed between 3,500 and 4,000 rpm for at least 1 minute under no load. Let engine idle for 2 minutes. If 1st trip DTC is detected, go to EC-994, "Diagnostic Procedure" . SEF174Y WITH GST Follow the procedure “WITH CONSULT-II” above. EC-992 DTC P0138 HO2S2 [HR (WITH EURO-OBD)] Wiring Diagram BBS004CJ A EC C D E F G H I J K L M MBWA1463E EC-993 DTC P0138 HO2S2 [HR (WITH EURO-OBD)] Specification data are reference values and are measured between each terminal and ground. Pulse signal is measured by CONSULT-II. CAUTION: Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM's transistor. Use a ground other than ECM terminals, such as the ground. TERMINAL NO. WIRE COLOR ITEM CONDITION DATA (DC Voltage) Approximately 10V [Engine is running] 5 GR ● Below 3,600 rpm after the following conditions are met. – Engine: After warming up – Keeping the engine speed between 3,500 and 4,000 rpm for 1 minute and at idle for 1 minute under no load Heated oxygen sensor 2 heater PBIA8148J [Ignition switch: ON] ● Engine stopped BATTERY VOLTAGE (11 - 14V) [Engine is running] ● Engine speed: Above 3,600 rpm [Engine is running] 50 B Heated oxygen sensor 2 ● Revving engine from idle to 3,000 rpm quickly after the following conditions are met. – Engine: After warming up – Keeping the engine speed between 3,500 and 4,000 rpm for 1 minute and at idle for 1 minute under no load. 0 - Approximately 1.0V [Engine is running] 59 LG Sensor ground (Heated oxygen sensor 2) ● Warm-up condition ● Idle speed Approximately 0V : Average voltage for pulse signal (Actual pulse signal can be confirmed by oscilloscope.) Diagnostic Procedure BBS004CK 1. CHECK GROUND CONNECTIONS 1. 2. Turn ignition switch OFF. Loosen and retighten ground screws on the body. Refer to EC-924, "Ground Inspection" . MBIB1550E 1. IPDM E/R 2. Body ground OK or NG OK >> GO TO 2. NG >> Repair or replace ground connections. EC-994 3. Body ground DTC P0138 HO2S2 [HR (WITH EURO-OBD)] 2. CHECK HO2S2 GROUND CIRCUIT FOR OPEN AND SHORT 1. – 2. 3. A Disconnect heated oxygen sensor 2 harness connector (2). Heated oxygen sensor 2 (1) Disconnect ECM harness connector. Check harness continuity between HO2S2 terminal 1 and ECM terminal 59. Refer to Wiring Diagram. EC C Continuity should exist. 4. Also check harness for short to ground and short to power. OK or NG OK >> GO TO 3. NG >> Repair open circuit or short to ground or short to power in harness or connectors. D PBIB2949E E 3. CHECK HO2S2 INPUT SIGNAL CIRCUIT FOR OPEN AND SHORT 1. F Check harness continuity between HO2S2 terminal 4 ECM terminal 50. Refer to Wiring Diagram. Continuity should exist. 2. G Check harness continuity between ECM terminal 50 or HO2S2 terminal 4 and ground. Refer to Wiring Diagram. H Continuity should not exist. 3. Also check harness for short to power. OK or NG OK >> GO TO 4. NG >> Repair open circuit or short to ground or short to power in harness or connectors. I 4. CHECK HEATED OXYGEN SENSOR 2 J Refer to EC-995, "Component Inspection" . OK or NG OK >> GO TO 5. NG >> Replace heated oxygen sensor 2. K L 5. CHECK INTERMITTENT INCIDENT Refer to EC-917, "TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT" . M >> INSPECTION END Component Inspection BBS004CL HEATED OXYGEN SENSOR 2 With CONSULT-II 1. 2. 3. 4. Start engine and warm it up to the normal operating temperature. Turn ignition switch OFF and wait at least 10 seconds. Start engine and keep the engine speed between 3,500 and 4,000 rpm for at least 1 minute under no load. Let engine idle for 1 minute. EC-995 DTC P0138 HO2S2 [HR (WITH EURO-OBD)] 5. Select “FUEL INJECTION” in “ACTIVE TEST” mode, and select “HO2S2 (B1)” as the monitor item with CONSULT-II. SEF662Y 6. Check “HO2S2 (B1)” at idle speed when adjusting “FUEL INJECTION” to ±25%. PBIB0551E “HO2S2 (B1)” should be above 0.68V at least once when the “FUEL INJECTION” is +25%. “HO2S2 (B1)” should be below 0.50V at least once when the “FUEL INJECTION” is −25%. CAUTION: ● Discard any heated oxygen sensor which has been dropped from a height of more than 0.5 m (19.7 in) onto a hard surface such as a concrete floor; use a new one. ● Before installing new oxygen sensor, clean exhaust system threads using Oxygen Sensor Thread Cleaner tool and approved anti-seize lubricant. Without CONSULT-II 1. 2. 3. 4. 5. 6. Start engine and warm it up to the normal operating temperature. Turn ignition switch OFF and wait at least 10 seconds. Start engine and keep the engine speed between 3,500 and 4,000 rpm for at least 1 minute under no load. Let engine idle for 1 minute. Set voltmeter probes between ECM terminal 50 (HO2S2 signal) and ground. Check the voltage when revving up to 4,000 rpm under no load at least 10 times. (Depress and release accelerator pedal as soon as possible.) The voltage should be above 0.68V at least once during this procedure. If the voltage is above 0.68V at step 6, step 7 is not necessary. 7. Keep vehicle idling for 10 minutes, then check voltage. Or check the voltage when coasting from 80 km/h (50 MPH) in D position with “OD” OFF (A/T), 3rd gear position (M/T). The voltage should be below 0.50V at least once during this PBIB2996E procedure. 8. If NG, replace heated oxygen sensor 2. CAUTION: ● Discard any heated oxygen sensor which has been dropped from a height of more than 0.5 m (19.7 in) onto a hard surface such as a concrete floor; use a new one. ● Before installing new oxygen sensor, clean exhaust system threads using Oxygen Sensor Thread Cleaner tool and approved anti-seize lubricant. EC-996 DTC P0138 HO2S2 [HR (WITH EURO-OBD)] Removal and Installation BBS004CM A HEATED OXYGEN SENSOR 2 Refer to EX-3, "EXHAUST SYSTEM" . EC C D E F G H I J K L M EC-997 DTC P0139 HO2S2 [HR (WITH EURO-OBD)] DTC P0139 HO2S2 Component Description PFP:226A0 BBS004CN The heated oxygen sensor 2, after three way catalyst (manifold), monitors the oxygen level in the exhaust gas. Even if switching characteristics of the heated oxygen sensor 1 are shifted, the air-fuel ratio is controlled to stoichiometric, by the signal from the heated oxygen sensor 2. This sensor is made of ceramic zirconia. The zirconia generates voltage from approximately 1V in richer conditions to 0V in leaner conditions. Under normal conditions the heated oxygen sensor 2 is not used for engine control operation. SEF327R CONSULT-II Reference Value in Data Monitor Mode BBS004CO Specification data are reference values. MONITOR ITEM HO2S2 (B1) HO2S2 MNTR (B1) CONDITION SPECIFICATION ● Revving engine from idle to 3,000 rpm quickly after the following conditions are met. 0 - 0.3V ←→ Approx. 0.6 - 1.0V – Engine: After warming up – Keep the engine speed between 3,500 rpm and 4,000 rpm for 1 minute and idle for 1 minute under no load LEAN ←→ RICH On Board Diagnosis Logic BBS004CP The heated oxygen sensor 2 has a much longer switching time between rich and lean than the heated oxygen sensor 1. The oxygen storage capacity before the three way catalyst (manifold) causes the longer switching time. To judge the malfunctions of heated oxygen sensor 2, ECM monitors whether the switching response of the sensor's voltage is faster than specified during the various driving condition such as fuel-cut. SEF302U DTC No. P0139 0139 Trouble diagnosis name Heated oxygen sensor 2 circuit slow response DTC detecting condition It takes more time for the sensor to respond between rich and lean than the specified time. EC-998 Possible cause ● Harness or connectors (The sensor circuit is open or shorted.) ● Heated oxygen sensor 2 ● Fuel pressure ● Fuel injector ● Intake air leaks DTC P0139 HO2S2 [HR (WITH EURO-OBD)] DTC Confirmation Procedure BBS004CQ A CAUTION: Always drive vehicle at a safe speed. NOTE: ● “COMPLETED” will appear on CONSULT-II screen when all tests “COND1”, “COND2” and EC “COND3” are completed. ● If DTC Confirmation Procedure has been previously conducted, always turn ignition switch OFF and wait C at least 10 seconds before conducting the next test. TESTING CONDITION: Never stop engine during this procedure. If the engine is stopped, retry this procedure from step 2 in D Procedure for COND1. WITH CONSULT-II Procedure for COND1 For the best results, perform DTC WORK SUPPORT at a temperature of 0 to 30°(32 to 86°F). 1. Start engine and warm it up to normal operating temperature. 2. Turn ignition switch OFF and wait at least 10 seconds. 3. Start engine and keep the engine speed between 3,500 and 4,000 rpm for at least 1 minute under no load. 4. Let engine idle 1 minute. 5. Select “HO2S2 (B1) P0139” of “HO2S2” in “DTC WORK SUPPORT” mode with CONSULT-II. 6. Touch “START”. 7. Start engine and let it idle for at least 30 seconds. 8. Rev engine up to 2,000 rpm two or three times quickly under no load. If “COMPLETED” appears on CONSULT-II screen, go to step 2 in Procedure for COND3. If “COMPLETED” does not appear on CONSULT-II screen, go to the following step. 9. When the following conditions are met, “TESTING” will be displayed at “COND1” on the CONSULT-II screen. Maintain the conditions continuously until “TESTING” changes to “COMPLETED”. (It will take approximately 60 seconds.) ENG SPEED More than 1.0 msec COOLAN TEMP/S 70 - 119 °C (158 - 246°F) Shift level Suitable position F G H I J 1,000 - 3,600 rpm B/FUEL SCHDL E K L M PBIB0552E NOTE: If “TESTING” is not displayed after 5 minutes, retry from step 2 in Procedure for COND1. ● If “COMPLETED” already appears at “COND2” on CONSULT-II screen before Procedure for COND2 is conducted, it is unnecessary to conduct step 1 in Procedure for COND2. ● EC-999 DTC P0139 HO2S2 [HR (WITH EURO-OBD)] Procedure for COND2 1. While driving, release accelerator pedal completely with “OD” OFF (A/T) from the above condition [step 9] until “INCOMPLETE” at “COND2” on CONSULT-II screen has turned to “COMPLETED”. (It will take approximately 4 seconds.) NOTE: If “COMPLETED” already appears at “COND3” on CONSULT-II screen before Procedure for COND3 is conducted, it is unnecessary to conduct step 1 in Procedure for COND3. PBIB0553E Procedure for COND3 1. 2. a. b. c. d. Stop vehicle and let it idle until “INCOMPLETE” of “COND3” on CONSULT-II screen has turned to “COMPLETED”. (It will take a maximum of approximately 6 minutes.) Make sure that “OK” is displayed after touching “SELF-DIAG RESULTS”. If “NG” is displayed, refer to EC-1002, "Diagnostic Procedure" . If “CAN NOT BE DIAGNOSED” is displayed, perform the following. Turn ignition switch OFF and leave the vehicle in a cool place (soak the vehicle). Turn ignition switch ON and select “COOLAN TEMP/S” in “DATA MONITOR” mode with CONSULT-II. Start engine and warm it up while monitoring “COOLAN TEMP/S” indication on CONSULT-II. When “COOLAN TEMP/S” indication reaches to 70°(158°F), go to Procedure for COND1 step 3. Overall Function Check SEF668Y BBS004CR Use this procedure to check the overall function of the heated oxygen sensor 2 circuit. During this check, a 1st trip DTC might not be confirmed. WITH GST 1. 2. 3. 4. 5. 6. 7. 8. Start engine and warm it up to the normal operating temperature. Turn ignition switch OFF and wait at least 10 seconds. Start engine and keep the engine between 3,500 and 4,000 rpm for at least 1 minute under no load. Let engine idle for 1 minute. Set voltmeter probes between ECM terminal 50 (HO2S2 signal) and ground. Check the voltage when revving up to 4,000 rpm under no load at least 10 times. (Depress and release accelerator pedal as soon as possible.) A change of voltage should be more than 0.06V for 1 second during this procedure. If the voltage can be confirmed in step 6, step 7 is not necessary. Keep vehicle at idling for 10 minutes, then check the voltage. Or check the voltage when coasting from 80 km/h (50 MPH) in D position with “OD” OFF (A/T), 3rd gear position (M/T). A change of voltage should be more than 0.06V for 1 secPBIB2996E ond during this procedure. If NG, go to EC-1002, "Diagnostic Procedure" . EC-1000 DTC P0139 HO2S2 [HR (WITH EURO-OBD)] Wiring Diagram BBS004CS A EC C D E F G H I J K L M MBWA1463E EC-1001 DTC P0139 HO2S2 [HR (WITH EURO-OBD)] Specification data are reference values and are measured between each terminal and ground. Pulse signal is measured by CONSULT-II. CAUTION: Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM's transistor. Use a ground other than ECM terminals, such as the ground. TERMINAL NO. WIRE COLOR ITEM CONDITION DATA (DC Voltage) Approximately 10V [Engine is running] 5 GR ● Below 3,600 rpm after the following conditions are met. – Engine: After warming up – Keeping the engine speed between 3,500 and 4,000 rpm for 1 minute and at idle for 1 minute under no load Heated oxygen sensor 2 heater PBIA8148J [Ignition switch: ON] ● Engine stopped BATTERY VOLTAGE (11 - 14V) [Engine is running] ● Engine speed: Above 3,600 rpm [Engine is running] 50 B Heated oxygen sensor 2 ● Revving engine from idle to 3,000 rpm quickly after the following conditions are met. – Engine: After warming up – Keeping the engine speed between 3,500 and 4,000 rpm for 1 minute and at idle for 1 minute under no load. 0 - Approximately 1.0V [Engine is running] 59 LG Sensor ground (Heated oxygen sensor 2) ● Warm-up condition ● Idle speed Approximately 0V : Average voltage for pulse signal (Actual pulse signal can be confirmed by oscilloscope.) Diagnostic Procedure BBS004CT 1. CHECK GROUND CONNECTIONS 1. 2. Turn ignition switch OFF. Loosen and retighten ground screws on the body. Refer to EC-924, "Ground Inspection" . MBIB1550E 1. IPDM E/R 2. Body ground OK or NG OK >> GO TO 2. NG >> Repair or replace ground connections. EC-1002 3. Body ground DTC P0139 HO2S2 [HR (WITH EURO-OBD)] 2. CLEAR THE SELF-LEARNING DATA A With CONSULT-II Start engine and warm it up to normal operating temperature. Select “SELF-LEARNING CONT” in “WORK SUPPORT” mode with CONSULT-II. 3. Clear the self-learning control coefficient by touching “CLEAR”. 4. Run engine for at least 10 minutes at idle speed. Is the 1st trip DTC P0171 or P0172 detected? Is it difficult to start engine? 1. 2. EC C D E SEF215Z Without CONSULT-II 1. Start engine and warm it up to normal operating temperature. 2. Turn ignition switch OFF. 3. Disconnect mass air flow sensor (1) harness connector, and restart and run engine for at least 5 seconds at idle speed. 4. Stop engine and reconnect mass air flow sensor harness connector. 5. Make sure that DTC P0102 is displayed. 6. Erase the DTC memory. Refer to EC-841, "HOW TO ERASE EMISSION-RELATED DIAGNOSTIC INFORMATION" . 7. Make sure that DTC P0000 is displayed. 8. Run engine for at least 10 minutes at idle speed. Is the 1st trip DTC P0171 or P0172 detected? PBIB2948E Is it difficult to start engine? Yes or No Yes >> Perform trouble diagnosis for DTC P0171 or P0172. Refer to EC-1012, "DTC P0171 FUEL INJECTION SYSTEM FUNCTION" or EC-1019, "DTC P0172 FUEL INJECTION SYSTEM FUNCTION" . No >> GO TO 3. – 3. 4. Turn ignition switch OFF. Disconnect heated oxygen sensor 2 harness connector (2). Heated oxygen sensor 2 (1) Disconnect ECM harness connector. Check harness continuity between and HO2S2 terminal 1 and ECM terminal 59. Refer to Wiring Diagram. EC-1003 H I J K M Continuity should exist. 5. Also check harness for short to ground and short to power. OK or NG OK >> GO TO 4. NG >> Repair open circuit or short to ground or short to power in harness or connectors. G L 3. CHECK HO2S2 GROUND CIRCUIT FOR OPEN AND SHORT 1. 2. F PBIB2949E DTC P0139 HO2S2 [HR (WITH EURO-OBD)] 4. CHECK HO2S2 INPUT SIGNAL CIRCUIT FOR OPEN AND SHORT 1. Check harness continuity between HO2S2 terminal 4 and ECM terminal 50. Refer to Wiring Diagram. Continuity should exist. 2. Check harness continuity between ECM terminal 50 or HO2S2 terminal 4 and ground. Refer to Wiring Diagram. Continuity should not exist. 3. Also check harness for short to power. OK or NG OK >> GO TO 5. NG >> Repair open circuit or short to ground or short to power in harness or connectors. 5. CHECK HEATED OXYGEN SENSOR 2 Refer to EC-1004, "Component Inspection" . OK or NG OK >> GO TO 6. NG >> Replace heated oxygen sensor 2. 6. CHECK INTERMITTENT INCIDENT Refer to EC-917, "TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT" . >> INSPECTION END Component Inspection BBS004CU HEATED OXYGEN SENSOR 2 With CONSULT-II 1. 2. 3. 4. 5. Start engine and warm it up to the normal operating temperature. Turn ignition switch OFF and wait at least 10 seconds. Start engine and keep the engine speed between 3,500 and 4,000 rpm for at least 1 minute under no load. Let engine idle for 1 minute. Select “FUEL INJECTION” in “ACTIVE TEST” mode, and select “HO2S2 (B1)” as the monitor item with CONSULT-II. SEF662Y EC-1004 DTC P0139 HO2S2 [HR (WITH EURO-OBD)] 6. Check “HO2S2 (B1)” at idle speed when adjusting “FUEL INJECTION” to ±25%. A EC C PBIB0551E “HO2S2 (B1)” should be above 0.68V at least once when the “FUEL INJECTION” is +25%. “HO2S2 (B1)” should be below 0.50V at least once when the “FUEL INJECTION” is −25%. CAUTION: ● Discard any heated oxygen sensor which has been dropped from a height of more than 0.5 m (19.7 in) onto a hard surface such as a concrete floor; use a new one. ● Before installing new oxygen sensor, clean exhaust system threads using Oxygen Sensor Thread Cleaner tool and approved anti-seize lubricant. D E F Without CONSULT-II 1. 2. 3. 4. 5. 6. Start engine and warm it up to the normal operating temperature. Turn ignition switch OFF and wait at least 10 seconds. Start engine and keep the engine speed between 3,500 and 4,000 rpm for at least 1 minute under no load. Let engine idle for 1 minute. Set voltmeter probes between ECM terminal 50 (HO2S2 signal) and ground. Check the voltage when revving up to 4,000 rpm under no load at least 10 times. (Depress and release accelerator pedal as soon as possible.) The voltage should be above 0.68V at least once during this procedure. If the voltage is above 0.68V at step 6, step 7 is not necessary. 7. Keep vehicle idling for 10 minutes, then check voltage. Or check the voltage when coasting from 80 km/h (50 MPH) in D position with “OD” OFF (A/T), 3rd gear position (M/T). The voltage should be below 0.50V at least once during this PBIB2996E procedure. 8. If NG, replace heated oxygen sensor 2. CAUTION: ● Discard any heated oxygen sensor which has been dropped from a height of more than 0.5 m (19.7 in) onto a hard surface such as a concrete floor; use a new one. ● Before installing new oxygen sensor, clean exhaust system threads using Oxygen Sensor Thread Cleaner tool and approved anti-seize lubricant. Removal and Installation BBS004CV HEATED OXYGEN SENSOR 2 Refer to EX-3, "EXHAUST SYSTEM" EC-1005 G H I J K L M DTC P0141 HO2S2 HEATER [HR (WITH EURO-OBD)] DTC P0141 HO2S2 HEATER Description PFP:23710 BBS004CW SYSTEM DESCRIPTION Sensor Input Signal to ECM Camshaft position sensor (PHASE) ECM Function Actuator Heated oxygen sensor 2 heater control Heated oxygen sensor 2 heater Engine speed Crankshaft position sensor (POS) Engine coolant temperature sensor Engine coolant temperature Mass air flow sensor Amount of intake air The ECM performs ON/OFF control of the heated oxygen sensor 2 heater corresponding to the engine speed, amount of intake air and engine coolant temperature. OPERATION Engine speed Heated oxygen sensor 2 heater Above 3,600 rpm OFF ● Below 3,600 rpm after the following conditions are met. – Engine: After warming up – Keeping the engine speed between 3,500 and 4,000 rpm for 1 minute and at idle for 1 minute under no load ON CONSULT-II Reference Value in Data Monitor Mode BBS004CX Specification data are reference values. MONITOR ITEM HO2S2 HTR (B1) CONDITION SPECIFICATION ● Engine speed: Above 3,600 rpm ● Below 3,600 rpm after the following conditions are met. OFF – Engine: After warming up – Keeping the engine speed between 3,500 and 4,000 rpm for 1 minute and at idle for 1 minute under no load ON On Board Diagnosis Logic DTC No. P0141 0141 Trouble diagnosis name Heated oxygen sensor 2 heater control circuit BBS004CY DTC detecting condition The current amperage in the heated oxygen sensor 2 heater circuit is out of the normal range. (An excessively low voltage signal is sent to ECM through the heated oxygen sensor 2 heater.) EC-1006 Possible cause ● Harness or connectors (The heated oxygen sensor 2 heater circuit is open or shorted.) ● Heated oxygen sensor 2 heater DTC P0141 HO2S2 HEATER [HR (WITH EURO-OBD)] DTC Confirmation Procedure BBS004CZ A NOTE: If DTC Confirmation Procedure has been previously conducted, always turn ignition switch OFF and wait at least 10 seconds before conducting the next test. EC TESTING CONDITION: Before performing the following procedure, confirm that battery voltage is between 11V and 16V at idle. C WITH CONSULT-II 1. 2. 3. 4. Turn ignition switch ON. Select “DATA MONITOR” mode with CONSULT-II. Wait at least 5 seconds. If 1st trip DTC is detected, go to EC-1009, "Diagnostic Procedure" . D E F SEF058Y WITH GST G Follow the procedure “WITH CONSULT-II” above. H I J K L M EC-1007 DTC P0141 HO2S2 HEATER [HR (WITH EURO-OBD)] Wiring Diagram BBS004D0 MBWA1464E EC-1008 DTC P0141 HO2S2 HEATER [HR (WITH EURO-OBD)] Specification data are reference values and are measured between each terminal and ground. Pulse signal is measured by CONSULT-II. A CAUTION: Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM's transistor. Use a ground other than ECM terminals, such as the ground. EC TERMINAL NO. WIRE COLOR ITEM CONDITION DATA (DC Voltage) C Approximately 10V [Engine is running] 5 GR ● Below 3,600 rpm after the following conditions are met. – Engine: After warming up – Keeping the engine speed between 3,500 and 4,000 rpm for 1 minute and at idle for 1 minute under no load Heated oxygen sensor 2 heater D E PBIA8148J [Ignition switch: ON] ● Engine stopped ● F BATTERY VOLTAGE (11 - 14V) [Engine is running] Engine speed: Above 3,600 rpm G [Engine is running] 50 B Heated oxygen sensor 2 ● Revving engine from idle to 3,000 rpm quickly after the following conditions are met. – Engine: After warming up – Keeping the engine speed between 3,500 and 4,000 rpm for 1 minute and at idle for 1 minute under no load. H 0 - Approximately 1.0V I [Engine is running] 59 LG Sensor ground (Heated oxygen sensor 2) ● Warm-up condition ● Idle speed Approximately 0V J : Average voltage for pulse signal (Actual pulse signal can be confirmed by oscilloscope.) Diagnostic Procedure BBS004D1 K 1. CHECK GROUND CONNECTIONS 1. 2. L Turn ignition switch OFF. Loosen and retighten ground screws on the body. Refer to EC-924, "Ground Inspection" . M MBIB1550E 1. IPDM E/R 2. Body ground OK or NG OK >> GO TO 2. NG >> Repair or replace ground connections. EC-1009 3. Body ground DTC P0141 HO2S2 HEATER [HR (WITH EURO-OBD)] 2. CHECK HO2S2 POWER SUPPLY CIRCUIT 1. – 2. Disconnect heated oxygen sensor 2 harness connector (2). Heated oxygen sensor 2 (1) Turn ignition switch ON. PBIB2949E 3. Check voltage between HO2S2 terminal 2 and ground with CONSULT-II or tester. Voltage: Battery voltage OK or NG OK >> GO TO 4. NG >> GO TO 3. PBIA9576J 3. DETECT MALFUNCTIONING PART Check the following. ● Harness connectors E59, F1 ● IPDM E/R connector E10 ● 10A fuse ● Harness for open or short between heated oxygen sensor 2 and fuse >> Repair open circuit or short to ground or short to power in harness or connectors. 4. CHECK HO2S2 OUTPUT SIGNAL CIRCUIT FOR OPEN AND SHORT 1. 2. 3. Turn ignition switch OFF. Disconnect ECM harness connector. Check harness continuity between ECM terminal 5 and HO2S2 terminal 3. Refer to Wiring Diagram. Continuity should exist. 4. Also check harness for short to ground and short to power. OK or NG OK >> GO TO 5. NG >> Repair open circuit or short to ground or short to power in harness or connectors. 5. CHECK HEATED OXYGEN SENSOR 2 HEATER Refer to EC-1011, "Component Inspection" . OK or NG OK >> GO TO 6. NG >> Replace heated oxygen sensor 2. EC-1010 DTC P0141 HO2S2 HEATER [HR (WITH EURO-OBD)] 6. CHECK INTERMITTENT INCIDENT A Refer to EC-917, "TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT" . EC >> INSPECTION END Component Inspection BBS004D2 HEATED OXYGEN SENSOR 2 HEATER 1. C Check resistance between HO2S2 terminals as follows. Terminal No. Resistance 2 and 3 3.4 - 4.4 Ω [at 25°C (77°F)] 1 and 2, 3, 4 ∞Ω (Continuity should not exist) 4 and 1, 2, 3 D E 2. If NG, replace heated oxygen sensor 2. CAUTION: ● Discard any heated oxygen sensor which has been dropped from a height of more than 0.5 m (19.7 in) onto a hard surface such as a concrete floor; use a new one. ● Before installing new oxygen sensor, clean exhaust system threads using Oxygen Sensor Thread Cleaner tool and approved anti-seize lubricant. F G H I PBIA9577J J Removal and Installation BBS004D3 HEATED OXYGEN SENSOR 2 Refer to EX-3, "EXHAUST SYSTEM" . K L M EC-1011 DTC P0171 FUEL INJECTION SYSTEM FUNCTION [HR (WITH EURO-OBD)] DTC P0171 FUEL INJECTION SYSTEM FUNCTION On Board Diagnosis Logic PFP:16600 BBS004D4 With the Air-Fuel Mixture Ratio Self-Learning Control, the actual mixture ratio can be brought closely to the theoretical mixture ratio based on the mixture ratio feedback signal from the heated oxygen sensor 1. The ECM calculates the necessary compensation to correct the offset between the actual and the theoretical ratios. In case the amount of the compensation value is extremely large (The actual mixture ratio is too lean.), the ECM judges the condition as the fuel injection system malfunction and lights up the MI (2 trip detection logic). Sensor Heated oxygen sensor 1 Input Signal to ECM Density of oxygen in exhaust gas (Mixture ratio feedback signal) Trouble diagnosis name DTC No. Fuel injection system too lean Fuel injection control Actuator Fuel injector DTC detecting condition ● P0171 0171 ECM function ● Possible cause ● Intake air leaks ● Heated oxygen sensor 1 Fuel injection system does not operate properly. ● Fuel injector The amount of mixture ratio compensation is too large. (The mixture ratio is too lean.) ● Exhaust gas leaks ● Incorrect fuel pressure ● Lack of fuel ● Mass air flow sensor ● Incorrect PCV hose connection DTC Confirmation Procedure BBS004D5 NOTE: If DTC Confirmation Procedure has been previously conducted, always turn ignition switch OFF and wait at least 10 seconds before conducting the next test. WITH CONSULT-II 1. 2. 3. 4. 5. 6. a. b. Start engine and warm it up to normal operating temperature. Turn ignition switch OFF and wait at least 10 seconds. Turn ignition switch ON and select “SELF-LEARNING CONT” in “WORK SUPPORT” mode with CONSULT-II. Clear the self-learning control coefficient by touching “CLEAR”. Select “DATA MONITOR” mode with CONSULT-II. Start engine again and let it idle for at least 10 minutes. The 1st trip DTC P0171 should be detected at this stage, if a malfunction exists. If so, go to EC-1016, "Diagnostic Procedure" . NOTE: If 1st trip DTC is not detected during above procedure, performing the following procedure is advised. Turn ignition switch OFF and wait at least 10 seconds. SEF215Z Start engine and drive the vehicle under the similar conditions to (1st trip) Freeze Frame Data for 10 minutes. Refer to the table below. Hold the accelerator pedal as steady as possible. The similar conditions to (1st trip) Freeze Frame Data means the vehicle operation that the following conditions should be satisfied at the same time. Engine speed Engine speed in the freeze frame data ± 400 rpm Vehicle speed Vehicle speed in the freeze frame data ± 10 km/h (6 MPH) EC-1012 DTC P0171 FUEL INJECTION SYSTEM FUNCTION [HR (WITH EURO-OBD)] Engine coolant temperature (T) condition 7. 8. When the freeze frame data shows lower than 70 °C (158 °F), T should be lower than 70 °C (158 °F). A When the freeze frame data shows higher than or equal to 70 °C (158 °F), T should be higher than or equal to 70 °C (158 °F). EC If it is difficult to start engine at step 6, the fuel injection system has a malfunction, too. Crank engine while depressing accelerator pedal. If engine starts, go to EC-1016, "Diagnostic Procedure" . If engine does not start, check exhaust and intake air leak visually. C WITH GST 1. 2. 3. 4. 5. 6. 7. 8. 9. a. b. Start engine and warm it up to normal operating temperature. Turn ignition switch OFF and wait at least 10 seconds. Disconnect mass air flow sensor (1) harness connector. Restart engine and let idle for at least 5 seconds. Stop engine and reconnect mass air flow sensor harness connector. Select Service $03 with GST. Make sure DTC P0102 is detected. Select Service $04 with GST and erase the DTC P0102. Start engine again and let it idle for at least 10 minutes. Select Service $07 with GST. The 1st trip DTC P0171 should be PBIB2948E detected at this stage, if a malfunction exists. If so, go to EC1016, "Diagnostic Procedure" . NOTE: If 1st trip DTC is not detected during above procedure, performing the following procedure is advised. Turn ignition switch OFF and wait at least 10 seconds. Start engine and drive the vehicle under the similar conditions to (1st trip) Freeze Frame Data for 10 minutes. Refer to the table below. Hold the accelerator pedal as steady as possible. D E F G H I J The similar conditions to (1st trip) Freeze Frame Data means the vehicle operation that the following conditions should be satisfied at the same time. Engine speed Engine speed in the freeze frame data ± 400 rpm Vehicle speed Vehicle speed in the freeze frame data ± 10 km/h (6 MPH) Engine coolant temperature (T) condition When the freeze frame data shows lower than 70 °C (158 °F), T should be lower than 70 °C (158 °F). When the freeze frame data shows higher than or equal to 70 °C (158 °F), T should be higher than or equal to 70 °C (158 °F). 10. If it is difficult to start engine at step 8, the fuel injection system has a malfunction. 11. Crank engine while depressing accelerator pedal. If engine starts, go to EC-1016, "Diagnostic Procedure" . If engine does not start, check exhaust and intake air leak visually. EC-1013 K L M DTC P0171 FUEL INJECTION SYSTEM FUNCTION [HR (WITH EURO-OBD)] Wiring Diagram BBS004D6 MBWA1465E EC-1014 DTC P0171 FUEL INJECTION SYSTEM FUNCTION [HR (WITH EURO-OBD)] Specification data are reference values and are measured between each terminal and ground. Pulse signal is measured by CONSULT-II. A CAUTION: Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM's transistor. Use a ground other than ECM terminals, such as the ground. EC TERMINAL NO. WIRE COLOR ITEM CONDITION DATA (DC Voltage) C Approximately 10V [Engine is running] 3 Y ● Warm-up condition ● Engine speed: Below 3,600 rpm D Heated oxygen sensor 1 heater E PBIA8148J [Ignition switch: ON] ● Engine stopped [Engine is running] ● F BATTERY VOLTAGE (11 - 14V) Engine speed: Above 3,600 rpm G BATTERY VOLTAGE [Engine is running] 25 29 30 31 R O GR L ● Warm-up condition ● Idle speed (11 - 14V) H NOTE: The pulse cycle changes depending on rpm at idle Fuel injector No. 4 Fuel injector No. 3 Fuel injector No. 2 Fuel injector No. 1 I PBIB0529E BATTERY VOLTAGE J (11 - 14V) [Engine is running] ● Warm-up condition ● Engine speed: 2,000 rpm K L PBIA4943J [Engine is running] 49 56 BR R Heated oxygen sensor 1 Sensor ground (Heated oxygen sensor 1) ● Warm-up condition ● Engine speed: 2,000 rpm [Engine is running] ● Idle speed : Average voltage for pulse signal (Actual pulse signal can be confirmed by oscilloscope.) EC-1015 0 - Approximately 1.0V (Periodically change) Approximately 0V M DTC P0171 FUEL INJECTION SYSTEM FUNCTION [HR (WITH EURO-OBD)] Diagnostic Procedure BBS004D7 1. CHECK EXHAUST GAS LEAK 1. 2. Start engine and run it at idle. Listen for an exhaust gas leak before three way catalyst (manifold). SEC502D OK or NG OK >> GO TO 2. NG >> Repair or replace. 2. CHECK FOR INTAKE AIR LEAK AND PCV HOSE 1. Listen for an intake air leak after the mass air flow sensor. 2. Check PCV hose connection. OK or NG OK >> GO TO 3. NG >> Repair or replace. 3. CHECK HEATED OXYGEN SENSOR 1 CIRCUIT FOR OPEN AND SHORT 1. 2. Turn ignition switch OFF. Disconnect heated oxygen sensor 1 harness connector (1). – : Vehicle front Disconnect ECM harness connector. Check harness continuity between HO2S1 terminal 4 and ECM terminal 49. Refer to Wiring Diagram. 3. 4. Continuity should exist. 5. Check harness continuity between ECM terminal 49 or HO2S1 terminal 4 and ground. Refer to Wiring Diagram. Continuity should not exist. 6. Also check harness for short to power. OK or NG OK >> GO TO 4. NG >> Repair open circuit or short to ground or short to power in harness or connectors. EC-1016 PBIB2967E DTC P0171 FUEL INJECTION SYSTEM FUNCTION [HR (WITH EURO-OBD)] 4. CHECK FUEL PRESSURE 1. 2. A Release fuel pressure to zero. Refer to EC-860, "FUEL PRESSURE RELEASE" . Install fuel pressure gauge and check fuel pressure. Refer to EC-860, "FUEL PRESSURE CHECK" . At idling: Approximately 350 kPa (3.5 bar, 3.57 kg/cm2 , 51 psi) EC OK or NG OK >> GO TO 5. NG >> Follow the construction of EC-860, "FUEL PRESSURE CHECK" . C 5. CHECK MASS AIR FLOW SENSOR D With CONSULT-II 1. Install all removed parts. 2. Check “MASS AIR FLOW” in “DATA MONITOR” mode with CONSULT-II. E 1.0 - 4.0 g·m/sec: 2.0 - 10.0 g·m/sec: 1. 2. at idling at 2,500 rpm F With GST Install all removed parts. Check mass air flow sensor signal in Service $01 with GST. 1.0 - 4.0 g·m/sec: 2.0 - 10.0 g·m/sec: at idling at 2,500 rpm G H OK or NG OK >> GO TO 6. NG >> Check connectors for rusted terminals or loose connections in the mass air flow sensor circuit or ground. Refer to EC-935, "DTC P0102, P0103 MAF SENSOR" . I J K L M EC-1017 DTC P0171 FUEL INJECTION SYSTEM FUNCTION [HR (WITH EURO-OBD)] 6. CHECK FUNCTION OF FUEL INJECTORS With CONSULT-II Start engine. Perform “POWER BALANCE” in “ACTIVE TEST” mode with CONSULT-II. 3. Make sure that each circuit produces a momentary engine speed drop. 1. 2. PBIB0133E Without CONSULT-II 1. Start engine. 2. Listen to each fuel injector operating sound. Clicking noise should be heard. OK or NG OK >> GO TO 7. NG >> Perform trouble diagnosis for EC-1209, "FUEL INJECTOR" . PBIB1986E 7. CHECK FUEL INJECTOR 1. 2. 3. 4. 5. 6. Confirm that the engine is cooled down and there are no fire hazards near the vehicle. Turn ignition switch OFF. Remove fuel tube assembly. Refer to EM-135, "FUEL INJECTOR AND FUEL TUBE" . Keep fuel hose and all fuel injectors connected to fuel tube. The fuel injector harness connectors should remain connected. Disconnect all ignition coil harness connectors. Prepare pans or saucers under each fuel injector. Crank engine for about 3 seconds. Make sure that fuel sprays out from fuel injectors. Fuel should be sprayed evenly for each fuel injector. OK or NG OK >> GO TO 8. NG >> Replace fuel injectors from which fuel does not spray out. Always replace O-ring with new ones. PBIB1726E 8. CHECK INTERMITTENT INCIDENT Refer to EC-917, "TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT" . >> INSPECTION END EC-1018 DTC P0172 FUEL INJECTION SYSTEM FUNCTION [HR (WITH EURO-OBD)] DTC P0172 FUEL INJECTION SYSTEM FUNCTION On Board Diagnosis Logic PFP:16600 A BBS004D8 With the Air-Fuel Mixture Ratio Self-Learning Control, the actual mixture ratio can be brought closely to the theoretical mixture ratio based on the mixture ratio feedback signal from the heated oxygen sensors 1. The EC ECM calculates the necessary compensation to correct the offset between the actual and the theoretical ratios. In case the amount of the compensation value is extremely large (The actual mixture ratio is too rich.), the C ECM judges the condition as the fuel injection system malfunction and lights up the MI (2 trip detection logic). Sensor Heated oxygen sensor 1 Density of oxygen in exhaust gas (Mixture ratio feedback signal) Trouble diagnosis name DTC No. P0172 0172 Input Signal to ECM Fuel injection system too rich ECM function Fuel injection control DTC detecting condition ● Fuel injection system does not operate properly. ● The amount of mixture ratio compensation is too large. (The mixture ratio is too rich.) Actuator D Fuel injector E Possible cause ● Heated oxygen sensor 1 ● Fuel injector ● Exhaust gas leaks ● Incorrect fuel pressure ● Mass air flow sensor DTC Confirmation Procedure F G BBS004D9 NOTE: If DTC Confirmation Procedure has been previously conducted, always turn ignition switch OFF and wait at least 10 seconds before conducting the next test. WITH CONSULT-II 1. 2. 3. 4. 5. 6. a. b. I Start engine and warm it up to normal operating temperature. Turn ignition switch OFF and wait at least 10 seconds. Turn ignition switch ON and select “SELF-LEARNING CONT” in “WORK SUPPORT” mode with CONSULT-II. Clear the self-learning control coefficient by touching “CLEAR”. Select “DATA MONITOR” mode with CONSULT-II. Start engine again and let it idle for at least 10 minutes. The 1st trip DTC P0172 should be detected at this stage, if a malfunction exists. If so, go to EC-1023, "Diagnostic Procedure" . NOTE: If 1st trip DTC is not detected during above procedure, performing the following procedure is advised. Turn ignition switch OFF and wait at least 10 seconds. SEF215Z Start engine and drive the vehicle under the similar conditions to (1st trip) Freeze Frame Data for 10 minutes. Refer to the table below. Hold the accelerator pedal as steady as possible. The similar conditions to (1st trip) Freeze Frame Data means the vehicle operation that the following conditions should be satisfied at the same time. Engine speed Engine speed in the freeze frame data ± 400 rpm Vehicle speed Vehicle speed in the freeze frame data ± 10 km/h (6 MPH) Engine coolant temperature (T) condition 7. H When the freeze frame data shows lower than 70 °C (158 °F), T should be lower than 70 °C (158 °F). When the freeze frame data shows higher than or equal to 70 °C (158 °F), T should be higher than or equal to 70 °C (158 °F). If it is difficult to start engine at step 6, the fuel injection system has a malfunction, too. EC-1019 J K L M DTC P0172 FUEL INJECTION SYSTEM FUNCTION [HR (WITH EURO-OBD)] 8. Crank engine while depressing accelerator pedal. If engine starts, go to EC-1023, "Diagnostic Procedure" . If engine does not start, remove ignition plugs and check for fouling, etc. WITH GST 1. 2. 3. 4. 5. 6. 7. 8. 9. a. b. Start engine and warm it up to normal operating temperature. Turn ignition switch OFF and wait at least 10 seconds. Disconnect mass air flow sensor (1) harness connector. Restart engine and let idle for at least 5 seconds. Stop engine and reconnect mass air flow sensor harness connector. Select Service $03 with GST. Make sure DTC P0102 is detected. Select Service $04 with GST and erase the DTC P0102. Start engine again and let it idle for at least 10 minutes. Select Service $07 with GST. The 1st trip DTC P0172 should be PBIB2948E detected at this stage, if a malfunction exists. If so, go to EC1023, "Diagnostic Procedure" . NOTE: If 1st trip DTC is not detected during above procedure, performing the following procedure is advised. Turn ignition switch OFF and wait at least 10 seconds. Start engine and drive the vehicle under the similar conditions to (1st trip) Freeze Frame Data for 10 minutes. Refer to the table below. Hold the accelerator pedal as steady as possible. The similar conditions to (1st trip) Freeze Frame Data means the vehicle operation that the following conditions should be satisfied at the same time. Engine speed Engine speed in the freeze frame data ± 400 rpm Vehicle speed Vehicle speed in the freeze frame data ± 10 km/h (6 MPH) Engine coolant temperature (T) condition When the freeze frame data shows lower than 70 °C (158 °F), T should be lower than 70 °C (158 °F). When the freeze frame data shows higher than or equal to 70 °C (158 °F), T should be higher than or equal to 70 °C (158 °F). 10. If it is difficult to start engine at step 8, the fuel injection system has a malfunction. 11. Crank engine while depressing accelerator pedal. If engine starts, go to EC-1023, "Diagnostic Procedure" . If engine does not start, remove ignition plugs and check for fouling, etc. EC-1020 DTC P0172 FUEL INJECTION SYSTEM FUNCTION [HR (WITH EURO-OBD)] Wiring Diagram BBS004DA A EC C D E F G H I J K L M MBWA1465E EC-1021 DTC P0172 FUEL INJECTION SYSTEM FUNCTION [HR (WITH EURO-OBD)] Specification data are reference values and are measured between each terminal and ground. Pulse signal is measured by CONSULT-II. CAUTION: Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM's transistor. Use a ground other than ECM terminals, such as the ground. TERMINAL NO. WIRE COLOR ITEM CONDITION DATA (DC Voltage) Approximately 10V [Engine is running] 3 Y ● Warm-up condition ● Engine speed: Below 3,600 rpm Heated oxygen sensor 1 heater PBIA8148J [Ignition switch: ON] ● Engine stopped [Engine is running] ● BATTERY VOLTAGE (11 - 14V) Engine speed: Above 3,600 rpm BATTERY VOLTAGE [Engine is running] 25 29 30 31 R O GR L ● Warm-up condition ● Idle speed (11 - 14V) NOTE: The pulse cycle changes depending on rpm at idle Fuel injector No. 4 Fuel injector No. 3 Fuel injector No. 2 Fuel injector No. 1 PBIB0529E BATTERY VOLTAGE (11 - 14V) [Engine is running] ● Warm-up condition ● Engine speed: 2,000 rpm PBIA4943J [Engine is running] 49 56 BR R Heated oxygen sensor 1 ● Warm-up condition ● Engine speed: 2,000 rpm Sensor ground (Heated oxygen sensor 1) [Engine is running] ● Idle speed : Average voltage for pulse signal (Actual pulse signal can be confirmed by oscilloscope.) EC-1022 0 - Approximately 1.0V (Periodically change) Approximately 0V DTC P0172 FUEL INJECTION SYSTEM FUNCTION [HR (WITH EURO-OBD)] Diagnostic Procedure BBS004DB 1. CHECK EXHAUST GAS LEAK 1. 2. A Start engine and run it at idle. Listen for an exhaust gas leak before three way catalyst (manifold). EC C D E SEC502D OK or NG OK >> GO TO 2. NG >> Repair or replace. F 2. CHECK FOR INTAKE AIR LEAK G Listen for an intake air leak after the mass air flow sensor. OK or NG OK >> GO TO 3. NG >> Repair or replace. H 3. CHECK HEATED OXYGEN SENSOR 1 CIRCUIT FOR OPEN AND SHORT I 1. 2. Turn ignition switch OFF. Disconnect heated oxygen sensor 1 harness connector (1). J – : Vehicle front Disconnect ECM harness connector. Check harness continuity between HO2S1 terminal 4 and ECM terminal 49. Refer to Wiring Diagram. K 3. 4. L Continuity should exist. 5. Check harness continuity between ECM terminal 49 or HO2S1 terminal 4 and ground. Refer to Wiring Diagram. Continuity should not exist. 6. Also check harness for short to power. OK or NG OK >> GO TO 4. NG >> Repair open circuit or short to ground or short to power in harness or connectors. EC-1023 PBIB2967E M DTC P0172 FUEL INJECTION SYSTEM FUNCTION [HR (WITH EURO-OBD)] 4. CHECK FUEL PRESSURE 1. 2. Release fuel pressure to zero. Refer to EC-860, "FUEL PRESSURE RELEASE" . Install fuel pressure gauge and check fuel pressure. Refer to EC-860, "FUEL PRESSURE CHECK" . At idling: 350 kPa (3.5 bar, 3.57 kg/cm2, 51 psi) OK or NG OK >> GO TO 5. NG >> Follow the construction of EC-860, "FUEL PRESSURE CHECK" . 5. CHECK MASS AIR FLOW SENSOR With CONSULT-II 1. Install all removed parts. 2. Check “MASS AIR FLOW” in “DATA MONITOR” mode with CONSULT-II. 1.0 - 4.0 g·m/sec: 2.0 - 10.0 g·m/sec: at idling at 2,500 rpm With GST 1. Install all removed parts. 2. Check mass air flow sensor signal in Service $01 with GST. 1.0 - 4.0 g·m/sec: 2.0 - 10.0 g·m/sec: at idling at 2,500 rpm OK or NG OK >> GO TO 6. NG >> Check connectors for rusted terminals or loose connections in the mass air flow sensor circuit or ground. Refer to EC-935, "DTC P0102, P0103 MAF SENSOR" . EC-1024 DTC P0172 FUEL INJECTION SYSTEM FUNCTION [HR (WITH EURO-OBD)] 6. CHECK FUNCTION OF FUEL INJECTORS A With CONSULT-II Start engine. Perform “POWER BALANCE” in “ACTIVE TEST” mode with CONSULT-II. 3. Make sure that each circuit produces a momentary engine speed drop. 1. 2. EC C D E PBIB0133E Without CONSULT-II 1. Start engine. 2. Listen to each fuel injector operating sound. F Clicking noise should be heard. G OK or NG OK >> GO TO 7. NG >> Perform trouble diagnosis for EC-1209, "FUEL INJECTOR" . H I PBIB1986E 7. CHECK FUEL INJECTOR J Remove fuel injector assembly. Refer to EM-135, "FUEL INJECTOR AND FUEL TUBE" . Keep fuel hose and all fuel injectors connected to fuel tube. 2. Confirm that the engine is cooled down and there are no fire hazards near the vehicle. 3. Disconnect fuel injector harness connectors. 4. Disconnect all ignition coil harness connectors. 5. Prepare pans or saucers under each fuel injectors. 6. Crank engine for about 3 seconds. Make sure fuel does not drip from fuel injector. OK or NG OK (Does not drip.)>>GO TO 8. NG (Drips.)>>Replace the fuel injectors from which fuel is dripping. Always replace O-ring with new one. 1. 8. CHECK INTERMITTENT INCIDENT Refer to EC-917, "TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT" . >> INSPECTION END EC-1025 K L M DTC P0222, P0223 TP SENSOR [HR (WITH EURO-OBD)] DTC P0222, P0223 TP SENSOR Component Description PFP:16119 BBS004DC Electric throttle control actuator consists of throttle control motor, throttle position sensor, etc. The throttle position sensor responds to the throttle valve movement. The throttle position sensor has the two sensors. These sensors are a kind of potentiometers which transform the throttle valve position into output voltage, and emit the voltage signal to the ECM. In addition, these sensors detect the opening and closing speed of the throttle valve and feed the voltage signals to the ECM. The ECM judges the current opening angle of the throttle valve from these signals and the ECM controls the throttle control motor to make the throttle valve opening angle properly in response to driving condition. PBIB0145E CONSULT-II Reference Value in Data Monitor Mode BBS004DD Specification data are reference values. MONITOR ITEM CONDITION ● Ignition switch: ON (Engine stopped) ● Shift lever: D (A/T), 1st (M/T) THRTL SEN 1 THRTL SEN 2* SPECIFICATION Accelerator pedal: Fully released More than 0.36V Accelerator pedal: Fully depressed Less than 4.75V *: Throttle position sensor 2 signal is converted by ECM internally. Thus, it differs from ECM terminal voltage signal. On Board Diagnosis Logic BBS004DE These self-diagnoses have the one trip detection logic. NOTE: If DTC P0222 or P0223 is displayed with DTC P1229, first perform the trouble diagnosis for DTC P1229. Refer to EC-1150, "DTC P1229 SENSOR POWER SUPPLY" . DTC No. Trouble diagnosis name DTC detecting condition Possible cause P0222 0222 Throttle position sensor 1 circuit low input An excessively low voltage from the TP sensor 1 is sent to ECM. ● Harness or connectors (TP sensor 1 circuit is open or shorted.) P0223 0223 Throttle position sensor 1 circuit high input An excessively high voltage from the TP sensor 1 is sent to ECM. ● Electric throttle control actuator (TP sensor 1) FAIL-SAFE MODE When the malfunction is detected, ECM enters fail-safe mode and the MI lights up. Engine operation condition in fail-safe mode The ECM controls the electric throttle control actuator in regulating the throttle opening in order for the idle position to be within +10 degrees. The ECM regulates the opening speed of the throttle valve to be slower than the normal condition. So, the acceleration will be poor. EC-1026 DTC P0222, P0223 TP SENSOR [HR (WITH EURO-OBD)] DTC Confirmation Procedure BBS004DF A NOTE: If DTC Confirmation Procedure has been previously conducted, always turn ignition switch OFF and wait at least 10 seconds before conducting the next test. EC TESTING CONDITION: Before performing the following procedure, confirm that battery voltage is more than 10V at idle. WITH CONSULT-II 1. 2. 3. 4. C Turn ignition switch ON. Select “DATA MONITOR” mode with CONSULT-II. Start engine and let it idle for 1 second. If DTC is detected, go to EC-1029, "Diagnostic Procedure" . D E F SEF058Y WITH GST G Follow the procedure “WITH CONSULT-II” above. H I J K L M EC-1027 DTC P0222, P0223 TP SENSOR [HR (WITH EURO-OBD)] Wiring Diagram BBS004DG MBWA1466E EC-1028 DTC P0222, P0223 TP SENSOR [HR (WITH EURO-OBD)] Specification data are reference values and are measured between each terminal and ground. CAUTION: Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM's transistor. Use a ground other than ECM terminals, such as the ground. TERMINAL NO. WIRE COLOR EC ITEM CONDITION DATA (DC Voltage) [Ignition switch: ON] 33 Y A ● Engine stopped ● Shift lever: D (A/T), 1st (M/T) ● Accelerator pedal: Fully released Throttle position sensor 1 C More than 0.36V D [Ignition switch: ON] ● Engine stopped ● Shift lever: D (A/T), 1st (M/T) ● Accelerator pedal: Fully depressed Less than 4.75V E [Ignition switch: ON] ● 34 R Throttle position sensor 2 F Engine stopped ● Shift lever: D (A/T), 1st (M/T) ● Accelerator pedal: Fully released Less than 4.75V G [Ignition switch: ON] ● Engine stopped ● Shift lever: D (A/T), 1st (M/T) ● Accelerator pedal: Fully depressed More than 0.36V H [Engine is running] 36 72 BR L Sensor ground (Throttle position sensor) Sensor power supply (Throttle position sensor) ● Warm-up condition ● Idle speed [Ignition switch: ON] Approximately 0V I Approximately 5V J Diagnostic Procedure BBS004DH 1. CHECK GROUND CONNECTIONS K 1. 2. L Turn ignition switch OFF. Loosen and retighten ground screws on the body. Refer to EC-924, "Ground Inspection" . M MBIB1550E 1. IPDM E/R 2. Body ground OK or NG OK >> GO TO 2. NG >> Repair or replace ground connections. EC-1029 3. Body ground DTC P0222, P0223 TP SENSOR [HR (WITH EURO-OBD)] 2. CHECK THROTTLE POSITION SENSOR 1 POWER SUPPLY CIRCUIT 1. Disconnect electric throttle control actuator (1) harness connector. – : Vehicle front Turn ignition switch ON. 2. PBIB2965E 3. Check voltage between electric throttle control actuator terminal 1 and ground with CONSULT-II or tester. Voltage: Approximately 5V OK or NG OK >> GO TO 3. NG >> Repair open circuit or short to ground or short to power in harness or connectors. PBIA9580J 3. CHECK THROTTLE POSITION SENSOR 1 GROUND CIRCUIT FOR OPEN AND SHORT 1. 2. 3. Turn ignition switch OFF. Disconnect ECM harness connector. Check harness continuity between electric throttle control actuator terminal 4 and ECM terminal 36. Refer to Wiring Diagram. Continuity should exist. 4. Also check harness for short to ground and short to power. OK or NG OK >> GO TO 4. NG >> Repair open circuit or short to ground or short to power in harness or connectors. 4. CHECK THROTTLE POSITION SENSOR 1 INPUT SIGNAL CIRCUIT FOR OPEN AND SHORT 1. Check harness continuity between ECM terminal 33 and electric throttle control actuator terminal 2. Refer to Wiring Diagram. Continuity should exist. 2. Also check harness for short to ground and short to power. OK or NG OK >> GO TO 5. NG >> Repair open circuit or short to ground or short to power in harness or connectors. 5. CHECK THROTTLE POSITION SENSOR Refer to EC-1031, "Component Inspection" . OK or NG OK >> GO TO 7. NG >> GO TO 6. EC-1030 DTC P0222, P0223 TP SENSOR [HR (WITH EURO-OBD)] 6. REPLACE ELECTRIC THROTTLE CONTROL ACTUATOR 1. 2. 3. A Replace the electric throttle control actuator. Perform EC-857, "Throttle Valve Closed Position Learning" . Perform EC-858, "Idle Air Volume Learning" . EC >> INSPECTION END C 7. CHECK INTERMITTENT INCIDENT Refer to EC-917, "TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT" . D >> INSPECTION END E Component Inspection BBS004DI THROTTLE POSITION SENSOR 1. 2. 3. 4. 5. Reconnect all harness connectors disconnected. Perform EC-857, "Throttle Valve Closed Position Learning" . Turn ignition switch ON. Set shift lever to D (A/T), 1st (M/T) position. Check voltage between ECM terminals 33 (TP sensor 1 signal), 34 (TP sensor 2 signal) and ground under the following conditions. Terminal Accelerator pedal Voltage 33 (Throttle position sensor 1) Fully released More than 0.36V Fully depressed Less than 4.75V Fully released Less than 4.75V Fully depressed More than 0.36V 34 (Throttle position sensor 2) 6. 7. 8. If NG, replace electric throttle control actuator and go to the next step. Perform EC-857, "Throttle Valve Closed Position Learning" . Perform EC-858, "Idle Air Volume Learning" . Removal and Installation F G H I J PBIB3038E K BBS004DJ ELECTRIC THROTTLE CONTROL ACTUATOR L Refer to EM-120, "INTAKE MANIFOLD" . M EC-1031 DTC P0300 - P0304 MULTIPLE CYLINDER MISFIRE, NO. 1 - 4 CYLINDER MISFIRE [HR (WITH EURO-OBD)] DTC P0300 - P0304 MULTIPLE CYLINDER MISFIRE, NO. 1 - 4 CYLINDER MISFIRE PFP:00000 On Board Diagnosis Logic BBS004DK When a misfire occurs, engine speed will fluctuate. If the engine speed fluctuates enough to cause the crankshaft position (CKP) sensor (POS) signal to vary, ECM can determine that a misfire is occurring. Sensor Crankshaft position sensor (POS) Input Signal to ECM ECM function Engine speed On board diagnosis of misfire The misfire detection logic consists of the following two conditions. 1. One Trip Detection Logic (Three Way Catalyst Damage) On the first trip that a misfire condition occurs that can damage the three way catalyst (TWC) due to overheating, the MI will blink. When a misfire condition occurs, the ECM monitors the CKP sensor (POS) signal every 200 engine revolutions for a change. When the misfire condition decreases to a level that will not damage the TWC, the MI will turn off. If another misfire condition occurs that can damage the TWC on a second trip, the MI will blink. When the misfire condition decreases to a level that will not damage the TWC, the MI will remain on. If another misfire condition occurs that can damage the TWC, the MI will begin to blink again. 2. Two Trip Detection Logic (Exhaust quality deterioration) For misfire conditions that will not damage the TWC (but will affect vehicle emissions), the MI will only light when the misfire is detected on a second trip. During this condition, the ECM monitors the CKP sensor signal every 1,000 engine revolutions. A misfire malfunction can be detected on any one cylinder or on multiple cylinders. DTC No. Trouble diagnosis name DTC detecting condition P0300 0300 Multiple cylinder misfire detected Multiple cylinder misfire. P0301 0301 No.1 cylinder misfire detected No. 1 cylinder misfires. P0302 0302 No. 2 cylinder misfire detected No. 2 cylinder misfires. P0303 0303 No. 3 cylinder misfire detected P0304 0304 No. 4 cylinder misfire detected No. 3 cylinder misfires. No. 4 cylinder misfires. EC-1032 Possible cause ● Improper spark plug ● Insufficient compression ● Incorrect fuel pressure ● Fuel injector circuit is open or shorted ● Fuel injector ● Intake air leak ● The ignition signal circuit is open or shorted ● Lack of fuel ● Drive plate or flywheel ● Heated oxygen sensor 1 ● Incorrect PCV hose connection DTC P0300 - P0304 MULTIPLE CYLINDER MISFIRE, NO. 1 - 4 CYLINDER MISFIRE [HR (WITH EURO-OBD)] DTC Confirmation Procedure BBS004DL A CAUTION: Always drive vehicle in safe manner according to traffic conditions and obey all traffic laws when driving. EC NOTE: If DTC Confirmation Procedure has been previously conducted, always turn ignition switch OFF and wait at least 10 seconds before conducting the next test. C WITH CONSULT-II 1. 2. 3. 4. 5. a. b. Turn ignition switch ON, and select “DATA MONITOR” mode with CONSULT-II. Start engine and warm it up to normal operating temperature. Turn ignition switch OFF and wait at least 10 seconds. Restart engine and let it idle for about 15 minutes. If 1st trip DTC is detected, go to EC-1033, "Diagnostic Procedure" . NOTE: If 1st trip DTC is not detected during above procedure, performing the following procedure is advised. PBIB0164E Turn ignition switch OFF and wait at least 10 seconds. Start engine and drive the vehicle under the similar conditions to (1st trip) Freeze Frame Data for a certain time. Refer to table below. Hold the accelerator pedal as steady as possible. D E F G H The similar conditions to (1st trip) Freeze Frame Data means the vehicle operation that the following condition should be satisfied at the same time: Engine speed Engine speed in the freeze frame data ± 400 rpm Vehicle speed Vehicle speed in the freeze frame data ± 10 km/h (6 MPH) I When the freeze frame data shows lower than 70°C (158°F), T should be lower than 70°C (158°F) Engine coolant temperature (T) condition J When the freeze frame data shows higher than or equal to 70°C (158°F), T should be higher than or equal to 70°C (158°F) K The time to driving varies according to the engine speed in the freeze frame data. Refer to the following table. Engine speed Time Around 1,000 rpm Approximately 10 minutes Around 2,000 rpm Approximately 5 minutes More than 3,000 rpm Approximately 3.5 minutes L M WITH GST Follow the procedure “WITH CONSULT-II” above. Diagnostic Procedure BBS004DM 1. CHECK FOR INTAKE AIR LEAK AND PCV HOSE 1. Start engine and run it at idle speed. 2. Listen for the sound of the intake air leak. 3. Check PCV hose connection. OK or NG OK >> GO TO 2. NG >> Repair or replace. EC-1033 DTC P0300 - P0304 MULTIPLE CYLINDER MISFIRE, NO. 1 - 4 CYLINDER MISFIRE [HR (WITH EURO-OBD)] 2. CHECK FOR EXHAUST SYSTEM CLOGGING Stop engine and visually check exhaust tube, three way catalyst and muffler for dents. OK or NG OK >> GO TO 3. NG >> Repair or replace. 3. PERFORM POWER BALANCE TEST With CONSULT-II 1. Perform “POWER BALANCE” in “ACTIVE TEST” mode. 2. Is there any cylinder which does not produce a momentary engine speed drop? PBIB0133E Without CONSULT-II When disconnecting each fuel injector (2) harness connector one at a time, is there any cylinder which does not produce a momentary engine speed drop? ● Ignition coil (1) PBIB2968E Yes or No Yes >> GO TO 4. No >> GO TO 9. 4. CHECK FUEL INJECTOR Does each fuel injector make an operating sound at idle? Yes or No Yes >> GO TO 5. No >> Check fuel injector(s) and circuit(s). Refer to EC-1209, "FUEL INJECTOR" . PBIB1986E EC-1034 DTC P0300 - P0304 MULTIPLE CYLINDER MISFIRE, NO. 1 - 4 CYLINDER MISFIRE [HR (WITH EURO-OBD)] 5. CHECK FUNCTION OF IGNITION COIL-I A CAUTION: Do the following procedure in the place where ventilation is good without the combustible. 1. Turn ignition switch OFF. 2. Remove fuel pump fuse in IPDM E/R to release fuel pressure. NOTE: Do not use CONSULT-II to release fuel pressure, or fuel pressure applies again during the following procedure. 3. Start engine. 4. After engine stalls, crank it two or three times to release all fuel pressure. 5. Turn ignition switch OFF. 6. Remove all ignition coil harness connectors to avoid the electrical discharge from the ignition coils. 7. Remove ignition coil and spark plug of the cylinder to be checked. 8. Crank engine for 5 seconds or more to remove combustion gas in the cylinder. 9. Connect spark plug and harness connector to ignition coil. 10. Fix ignition coil using a rope etc. with gap of 13 - 17 mm between the edge of the spark plug and grounded metal portion as shown in the figure. 11. Crank engine for about three seconds, and check whether spark is generated between the spark plug and the grounded metal portion. EC C D E MBIB0277E G H I Spark should be generated. CAUTION: ● Do not approach to the spark plug and the ignition coil within 50cm. Be careful not to get an electrical shock PBIB2325E while checking, because the electrical discharge voltage becomes 20kV or more. ● It might cause to damage the ignition coil if the gap of more than 17 mm is taken. NOTE: When the gap is less than 13 mm, the spark might be generated even if the coil is malfunctioning. OK or NG OK >> GO TO 9. NG >> GO TO 6. J K L M 6. CHECK FUNCTION OF IGNITION COIL-II 1. 2. 3. F Turn ignition switch OFF. Disconnect spark plug and connect a known-good spark plug. Crank engine for about three seconds, and recheck whether spark is generated between the spark plug and the grounded metal portion. Spark should be generated. OK or NG OK >> GO TO 7. NG >> Check ignition coil, power transistor and their circuits. Refer to EC-1221, "IGNITION SIGNAL" . EC-1035 DTC P0300 - P0304 MULTIPLE CYLINDER MISFIRE, NO. 1 - 4 CYLINDER MISFIRE [HR (WITH EURO-OBD)] 7. CHECK SPARK PLUG Check the initial spark plug for fouling, etc. OK or NG OK >> Replace spark plug(s) with standard type one(s). For spark plug type, refer to EM-133, "SPARK PLUG (PLATINUM-TIPPED TYPE)" . NG >> 1. Repair or clean spark plug. 2. GO TO 8. SEF156I 8. CHECK FUNCTION OF IGNITION COIL-III 1. 2. Reconnect the initial spark plugs. Crank engine for about three seconds, and recheck whether spark is generated between the spark plug and the grounded portion. Spark should be generated. OK or NG OK >> INSPECTION END NG >> Replace spark plug(s) with standard type one(s). For spark plug type, refer to EM-133, "SPARK PLUG (PLATINUM-TIPPED TYPE)" . 9. CHECK COMPRESSION PRESSURE Check compression pressure. Refer to EM-173, "CHECKING COMPRESSION PRESSURE" . OK or NG OK >> GO TO 10. NG >> Check pistons, piston rings, valves, valve seats and cylinder head gaskets. 10. CHECK FUEL PRESSURE 1. 2. 3. Install all removed parts. Release fuel pressure to zero. Refer to EC-860, "FUEL PRESSURE RELEASE" . Install fuel pressure gauge and check fuel pressure. Refer to EC-860, "FUEL PRESSURE CHECK" . At idle: Approx. 350 kPa (3.5 bar, 3.57 kg/cm2 , 51 psi) OK or NG OK >> GO TO 12. NG >> GO TO 11. 11. DETECT MALFUNCTIONING PART Check the following. Fuel pump and circuit (Refer to EC-1215, "FUEL PUMP" .) ● Fuel pressure regulator (Refer to EC-860, "FUEL PRESSURE CHECK" .) ● Fuel lines ● Fuel filter for clogging ● >> Repair or replace. EC-1036 DTC P0300 - P0304 MULTIPLE CYLINDER MISFIRE, NO. 1 - 4 CYLINDER MISFIRE [HR (WITH EURO-OBD)] 12. CHECK IGNITION TIMING A Check the following items. Refer to EC-851, "Basic Inspection" . Items Specifications Target idle speed Ignition timing A/T models 700 ± 50 rpm (in P or N position) M/T models 650 ± 50 rpm (in Neutral position) A/T models 6 ± 5° BTDC (in P or N position) M/T models 6 ± 5° BTDC (in Neutral position) OK or NG OK >> GO TO 13. NG >> Follow the EC-851, "Basic Inspection" . EC C D 13. CHECK HEATED OXYGEN SENSOR 1 E Refer to EC-975, "Component Inspection" . OK or NG OK >> GO TO 14. NG >> Replace heated oxygen sensor 1. F G 14. CHECK MASS AIR FLOW SENSOR With CONSULT-II Check mass air flow sensor signal in “DATA MONITOR” mode with CONSULT-II. 1.0 - 4.0 g·m/sec: 2.0 - 10.0 g·m/sec: at idling at 2,500 rpm H I With GST Check mass air flow sensor signal in Service $01 with GST. 1.0 - 4.0 g·m/sec: 2.0 - 10.0 g·m/sec: J at idling at 2,500 rpm OK or NG OK >> GO TO 15. NG >> Check connectors for rusted terminals or loose connections in the mass air flow sensor circuit or ground. Refer to EC-935, "DTC P0102, P0103 MAF SENSOR" . K L 15. CHECK SYMPTOM MATRIX CHART Check items on the rough idle symptom in EC-871, "Symptom Matrix Chart" . OK or NG OK >> GO TO 16. NG >> Repair or replace. 16. ERASE THE 1ST TRIP DTC Some tests may cause a 1st trip DTC to be set. Erase the 1st trip DTC from the ECM memory after performing the tests. Refer to EC-841, "HOW TO ERASE EMISSION-RELATED DIAGNOSTIC INFORMATION" . >> GO TO 17. 17. CHECK INTERMITTENT INCIDENT Refer to EC-917, "TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT" . >> INSPECTION END EC-1037 M DTC P0327, P0328 KS [HR (WITH EURO-OBD)] DTC P0327, P0328 KS Component Description PFP:22060 BBS004DN The knock sensor (1) is attached to the cylinder block. It senses engine knocking using a piezoelectric element. A knocking vibration from the cylinder block is sensed as vibrational pressure. This pressure is converted into a voltage signal and sent to the ECM. : Vehicle front ● PBIB2969E On Board Diagnosis Logic BBS004DO The MI will not light up for these self-diagnoses. DTC No. Trouble Diagnosis Name DTC Detected Condition Possible Cause P0327 0327 Knock sensor circuit low input An excessively low voltage from the sensor is sent to ECM. ● Harness or connectors (The sensor circuit is open or shorted.) P0328 0328 Knock sensor circuit high input An excessively high voltage from the sensor is sent to ECM. ● Knock sensor DTC Confirmation Procedure BBS004DP NOTE: If DTC Confirmation Procedure has been previously conducted, always turn ignition switch OFF and wait at least 10 seconds before conducting the next test. TESTING CONDITION: Before performing the following procedure, confirm that battery voltage is more than 10V at idle. WITH CONSULT-II 1. 2. 3. Turn ignition switch ON and select “DATA MONITOR” mode with CONSULT-II. Start engine and run it for at least 5 seconds at idle speed. If 1st trip DTC is detected, go to EC-1040, "Diagnostic Procedure" . SEF058Y WITH GST Follow the procedure “WITH CONSULT-II” above. EC-1038 DTC P0327, P0328 KS [HR (WITH EURO-OBD)] Wiring Diagram BBS004DQ A EC C D E F G H I J K L M MBWA1467E EC-1039 DTC P0327, P0328 KS [HR (WITH EURO-OBD)] Specification data are reference values and are measured between each terminal and ground. CAUTION: Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM's transistor. Use a ground other than ECM terminals, such as the ground. TERMINAL NO. 37 WIRE COLOR W ITEM Knock sensor CONDITION [Engine is running] ● Idle speed DATA (DC Voltage) Approximately 2.5V [Engine is running] 40 — Sensor ground (Knock sensor) ● Warm-up condition ● Idle speed Approximately 0V Diagnostic Procedure BBS004DR 1. CHECK KNOCK SENSOR INPUT SIGNAL CIRCUIT-I 1. 2. 3. Turn ignition switch OFF. Disconnect ECM harness connector. Check resistance between ECM terminal 37 and ground. Refer to Wiring Diagram. NOTE: It is necessary to use an ohmmeter which can measure more than 10 MΩ. Resistance: Approximately 530 - 590kΩ [at 20°C (68°F)] 4. Also check harness for short to ground and short to power. OK or NG OK >> GO TO 4. NG >> GO TO 2. 2. CHECK KNOCK SENSOR INPUT SIGNAL CIRCUIT-II 1. Disconnect knock sensor (1) harness connector. – : Vehicle front Check harness continuity between ECM terminal 37 and knock sensor terminal 1. Refer to Wiring Diagram. 2. Continuity should exist. 3. Also check harness for short to ground and short to power. OK or NG OK >> GO TO 3. NG >> Repair open circuit or short to ground or short to power in harness or connectors. 3. CHECK KNOCK SENSOR Refer to EC-1041, "Component Inspection" . OK or NG OK >> GO TO 6. NG >> Replace knock sensor. EC-1040 PBIB2969E DTC P0327, P0328 KS [HR (WITH EURO-OBD)] 4. CHECK GROUND CONNECTIONS A Loosen and retighten ground screws on the body. Refer to EC-924, "Ground Inspection" . EC C D MBIB1550E 1. IPDM E/R 2. Body ground 3. E Body ground OK or NG OK >> GO TO 5. NG >> Repair or replace ground connections. F 5. CHECK KNOCK SENSOR SHIELD CIRCUIT FOR OPEN AND SHORT G 1. 2. Reconnect knock sensor harness connector. Check harness continuity between ECM terminal 40 and knock sensor terminal 2. H Continuity should exist I 3. Also check harness for short to ground and short to power. OK or NG OK >> GO TO 6. NG >> Repair open circuit or short to ground or short to power in harness or connectors. J 6. CHECK INTERMITTENT INCIDENT K Refer to EC-917, "TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT" . >> INSPECTION END L Component Inspection BBS004DS KNOCK SENSOR M Check resistance between knock sensor terminal 1 and ground. NOTE: It is necessary to use an ohmmeter which can measure more than 10 MΩ. Resistance: Approximately 530 - 590kΩ [at 20°C (68°F)] CAUTION: Do not use any knock sensors that have been dropped or physically damaged. Use only new ones. SEF227W Removal and Installation BBS004DT KNOCK SENSOR Refer to EM-189, "CYLINDER BLOCK" . EC-1041 DTC P0335 CKP SENSOR (POS) [HR (WITH EURO-OBD)] DTC P0335 CKP SENSOR (POS) Component Description PFP:23731 BBS004DU The crankshaft position sensor (POS) is located on the cylinder block rear housing facing the gear teeth (cogs) of the signal plate at the end of the crankshaft. It detects the fluctuation of the engine revolution. The sensor consists of a permanent magnet and Hall IC. When the engine is running, the high and low parts of the teeth cause the gap with the sensor to change. The changing gap causes the magnetic field near the sensor to change. Due to the changing magnetic field, the voltage from the sensor changes. The ECM receives the voltage signal and detects the fluctuation of the engine revolution. ECM receives the signals as shown in the figure. PBIA9209J PBIB2382E CONSULT-II Reference Value in Data Monitor Mode BBS004DV Specification data are reference values. MONITOR ITEM ENG SPEED CONDITION ● SPECIFICATION Run engine and compare CONSULT-II value with the tachometer indication. Almost the same speed as the tachometer indication. On Board Diagnosis Logic DTC No. P0335 0335 Trouble diagnosis name Crankshaft position sensor (POS) circuit BBS004DW DTC detecting condition ● The crankshaft position sensor (POS) signal is not detected by the ECM during the first few seconds of engine cranking. ● The proper pulse signal from the crankshaft position sensor (POS) is not sent to ECM while the engine is running. ● The crankshaft position sensor (POS) signal is not in the normal pattern during engine running. EC-1042 Possible cause ● Harness or connectors [Crankshaft position sensor (POS) circuit is open or shorted.] (Accelerator pedal position sensor circuit is shorted.) (Refrigerant pressure sensor circuit is shorted.) ● Crankshaft position sensor (POS) ● Accelerator pedal position sensor ● Refrigerant position sensor ● Signal plate DTC P0335 CKP SENSOR (POS) [HR (WITH EURO-OBD)] DTC Confirmation Procedure BBS004DX A NOTE: If DTC Confirmation Procedure has been previously conducted, always turn ignition switch OFF and wait at least 10 seconds before conducting the next test. EC TESTING CONDITION: Before performing the following procedure, confirm that battery voltage is more than 10.5V with ignition switch ON. C WITH CONSULT-II 1. 2. 3. Turn ignition switch ON and select “DATA MONITOR” mode with CONSULT-II. Crank engine for at least 2 seconds and run it for at least 5 seconds at idle speed. If 1st trip DTC is detected, go to EC-1046, "Diagnostic Procedure" . D E F SEF058Y WITH GST G Follow the procedure “WITH CONSULT-II” above. H I J K L M EC-1043 DTC P0335 CKP SENSOR (POS) [HR (WITH EURO-OBD)] Wiring Diagram BBS004DY MBWA1468E EC-1044 DTC P0335 CKP SENSOR (POS) [HR (WITH EURO-OBD)] Specification data are reference values and are measured between each terminal and ground. Pulse signal is measured by CONSULT-II. A CAUTION: Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM's transistor. Use a ground other than ECM terminals, such as the ground. EC TERMINAL NO. WIRE COLOR ITEM CONDITION DATA (DC Voltage) C [Engine is running] ● Warm-up condition ● Idle speed 0 - 1.0V D NOTE: The pulse cycle changes depending on rpm at idle 61 Y E MBIB1453E Crankshaft position sensor (POS) 0 - 1.0V F [Engine is running] ● Engine speed: 2,000 rpm G MBIB1454E 62 W Sensor ground [Crankshaft position sensor (POS)] H [Engine is running] ● Warm-up condition ● Idle speed Approximately 0V I W Sensor power supply (Refrigerant pressure sensor) [Ignition switch: ON] 75 G Sensor power supply [Crankshaft position sensor (POS)] [Ignition switch: ON] Approximately 5V 102 BR Sensor power supply (APP sensor 2) [Ignition switch: ON] Approximately 5V 74 Approximately 5V J K : Average voltage for pulse signal (Actual pulse signal can be confirmed by oscilloscope.) L M EC-1045 DTC P0335 CKP SENSOR (POS) [HR (WITH EURO-OBD)] Diagnostic Procedure BBS004DZ 1. CHECK GROUND CONNECTIONS 1. 2. Turn ignition switch OFF. Loosen and retighten ground screws on the body. Refer to EC-924, "Ground Inspection" . MBIB1550E 1. IPDM E/R 2. Body ground 3. Body ground OK or NG OK >> GO TO 2. NG >> Repair or replace ground connections. 2. CHECK CRANKSHAFT POSITION (CKP) SENSOR (POS) POWER SUPPLY CIRCUIT-I 1. 2. Disconnect crankshaft position (CKP) sensor (POS) (1) harness connector. Turn ignition switch ON. PBIB2970E 3. Check voltage between CKP sensor (POS) terminal 1 and ground with CONSULT-II or tester. Voltage: Approximately 5V OK or NG OK >> GO TO 6. NG >> GO TO 3. PBIB2609E EC-1046 DTC P0335 CKP SENSOR (POS) [HR (WITH EURO-OBD)] 3. CHECK CKP SENSOR (POS) POWER SUPPLY CIRCUIT-II 1. 2. 3. A Turn ignition switch OFF. Disconnect ECM harness connector. Check harness continuity between CKP sensor (POS) terminal 1 and ECM terminal 75. Refer to Wiring Diagram. Continuity should exist. EC C OK or NG OK >> GO TO 4. NG >> Repair open circuit. D 4. CHECK CKP SENSOR (POS) POWER SUPPLY CIRCUIT-III Check harness for short to power and short to ground, between the following terminals. ECM terminal Sensor terminal E Reference Wiring Diagram 74 Refrigerant pressure sensor terminal 3 EC-1232, "Wiring Diagram" 75 Crankshaft position sensor (POS) terminal 1 EC-1044, "Wiring Diagram" 102 APP sensor terminal 5 EC-1183, "Wiring Diagram" OK or NG OK >> GO TO 5. NG >> Repair short to ground or short to power in harness or connectors. F G H 5. CHECK COMPONENTS Check the following. ● Accelerator pedal position sensor (Refer to EC-1190, "Component Inspection" .) ● Refrigerant pressure sensor (Refer to ATC-85, "Refrigerant Pressure Sensor" .) OK or NG OK >> GO TO 10. NG >> Replace malfunctioning component. 6. CHECK CKP SENSOR (POS) GROUND CIRCUIT FOR OPEN AND SHORT 1. 2. 3. Turn ignition switch OFF. Disconnect ECM harness connector. Check harness continuity between CKP sensor (POS) terminal 2 and ECM terminal 62. Refer to Wiring Diagram. Continuity should exist. 4. Also check harness for short to ground and short to power. OK or NG OK >> GO TO 7. NG >> Repair open circuit or short to ground or short to power in harness or connectors. 7. CHECK CKP SENSOR (POS) INPUT SIGNAL CIRCUIT FOR OPEN AND SHORT 1. Check harness continuity between CKP sensor (POS) terminal 3 and ECM terminal 61. Refer to Wiring Diagram. Continuity should exist. 2. Also check harness for short to ground and short to power. OK or NG OK >> GO TO 8. NG >> Repair open circuit or short to ground or short to power in harness or connectors. EC-1047 I J K L M DTC P0335 CKP SENSOR (POS) [HR (WITH EURO-OBD)] 8. CHECK CRANKSHAFT POSITION SENSOR (POS) Refer to EC-1048, "Component Inspection" . OK or NG OK >> GO TO 9. NG >> Replace crankshaft position sensor (POS). 9. CHECK GEAR TOOTH Visually check for chipping signal plate gear tooth. OK or NG OK >> GO TO 10. NG >> Replace the signal plate. 10. CHECK INTERMITTENT INCIDENT Refer to EC-917, "TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT" . >> INSPECTION END Component Inspection BBS004E0 CRANKSHAFT POSITION SENSOR (POS) 1. 2. 3. 4. Loosen the fixing bolt of the sensor. Disconnect crankshaft position sensor (POS) harness connector. Remove the sensor. Visually check the sensor for chipping. PBIA9210J 5. Check resistance as shown in the figure. Terminal No. (Polarity) Resistance Ω [at 25°C (77°F)] 1 (+) - 2 (-) 1 (+) - 3 (-) Except 0 or ∞ 2 (+) - 3 (-) 6. If NG, replace crankshaft position sensor (POS). PBIA9584J Removal and Installation BBS004E1 CRANKSHAFT POSITION SENSOR (POS) Refer to EM-189, "CYLINDER BLOCK" . EC-1048 DTC P0340 CMP SENSOR (PHASE) [HR (WITH EURO-OBD)] DTC P0340 CMP SENSOR (PHASE) Component Description PFP:23731 A BBS004E2 The camshaft position sensor (PHASE) senses the protrusion of camshaft (INT) to identify a particular cylinder. The camshaft position sensor (PHASE) senses the piston position. When the crankshaft position sensor (POS) system becomes inoperative, the camshaft position sensor (PHASE) provides various controls of engine parts instead, utilizing timing of cylinder identification signals. The sensor consists of a permanent magnet and Hall IC. When engine is running, the high and low parts of the teeth cause the gap with the sensor to change. The changing gap causes the magnetic field near the sensor to change. Due to the changing magnetic field, the voltage from the sensor changes. ECM receives the signals as shown in the figure. EC C D PBIA9209J E F G H PBIB2382E I On Board Diagnosis Logic BBS004E3 NOTE: If DTC P0340 is displayed with DTC P1229, first perform the trouble diagnosis for DTC P1229. Refer to EC-1150, "DTC P1229 SENSOR POWER SUPPLY" . DTC No. Trouble diagnosis name DTC detecting condition ● P0340 0340 Camshaft position sensor (PHASE) circuit The cylinder No. signal is not sent to ECM for the first few seconds during engine cranking. Possible cause ● Harness or connectors (The sensor circuit is open or shorted.) ● Camshaft position sensor (PHASE) ● Camshaft (Intake) ● The cylinder No. signal is not set to ECM during engine running. ● Starter motor (Refer to SC-45, "STARTING SYSTEM" .) ● The cylinder No. signal is not in the normal pattern during engine running. ● Starting system circuit (Refer to SC-45, "STARTING SYSTEM" .) ● Dead (Weak) battery EC-1049 J K L M DTC P0340 CMP SENSOR (PHASE) [HR (WITH EURO-OBD)] DTC Confirmation Procedure BBS004E4 NOTE: If DTC Confirmation Procedure has been previously conducted, always turn ignition switch OFF and wait at least 10 seconds before conducting the next test. TESTING CONDITION: Before performing the following procedure, confirm that battery voltage is more than 10.5V with ignition switch ON. WITH CONSULT-II 1. 2. 3. 4. 5. 6. Turn ignition switch ON. Select “DATA MONITOR” mode with CONSULT-II. Crank engine for at least 2 seconds and run it for at least 5 seconds at idle speed. If 1st trip DTC is detected, go to EC-1052, "Diagnostic Procedure" . If 1st trip DTC is not detected, go to next step. Maintain engine speed at more than 800 rpm for at least 5 seconds. If 1st trip DTC is detected, go to EC-1052, "Diagnostic Procedure" . WITH GST Follow the procedure “WITH CONSULT-II” above. EC-1050 SEF058Y DTC P0340 CMP SENSOR (PHASE) [HR (WITH EURO-OBD)] Wiring Diagram BBS004E5 A EC C D E F G H I J K L M MBWA1469E EC-1051 DTC P0340 CMP SENSOR (PHASE) [HR (WITH EURO-OBD)] Specification data are reference values and are measured between each terminal and ground. Pulse signal is measured by CONSULT-II. CAUTION: Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM's transistor. Use a ground other than ECM terminals, such as the ground. TERMINAL NO. 63 WIRE COLOR B ITEM Sensor ground [Camshaft position sensor (PHASE)] CONDITION DATA (DC Voltage) [Engine is running] ● Warm-up condition ● Idle speed [Engine is running] ● Warm-up condition ● Idle speed Approximately 0V 0 - 1.0V NOTE: The pulse cycle changes depending on rpm at idle 65 R MBIB1455E Camshaft position sensor (PHASE) 0 - 1.0V [Engine is running] ● Engine speed: 2,000 rpm MBIB1456E 78 O Sensor power supply [Camshaft position sensor (PHASE)] [Ignition switch: ON] Approximately 5V : Average voltage for pulse signal (Actual pulse signal can be confirmed by oscilloscope.) Diagnostic Procedure BBS004E6 1. CHECK STARTING SYSTEM Turn ignition switch to START position. Does the engine turn over? Does the starter motor operate? Yes or No Yes >> GO TO 2. No >> Check starting system. (Refer to SC-45, "STARTING SYSTEM" .) EC-1052 DTC P0340 CMP SENSOR (PHASE) [HR (WITH EURO-OBD)] 2. CHECK GROUND CONNECTIONS 1. 2. A Turn ignition switch OFF. Loosen and retighten ground screws on the body. Refer to EC-924, "Ground Inspection" . EC C D E MBIB1550E 1. IPDM E/R 2. Body ground 3. Body ground F OK or NG OK >> GO TO 3. NG >> Repair or replace ground connections. G 3. CHECK CAMSHAFT POSITION (CMP) SENSOR (PHASE) POWER SUPPLY CIRCUIT 1. Disconnect camshaft position (CMP) sensor (PHASE) (1) harness connector. – : Vehicle front Turn ignition switch ON. 2. H I J PBIB2971E 3. Check voltage between CMP sensor (PHASE) terminal 1 and ground with CONSULT-II or tester. K L Voltage: Battery voltage OK or NG OK >> GO TO 4. NG >> Repair open circuit or short to ground or short to power in harness or connectors. M PBIB2609E EC-1053 DTC P0340 CMP SENSOR (PHASE) [HR (WITH EURO-OBD)] 4. CHECK CMP SENSOR (PHASE) GROUND CIRCUIT FOR OPEN AND SHORT 1. 2. 3. Turn ignition switch OFF. Disconnect ECM harness connector. Check harness continuity between CMP sensor (PHASE) terminal 2 and ECM terminal 63. Refer to Wiring Diagram. Continuity should exist. 4. Also check harness for short to ground and short to power. OK or NG OK >> GO TO 5. NG >> Repair open circuit or short to ground or short to power in harness or connectors. 5. CHECK CMP SENSOR (PHASE) INPUT SIGNAL CIRCUIT FOR OPEN AND SHORT 1. Check harness continuity between CMP sensor (PHASE) terminal 3 and ECM terminal 65. Refer to Wiring Diagram. Continuity should exist. 2. Also check harness for short to ground and short to power. OK or NG OK >> GO TO 6. NG >> Repair open circuit or short to ground or short to power in harness or connectors. 6. CHECK CAMSHAFT POSITION SENSOR (PHASE) Refer to EC-1054, "Component Inspection" . OK or NG OK >> GO TO 7. NG >> Replace camshaft position sensor (PHASE). 7. CHECK CAMSHAFT (INTAKE) Check the following. Accumulation of debris to the signal plate of camshaft (1) rear end ● Chipping signal plate of camshaft rear end OK or NG OK >> GO TO 8. NG >> Remove debris and clean the signal plate of camshaft rear end or replace camshaft. ● PBIA9557J 8. CHECK INTERMITTENT INCIDENT Refer to EC-917, "TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT" . >> INSPECTION END Component Inspection BBS004E7 CAMSHAFT POSITION SENSOR (PHASE) 1. 2. 3. Loosen the fixing bolt of the sensor. Disconnect camshaft position sensor (PHASE) harness connector. Remove the sensor. EC-1054 DTC P0340 CMP SENSOR (PHASE) [HR (WITH EURO-OBD)] 4. Visually check the sensor for chipping. A EC C PBIA9210J D 5. Check resistance as shown in the figure. Terminal No. (Polarity) Resistance Ω [at 25°C (77°F)] E 1 (+) - 2 (-) 1 (+) - 3 (-) Except 0 or ∞ 2 (+) - 3 (-) F G PBIA9584J Removal and Installation BBS004E8 H CAMSHAFT POSITION SENSOR (PHASE) Refer to EM-151, "CAMSHAFT" . I J K L M EC-1055 DTC P0420 THREE WAY CATALYST FUNCTION [HR (WITH EURO-OBD)] DTC P0420 THREE WAY CATALYST FUNCTION On Board Diagnosis Logic PFP:20905 BBS004E9 The ECM monitors the switching frequency ratio of heated oxygen sensors 1 and 2. A three way catalyst (manifold) with high oxygen storage capacity will indicate a low switching frequency of heated oxygen sensor 2. As oxygen storage capacity decreases, the heated oxygen sensor 2 switching frequency will increase. When the frequency ratio of heated oxygen sensors 1 and 2 approaches a specified limit value, the three way catalyst (manifold) malfunction is diagnosed. SEF484YF DTC No. P0420 0420 Trouble diagnosis name Catalyst system efficiency below threshold DTC detecting condition ● Three way catalyst (manifold) does not operate properly. ● Three way catalyst (manifold) does not have enough oxygen storage capacity. DTC Confirmation Procedure Possible cause ● Three way catalyst (manifold) ● Exhaust tube ● Intake air leaks ● Fuel injector ● Fuel injector leaks ● Spark plug ● Improper ignition timing BBS004EA NOTE: If DTC Confirmation Procedure has been previously conducted, always turn ignition switch OFF and wait at least 10 seconds before conducting the next test. WITH CONSULT-II TESTING CONDITION: ● Open engine hood before conducting the following procedure. ● Do not hold engine speed for more than the specified minutes below. 1. Start engine and warm it up to the normal operating temperature. 2. Turn ignition switch OFF and wait at least 10 seconds. 3. Start engine and keep the engine speed between 3,500 and 4,000 rpm for at least 1 minute under no load. 4. Let engine idle for 1 minute. 5. Select “DTC & SRT CONFIRMATION” then “SRT WORK SUPPORT” mode with CONSULT-II. 6. Start engine. 7. Rev engine up to 2,000 to 3,000 rpm and hold it for 3 consecutive minutes then release the accelerator pedal completely. If “INCMP” of “CATALYST” changed to “COMPLT”, go to step 10 8. Wait 5 seconds at idle. PBIB0566E EC-1056 DTC P0420 THREE WAY CATALYST FUNCTION [HR (WITH EURO-OBD)] 9. Rev engine up to 2,000 to 3,000 rpm and maintain it until “INCMP” of “CATALYST” changes to “CMPLT” (It will take approximately 5 minutes). If not “CMPLT”, stop engine and cool it down to less than 70°C (158°F) and then retest from step 1. A EC C PBIB0567E D a. b. c. d. Turn ignition switch OFF and leave the vehicle in a cool place (soak the vehicle) Turn ignition switch ON and select “COOLAN TEMP/S” in “DATA MONITOR” mode with CONSULT-II. Start engine and warm it up while monitoring “COOLAN TEMP/ S” indication on CONSULT-II. When “COOLAN TEMP/S” indication reaches to 70°(158°F), go to step 3. E F G SEF013Y 10. Select “SELF-DIAG RESULTS” mode with CONSULT-II. 11. Confirm that the 1st trip DTC is not detected. If the 1st trip DTC is detected, go to EC-1059, "Diagnostic Procedure" . H I J SEF535Z Overall Function Check K BBS004EB Use this procedure to check the overall function of the three way catalyst (manifold). During this check, a 1st trip DTC might not be confirmed. L WITH GST 1. 2. 3. 4. 5. 6. Start engine and warm it up to the normal operating temperature. Turn ignition switch OFF and wait at least 10 seconds. Start engine and keep the engine speed between 3,500 and 4,000 rpm for at least 1 minute under no load. Let engine idle for 1 minute. Set voltmeters probes between ECM terminal 49 (HO2S1 signal) and ground, and ECM terminal 50 (HO2S2 signal) and ground. Keep engine speed at 2,000 rpm constant under no load. PBIA9566J EC-1057 M DTC P0420 THREE WAY CATALYST FUNCTION [HR (WITH EURO-OBD)] 7. Make sure that the voltage switching frequency (high & low) between ECM terminal 50 and ground is very less than that of ECM terminal 49 and ground. Switching frequency ratio = A/B A: Heated oxygen sensor 2 voltage switching frequency B: Heated oxygen sensor 1 voltage switching frequency This ratio should be less than 0.75. If the ratio is greater than above, it means three way catalyst does not operate properly. Go to EC-1059, "Diagnostic Procedure" . NOTE: PBIB3000E If the voltage at terminal 49 does not switch periodically more than 5 times within 10 seconds at step 7, perform trouble diagnosis for DTC P0133 first. (See EC-967, "DTC P0133 HO2S1" .) EC-1058 DTC P0420 THREE WAY CATALYST FUNCTION [HR (WITH EURO-OBD)] Diagnostic Procedure BBS004EC 1. CHECK EXHAUST SYSTEM A Visually check exhaust tubes and muffler for dent. OK or NG OK >> GO TO 2. NG >> Repair or replace. EC C 2. CHECK EXHAUST GAS LEAK 1. 2. Start engine and run it at idle. Listen for an exhaust gas leak before the three way catalyst (manifold). D E F G SEC502D OK or NG OK >> GO TO 3. NG >> Repair or replace. H 3. CHECK INTAKE AIR LEAK I Listen for an intake air leak after the mass air flow sensor. OK or NG OK >> GO TO 4. NG >> Repair or replace. J K 4. CHECK IGNITION TIMING Check the following items. Refer to EC-851, "Basic Inspection" . Items Target idle speed Ignition timing L Specifications A/T models 700 ± 50 rpm (in P or N position) M/T models 650 ± 50 rpm (in Neutral position) A/T models 6 ± 5° BTDC (in P or N position) M/T models 6 ± 5° BTDC (in Neutral position) OK or NG OK >> GO TO 5. NG >> Follow the EC-851, "Basic Inspection" . EC-1059 M DTC P0420 THREE WAY CATALYST FUNCTION [HR (WITH EURO-OBD)] 5. CHECK FUEL INJECTORS 1. 2. 3. Refer to Wiring Diagram for fuel injectors, EC-1210, "Wiring Diagram" . Stop engine and then turn ignition switch ON. Check voltage between ECM terminals 25, 29, 30, 31 and ground with CONSULT-II or tester. Voltage: Battery voltage OK or NG OK >> GO TO 6. NG >> Perform EC-1211, "Diagnostic Procedure" . PBIB3001E 6. CHECK FUNCTION OF IGNITION COIL-I CAUTION: Do the following procedure in the place where ventilation is good without the combustible. 1. Turn ignition switch OFF. 2. Remove fuel pump fuse in IPDM E/R to release fuel pressure. NOTE: Do not use CONSULT-II to release fuel pressure, or fuel pressure applies again during the following procedure. 3. Start engine. 4. After engine stalls, crank it two or three times to release all fuel pressure. 5. Turn ignition switch OFF. 6. Remove all ignition coil harness connectors to avoid the electrical discharge from the ignition coils. 7. Remove ignition coil and spark plug of the cylinder to be checked. 8. Crank engine for 5 seconds or more to remove combustion gas in the cylinder. 9. Connect spark plug and harness connector to ignition coil. 10. Fix ignition coil using a rope etc. with gap of 13 - 17 mm between the edge of the spark plug and grounded metal portion as shown in the figure. 11. Crank engine for about three seconds, and check whether spark is generated between the spark plug and the grounded metal portion. MBIB0277E Spark should be generated. CAUTION: Do not approach to the spark plug and the ignition coil within 50cm. Be careful not to get an electrical shock PBIB2325E while checking, because the electrical discharge voltage becomes 20kV or more. ● It might cause to damage the ignition coil if the gap of more than 17 mm is taken. NOTE: When the gap is less than 13 mm, the spark might be generated even if the coil is malfunctioning. OK or NG OK >> GO TO 10. NG >> GO TO 7. ● EC-1060 DTC P0420 THREE WAY CATALYST FUNCTION [HR (WITH EURO-OBD)] 7. CHECK FUNCTION OF IGNITION COIL-II 1. 2. 3. A Turn ignition switch OFF. Disconnect spark plug and connect a known-good spark plug. Crank engine for about three seconds, and recheck whether spark is generated between the spark plug EC and the grounded metal portion. Spark should be generated. C OK or NG OK >> GO TO 8. NG >> Check ignition coil, power transistor and their circuits. Refer to EC-1221, "IGNITION SIGNAL" . D 8. CHECK SPARK PLUG E Check the initial spark plug for fouling, etc. OK or NG OK >> Replace spark plug(s) with standard type one(s). For spark plug type, refer to EM-133, "SPARK PLUG (PLATINUM-TIPPED TYPE)" . NG >> 1. Repair or clean spark plug. 2. GO TO 9. F G SEF156I H 9. CHECK FUNCTION OF IGNITION COIL-III 1. 2. Reconnect the initial spark plugs. Crank engine for about three seconds, and recheck whether spark is generated between the spark plug and the grounded portion. I J Spark should be generated. OK or NG OK >> INSPECTION END NG >> Replace spark plug(s) with standard type one(s). For spark plug type, refer to EM-133, "SPARK PLUG (PLATINUM-TIPPED TYPE)" . 10. CHECK FUEL INJECTOR 1. 2. Turn ignition switch OFF. Remove fuel injector assembly. Refer to EM-135, "FUEL INJECTOR AND FUEL TUBE" . Keep fuel hose and all fuel injectors connected to fuel tube. 3. Disconnect all ignition coil harness connectors. 4. Reconnect all fuel injector harness connectors disconnected. 5. Turn ignition switch ON. Make sure fuel does not drip from fuel injector. OK or NG OK (Does not drip.)>>GO TO 11. NG (Drips.)>>Replace the fuel injector(s) from which fuel is dripping. EC-1061 K L M DTC P0420 THREE WAY CATALYST FUNCTION [HR (WITH EURO-OBD)] 11. CHECK INTERMITTENT INCIDENT Refer to EC-917, "TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT" . Trouble is fixed.>>INSPECTION END Trouble is not fixed.>>Replace three way catalyst (manifold). EC-1062 DTC P0444 EVAP CANISTER PURGE VOLUME CONTROL SOLENOID VALVE [HR (WITH EURO-OBD)] DTC P0444 EVAP CANISTER PURGE VOLUME CONTROL SOLENOID VALVE PFP:14920 Description A BBS004ED SYSTEM DESCRIPTION Sensor Input Signal to ECM Crankshaft position sensor (POS) Camshaft position sensor (PHASE) Engine speed*1 Mass air flow sensor Amount of intake air Engine coolant temperature sensor Engine coolant temperature Battery Battery voltage*1 Throttle position sensor Throttle position ECM function C EVAP canister purge flow control Accelerator pedal position sensor Accelerator pedal position Heated oxygen sensor 1 Density of oxygen in exhaust gas (Mixture ratio feedback signal) Wheel sensor Vehicle speed*2 EC Actuator EVAP canister purge volume control solenoid valve D E F *1: ECM determines the start signal status by the signals of engine speed and battery voltage. *2: This signal is sent to the ECM through CAN communication line. This system controls flow rate of fuel vapor from the EVAP canister. The opening of the vapor by-pass passage in the EVAP canister purge volume control solenoid valve changes to control the flow rate. The EVAP canister purge volume control solenoid valve repeats ON/OFF operation according to the signal sent from the ECM. The opening of the valve varies for optimum engine control. The optimum value stored in the ECM is determined by considering various engine conditions. When the engine is operating, the flow rate of fuel vapor from the EVAP canister is regulated as the air flow changes. G COMPONENT DESCRIPTION I The EVAP canister purge volume control solenoid valve uses a ON/ OFF duty to control the flow rate of fuel vapor from the EVAP canister. The EVAP canister purge volume control solenoid valve is moved by ON/OFF pulses from the ECM. The longer the ON pulse, the greater the amount of fuel vapor that will flow through the valve. J H K L PBIA9215J CONSULT-II Reference Value in Data Monitor Mode BBS004EE Specification data are reference values. MONITOR ITEM CONDITION ● Engine: After warming up ● Shift lever: P or N (A/T), Neutral (M/T) ● Air conditioner switch: OFF ● No load PURG VOL C/V SPECIFICATION Idle 0% 2,000 rpm 0 - 50% On Board Diagnosis Logic DTC No. P0444 0444 Trouble diagnosis name EVAP canister purge volume control solenoid valve circuit open BBS004EF DTC detecting condition Possible cause ● Harness or connectors (The solenoid valve circuit is open or shorted.) ● EVAP canister purge volume control solenoid valve An excessively low voltage signal is sent to ECM through the valve EC-1063 M DTC P0444 EVAP CANISTER PURGE VOLUME CONTROL SOLENOID VALVE [HR (WITH EURO-OBD)] DTC Confirmation Procedure BBS004EG NOTE: If DTC Confirmation Procedure has been previously conducted, always turn ignition switch OFF and wait at least 10 seconds before conducting the next test. TESTING CONDITION: Before performing the following procedure, confirm battery voltage is more than 11V at idle. WITH CONSULT-II 1. 2. 3. 4. Turn ignition switch ON. Select “DATA MONITOR” mode with CONSULT-II. Start engine and let it idle for at least 13 seconds. If 1st trip DTC is detected, go to EC-1067, "Diagnostic Procedure" . SEF058Y WITH GST Follow the procedure “WITH CONSULT-II” above. EC-1064 DTC P0444 EVAP CANISTER PURGE VOLUME CONTROL SOLENOID VALVE [HR (WITH EURO-OBD)] Wiring Diagram BBS004EH A EC C D E F G H I J K L M MBWA1470E EC-1065 DTC P0444 EVAP CANISTER PURGE VOLUME CONTROL SOLENOID VALVE [HR (WITH EURO-OBD)] Specification data are reference values and are measured between each terminal and ground. Pulse signal is measured by CONSULT-II. CAUTION: Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM's transistor. Use a ground other than ECM terminals, such as the ground. TERMINAL NO. WIRE COLOR ITEM CONDITION DATA (DC Voltage) BATTERY VOLTAGE (11 - 14V) [Engine is running] ● 9 LG Idle speed EVAP canister purge volume control solenoid valve PBIB0050E Approximately 10V [Engine is running] ● Engine speed: About 2,000 rpm (More than 100 seconds after starting engine) PBIB0520E [Engine is running] [Ignition switch: OFF] ● 32 P ECM relay (Self shut-off) [Ignition switch: OFF] ● 105 G Power supply for ECM For a few seconds after turning ignition switch OFF More than a few seconds after turning ignition switch OFF [Ignition switch: ON] : Average voltage for pulse signal (Actual pulse signal can be confirmed by oscilloscope.) EC-1066 0 - 1.0V BATTERY VOLTAGE (11 - 14V) BATTERY VOLTAGE (11 - 14V) DTC P0444 EVAP CANISTER PURGE VOLUME CONTROL SOLENOID VALVE [HR (WITH EURO-OBD)] Diagnostic Procedure BBS004EI 1. CHECK EVAP CANISTER PURGE VOLUME CONTROL SOLENOID VALVE POWER SUPPLY CIR- A CUIT 1. 2. Turn ignition switch OFF. Disconnect EVAP canister purge volume control solenoid valve (1) harness connector. – : Vehicle front Turn ignition switch ON. 3. EC C D E PBIB2972E 4. F Check voltage between EVAP canister purge volume control solenoid valve terminal 1 and ground with CONSULT-II or tester. Voltage: Battery voltage G OK or NG OK >> GO TO 3. NG >> GO TO 2. H PBIB0148E I 2. DETECT MALFUNCTIONING PART Check the following. ● Harness connectors E59, F1 ● Harness for open or short between EVAP canister purge volume control solenoid valve and IPDM E/R ● Harness for open or short between EVAP canister purge volume control solenoid valve and ECM >> Repair open circuit or short to ground or short to power in harness or connectors. J K L 3. CHECK EVAP CANISTER PURGE VOLUME CONTROL SOLENOID VALVE OUTPUT SIGNAL CIRCUIT FOR OPEN AND SHORT 1. 2. 3. M Turn ignition switch OFF. Disconnect ECM harness connector. Check harness continuity between ECM terminal 9 and EVAP canister purge volume control solenoid valve terminal 2. Refer to Wiring Diagram. Continuity should exist. 4. Also check harness for short to ground and short to power. OK or NG OK (With CONSULT-II)>>GO TO 4. OK (Without CONSULT-II)>>GO TO 5. NG >> Repair open circuit or short to ground or short to power in harness or connectors. EC-1067 DTC P0444 EVAP CANISTER PURGE VOLUME CONTROL SOLENOID VALVE [HR (WITH EURO-OBD)] 4. CHECK EVAP CANISTER PURGE VOLUME CONTROL SOLENOID VALVE OPERATION With CONSULT-II Reconnect all harness connectors disconnected. Start engine. Perform “PURG VOL CONT/V” in “ACTIVE TEST” mode with CONSULT-II. Check that engine speed varies according to the valve opening. OK or NG OK >> GO TO 6. NG >> GO TO 5. 1. 2. 3. PBIB0569E 5. CHECK EVAP CANISTER PURGE VOLUME CONTROL SOLENOID VALVE Refer to EC-1068, "Component Inspection" . OK or NG OK >> GO TO 6. NG >> Replace EVAP canister purge volume control solenoid valve. 6. CHECK INTERMITTENT INCIDENT Refer to EC-917, "TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT" . >> INSPECTION END Component Inspection BBS004EJ EVAP CANISTER PURGE VOLUME CONTROL SOLENOID VALVE With CONSULT-II Check air passage continuity of EVAP canister purge volume control solenoid valve under the following conditions. Condition (PURG VOL CONT/V value) Air passage continuity between A and B 100% Yes 0% No PBIA9668J Without CONSULT-II Check air passage continuity of EVAP canister purge volume control solenoid valve under the following conditions. Condition Air passage continuity between A and B 12V direct current supply between terminals 1 and 2 Yes No supply No PBIA9560J EC-1068 DTC P0444 EVAP CANISTER PURGE VOLUME CONTROL SOLENOID VALVE [HR (WITH EURO-OBD)] Removal and Installation BBS004EK EVAP CANISTER PURGE VOLUME CONTROL SOLENOID VALVE A Refer to EM-120, "INTAKE MANIFOLD" . EC C D E F G H I J K L M EC-1069 DTC P0500 VSS [HR (WITH EURO-OBD)] DTC P0500 VSS Description PFP:32702 BBS004EL NOTE: ● If DTC P0500 is displayed with DTC U1000 or U1001, first perform the trouble diagnosis for DTC U1000, U1001. Refer to EC-925, "DTC U1000, U1001 CAN COMMUNICATION LINE" . ● If DTC P0500 is displayed with DTC U1010, first perform the trouble diagnosis for DTC U1010. Refer to EC-928, "DTC U1010 CAN COMMUNICATION" . The vehicle speed signal is sent to the combination meter from “ABS actuator and electric unit (control unit)” through CAN communication line. The combination meter then sends a signal to the ECM through CAN communication line. On Board Diagnosis Logic DTC No. P0500 0500 Trouble diagnosis name Vehicle speed sensor BBS004EM DTC detecting condition The almost 0 km/h (0 MPH) signal from vehicle speed sensor is sent to ECM even when vehicle is being driven. DTC Confirmation Procedure Possible cause ● Harness or connectors (The CAN communication line is open or shorted.) ● Harness or connectors (Wheel sensor circuit is open or shorted) ● ABS actuator and electric unit (control unit) ● Wheel sensor ● Combination meter BBS004EN CAUTION: Always drive vehicle at a safe speed. NOTE: If DTC Confirmation Procedure has been previously conducted, always turn ignition switch OFF and wait at least 10 seconds before conducting the next test. TESTING CONDITION: Steps 1 and 2 may be conducted with the drive wheels lifted in the shop or by driving the vehicle. If a road test is expected to be easier, it is unnecessary to lift the vehicle. WITH CONSULT-II 1. 2. 3. 4. 5. Start engine. Read “VHCL SPEED SE” in “DATA MONITOR” mode with CONSULT-II. The vehicle speed on CONSULTII should exceed 10 km/h (6 MPH) when rotating wheels with suitable gear position. If NG, go to EC-1071, "Diagnostic Procedure" . If OK, go to following step. Select “DATA MONITOR” mode with CONSULT-II. Warm engine up to normal operating temperature. Maintain the following conditions for at least 60 consecutive seconds. ENG SPEED A/T: More than 1,900 rpm M/T: More than 2,500 rpm COOLAN TEMP/S More than 70°C (158°F) B/FUEL SCHDL A/T: 4.8 - 31.8 msec M/T: 3.8 - 31.8 msec Shift lever Suitable position PW/ST SIGNAL OFF SEF196Y 6. If 1st trip DTC is detected, go to EC-1071, "Diagnostic Procedure" . EC-1070 DTC P0500 VSS [HR (WITH EURO-OBD)] Overall Function Check BBS004EO Use this procedure to check the overall function of the vehicle speed signal circuit. During this check, a 1st trip DTC might not be confirmed. WITH GST 1. 2. 3. 4. A EC Lift up drive wheels. Start engine. Read vehicle speed signal in Service $01 with GST. The vehicle speed signal on GST should be able to exceed 10 km/h (6 MPH) when rotating wheels with suitable gear position. If NG, go to EC-1071, "Diagnostic Procedure" . Diagnostic Procedure C D BBS004EP 1. CHECK DTC WITH “ABS ACTUATOR AND ELECTRIC UNIT (CONTROL UNIT)” Refer to BRC-49, "TROUBLE DIAGNOSIS" (models with ESP) or BRC-8, "TROUBLE DIAGNOSIS" (models without ESP). OK or NG OK >> GO TO 2. NG >> Repair or replace. E F G 2. CHECK COMBINATION METER Check combination meter function. Refer to DI-4, "COMBINATION METERS" . H >> INSPECTION END I J K L M EC-1071 DTC P0605 ECM [HR (WITH EURO-OBD)] DTC P0605 ECM Component Description PFP:23710 BBS004EQ The ECM consists of a microcomputer and connectors for signal input and output and for power supply. The ECM controls the engine. PBIA9222J On Board Diagnosis Logic BBS004ER This self-diagnosis has one or two trip detection logic. DTC No. P0605 0605 Trouble diagnosis name Engine control module DTC detecting condition A) ECM calculation function is malfunctioning. B) ECM EEP-ROM system is malfunctioning. C) ECM self shut-off function is malfunctioning. Possible cause ● ECM FAIL-SAFE MODE ECM enters fail-safe mode when malfunction A is detected. Detected items Malfunction A Engine operation condition in fail-safe mode ECM stops the electric throttle control actuator control, throttle valve is maintained at a fixed opening (approx. 5 degrees) by the return spring. DTC Confirmation Procedure BBS004ES Perform PROCEDURE FOR MALFUNCTION A first. If the 1st trip DTC cannot be confirmed, perform PROCEDURE FOR MALFUNCTION B. If there is no malfunction on PROCEDURE FOR MALFUNCTION B, perform PROCEDURE FOR MALFUNCTION C. NOTE: If DTC Confirmation Procedure has been previously conducted, always turn ignition switch OFF and wait at least 10 seconds before conducting the next test. PROCEDURE FOR MALFUNCTION A With CONSULT-II 1. 2. 3. Turn ignition switch ON. Select “DATA MONITOR” mode with CONSULT-II. If 1st trip DTC is detected, go to EC-1073, "Diagnostic Procedure" . SEF058Y With GST Follow the procedure “With CONSULT-II” above. EC-1072 DTC P0605 ECM [HR (WITH EURO-OBD)] PROCEDURE FOR MALFUNCTION B With CONSULT-II 1. 2. 3. 4. A Turn ignition switch ON and wait at least 1 second. Select “DATA MONITOR” mode with CONSULT-II. Turn ignition switch OFF, wait at least 10 seconds and then turn ON. If 1st trip DTC is detected, go to EC-1073, "Diagnostic Procedure" . EC C D SEF058Y E With GST Follow the procedure “With CONSULT-II” above. F PROCEDURE FOR MALFUNCTION C With CONSULT-II 1. 2. 3. 4. 5. Turn ignition switch ON and wait at least 1 second. Select “DATA MONITOR” mode with CONSULT-II. Turn ignition switch OFF, wait at least 10 seconds and then turn ON. Repeat step 3 for 32 times. If 1st trip DTC is detected, go to EC-1073, "Diagnostic Procedure" . G H I J SEF058Y With GST Follow the procedure “With CONSULT-II” above. K Diagnostic Procedure BBS004ET 1. INSPECTION START L With CONSULT-II Turn ignition switch ON. Select “SELF DIAG RESULTS” mode with CONSULT-II. Touch “ERASE”. Perform DTC Confirmation Procedure. See EC-1072, "DTC Confirmation Procedure" . 5. Is the 1st trip DTC P0605 displayed again? 1. 2. 3. 4. With GST Turn ignition switch ON. Select Service $04 with GST. Perform DTC Confirmation Procedure. See EC-1072, "DTC Confirmation Procedure" . 4. Is the 1st trip DTC P0605 displayed again? Yes or No Yes >> GO TO 2. No >> INSPECTION END 1. 2. 3. EC-1073 M DTC P0605 ECM [HR (WITH EURO-OBD)] 2. REPLACE ECM 1. 2. 3. 4. 5. Replace ECM. Perform initialization of NATS system and registration of all NATS ignition key IDs. Refer to BL-218, "ECM Re-communicating Function" . Perform EC-857, "Accelerator Pedal Released Position Learning" . Perform EC-857, "Throttle Valve Closed Position Learning" . Perform EC-858, "Idle Air Volume Learning" . >> INSPECTION END EC-1074 DTC P1065 ECM [HR (WITH EURO-OBD)] DTC P1065 ECM Component Description PFP:23710 A BBS004EU ECM has the memory function of the DTC memory, the air-fuel ratio feedback compensation value memory, the Idle Air Volume Learning value memory, etc. even when the ignition switch is turned OFF. EC C D PBIA9222J E On Board Diagnosis Logic DTC No. P1065* 1065 Trouble diagnosis name Engine control module BBS004EV DTC detecting condition ECM back-up RAM system does not function properly. Possible cause F ● ECM *: This self-diagnosis is not for ECM power supply circuit, even though “ECM BACK UP/CIRCUIT” is displayed on CONSULT-II screen. DTC Confirmation Procedure NOTE: If DTC Confirmation Procedure has been previously conducted, always turn ignition switch OFF and wait at least 10 seconds before conducting the next test. WITH CONSULT-II 1. 2. 3. 4. 5. 6. G BBS004EW H I Turn ignition switch ON and wait at least 1 second. Select “DATA MONITOR” mode with CONSULT-II. Start engine and let it idle for 1 second. Turn ignition switch OFF, wait at least 10 seconds and then turn ON. Repeat steps 3 and 4 for 4 times. If 1st trip DTC is detected, go to EC-1076, "Diagnostic Procedure" . J K L SEF058Y WITH GST M Follow the procedure “WITH CONSULT-II” above. EC-1075 DTC P1065 ECM [HR (WITH EURO-OBD)] Diagnostic Procedure BBS004EX 1. INSPECTION START 1. 2. 3. 4. 5. With CONSULT-II Turn ignition switch ON. Select “SELF-DIAG RESULTS” mode with CONSULT-II. Touch “ERASE”. Perform DTC Confirmation Procedure. See EC-1075, "DTC Confirmation Procedure" . Is the 1st trip DTC P1065 displayed again? With GST 1. Turn ignition switch ON. 2. Select Service $04 with GST. 3. Perform DTC Confirmation Procedure. See EC-1075, "DTC Confirmation Procedure" . 4. Is the 1st trip DTC P1065 displayed again? Yes or No Yes >> GO TO 2. No >> INSPECTION END 2. REPLACE ECM 1. 2. 3. 4. 5. Replace ECM. Perform initialization of NATS system and registration of all NATS ignition key IDs. Refer to BL-218, "ECM Re-communicating Function" . Perform EC-857, "Accelerator Pedal Released Position Learning" . Perform EC-857, "Throttle Valve Closed Position Learning" . Perform EC-858, "Idle Air Volume Learning" . >> INSPECTION END EC-1076 DTC P1111 IVT CONTROL SOLENOID VALVE [HR (WITH EURO-OBD)] DTC P1111 IVT CONTROL SOLENOID VALVE Component Description PFP:23796 A BBS004EY Intake valve timing control solenoid valve is activated by ON/OFF pulse duty (ratio) signals from the ECM. The intake valve timing control solenoid valve changes the oil amount and direction of flow through intake valve timing control unit or stops oil flow. The longer pulse width advances valve angle. The shorter pulse width retards valve angle. When ON and OFF pulse widths become equal, the solenoid valve stops oil pressure flow to fix the intake valve angle at the control position. EC C D PBIB1842E E CONSULT-II Reference Value in Data Monitor Mode BBS004EZ Specification data are reference values. MONITOR ITEM INT/V SOL (B1) CONDITION ● Engine: After warming up ● Air conditioner switch: OFF ● Shift lever: P or N (A/T), Neutral (M/T) ● No load 0% - 2% 2,500 rpm Approx. 0% - 90% G H On Board Diagnosis Logic DTC No. P1111 1111 Trouble diagnosis name Intake valve timing control solenoid valve circuit F SPECIFICATION Idle BBS004F0 DTC detecting condition An improper voltage is sent to the ECM through intake valve timing control solenoid valve. DTC Confirmation Procedure Possible cause I ● Harness or connectors (Solenoid valve circuit is open or shorted.) ● Intake valve timing control solenoid valve BBS004F1 NOTE: If DTC Confirmation Procedure has been previously conducted, always turn ignition switch OFF and wait at least 10 seconds before conducting the next test. WITH CONSULT-II 1. 2. 3. 4. J L Turn ignition switch ON. Select “DATA MONITOR” mode with CONSULT-II. Start engine and let it idle for 5 seconds. If 1st trip DTC is detected, go to EC-1080, "Diagnostic Procedure" . M SEF058Y WITH GST Following the procedure “WITH CONSULT-II” above. EC-1077 K DTC P1111 IVT CONTROL SOLENOID VALVE [HR (WITH EURO-OBD)] Wiring Diagram BBS004F2 MBWA1471E EC-1078 DTC P1111 IVT CONTROL SOLENOID VALVE [HR (WITH EURO-OBD)] Specification data are reference values and are measured between each terminal and ground. Pulse signal is measured by CONSULT-II. A CAUTION: Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM's transistor. Use a ground other than ECM terminals, such as the ground. EC TERMINAL NO. WIRE COLOR ITEM CONDITION C [Engine is running] [Ignition switch: OFF] ● 32 DATA (DC Voltage) P ECM relay (Self shut-off) For a few seconds after turning ignition switch OFF [Ignition switch: OFF] ● More than a few seconds after turning ignition switch OFF 0 - 1.0V D BATTERY VOLTAGE (11 - 14V) E BATTERY VOLTAGE (11 - 14V) F [Engine is running] ● Warm-up condition ● Idle speed 7 - 10V 73 LG Intake valve timing control solenoid valve G [Engine is running] ● Warm-up condition ● Engine speed: 2,000 rpm H PBIA4937J 105 G Power supply for ECM [Ignition switch: ON] : Average voltage for pulse signal (Actual pulse signal can be confirmed by oscilloscope.) BATTERY VOLTAGE (11 - 14V) I J K L M EC-1079 DTC P1111 IVT CONTROL SOLENOID VALVE [HR (WITH EURO-OBD)] Diagnostic Procedure BBS004F3 1. CHECK INTAKE VALVE TIMING CONTROL SOLENOID VALVE POWER SUPPLY CIRCUIT 1. 2. 3. Turn ignition switch OFF. Disconnect intake valve timing control solenoid valve (1) harness connector. Turn ignition switch ON. MBIB1546E 4. Check voltage between intake valve timing control solenoid valve terminal 2 and ground with CONSULT-II or tester. Voltage: Battery voltage OK or NG OK >> GO TO 3. NG >> GO TO 2. PBIB0192E 2. DETECT MALFUNCTION PART Check the following. ● Harness connectors E59, F1 ● Harness for open or short between intake valve timing control solenoid valve and IPDM E/R >> Repair or replace harness or connectors. 3. CHECK INTAKE VALVE TIMING CONTROL SOLENOID VALVE OUTPUT SIGNAL CIRCUIT FOR OPEN AND SHORT 1. 2. 3. Turn ignition switch OFF. Disconnect ECM harness connector. Check harness continuity between ECM terminal 73 and intake valve timing control solenoid valve terminal 1. Refer to Wiring Diagram. Continuity should exist. 4. Also check harness for short to ground and short to power. OK or NG OK >> GO TO 4. NG >> Repair open circuit or short to ground or short to power in harness or connectors. 4. CHECK INTAKE VALVE TIMING CONTROL SOLENOID VALVE Refer to EC-1081, "Component Inspection" . OK or NG OK >> GO TO 5. NG >> Replace intake valve timing control solenoid valve. EC-1080 DTC P1111 IVT CONTROL SOLENOID VALVE [HR (WITH EURO-OBD)] 5. CHECK INTERMITTENT INCIDENT A Refer to EC-917, "TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT" . EC >> INSPECTION END Component Inspection BBS004F4 INTAKE VALVE TIMING CONTROL SOLENOID VALVE 1. 2. 3. 4. C Disconnect intake valve timing control solenoid valve harness connector. Check resistance between intake valve timing control solenoid valve as follows. Terminal Resistance 1 and 2 6.7 - 7.7Ω [at 20°C (68°F)] 1 or 2 and ground ∞Ω (Continuity should not exist.) If NG, replace intake valve timing control solenoid valve. If OK, go to next step. Remove intake valve timing control solenoid valve. Provide 12V DC between intake valve timing control solenoid valve terminals and then interrupt it. Make sure that the plunger moves as shown in the figure. CAUTION: Do not apply 12V DC continuously for 5 seconds or more. Doing so may result in damage to the coil in intake valve timing control solenoid valve. If NG, replace intake valve timing control solenoid valve. NOTE: Always replace O-ring when intake valve timing control solenoid valve is removed. Removal and Installation D E F PBIB0193E G H I J PBIB2275E BBS004F5 INTAKE VALVE TIMING CONTROL SOLENOID VALVE K Refer to EM-142, "TIMING CHAIN" . L M EC-1081 DTC P1121 ELECTRIC THROTTLE CONTROL ACTUATOR [HR (WITH EURO-OBD)] DTC P1121 ELECTRIC THROTTLE CONTROL ACTUATOR Component Description PFP:16119 BBS004F6 Electric throttle control actuator consists of throttle control motor, throttle position sensor, etc. The throttle control motor is operated by the ECM and it opens and closes the throttle valve. The throttle position sensor detects the throttle valve position, and the opening and closing speed of the throttle valve and feeds the voltage signals to the ECM. The ECM judges the current opening angle of the throttle valve from these signals and the ECM controls the throttle control motor to make the throttle valve opening angle properly in response to driving condition. On Board Diagnosis Logic BBS004F7 This self-diagnosis has the one trip detection logic. DTC No. P1121 1121 Trouble diagnosis name Electric throttle control actuator DTC detecting condition A) Electric throttle control actuator does not function properly due to the return spring malfunction. B) Throttle valve opening angle in fail-safe mode is not in specified range. C) ECM detect the throttle valve is stuck open. Possible cause ● Electric throttle control actuator FAIL-SAFE MODE When the malfunction is detected, the ECM enters fail-safe mode and the MI lights up. Detected items Engine operating condition in fail-safe mode Malfunction A The ECM controls the electric throttle actuator by regulating the throttle opening around the idle position. The engine speed will not rise more than 2,000 rpm. Malfunction B ECM controls the electric throttle control actuator by regulating the throttle opening to 20 degrees or less. Malfunction C While the vehicle is driving, it slows down gradually by fuel cut. After the vehicle stops, the engine stalls. The engine can restart in N or P position (A/T), Neutral position (M/T), and engine speed will not exceed 1,000 rpm or more. DTC Confirmation Procedure BBS004F8 NOTE: ● Perform PROCEDURE FOR MALFUNCTION A AND B first. If the DTC cannot be confirmed, perform PROCEDURE FOR MALFUNCTION C. ● If DTC Confirmation Procedure has been previously conducted, always turn ignition switch OFF and wait at least 10 seconds before conducting the next test. PROCEDURE FOR MALFUNCTION A AND B With CONSULT-II 1. 2. 3. Turn ignition witch ON and wait at least 1 second. Select “DATA MONITOR” mode with CONSULT-II. Set shift lever to D position (A/T), 1st position (M/T) and wait at least 3 seconds. 4. Set shift lever to P position (A/T), Neutral position (M/T). 5. Turn ignition switch OFF and wait at least 10 seconds. 6. Turn ignition switch ON and wait at least 1 second. 7. Set shift lever to D position (A/T), 1st position (M/T) and wait at least 3 seconds. 8. Set shift lever to P position (A/T), Neutral position (M/T). 9. Turn ignition switch OFF, wait at least 10 seconds and then turn ON. 10. If DTC is detected, go to EC-1083, "Diagnostic Procedure" . EC-1082 SEF058Y DTC P1121 ELECTRIC THROTTLE CONTROL ACTUATOR [HR (WITH EURO-OBD)] With GST A Follow the procedure “With CONSULT-II” above. PROCEDURE FOR MALFUNCTION C With CONSULT-II 1. 2. 3. 4. 5. 6. EC Turn ignition switch ON and wait at least 1 second. Select “DATA MONITOR” mode with CONSULT-II. Set shift lever to D position (A/T), 1st position (M/T) and wait at least 3 seconds. Set shift lever to P position (A/T), Neutral position (M/T). Start engine and let it idle for 3 seconds. If DTC is detected, go to EC-1083, "Diagnostic Procedure" . C D E SEF058Y F With GST Follow the procedure “With CONSULT-II” above. Diagnostic Procedure BBS004F9 1. CHECK ELECTRIC THROTTLE CONTROL ACTUATOR VISUALLY 1. 2. Remove the intake air duct. Check if a foreign matter is caught between the throttle valve (1) and the housing. G H – : Vehicle front OK or NG OK >> GO TO 2. NG >> Remove the foreign matter and clean the electric throttle control actuator inside. I J K PBIB2974E 2. REPLACE ELECTRIC THROTTLE CONTROL ACTUATOR 1. 2. 3. L Replace the electric throttle control actuator. Perform EC-857, "Throttle Valve Closed Position Learning" . Perform EC-858, "Idle Air Volume Learning" . M >> INSPECTION END Removal and Installation BBS004FA Refer to EM-120, "INTAKE MANIFOLD" . EC-1083 DTC P1122 ELECTRIC THROTTLE CONTROL FUNCTION [HR (WITH EURO-OBD)] DTC P1122 ELECTRIC THROTTLE CONTROL FUNCTION Description PFP:16119 BBS004FB NOTE: If DTC P1122 is displayed with DTC P1121 or P1126, first perform the trouble diagnosis for DTC P1121 or P1126. Refer to EC-1082, "DTC P1121 ELECTRIC THROTTLE CONTROL ACTUATOR" or EC-1090, "DTC P1124, P1126 THROTTLE CONTROL MOTOR RELAY" . Electric throttle control actuator consists of throttle control motor, throttle position sensor, etc. The throttle control motor is operated by the ECM and it opens and closes the throttle valve. The current opening angle of the throttle valve is detected by the throttle position sensor and it provides feedback to the ECM to control the throttle control motor to make the throttle valve opening angle properly in response to driving condition. On Board Diagnosis Logic BBS004FC This self-diagnosis has the one trip detection logic. DTC No. P1122 1122 Trouble diagnosis name Electric throttle control performance DTC detecting condition Possible cause ● Harness or connectors (Throttle control motor circuit is open or shorted) ● Electric throttle control actuator Electric throttle control function does not operate properly. FAIL-SAFE MODE When the malfunction is detected, ECM enters fail-safe mode and the MI lights up. Engine operating condition in fail-safe mode ECM stops the electric throttle control actuator control, throttle valve is maintained at a fixed opening (approx. 5 degrees) by the return spring. DTC Confirmation Procedure BBS004FD NOTE: If DTC Confirmation Procedure has been previously conducted, always turn ignition switch OFF and wait at least 10 seconds before conducting the next test. TESTING CONDITION: Before performing the following procedure, confirm that battery voltage is more than 11V when engine is running. WITH CONSULT-II 1. 2. 3. 4. Turn ignition switch ON and wait at least 2 seconds. Select “DATA MONITOR” mode with CONSULT-II. Start engine and let it idle for 5 seconds. If DTC is detected, go to EC-1086, "Diagnostic Procedure" . SEF058Y WITH GST Follow the procedure “WITH CONSULT-II” above. EC-1084 DTC P1122 ELECTRIC THROTTLE CONTROL FUNCTION [HR (WITH EURO-OBD)] Wiring Diagram BBS004FE A EC C D E F G H I J K L M MBWA1472E EC-1085 DTC P1122 ELECTRIC THROTTLE CONTROL FUNCTION [HR (WITH EURO-OBD)] Specification data are reference values and are measured between each terminal and ground. Pulse signal is measured by CONSULT-II. CAUTION: Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM's transistor. Use a ground other than ECM terminals, such as the ground. TERMINAL NO. WIRE COLOR ITEM CONDITION DATA (DC Voltage) 0 - 14V [Ignition switch: ON] 1 P Throttle control motor (Open) ● Engine stopped ● Shift lever: D (A/T), 1st (M/T) ● Accelerator pedal: Fully depressed PBIB1105E 2 LG Throttle control motor relay power supply BATTERY VOLTAGE (11 - 14V) [Ignition switch: ON] 0 - 14V [Ignition switch: ON] 4 L Throttle control motor (Close) ● Engine stopped ● Shift lever: D (A/T), 1st (M/T) ● Accelerator pedal: Released PBIB1104E 15 G Throttle control motor relay [Ignition switch: OFF] BATTERY VOLTAGE (11 - 14V) [Ignition switch: ON] 0 - 1.0V : Average voltage for pulse signal (Actual pulse signal can be confirmed by oscilloscope.) Diagnostic Procedure BBS004FF 1. CHECK GROUND CONNECTIONS 1. 2. Turn ignition switch OFF. Loosen and retighten ground screws on the body. Refer to EC-924, "Ground Inspection" . MBIB1550E 1. IPDM E/R 2. Body ground OK or NG OK >> GO TO 2. NG >> Repair or replace ground connections. EC-1086 3. Body ground DTC P1122 ELECTRIC THROTTLE CONTROL FUNCTION [HR (WITH EURO-OBD)] 2. CHECK THROTTLE CONTROL MOTOR RELAY INPUT SIGNAL CIRCUIT-I A Check voltage between ECM terminal 2 and ground under the following conditions with CONSULT-II or tester. Ignition switch Voltage OFF Approximately 0V ON Battery voltage (11 - 14V) OK or NG OK >> GO TO 10. NG >> GO TO 3. EC C D PBIA9568J 3. CHECK THROTTLE CONTROL MOTOR RELAY POWER SUPPLY CIRCUIT-I 1. 2. E Turn ignition switch OFF. Check voltage between ECM terminal 15 and ground with CONSULT-II or tester. F Voltage: Battery voltage G OK or NG OK >> GO TO 7. NG >> GO TO 4. H PBIA9569J I 4. CHECK THROTTLE CONTROL MOTOR RELAY POWER SUPPLY CIRCUIT-II 1. 2. 3. Disconnect ECM harness connector. Disconnect IPDM E/R harness connector E5. Check harness continuity between ECM terminal 15 and IPDM E/R terminal 70. Refer to Wiring Diagram. J K Continuity should exist. 4. Also check harness for short to ground and short to power. OK or NG OK >> GO TO 6. NG >> GO TO 5. 5. DETECT MALFUNCTIONING PART Check the following. ● Harness connectors E59, F1 ● Harness for open or short between ECM and IPDM E/R >> Repair open circuit or short to ground or short to power in harness or connectors. 6. CHECK FUSE 1. Disconnect 20A fuse. 2. Check 20A fuse for blown. OK or NG OK >> GO TO 9. NG >> Replace 20A fuse. EC-1087 L M DTC P1122 ELECTRIC THROTTLE CONTROL FUNCTION [HR (WITH EURO-OBD)] 7. CHECK THROTTLE CONTROL MOTOR RELAY INPUT SIGNAL CIRCUIT-II 1. 2. 3. Disconnect ECM harness connector. Disconnect IPDM E/R harness connector E7. Check harness continuity between ECM terminal 2 and IPDM E/R terminal 28. Refer to Wiring Diagram. Continuity should exist. 4. Also check harness for short to ground and short to power. OK or NG OK >> GO TO 9. NG >> GO TO 8. 8. DETECT MALFUNCTIONING PART Check the following. ● Harness connectors E59, F1 ● Harness for open or short between ECM and IPDM E/R >> Repair open circuit or short to ground or short to power in harness or connectors. 9. CHECK INTERMITTENT INCIDENT Refer to EC-917, "TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT" . OK or NG OK >> Replace IPDM E/R. Refer to PG-18, "IPDM E/R (INTELLIGENT POWER DISTRIBUTION MODULE ENGINE ROOM)" . NG >> Repair or replace harness or connectors. 10. CHECK THROTTLE CONTROL MOTOR OUTPUT SIGNAL CIRCUIT FOR OPEN OR SHORT 1. 2. Turn ignition switch OFF. Disconnect electric throttle control actuator (1) harness connector. – : Vehicle front Disconnect ECM harness connector. Check harness continuity between the following terminals. Refer to Wiring Diagram. 3. 4. Electric throttle control actuator terminal 5 6 ECM terminal Continuity 1 Should not exist 4 Should exist 1 Should exist 4 Should not exist PBIB2965E 5. Also check harness for short to ground and short to power. OK or NG OK >> GO TO 11. NG >> Repair or replace. EC-1088 DTC P1122 ELECTRIC THROTTLE CONTROL FUNCTION [HR (WITH EURO-OBD)] 11. CHECK ELECTRIC THROTTLE CONTROL ACTUATOR VISUALLY 1. 2. A Remove the intake air duct. Check if foreign matter is caught between the throttle valve (1) and the housing. EC : Vehicle front – Illustration shows the view with intake air duct removed. OK or NG OK >> GO TO 12. NG >> Remove the foreign matter and clean the electric throttle control actuator inside. – C D PBIB2974E E 12. CHECK THROTTLE CONTROL MOTOR Refer to EC-1089, "Component Inspection" . OK or NG OK >> GO TO 13. NG >> GO TO 14. F G 13. CHECK INTERMITTENT INCIDENT H Refer to EC-917, "TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT" . OK or NG OK >> GO TO 14. NG >> Repair or replace harness or connectors. I 14. REPLACE ELECTRIC THROTTLE CONTROL ACTUATOR 1. 2. 3. J Replace the electric throttle control actuator. Perform EC-857, "Throttle Valve Closed Position Learning" . Perform EC-858, "Idle Air Volume Learning" . K >> INSPECTION END Component Inspection BBS004FG L THROTTLE CONTROL MOTOR 1. 2. Disconnect electric throttle control actuator harness connector. Check resistance between terminals 5 and 6. M Resistance: Approximately 1 - 15 Ω [at 25 °C (77°F)] 3. 4. 5. If NG, replace electric throttle control actuator and go to next step. Perform EC-857, "Throttle Valve Closed Position Learning" . Perform EC-858, "Idle Air Volume Learning" . PBIB2909E Removal and Installation BBS004FH ELECTRIC THROTTLE CONTROL ACTUATOR Refer to EM-120, "INTAKE MANIFOLD" . EC-1089 DTC P1124, P1126 THROTTLE CONTROL MOTOR RELAY [HR (WITH EURO-OBD)] DTC P1124, P1126 THROTTLE CONTROL MOTOR RELAY Component Description PFP:16119 BBS004FI Power supply for the throttle control motor is provided to the ECM via throttle control motor relay. The throttle control motor relay is ON/OFF controlled by the ECM. When the ignition switch is turned ON, the ECM sends an ON signal to throttle control motor relay and battery voltage is provided to the ECM. When the ignition switch is turned OFF, the ECM sends an OFF signal to throttle control motor relay and battery voltage is not provided to the ECM. CONSULT-II Reference Value in Data Monitor Mode BBS004FJ Specification data are reference values. MONITOR ITEM THRTL RELAY CONDITION ● SPECIFICATION Ignition switch: ON ON On Board Diagnosis Logic BBS004FK These self-diagnoses have the one trip detection logic. DTC No. P1124 1124 P1126 1126 Trouble diagnosis name Throttle control motor relay circuit short Throttle control motor relay circuit open DTC detecting condition Possible cause ● Harness or connectors (Throttle control motor relay circuit is shorted) ● Throttle control motor relay ● Harness or connectors (Throttle control motor relay circuit is open) ● Throttle control motor relay ECM detect the throttle control motor relay is stuck ON. ECM detects a voltage of power source for throttle control motor is excessively low. FAIL-SAFE MODE When the malfunction is detected, ECM enters fail-safe mode and the MI lights up. Engine operating condition in fail-safe mode ECM stops the electric throttle control actuator control, throttle valve is maintained at a fixed opening (approx. 5 degrees) by the return spring. DTC Confirmation Procedure BBS004FL NOTE: If DTC Confirmation Procedure has been previously conducted, always turn ignition switch OFF and wait at least 10 seconds before conducting the next test. PROCEDURE FOR DTC P1124 With CONSULT-II 1. 2. 3. Turn ignition switch ON and wait at least 1 seconds. Select “DATA MONITOR” mode with CONSULT-II. If DTC is detected, go to EC-1093, "Diagnostic Procedure" . SEF058Y With GST Follow the procedure “With CONSULT-II” above. EC-1090 DTC P1124, P1126 THROTTLE CONTROL MOTOR RELAY [HR (WITH EURO-OBD)] PROCEDURE FOR DTC P1126 A TESTING CONDITION: Before performing the following procedure, confirm that battery voltage is more than 8V. With CONSULT-II 1. 2. 3. 4. EC Turn ignition switch ON and wait at least 2 second. Select “DATA MONITOR” mode with CONSULT-II. Start engine and let it idle for 5 seconds. If DTC is detected, go to EC-1093, "Diagnostic Procedure" . C D E SEF058Y With GST F Follow the procedure “With CONSULT-II” above. G H I J K L M EC-1091 DTC P1124, P1126 THROTTLE CONTROL MOTOR RELAY [HR (WITH EURO-OBD)] Wiring Diagram BBS004FM MBWA1473E EC-1092 DTC P1124, P1126 THROTTLE CONTROL MOTOR RELAY [HR (WITH EURO-OBD)] Specification data are reference values and are measured between each terminal and ground. Pulse signal is measured by CONSULT-II. A CAUTION: Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM's transistor. Use a ground other than ECM terminals, such as the ground. EC TERMINAL NO. WIRE COLOR ITEM CONDITION DATA (DC Voltage) C 0 - 14V [Ignition switch: ON] 1 P Throttle control motor (Open) ● Engine stopped ● Shift lever: D (A/T), 1st (M/T) ● Accelerator pedal: Fully depressed D E PBIB1105E 2 LG Throttle control motor relay power supply [Ignition switch: ON] BATTERY VOLTAGE (11 - 14V) F 0 - 14V [Ignition switch: ON] 4 L Throttle control motor (Close) ● Engine stopped ● Shift lever: D (A/T), 1st (M/T) ● Accelerator pedal: Released G H PBIB1104E 15 G Throttle control motor relay [Ignition switch: OFF] BATTERY VOLTAGE (11 - 14V) [Ignition switch: ON] 0 - 1.0V I : Average voltage for pulse signal (Actual pulse signal can be confirmed by oscilloscope.) Diagnostic Procedure J BBS004FN 1. CHECK THROTTLE CONTROL MOTOR RELAY POWER SUPPLY CIRCUIT-I 1. 2. K Turn ignition switch OFF. Check voltage between ECM terminal 15 and ground with CONSULT-II or tester. L Voltage: Battery voltage OK or NG OK >> GO TO 5. NG >> GO TO 2. M PBIA9569J EC-1093 DTC P1124, P1126 THROTTLE CONTROL MOTOR RELAY [HR (WITH EURO-OBD)] 2. CHECK THROTTLE CONTROL MOTOR RELAY POWER SUPPLY CIRCUIT-II 1. 2. 3. Disconnect ECM harness connector. Disconnect IPDM E/R harness connector E5. Check continuity between ECM terminal 15 and IPDM E/R terminal 70. Refer to Wiring Diagram. Continuity should exist. 4. Also check harness for short to ground and short to power. OK or NG OK >> GO TO 4. NG >> GO TO 3. 3. DETECT MALFUNCTIONING PART Check the following. ● Harness connectors E59, F1 ● Harness for open or short between ECM and IPDM E/R >> Repair open circuit or short to ground or short to power in harness or connectors. 4. CHECK FUSE 1. Disconnect 20A fuse. 2. Check 20A fuse for blown. OK or NG OK >> GO TO 8. NG >> Replace 20A fuse. 5. CHECK THROTTLE CONTROL MOTOR RELAY INPUT SIGNAL CIRCUIT-I 1. Check voltage between ECM terminal 2 and ground under the following conditions with CONSULT-II or tester. Ignition switch Voltage OFF Approximately 0V ON Battery voltage (11 - 14V) OK or NG OK >> GO TO 8. NG >> GO TO 6. PBIA9568J 6. CHECK THROTTLE CONTROL MOTOR RELAY INPUT SIGNAL CIRCUIT-II 1. 2. 3. 4. Turn ignition switch OFF. Disconnect ECM harness connector. Disconnect IPDM E/R harness connector E7. Check continuity between ECM terminal 2 and IPDM E/R terminal 28. Refer to Wiring Diagram. Continuity should exist. 5. Also check harness for short to ground and short to power. OK or NG OK >> GO TO 8. NG >> GO TO 7. EC-1094 DTC P1124, P1126 THROTTLE CONTROL MOTOR RELAY [HR (WITH EURO-OBD)] 7. DETECT MALFUNCTIONING PART A Check the following. ● Harness connectors E59, F1 ● Harness for open or short between ECM and IPDM E/R >> Repair open circuit or short to ground or short to power in harness or connectors. EC C 8. CHECK INTERMITTENT INCIDENT Refer to EC-917, "TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT" . OK or NG OK >> Replace IPDM E/R. Refer to PG-18, "IPDM E/R (INTELLIGENT POWER DISTRIBUTION MODULE ENGINE ROOM)" . NG >> Repair or replace harness or connectors. D E F G H I J K L M EC-1095 DTC P1128 THROTTLE CONTROL MOTOR [HR (WITH EURO-OBD)] DTC P1128 THROTTLE CONTROL MOTOR Component Description PFP:16119 BBS004FO The throttle control motor is operated by the ECM and it opens and closes the throttle valve. The current opening angle of the throttle valve is detected by the throttle position sensor and it provides feedback to the ECM to control the throttle control motor to make the throttle valve opening angle properly in response to driving condition. On Board Diagnosis Logic BBS004FP This self-diagnosis has the one trip detection logic. DTC No. P1128 1128 Trouble diagnosis name Throttle control motor circuit short DTC detecting condition ECM detects short in both circuits between ECM and throttle control motor. Possible cause ● Harness or connectors (Throttle control motor circuit is shorted.) ● Electric throttle control actuator (Throttle control motor) FAIL-SAFE MODE When the malfunction is detected, ECM enters fail-safe mode and the MI lights up. Engine operating condition in fail-safe mode ECM stops the electric throttle control actuator control, throttle valve is maintained at a fixed opening (approx. 5 degrees) by the return spring. DTC Confirmation Procedure BBS004FQ NOTE: If DTC Confirmation Procedure has been previously conducted, always turn ignition switch OFF and wait at least 10 seconds before conducting the next test. WITH CONSULT-II 1. 2. 3. 4. Turn ignition switch ON and wait at least 2 seconds. Select “DATA MONITOR” mode with CONSULT-II. Start engine and let it idle for 5 seconds. If DTC is detected, go to EC-1098, "Diagnostic Procedure" . SEF058Y WITH GST Follow the procedure “WITH CONSULT-II” above. EC-1096 DTC P1128 THROTTLE CONTROL MOTOR [HR (WITH EURO-OBD)] Wiring Diagram BBS004FR A EC C D E F G H I J K L M MBWA1474E EC-1097 DTC P1128 THROTTLE CONTROL MOTOR [HR (WITH EURO-OBD)] Specification data are reference values and are measured between each terminal and ground. Pulse signal is measured by CONSULT-II. CAUTION: Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM's transistor. Use a ground other than ECM terminals, such as the ground. TERMINAL NO. WIRE COLOR ITEM CONDITION DATA (DC Voltage) 0 - 14V [Ignition switch: ON] 1 P Throttle control motor (Open) ● Engine stopped ● Shift lever: D (A/T), 1st (M/T) ● Accelerator pedal: Fully depressed PBIB1105E 2 LG Throttle control motor relay power supply BATTERY VOLTAGE (11 - 14V) [Ignition switch: ON] 0 - 14V [Ignition switch: ON] 4 L Throttle control motor (Close) ● Engine stopped ● Shift lever: D (A/T), 1st (M/T) ● Accelerator pedal: Released PBIB1104E 15 G Throttle control motor relay [Ignition switch: OFF] BATTERY VOLTAGE (11 - 14V) [Ignition switch: ON] 0 - 1.0V : Average voltage for pulse signal (Actual pulse signal can be confirmed by oscilloscope.) Diagnostic Procedure BBS004FS 1. CHECK GROUND CONNECTIONS 1. 2. Turn ignition switch OFF. Loosen and retighten ground screws on the body. Refer to EC-924, "Ground Inspection" . MBIB1550E 1. IPDM E/R 2. Body ground OK or NG OK >> GO TO 2. NG >> Repair or replace ground connections. EC-1098 3. Body ground DTC P1128 THROTTLE CONTROL MOTOR [HR (WITH EURO-OBD)] 2. CHECK THROTTLE CONTROL MOTOR OUTPUT SIGNAL CIRCUIT FOR OPEN AND SHORT 1. Disconnect electric throttle control actuator (1) harness connector. – : Vehicle front Disconnect ECM harness connector. Check harness continuity between the following terminals. Refer to Wiring Diagram. 2. 3. Electric throttle control actuator terminal 5 6 ECM terminal A EC C Continuity D 1 Should not exist 4 Should exist 1 Should exist 4 Should not exist PBIB2965E 4. Also check harness for short to ground and short to power. OK or NG OK >> GO TO 3. NG >> Repair or replace. E F G 3. CHECK THROTTLE CONTROL MOTOR Refer to EC-1100, "Component Inspection" . OK or NG OK >> GO TO 4. NG >> GO TO 5. H I 4. CHECK INTERMITTENT INCIDENT Refer to EC-917, "TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT" . OK or NG OK >> GO TO 5. NG >> Repair or replace harness or connectors. J K 5. REPLACE ELECTRIC THROTTLE CONTROL ACTUATOR L 1. 2. 3. Replace the electric throttle control actuator. Perform EC-857, "Throttle Valve Closed Position Learning" . Perform EC-858, "Idle Air Volume Learning" . >> INSPECTION END EC-1099 M DTC P1128 THROTTLE CONTROL MOTOR [HR (WITH EURO-OBD)] Component Inspection BBS004FT THROTTLE CONTROL MOTOR 1. 2. Disconnect electric throttle control actuator harness connector. Check resistance between terminals 5 and 6. Resistance: Approximately 1 - 15 Ω [at 25 °C (77°F)] 3. 4. 5. If NG, replace electric throttle control actuator and go to next step. Perform EC-857, "Throttle Valve Closed Position Learning" . Perform EC-858, "Idle Air Volume Learning" . PBIB2909E Removal and Installation BBS004FU ELECTRIC THROTTLE CONTROL ACTUATOR Refer to EM-120, "INTAKE MANIFOLD" . EC-1100 DTC P1143 HO2S1 [HR (WITH EURO-OBD)] DTC P1143 HO2S1 Component Description PFP:22690 A BBS004FV The heated oxygen sensor 1 is placed into the exhaust manifold. It detects the amount of oxygen in the exhaust gas compared to the outside air. The heated oxygen sensor 1 has a closed-end tube made of ceramic zirconia. The zirconia generates voltage from approximately 1V in richer conditions to 0V in leaner conditions. The heated oxygen sensor 1 signal is sent to the ECM. The ECM adjusts the injection pulse duration to achieve the ideal air-fuel ratio. The ideal air-fuel ratio occurs near the radical change from 1V to 0V. EC C D SEF463R E F G H SEF288D CONSULT-II Reference Value in Data Monitor Mode BBS004FW I Specification data are reference values. MONITOR ITEM CONDITION SPECIFICATION J 0 - 0.3V ←→ Approx. 0.6 - 1.0V HO2S1 (B1) ● HO2S1 MNTR (B1) Engine: After warming up Maintaining engine speed at 2,000 rpm LEAN ←→ RICH Changes more than 5 times during 10 seconds. On Board Diagnosis Logic BBS004FX L To judge the malfunction, the output from the heated oxygen sensor 1 is monitored to determine whether the “rich” output is sufficiently high and whether the “lean” output is sufficiently low. When both the outputs are shifting to the lean side, the malfunction will be detected. M SEF300U DTC No. P1143 1143 Trouble diagnosis name Heated oxygen sensor 1 lean shift monitoring K DTC detecting condition The maximum and minimum voltage from the sensor are not reached to the specified voltages. EC-1101 Possible cause ● Heated oxygen sensor 1 ● Heated oxygen sensor 1 heater ● Fuel pressure ● Fuel injector ● Intake air leaks DTC P1143 HO2S1 [HR (WITH EURO-OBD)] DTC Confirmation Procedure BBS004FY CAUTION: Always drive vehicle at a safe speed. NOTE: If DTC Confirmation Procedure has been previously conducted, always turn ignition switch OFF and wait at least 10 seconds before conducting the next test. TESTING CONDITION: ● Always perform at a temperature above −10°C (14°F). ● Before performing following procedure, confirm that battery voltage is more than 11V at idle. WITH CONSULT-II 1. 2. 3. 4. 5. Start engine and warm it up to normal operating temperature. Stop engine and wait at least 10 seconds. Turn ignition switch ON and select “HO2S1 (B1) P1143” of “HO2S1” in “DTC WORK SUPPORT” mode with CONSULT-II. Touch “START”. Start engine and let it idle for at least 3 minutes. NOTE: Never raise engine speed above 3,600 rpm after this step. If the engine speed limit is exceeded, return to step 5. PBIB0546E 6. When the following conditions are met, “TESTING” will be displayed on the CONSULT-II screen. Maintain the conditions continuously until “TESTING” changes to “COMPLETED”. (It will take approximately 50 seconds or more.) ENG SPEED A/T: 1,300 - 2,800 rpm M/T: 1,500 - 3,600 rpm VHCL SPEED SE Less than 100 km/h (62 MPH) B/FUEL SCHDL A/T: 2.8 - 11.2 msec M/T: 2.0 - 11.2 msec Shift lever Suitable position 7. PBIB0547E If “TESTING” is not displayed after 5 minutes, retry from step 2. Make sure that “OK” is displayed after touching “SELF-DIAG RESULTS”. If “NG” is displayed, refer to EC-1103, "Diagnostic Procedure" . SEC769C EC-1102 DTC P1143 HO2S1 [HR (WITH EURO-OBD)] Overall Function Check BBS004FZ Use this procedure to check the overall function of the heated oxygen sensor 1 circuit. During this check, a 1st trip DTC might not be confirmed. WITH GST 1. 2. 3. ● ● 4. A EC Start engine and warm it up to normal operating temperature. Set voltmeter probes between ECM terminal 49 (HO2S1 signal) and ground. Check one of the following with engine speed held at 2,000 rpm constant under no load. The maximum voltage is over 0.6V at least 1 time. The minimum voltage is over 0.1V at least 1 time. If NG, go to EC-1103, "Diagnostic Procedure" . C D E PBIA9566J Diagnostic Procedure BBS004G0 1. CHECK GROUND CONNECTIONS 1. 2. F G Turn ignition switch OFF. Loosen and retighten ground screws on the body. Refer to EC-924, "Ground Inspection" . H I J K MBIB1550E 1. IPDM E/R 2. Body ground 3. Body ground L OK or NG OK >> GO TO 2. NG >> Repair or replace ground connections. M 2. RETIGHTEN HEATED OXYGEN SENSOR 1 Loosen and retighten heated oxygen sensor 1 (1). ● ● : Vehicle front Exhaust manifold (2) Tightening torque: 50 N·m (5.1 kg-m, 37 ft-lb) >> GO TO 3. PBIB2966E EC-1103 DTC P1143 HO2S1 [HR (WITH EURO-OBD)] 3. CLEAR THE SELF-LEARNING DATA 1. 2. 3. 4. With CONSULT-II Start engine and warm it up to normal operating temperature. Select “SELF-LEARNING CONT” in “WORK SUPPORT” mode with CONSULT-II. Clear the self-learning control coefficient by touching “CLEAR”. Run engine for at least 10 minutes at idle speed. Is the 1st trip DTC P0171 detected? Is it difficult to start engine? SEF215Z Without CONSULT-II Start engine and warm it up to normal operating temperature. Turn ignition switch OFF. Disconnect mass air flow sensor (1) harness connector, and restart and run engine for at least 5 seconds at idle speed. 4. Stop engine and reconnect mass air flow sensor harness connector. 5. Make sure that DTC P0102 is displayed. 6. Erase the DTC memory. Refer to EC-841, "HOW TO ERASE EMISSION-RELATED DIAGNOSTIC INFORMATION" . 7. Make sure that DTC P0000 is displayed. 8. Run engine for at least 10 minutes at idle speed. Is the 1st trip DTC P0171 detected? PBIB2948E Is it difficult to start engine? Yes or No Yes >> Perform trouble diagnosis for DTC P0171. Refer to EC-1012, "DTC P0171 FUEL INJECTION SYSTEM FUNCTION" . No >> GO TO 4. 1. 2. 3. 4. CHECK HEATED OXYGEN SENSOR 1 HEATER Refer to EC-990, "Component Inspection" . OK or NG OK >> GO TO 5. NG >> Replace heated oxygen sensor 1. 5. CHECK HEATED OXYGEN SENSOR 1 Refer to EC-975, "Component Inspection" . OK or NG OK >> GO TO 6. NG >> Replace heated oxygen sensor 1. 6. CHECK INTERMITTENT INCIDENT Refer to EC-917, "TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT" . For circuit, refer to EC-970, "Wiring Diagram" . >> INSPECTION END EC-1104 DTC P1143 HO2S1 [HR (WITH EURO-OBD)] Component Inspection BBS004G1 A HEATED OXYGEN SENSOR 1 With CONSULT-II 1. 2. 3. 4. 5. Start engine and warm it up to normal operating temperature. Select “MANU TRIG” and adjust “TRIGGER POINT” to 100% in “DATA MONITOR” mode with CONSULT- EC II. Select “HO2S1 (B1)” and “HO2S1 MNTR (B1)”. C Hold engine speed at 2,000 rpm under no load during the following steps. Touch “RECORD” on CONSULT-II screen. D E SEF646Y F 6. Check the following. ● “HO2S1 MNTR (B1)” in “DATA MONITOR” mode changes from “RICH” to “LEAN” to “RICH” more than 5 times in 10 seconds. 5 times (cycles) are counted as shown in the figure. ● “HO2S1 (B1)” voltage goes above 0.6V at least once. ● “HO2S1 (B1)” voltage goes below 0.3V at least once. ● “HO2S1 (B1)” voltage never exceeds 1.0V. G H I SEF217YA J K L SEF648Y CAUTION: ● Discard any heated oxygen sensor which has been dropped from a height of more than 0.5 m (19.7 in) onto a hard surface such as a concrete floor; use a new one. ● Before installing new oxygen sensor, clean exhaust system threads using Oxygen Sensor Thread Cleaner tool and approved anti-seize lubricant. Without CONSULT-II 1. 2. Start engine and warm it up to normal operating temperature. Set voltmeter probes between ECM terminal 49 (HO2S1 signal) and ground. EC-1105 M DTC P1143 HO2S1 [HR (WITH EURO-OBD)] 3. Check the following with engine speed held at 2,000 rpm constant under no load. ● The voltage fluctuates between 0 to 0.3V and 0.6 to 1.0V more than 5 times within 10 seconds. ● The maximum voltage is over 0.6V at least 1 time. ● The minimum voltage is below 0.3V at least 1 time. ● The voltage never exceeds 1.0V. 1 time: 0 - 0.3V → 0.6 - 1.0V → 0 - 0.3V 2 times: 0 - 0.3V → 0.6 - 1.0V → 0 - 0.3V → 0.6 - 1.0V → 0 - 0.3V PBIA9566J CAUTION: ● Discard any heated oxygen sensor which has been dropped from a height of more than 0.5 m (19.7 in) onto a hard surface such as a concrete floor; use a new one. ● Before installing new oxygen sensor, clean exhaust system threads using Oxygen Sensor Thread Cleaner tool and approved anti-seize lubricant. Removal and Installation BBS004G2 HEATED OXYGEN SENSOR 1 Refer to EM-124, "EXHAUST MANIFOLD" . EC-1106 DTC P1144 HO2S1 [HR (WITH EURO-OBD)] DTC P1144 HO2S1 Component Description PFP:22690 A BBS004G3 The heated oxygen sensor 1 is placed into the exhaust manifold. It detects the amount of oxygen in the exhaust gas compared to the outside air. The heated oxygen sensor 1 has a closed-end tube made of ceramic zirconia. The zirconia generates voltage from approximately 1V in richer conditions to 0V in leaner conditions. The heated oxygen sensor 1 signal is sent to the ECM. The ECM adjusts the injection pulse duration to achieve the ideal air-fuel ratio. The ideal air-fuel ratio occurs near the radical change from 1V to 0V. EC C D SEF463R E F G H SEF288D CONSULT-II Reference Value in Data Monitor Mode BBS004G4 I Specification data are reference values. MONITOR ITEM CONDITION SPECIFICATION J 0 - 0.3V ←→ Approx. 0.6 - 1.0V HO2S1 (B1) ● HO2S1 MNTR (B1) Engine: After warming up Maintaining engine speed at 2,000 rpm LEAN ←→ RICH Changes more than 5 times during 10 seconds. On Board Diagnosis Logic BBS004G5 L To judge the malfunction, the output from the heated oxygen sensor 1 is monitored to determine whether the “rich” output is sufficiently high and “lean” output is sufficiently low. When both the outputs are shifting to the rich side, the malfunction will be detected. M SEF299U DTC No. P1144 1144 K Trouble diagnosis name DTC detecting condition Heated oxygen sensor 1 rich shift monitoring The maximum and minimum voltages from the sensor are beyond the specified voltages. EC-1107 Possible cause ● Heated oxygen sensor 1 ● Heated oxygen sensor 1 heater ● Fuel pressure ● Fuel injector DTC P1144 HO2S1 [HR (WITH EURO-OBD)] DTC Confirmation Procedure BBS004G6 CAUTION: Always drive vehicle at a safe speed. NOTE: If DTC Confirmation Procedure has been previously conducted, always turn ignition switch OFF and wait at least 10 seconds before conducting the next test. TESTING CONDITION: ● Always perform at a temperature above −10°C (14°F). ● Before performing the following procedure, confirm that battery voltage is more than 11V at idle. WITH CONSULT-II 1. 2. 3. 4. 5. Start engine and warm it up to normal operating temperature. Stop engine and wait at least 5 seconds. Turn ignition switch ON and select “HO2S1 (B1) P1144” of “HO2S1” in “DTC WORK SUPPORT” mode with CONSULT-II. Touch “START”. Start engine and let it idle for at least 3 minutes. NOTE: Never raise engine speed above 3,600 rpm after this step. If the engine speed limit is exceeded, return to step 5. PBIB0548E 6. When the following conditions are met, “TESTING” will be displayed on the CONSULT-II screen. Maintain the conditions continuously until “TESTING” changes to “COMPLETED”. (It will take approximately 50 seconds or more.) ENG SPEED A/T: 1,300 - 2,800 rpm M/T: 1,500 - 3,600 rpm VHCL SPEED SE Less than 100 km/h (62 MPH) B/FUEL SCHDL A/T: 2.8 - 11.2 msec M/T: 2.0 - 11.2 msec Shift lever Suitable position 7. PBIB0549E If “TESTING” is not displayed after 5 minutes, retry from step 2. Make sure that “OK” is displayed after touching “SELF-DIAG RESULTS”. If “NG” is displayed, refer to EC-1109, "Diagnostic Procedure" . SEC772C EC-1108 DTC P1144 HO2S1 [HR (WITH EURO-OBD)] Overall Function Check BBS004G7 Use this procedure to check the overall function of the heated oxygen sensor 1 circuit. During this check, a 1st trip DTC might not be confirmed. WITH GST 1. 2. 3. ● ● 4. A EC Start engine and warm it up to normal operating temperature. Set voltmeter probes between ECM terminal 49 (HO2S1 signal) and ground. Check one of the following with engine speed held at 2,000 rpm constant under no load. The maximum voltage is below 0.8V at least 1 time. The minimum voltage is below 0.35V at least 1 time. If NG, go to EC-1109, "Diagnostic Procedure" . C D E PBIA9566J Diagnostic Procedure BBS004G8 1. CHECK GROUND CONNECTIONS 1. 2. F G Turn ignition switch OFF. Loosen and retighten ground screws on the body. Refer to EC-924, "Ground Inspection" . H I J K MBIB1550E 1. IPDM E/R 2. Body ground 3. Body ground L OK or NG OK >> GO TO 2. NG >> Repair or replace ground connections. M 2. RETIGHTEN HEATED OXYGEN SENSOR 1 Loosen and retighten heated oxygen sensor 1 (1). ● ● : Vehicle front Exhaust manifold (2) Tightening torque: 50 N·m (5.1 kg-m, 37 ft-lb) >> GO TO 3. PBIB2966E EC-1109 DTC P1144 HO2S1 [HR (WITH EURO-OBD)] 3. CLEAR THE SELF-LEARNING DATA 1. 2. 3. 4. With CONSULT-II Start engine and warm it up to normal operating temperature. Select “SELF-LEARNING CONT” in “WORK SUPPORT” mode with CONSULT-II. Clear the self-learning control coefficient by touching “CLEAR”. Run engine for at least 10 minutes at idle speed. Is the 1st trip DTC P0172 detected? Is it difficult to start engine? SEF215Z Without CONSULT-II Start engine and warm it up to normal operating temperature. Turn ignition switch OFF. Disconnect mass air flow sensor (1) harness connector, and restart and run engine for at least 5 seconds at idle speed. 4. Stop engine and reconnect mass air flow sensor harness connector. 5. Make sure that DTC P0102 is displayed. 6. Erase the DTC memory. Refer to EC-841, "HOW TO ERASE EMISSION-RELATED DIAGNOSTIC INFORMATION" . 7. Make sure that DTC P0000 is displayed. 8. Run engine for at least 10 minutes at idle speed. Is the 1st trip DTC P0172 detected? PBIB2948E Is it difficult to start engine? Yes or No Yes >> Perform trouble diagnosis for DTC P0172. Refer to EC-1019, "DTC P0172 FUEL INJECTION SYSTEM FUNCTION" . No >> GO TO 4. 1. 2. 3. 4. CHECK HO2S1 CONNECTOR FOR WATER 1. 2. Turn ignition switch OFF. Disconnect heated oxygen sensor 1 harness connector (1). – : Vehicle front Check connectors for water. 3. Water should not exist. OK or NG OK >> GO TO 5. NG >> Repair or replace harness or connectors. PBIB2967E EC-1110 DTC P1144 HO2S1 [HR (WITH EURO-OBD)] 5. CHECK HEATED OXYGEN SENSOR 1 HEATER A Refer to EC-990, "Component Inspection" . OK or NG OK >> GO TO 6. NG >> Replace heated oxygen sensor 1. EC 6. CHECK HEATED OXYGEN SENSOR 1 C Refer to EC-975, "Component Inspection" . OK or NG OK >> GO TO 7. NG >> Replace heated oxygen sensor 1. D 7. CHECK INTERMITTENT INCIDENT E Refer to EC-917, "TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT" . For circuit, refer to EC-970, "Wiring Diagram" . F >> INSPECTION END Component Inspection BBS004G9 HEATED OXYGEN SENSOR 1 With CONSULT-II 1. 2. 3. 4. 5. Start engine and warm it up to normal operating temperature. Select “MANU TRIG” and adjust “TRIGGER POINT” to 100% in “DATA MONITOR” mode with CONSULTII. Select “HO2S1 (B1)” and “HO2S1 MNTR (B1)”. Hold engine speed at 2,000 rpm under no load during the following steps. Touch “RECORD” on CONSULT-II screen. G H I J K L SEF646Y 6. Check the following. ● “HO2S1 MNTR (B1)” in “DATA MONITOR” mode changes from “RICH” to “LEAN” to “RICH” more than 5 times in 10 seconds. 5 times (cycles) are counted as shown in the figure. ● “HO2S1 (B1)” voltage goes above 0.6V at least once. ● “HO2S1 (B1)” voltage goes below 0.3V at least once. ● “HO2S1 (B1)” voltage never exceeds 1.0V. M SEF217YA EC-1111 DTC P1144 HO2S1 [HR (WITH EURO-OBD)] SEF648Y CAUTION: ● Discard any heated oxygen sensor which has been dropped from a height of more than 0.5 m (19.7 in) onto a hard surface such as a concrete floor; use a new one. ● Before installing new oxygen sensor, clean exhaust system threads using Oxygen Sensor Thread Cleaner tool and approved anti-seize lubricant. Without CONSULT-II 1. 2. 3. Start engine and warm it up to normal operating temperature. Set voltmeter probes between ECM terminal 49 (HO2S1 signal) and ground. Check the following with engine speed held at 2,000 rpm constant under no load. ● The voltage fluctuates between 0 to 0.3V and 0.6 to 1.0V more than 5 times within 10 seconds. ● The maximum voltage is over 0.6V at least 1 time. ● The minimum voltage is below 0.3V at least 1 time. ● The voltage never exceeds 1.0V. 1 time: 0 - 0.3V → 0.6 - 1.0V → 0 - 0.3V 2 times: 0 - 0.3V → 0.6 - 1.0V → 0 - 0.3V → 0.6 - 1.0V → 0 - 0.3V PBIA9566J CAUTION: ● Discard any heated oxygen sensor which has been dropped from a height of more than 0.5 m (19.7 in) onto a hard surface such as a concrete floor; use a new one. ● Before installing new oxygen sensor, clean exhaust system threads using Oxygen Sensor Thread Cleaner tool and approved anti-seize lubricant. Removal and Installation BBS004GA HEATED OXYGEN SENSOR 1 Refer to EM-124, "EXHAUST MANIFOLD" . EC-1112 DTC P1146 HO2S2 [HR (WITH EURO-OBD)] DTC P1146 HO2S2 Component Description PFP:226A0 A BBS004GB The heated oxygen sensor 2, after three way catalyst (manifold), monitors the oxygen level in the exhaust gas. Even if switching characteristics of the heated oxygen sensor 1 are shifted, the air-fuel ratio is controlled to stoichiometric, by the signal from the heated oxygen sensor 2. This sensor is made of ceramic zirconia. The zirconia generates voltage from approximately 1V in richer conditions to 0V in leaner conditions. Under normal conditions the heated oxygen sensor 2 is not used for engine control operation. EC C D SEF327R E CONSULT-II Reference Value in Data Monitor Mode BBS004GC Specification data are reference values. MONITOR ITEM HO2S2 (B1) HO2S2 MNTR (B1) F CONDITION SPECIFICATION ● Revving engine from idle to 3,000 rpm quickly after the following conditions are met. 0 - 0.3V ←→ Approx. 0.6 - 1.0V – Engine: After warming up – Keep the engine speed between 3,500 rpm and 4,000 rpm for 1 minute and idle for 1 minute under no load G LEAN ←→ RICH H On Board Diagnosis Logic BBS004GD The heated oxygen sensor 2 has a much longer switching time between rich and lean than the heated oxygen sensor 1. The oxygen storage capacity of the three way catalyst (manifold) causes the longer switching time. To judge the malfunctions of heated oxygen sensor 2, ECM monitors whether the minimum voltage of sensor is sufficiently low during the various driving condition such as fuel-cut. I J K PBIB0554E L DTC No. P1146 1146 Trouble diagnosis name Heated oxygen sensor 2 minimum voltage monitoring DTC detecting condition The minimum voltage from the sensor is not reached to the specified voltage. EC-1113 Possible cause ● Harness or connectors (The sensor circuit is open or shorted.) ● Heated oxygen sensor 2 ● Fuel pressure ● Fuel injector M DTC P1146 HO2S2 [HR (WITH EURO-OBD)] DTC Confirmation Procedure BBS004GE CAUTION: Always drive vehicle at a safe speed. NOTE: ● “COMPLETED” will appear on CONSULT-II screen when all tests “COND1”, “COND2” and “COND3” are completed. ● If DTC confirmation Procedure has been previously conducted, always turn ignition switch OFF and wait at least 10 seconds before conducting the next test. TESTING CONDITION: Never stop engine during this procedure. If the engine is stopped, retry procedure from step 2 in Procedure for COND1 WITH CONSULT-II Procedure for COND1 For the best results, perform “DTC WORK SUPPORT” at a temperature of 0 to 30°C(32 to 86°F). 1. Start engine and warm it up to normal operating temperature. 2. Turn ignition switch OFF and wait at least 10 seconds. 3. Start engine and keep the engine speed between 3,500 and 4,000 rpm for at least 1 minute under no load. 4. Let engine idle 1 minute. 5. Select “HO2S2 (B1) P1146” of “HO2S2” in “DTC WORK SUPPORT” mode with CONSULT-II. 6. Touch “START”. 7. Start engine and let it idle for at least 30 seconds. 8. Rev engine up to 2,000 rpm two or three times quickly under no load. If “COMPLETED” appears on CONSULT-II screen, go to step 2 in Procedure for COND3”. If “COMPLETED” does not appear on CONSULT-II screen, go to the following step. 9. When the following conditions are met, “TESTING” will be displayed at “COND1” on the CONSULT-II screen. Maintain the conditions continuously until “TESTING” changes to “COMPLETED”. (It will take approximately 60 seconds.) ENG SPEED 1,000 - 3,600 rpm B/FUEL SCHDL More than 1.0 msec COOLAN TEMP/S 70 - 119°C (158 - 246°F) Shift lever Suitable position PBIB0555E NOTE: If “TESTING” is not displayed after 5 minutes, retry from step 2 in Procedure for COND1. ● If “COMPLETED” already appears at “COND2” on CONSULT-II screen before Procedure for COND2 is conducted, it is unnecessary to conduct step 1 in Procedure for COND2. ● EC-1114 DTC P1146 HO2S2 [HR (WITH EURO-OBD)] Procedure for COND2 1. A While driving, release accelerator pedal completed with “OD” OFF (A/T) from the above condition [step 9] until “INCOMPLETE” at “COND2” on CONSULT-II screen has turned to “COMPLETED” (It will take approximately 4 seconds.) NOTE: If “COMPLETE” already appears at “COND3” on CONSULTII screen before Procedure for COND3 is conducted, it is unnecessary to conduct step 1 in Procedure for COND3. EC C PBIB0556E D Procedure for COND3 1. 2. a. b. c. d. Stop vehicle and let it idle until “INCOMPLETE” of “COND3” on CONSULT-II screen has turned to “COMPLETED”. (It will take a maximum of approximately 6 minutes.) Make sure that “OK” is displayed after touching “SELF-DIAG RESULTS”. If “NG” is displayed, refer to EC-1117, "Diagnostic Procedure" . If “CAN NOT BE DIAGNOSED” is displayed, performed the following. Turn ignition switch OFF and leave the vehicle in a cool place (soak the vehicle). SEC775C Turn ignition switch ON and select “COOLAN TEMP/S” in “DATA MONITOR” mode with CONSULT-II. Start engine and warm it up while monitoring “COOLAN TEMP/S” indication on CONSULT-II. When “COOLAN TEMP/S” indication reaches to 70°C(158°F), go to Procedure for COND1 step 3. Overall Function Check E F G H I BBS004GF Use this procedure to check the overall function of the heated oxygen sensor 2 circuit. During this check, a 1st trip DTC might not be confirmed. J WITH GST 1. 2. 3. 4. 5. 6. 7. 8. Start engine and warm it up to the operating temperature. Turn ignition switch OFF and wait at least 10 seconds. Start engine and keep the engine speed between 3,500 and 4,000 rpm for at least 1 minute under no load. Let engine idle for 1 minute. Set voltmeter probes between ECM terminal 50 (HO2S2 signal) and ground. Check the voltage when revving up to 4,000 rpm under no load at least 10 times. (Depress and release accelerator pedal as soon as possible.) The voltage should be below 0.50V at least once during this procedure. If the voltage can be confirmed in step 6, step 7 is not necessary. Keep vehicle at idling for 10 minutes, then check the voltage. Or check the voltage when coasting from 80 km/h (50 MPH) in D position with “OD” OFF (A/T), 3rd gear position (M/T). The voltage should be below 0.50V at least once during this PBIB2996E procedure. If NG, go to EC-1117, "Diagnostic Procedure" . EC-1115 K L M DTC P1146 HO2S2 [HR (WITH EURO-OBD)] Wiring Diagram BBS004GG MBWA1463E EC-1116 DTC P1146 HO2S2 [HR (WITH EURO-OBD)] Specification data are reference values and are measured between each terminal and ground. Pulse signal is measured by CONSULT-II. A CAUTION: Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM's transistor. Use a ground other than ECM terminals, such as the ground. EC TERMINAL NO. WIRE COLOR ITEM CONDITION DATA (DC Voltage) C Approximately 10V [Engine is running] 5 GR ● Below 3,600 rpm after the following conditions are met. – Engine: After warming up – Keeping the engine speed between 3,500 and 4,000 rpm for 1 minute and at idle for 1 minute under no load Heated oxygen sensor 2 heater D E PBIA8148J [Ignition switch: ON] ● Engine stopped ● F BATTERY VOLTAGE (11 - 14V) [Engine is running] Engine speed: Above 3,600 rpm G [Engine is running] 50 B Heated oxygen sensor 2 ● Revving engine from idle to 3,000 rpm quickly after the following conditions are met. – Engine: After warming up – Keeping the engine speed between 3,500 and 4,000 rpm for 1 minute and at idle for 1 minute under no load. H 0 - Approximately 1.0V I [Engine is running] 59 LG Sensor ground (Heated oxygen sensor 2) ● Warm-up condition ● Idle speed Approximately 0V J : Average voltage for pulse signal (Actual pulse signal can be confirmed by oscilloscope.) Diagnostic Procedure BBS004GH K 1. CHECK GROUND CONNECTIONS 1. 2. L Turn ignition switch OFF. Loosen and retighten ground screws on the body. Refer to EC-924, "Ground Inspection" . M MBIB1550E 1. IPDM E/R 2. Body ground OK or NG OK >> GO TO 2. NG >> Repair or replace ground connections. EC-1117 3. Body ground DTC P1146 HO2S2 [HR (WITH EURO-OBD)] 2. CLEAR THE SELF-LEARNING DATA With CONSULT-II Start engine and warm it up to normal operating temperature. Select “SELF-LEARNING CONT” in “WORK SUPPORT” mode with CONSULT-II. 3. Clear the self-learning control coefficient by touching “CLEAR”. 4. Run engine for at least 10 minutes at idle speed. Is the 1st trip DTC P0172 detected? Is it difficult to start engine? 1. 2. SEF215Z Without CONSULT-II 1. Start engine and warm it up to normal operating temperature. 2. Turn ignition switch OFF. 3. Disconnect mass air flow sensor (1) harness connector, and restart and run engine for at least 5 seconds at idle speed. 4. Stop engine and reconnect mass air flow sensor harness connector. 5. Make sure that DTC P0102 is displayed. 6. Erase the DTC memory. Refer to EC-841, "HOW TO ERASE EMISSION-RELATED DIAGNOSTIC INFORMATION" . 7. Make sure that DTC P0000 is displayed. 8. Run engine for at least 10 minutes at idle speed. Is the 1st trip DTC P0172 detected? PBIB2948E Is it difficult to start engine? Yes or No Yes >> Perform trouble diagnosis for DTC P0172. Refer to EC-1019, "DTC P0172 FUEL INJECTION SYSTEM FUNCTION" . No >> GO TO 3. 3. CHECK HO2S2 GROUND CIRCUIT FOR OPEN AND SHORT 1. 2. – 3. 4. Turn ignition switch OFF. Disconnect heated oxygen sensor 2 harness connector (2). Heated oxygen sensor 2 (1) Disconnect ECM harness connector. Check harness continuity between HO2S2 terminal 1 and ECM terminal 59. Refer to Wiring Diagram. Continuity should exist. 5. Also check harness for short to ground and short to power. OK or NG OK >> GO TO 4. NG >> Repair open circuit or short to ground or short to power in harness or connectors. EC-1118 PBIB2949E DTC P1146 HO2S2 [HR (WITH EURO-OBD)] 4. CHECK HO2S2 INPUT SIGNAL CIRCUIT FOR OPEN AND SHORT 1. A Check harness continuity between HO2S2 terminal 4 and ECM terminal 50. Refer to Wiring Diagram. EC Continuity should exist. 2. Check harness continuity between ECM terminal 50 or HO2S2 terminal 4 and ground. Refer to Wiring Diagram. C Continuity should not exist. 3. Also check harness for short to power. OK or NG OK >> GO TO 5. NG >> Repair open circuit or short to ground or short to power in harness or connectors. D E 5. CHECK HEATED OXYGEN SENSOR 2 Refer to EC-1119, "Component Inspection" . OK or NG OK >> GO TO 6. NG >> Replace heated oxygen sensor 2. F G 6. CHECK INTERMITTENT INCIDENT H Refer to EC-917, "TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT" . >> INSPECTION END I Component Inspection BBS004GI HEATED OXYGEN SENSOR 2 With CONSULT-II 1. 2. 3. 4. 5. J Start engine and warm it up to the normal operating temperature. Turn ignition switch OFF and wait at least 10 seconds. Start engine and keep the engine speed between 3,500 and 4,000 rpm for at least 1 minute under no load. Let engine idle for 1 minute. Select “FUEL INJECTION” in “ACTIVE TEST” mode, and select “HO2S2 (B1)” as the monitor item with CONSULT-II. K L M SEF662Y EC-1119 DTC P1146 HO2S2 [HR (WITH EURO-OBD)] 6. Check “HO2S2 (B1)” at idle speed when adjusting “FUEL INJECTION” to ±25%. PBIB0551E “HO2S2 (B1)” should be above 0.68V at least once when the “FUEL INJECTION” is +25%. “HO2S2 (B1)” should be below 0.50V at least once when the “FUEL INJECTION” is −25%. CAUTION: ● Discard any heated oxygen sensor which has been dropped from a height of more than 0.5 m (19.7 in) onto a hard surface such as a concrete floor; use a new one. ● Before installing new oxygen sensor, clean exhaust system threads using Oxygen Sensor Thread Cleaner tool and approved anti-seize lubricant. Without CONSULT-II 1. 2. 3. 4. 5. 6. Start engine and warm it up to the normal operating temperature. Turn ignition switch OFF and wait at least 10 seconds. Start engine and keep the engine speed between 3,500 and 4,000 rpm for at least 1 minute under no load. Let engine idle for 1 minute. Set voltmeter probes between ECM terminal 50 (HO2S2 signal) and ground. Check the voltage when revving up to 4,000 rpm under no load at least 10 times. (Depress and release accelerator pedal as soon as possible.) The voltage should be above 0.68V at least once during this procedure. If the voltage is above 0.68V at step 6, step 7 is not necessary. 7. Keep vehicle at idling for 10 minutes, then check voltage. Or check the voltage when coasting from 80 km/h (50 MPH) in D position with “OD” OFF (A/T), 3rd gear position (M/T). The voltage should be below 0.50V at least once during this PBIB2996E procedure. 8. If NG, replace heated oxygen sensor 2. CAUTION: ● Discard any heated oxygen sensor which has been dropped from a height of more than 0.5 m (19.7 in) onto a hard surface such as a concrete floor; use a new one. ● Before installing new oxygen sensor, clean exhaust system threads using Oxygen Sensor Thread Cleaner tool and approved anti-seize lubricant. Removal and Installation BBS004GJ HEATED OXYGEN SENSOR 2 Refer to EX-3, "EXHAUST SYSTEM" . EC-1120 DTC P1147 HO2S2 [HR (WITH EURO-OBD)] DTC P1147 HO2S2 Component Description PFP:226A0 A BBS004GK The heated oxygen sensor 2, after three way catalyst (manifold), monitors the oxygen level in the exhaust gas. Even if switching characteristics of the heated oxygen sensor 1 are shifted, the air-fuel ratio is controlled to stoichiometric, by the signal from the heated oxygen sensor 2. This sensor is made of ceramic zirconia. The zirconia generates voltage from approximately 1V in richer conditions to 0V in leaner conditions. Under normal conditions the heated oxygen sensor 2 is not used for engine control operation. EC C D SEF327R E CONSULT-II Reference Value in Data Monitor Mode BBS004GL Specification data are reference values. MONITOR ITEM HO2S2 (B1) HO2S2 MNTR (B1) F CONDITION SPECIFICATION ● Revving engine from idle to 3,000 rpm quickly after the following conditions are met. 0 - 0.3V ←→ Approx. 0.6 - 1.0V – Engine: After warming up – Keep the engine speed between 3,500 rpm and 4,000 rpm for 1 minute and idle for 1 minute under no load G LEAN ←→ RICH H On Board Diagnosis Logic BBS004GM The heated oxygen sensor 2 has a much longer switching time between rich and lean than the heated oxygen sensor 1. The oxygen storage capacity before the three way catalyst (manifold) causes the longer switching time. To judge the malfunctions of heated oxygen sensor 2, ECM monitors whether the maximum voltage of the sensor is sufficiently high during the various driving condition such as fuelcut. I J K SEF259VA L DTC No. P1147 1147 Trouble diagnosis name Heated oxygen sensor 2 maximum voltage monitoring DTC detecting condition The maximum voltage from the sensor is not reached to the specified voltage. EC-1121 Possible cause ● Harness or connectors (The sensor circuit open or shorted.) ● Heated oxygen sensor 2 ● Fuel pressure ● Fuel injector ● Intake air leaks M DTC P1147 HO2S2 [HR (WITH EURO-OBD)] DTC Confirmation Procedure BBS004GN CAUTION: Always drive vehicle at a safe speed. NOTE: ● “COMPLETED” will appear on CONSULT-II screen when all tests “COND1”, “COND2” and “COND3” are completed. ● If DTC confirmation Procedure has been previously conducted, always turn ignition switch OFF and wait at least 10 seconds before conducting the next test. TESTING CONDITION: Never stop engine during this procedure. If the engine is stopped, retry procedure from step 2 in “Procedure for COND1” WITH CONSULT-II Procedure for COND1 For the best results, perform “DTC WORK SUPPORT” at a temperature of 0 to 30°C(32 to 86°F). 1. Start engine and warm it up to normal operating temperature. 2. Turn ignition switch OFF and wait at least 10 seconds. 3. Start engine and keep the engine speed between 3,500 and 4,000 rpm for at least 1 minute under no load. 4. Let engine idle 1 minute. 5. Select “HO2S2 (B1) P1147” of “HO2S2” in “DTC WORK SUPPORT” mode with CONSULT-II. 6. Touch “START”. 7. Start engine and let it idle for at least 30 seconds. 8. Rev engine up to 2,000 rpm two or three times quickly under no load. If “COMPLETED” appears on CONSULT-II screen, go to step 2 in “Procedure for COND3”. If “COMPLETED” does not appear on CONSULT-II screen, go to the following step. 9. When the following conditions are met, “TESTING” will be displayed at COND1” on the CONSULT-II screen. Maintain the conditions continuously until “TESTING” changes to “COMPLETED”. (It will take approximately 60 seconds.) ENG SPEED 1,000 - 3,600 rpm B/FUEL SCHDL More than 1.0 msec COOLAN TEMP/S 70 - 119°C (158 - 246°F) Shift lever Suitable position PBIB0557E NOTE: If “TESTING” is not displayed after 5 minutes, retry from step 2 in Procedure for COND1. ● If “COMPLETED” already appears at “COND2” on CONSULT-II screen before Procedure for COND2 is conducted, it is unnecessary to conduct step 1 in Procedure for COND2. ● EC-1122 DTC P1147 HO2S2 [HR (WITH EURO-OBD)] Procedure for COND2 1. A While driving, release accelerator pedal completed with “OD” OFF (A/T) from the above condition [step 9] until “INCOMPLETE” at “COND2” on CONSULT-II screen has turned to “COMPLETED” (It will take approximately 4 seconds.) NOTE: If “COMPLETE” already appears at “COND3” on CONSULTII screen before Procedure for COND3 is conducted, it is unnecessary to conduct step 1 in “Procedure for COND3”. EC C PBIB0558E D Procedure for COND3 1. 2. a. b. c. d. Stop vehicle and let it idle until “INCOMPLETE” of “COND3” on CONSULT-II screen has turned to “COMPLETED”. (It will take a maximum of approximately 6 minutes.) Make sure that “OK” is displayed after touching “SELF-DIAG RESULTS”. If “NG” is displayed, refer to EC-1125, "Diagnostic Procedure" . If “CAN NOT BE DIAGNOSED” is displayed, perform the following. Turn ignition switch OFF and leave the vehicle in a cool place (soak the vehicle). SEC778C Turn ignition switch ON and select “COOLAN TEMP/S” in “DATA MONITOR” mode with CONSULT-II. Start engine and warm it up while monitoring “COOLAN TEMP/S” indication on CONSULT-II. When “COOLAN TEMP/S” indication reaches to 70°C(158°F), go to Procedure for COND1 step 3. Overall Function Check E F G H I BBS004GO Use this procedure to check the overall function of the heated oxygen sensor 2 circuit. During this check, a 1st trip DTC might not be confirmed. J WITH GST 1. 2. 3. 4. 5. 6. 7. 8. Start engine and warm it up to the normal operating temperature. Turn ignition switch OFF and wait at least 10 seconds. Start engine and keep the engine speed between 3,500 and 4,000 rpm for at least 1 minute under no load. Let engine idle for 1 minute. Set voltmeter probes between ECM terminal 50 (HO2S2 signal) and ground. Check the voltage when revving up to 4,000 rpm under no load at least 10 times. (Depress and release accelerator pedal as soon as possible.) The voltage should be above 0.68V at least once during this procedure. If the voltage can be confirmed in step 6, step 7 is not necessary. Keep vehicle idling for 10 minutes, then check the voltage. Or check the voltage when coasting from 80 km/h (50 MPH) in D position with “OD” OFF (A/T), 3rd gear position (M/T). The voltage should be above 0.68V at least once during this PBIB2996E procedure. If NG, go to EC-1125, "Diagnostic Procedure" . EC-1123 K L M DTC P1147 HO2S2 [HR (WITH EURO-OBD)] Wiring Diagram BBS004GP MBWA1463E EC-1124 DTC P1147 HO2S2 [HR (WITH EURO-OBD)] Specification data are reference values and are measured between each terminal and ground. Pulse signal is measured by CONSULT-II. A CAUTION: Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM's transistor. Use a ground other than ECM terminals, such as the ground. EC TERMINAL NO. WIRE COLOR ITEM CONDITION DATA (DC Voltage) C Approximately 10V [Engine is running] 5 GR ● Below 3,600 rpm after the following conditions are met. – Engine: After warming up – Keeping the engine speed between 3,500 and 4,000 rpm for 1 minute and at idle for 1 minute under no load Heated oxygen sensor 2 heater D E PBIA8148J [Ignition switch: ON] ● Engine stopped ● F BATTERY VOLTAGE (11 - 14V) [Engine is running] Engine speed: Above 3,600 rpm G [Engine is running] 50 B Heated oxygen sensor 2 ● Revving engine from idle to 3,000 rpm quickly after the following conditions are met. – Engine: After warming up – Keeping the engine speed between 3,500 and 4,000 rpm for 1 minute and at idle for 1 minute under no load. H 0 - Approximately 1.0V I [Engine is running] 59 LG Sensor ground (Heated oxygen sensor 2) ● Warm-up condition ● Idle speed Approximately 0V J : Average voltage for pulse signal (Actual pulse signal can be confirmed by oscilloscope.) Diagnostic Procedure BBS004GQ K 1. CHECK GROUND CONNECTIONS 1. 2. L Turn ignition switch OFF. Loosen and retighten ground screws on the body. Refer to EC-924, "Ground Inspection" . M MBIB1550E 1. IPDM E/R 2. Body ground OK or NG OK >> GO TO 2. NG >> Repair or replace ground connections. EC-1125 3. Body ground DTC P1147 HO2S2 [HR (WITH EURO-OBD)] 2. CLEAR THE SELF-LEARNING DATA With CONSULT-II Start engine and warm it up to normal operating temperature. Select “SELF-LEARNING CONT” in “WORK SUPPORT” mode with CONSULT-II. 3. Clear the self-learning control coefficient by touching “CLEAR”. 4. Run engine for at least 10 minutes at idle speed. Is the 1st trip DTC P0171 detected? Is it difficult to start engine? 1. 2. SEF215Z Without CONSULT-II 1. Start engine and warm it up to normal operating temperature. 2. Turn ignition switch OFF. 3. Disconnect mass air flow sensor (1) harness connector, and restart and run engine for at least 5 seconds at idle speed. 4. Stop engine and reconnect mass air flow sensor harness connector. 5. Make sure that DTC P0102 is displayed. 6. Erase the DTC memory. Refer to EC-841, "HOW TO ERASE EMISSION-RELATED DIAGNOSTIC INFORMATION" . 7. Make sure that DTC P0000 is displayed. 8. Run engine for at least 10 minutes at idle speed. Is the 1st trip DTC P0171 detected? PBIB2948E Is it difficult to start engine? Yes or No Yes >> Perform trouble diagnosis for DTC P0171. Refer to EC-1012, "DTC P0171 FUEL INJECTION SYSTEM FUNCTION" . No >> GO TO 3. 3. CHECK HO2S2 GROUND CIRCUIT FOR OPEN AND SHORT 1. 2. – 3. 4. Turn ignition switch OFF. Disconnect heated oxygen sensor 2 harness connector (2). Heated oxygen sensor 2 (1) Disconnect ECM harness connector. Check harness continuity between HO2S2 terminal 1 and ECM terminal 59. Refer to Wiring Diagram. Continuity should exist. 5. Also check harness for short to ground and short to power. OK or NG OK >> GO TO 4. NG >> Repair open circuit or short to ground or short to power in harness or connectors. EC-1126 PBIB2949E DTC P1147 HO2S2 [HR (WITH EURO-OBD)] 4. CHECK HO2S2 INPUT SIGNAL CIRCUIT FOR OPEN AND SHORT 1. A Check harness continuity between HO2S2 terminal 4 and ECM terminal 50. Refer to Wiring Diagram. EC Continuity should exist. 2. Check harness continuity between ECM terminal 50 or HO2S2 terminal 4 and ground. Refer to Wiring Diagram. C Continuity should not exist. 3. Also check harness for short to power. OK or NG OK >> GO TO 5. NG >> Repair open circuit or short to ground or short to power in harness or connectors. D E 5. CHECK HEATED OXYGEN SENSOR 2 Refer to EC-1127, "Component Inspection" . OK or NG OK >> GO TO 6. NG >> Replace heated oxygen sensor 2. F G 6. CHECK INTERMITTENT INCIDENT H Refer to EC-917, "TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT" . >> INSPECTION END I Component Inspection BBS004GR HEATED OXYGEN SENSOR 2 With CONSULT-II 1. 2. 3. 4. 5. J Start engine and warm it up to the normal operating temperature. Turn ignition switch OFF and wait at least 10 seconds. Start engine and keep the engine speed between 3,500 and 4,000 rpm for at least 1 minute under no load. Let engine idle for 1 minute. Select “FUEL INJECTION” in “ACTIVE TEST” mode, and select “HO2S2 (B1)” as the monitor item with CONSULT-II. K L M SEF662Y EC-1127 DTC P1147 HO2S2 [HR (WITH EURO-OBD)] 6. Check “HO2S2 (B1)” at idle speed when adjusting “FUEL INJECTION” to ±25%. PBIB0551E “HO2S2 (B1)” should be above 0.68V at least once when the “FUEL INJECTION” is +25%. “HO2S2 (B1)” should be below 0.50V at least once when the “FUEL INJECTION” is −25%. CAUTION: ● Discard any heated oxygen sensor which has been dropped from a height of more than 0.5 m (19.7 in) onto a hard surface such as a concrete floor; use a new one. ● Before installing new oxygen sensor, clean exhaust system threads using Oxygen Sensor Thread Cleaner tool and approved anti-seize lubricant. Without CONSULT-II 1. 2. 3. 4. 5. 6. Start engine and warm it up to the normal operating temperature. Turn ignition switch OFF and wait at least 10 seconds. Start engine and keep the engine speed between 3,500 and 4,000 rpm for at least 1 minute under no load. Let engine idle for 1 minute. Set voltmeter probes between ECM terminal 50 (HO2S2 signal) and ground. Check the voltage when revving up to 4,000 rpm under no load at least 10 times. (Depress and release accelerator pedal as soon as possible.) The voltage should be above 0.68V at least once during this procedure. If the voltage is above 0.68V at step 6, step 7 is not necessary. 7. Keep vehicle idling for 10 minutes, then check voltage. Or check the voltage when coasting from 80 km/h (50 MPH) in D position with “OD” OFF (A/T), 3rd gear position (M/T). The voltage should be below 0.50V at least once during this PBIB2996E procedure. 8. If NG, replace heated oxygen sensor 2. CAUTION: ● Discard any heated oxygen sensor which has been dropped from a height of more than 0.5 m (19.7 in) onto a hard surface such as a concrete floor; use a new one. ● Before installing new oxygen sensor, clean exhaust system threads using Oxygen Sensor Thread Cleaner tool and approved anti-seize lubricant. Removal and Installation BBS004GS HEATED OXYGEN SENSOR 2 Refer to EX-3, "EXHAUST SYSTEM" . EC-1128 DTC P1212 TCS COMMUNICATION LINE [HR (WITH EURO-OBD)] DTC P1212 TCS COMMUNICATION LINE Description PFP:47850 A BBS004GX NOTE: ● If DTC P1212 is displayed with DTC U1000 or U1001, first perform the trouble diagnosis for DTC EC U1000, U1001. Refer to EC-925, "DTC U1000, U1001 CAN COMMUNICATION LINE" . ● If DTC P1212 is displayed with DTC U1010, first perform the trouble diagnosis for DTC U1010. Refer to EC-928, "DTC U1010 CAN COMMUNICATION" . C This CAN communication line is used to control the smooth engine operation during the TCS operation. Pulse signals are exchanged between ECM and “ABS actuator and electric unit (control unit)”. Be sure to erase the malfunction information such as DTC not only for “ABS actuator and electric unit D (control unit)” but also for ECM after TCS related repair. On Board Diagnosis Logic BBS004GY E The MI will not light up for this self-diagnosis. Freeze frame data is not stored in the ECM for this self-diagnosis. DTC No. P1212 1212 Trouble diagnosis name TCS communication line DTC detecting condition ECM can not receive the information from “ABS actuator and electric unit (control unit)” continuously. DTC Confirmation Procedure Possible cause F ● Harness or connectors (The CAN communication line is open or shorted.) ● ABS actuator and electric unit (control unit) ● Dead (Weak) battery BBS004GZ G H TESTING CONDITION: Before performing the following procedure, confirm that battery voltage is more than 10.5V at idle. I WITH CONSULT-II 1. 2. 3. 4. Turn ignition switch ON. Select “DATA MONITOR” mode with CONSULT-II. Start engine and let it idle for at least 10 seconds. If 1st trip DTC is detected, go to EC-1129, "Diagnostic Procedure" . J K L SEF058Y WITH GST Follow the procedure “WITH CONSULT-II” above. Diagnostic Procedure BBS004H0 BRC-49, "TROUBLE DIAGNOSIS" EC-1129 M DTC P1217 ENGINE OVER TEMPERATURE [HR (WITH EURO-OBD)] DTC P1217 ENGINE OVER TEMPERATURE System Description PFP:00000 BBS004V3 SYSTEM DESCRIPTION NOTE: ● If DTC P1217 is displayed with DTC U1000 or U1001, first perform the trouble diagnosis for DTC U1000, U1001. Refer to EC-925, "DTC U1000, U1001 CAN COMMUNICATION LINE" . ● If DTC P1217 is displayed with DTC U1010, first perform the trouble diagnosis for DTC U1010. Refer to EC-928, "DTC U1010 CAN COMMUNICATION" . Cooling Fan Control Sensor Input Signal to ECM Crankshaft position sensor (POS) Camshaft position sensor (PHASE) Engine speed*1 Battery Battery voltage*1 Wheel sensor Vehicle speed*2 Engine coolant temperature sensor Air conditioner switch* 3 Refrigerant pressure sensor*3 ECM function Cooling fan control Actuator IPDM E/R (Cooling fan relays) Engine coolant temperature Air conditioner ON signal*2 Refrigerant pressure *1: The ECM determines the start signal status by the signals of engine speed and battery voltage. *2: This signal is sent to ECM through CAN communication line. *3: Models with air conditioner The ECM controls the cooling fan corresponding to the vehicle speed, engine coolant temperature, refrigerant pressure, and air conditioner ON signal. The control system has 3-step control [HIGH/LOW/OFF] (Models with A/C) or 2-step control [ON/OFF] (Models without A/C). Cooling Fan Operation Models with A/C MBIB1451E EC-1130 DTC P1217 ENGINE OVER TEMPERATURE [HR (WITH EURO-OBD)] Models without A/C A EC C MBIB1393E D Cooling Fan Relay Operation The ECM controls cooling fan relays in the IPDM E/R through CAN communication line. E Cooling fan relay Cooling fan speed LO HI Stop (OFF) OFF OFF Low (LOW) ON OFF High (HI) OFF ON F G CONSULT-II Reference Value in Data Monitor Mode BBS004V4 Specification data are reference values. MONITOR ITEM AIR COND SIG H CONDITION ● Engine: After warming up, idle the engine ● Engine: After warming up, idle the engine ● Air conditioner switch: OFF COOLING FAN SPECIFICATION Air conditioner switch: OFF OFF Air conditioner switch: ON (Compressor operates.) ON Engine coolant temperature is 97°C (207°F) or less OFF Engine coolant temperature is between 98°C (208°F) and 99°C (210°F) or more LOW* Engine coolant temperature is 100°C (212°F) or more HIGH* I J K *: Models without air conditioner, cooling fan operates only ON and OFF operation, but CONSULT-II display will change OFF, LOW and HI depends on engine coolant temperature. On Board Diagnosis Logic L BBS004V5 If the cooling fan or another component in the cooling system malfunctions, engine coolant temperature will rise. When the engine coolant temperature reaches an abnormally high temperature condition, a malfunction is indicated. This self-diagnosis has the one trip detection logic. EC-1131 M DTC P1217 ENGINE OVER TEMPERATURE [HR (WITH EURO-OBD)] DTC No. Trouble diagnosis name DTC detecting condition ● P1217 1217 Engine over temperature (Overheat) Cooling fan does not operate properly (Overheat). Possible cause ● Harness or connectors (The cooling fan circuit is open or shorted.) ● Cooling fan ● IPDM E/R (Cooling fan relays) ● Radiator hose Radiator ● Cooling fan system does not operate properly (Overheat). ● ● Reservoir tank (M/T models with A/C) ● Engine coolant was not added to the system using the proper filling method. ● Reservoir tank cap (M/T models with A/C) ● Engine coolant is not within the specified range. ● Radiator cap (M/T models without A/C and A/T models) ● Water pump ● Thermostat For more information, refer to EC-1144, "Main 12 Causes of Overheating" . CAUTION: When a malfunction is indicated, be sure to replace the coolant. Refer to MA-39, "Changing Engine Coolant" . Also, replace the engine oil. Refer to MA-45, "Changing Engine Oil" . 1. Fill radiator with coolant up to specified level with a filling speed of 2 liters per minute. Be sure to use coolant with the proper mixture ratio. Refer to MA-26, "Engine Coolant Mixture Ratio" . 2. After refilling coolant, run engine to ensure that no water-flow noise is emitted. Overall Function Check BBS004V6 Use this procedure to check the overall function of the cooling fan. During this check, a DTC might not be confirmed. WARNING: Never remove the reservoir tank cap (M/T models with A/C) or the radiator cap (M/T models without A/ C and A/T models) when the engine is hot. Serious burns could be caused by high pressure fluid escaping from the reservoir tank or the radiator. Wrap a thick cloth around cap. Carefully remove the cap by turning it a quarter turn to allow built-up pressure to escape. Then turn the cap all the way off. WITH CONSULT-II 1. 2. 3. Check the coolant level in the reservoir tank and radiator. Allow engine to cool before checking coolant level. If the coolant level in the reservoir tank and/or radiator is below the proper range, skip the following steps and go to EC-1137, "PROCEDURE FOR MODELS WITH AIR CONDITIONER" or EC-1141, "PROCEDURE FOR MODELS WITHOUT AIR CONDITIONER" . Confirm whether customer filled the coolant or not. If customer filled the coolant, skip the following steps and go to EC-1137, "PROCEDURE FOR MODELS WITH AIR CONDITIONER" or EC-1141, "PROCEDURE FOR MODELS WITHOUT AIR CONDITIONER" . Turn ignition switch ON. EC-1132 SEF621W DTC P1217 ENGINE OVER TEMPERATURE [HR (WITH EURO-OBD)] 4. 5. Perform “COOLING FAN” in “ACTIVE TEST” mode with CONSULT-II. If the results are NG, go to EC-1137, "PROCEDURE FOR MODELS WITH AIR CONDITIONER" or EC-1141, "PROCEDURE FOR MODELS WITHOUT AIR CONDITIONER" . A EC C SEF646X D WITH GST Models with Air Conditioner 1. Check the coolant level in the reservoir tank and radiator. Allow engine to cool before checking coolant level. If the coolant level in the reservoir tank and/or radiator is below the proper range, skip the following steps and go to EC-1137, "PROCEDURE FOR MODELS WITH AIR CONDITIONER" . 2. Confirm whether customer filled the coolant or not. If customer filled the coolant, skip the following steps and go to EC-1137, "PROCEDURE FOR MODELS WITH AIR CONDITIONER" . 3. Start engine. CAUTION: Be careful not to overheat engine. 4. Set temperature control switch to full cold position. 5. Turn air conditioner switch ON. 6. Turn blower fan switch ON. 7. Run engine at idle for a few minutes with air conditioner operating. CAUTION: Be careful not to overheat engine. 8. Make sure that cooling fans operates at low speed. If NG, go to EC-1137, "PROCEDURE FOR MODELS WITH AIR CONDITIONER" or . If OK, go to the following step. 9. Turn ignition switch OFF. 10. Turn air conditioner switch and blower fan switch OFF. 11. Disconnect engine coolant temperature sensor harness connector. 12. Connect 150Ω resistor to engine coolant temperature sensor harness connector. E F G SEF621W I J K L M MBIB0651E 13. Restart engine and make sure that cooling fan operates at higher speed than low speed. CAUTION: Be careful not to overheat engine. 14. If NG, go to EC-1137, "PROCEDURE FOR MODELS WITH AIR CONDITIONER" . SEF023R EC-1133 H DTC P1217 ENGINE OVER TEMPERATURE [HR (WITH EURO-OBD)] Models without Air Conditioner 1. 2. 3. 4. 5. 6. Check the coolant level in the reservoir tank and radiator. Allow engine to cool before checking coolant level. If the coolant level in the reservoir tank and/or radiator is below the proper range, skip the following steps and go to EC-1141, "PROCEDURE FOR MODELS WITHOUT AIR CONDITIONER" . Confirm whether customer filled the coolant or not. If customer filled the coolant, skip the following steps and go to EC-1141, "PROCEDURE FOR MODELS WITHOUT AIR CONDITIONER" . Disconnect engine coolant temperature sensor harness connector. Connect 150Ω resistor to engine coolant temperature sensor harness connector. Start engine and make that cooling fan operates. Be careful not to overheat engine. If NG, go to EC-1141, "PROCEDURE FOR MODELS WITHOUT AIR CONDITIONER" . SEF621W SEF023R EC-1134 DTC P1217 ENGINE OVER TEMPERATURE [HR (WITH EURO-OBD)] Wiring Diagram BBS004V7 A MODELS WITH AIR CONDITIONER EC C D E F G H I J K L M MBWA1475E EC-1135 DTC P1217 ENGINE OVER TEMPERATURE [HR (WITH EURO-OBD)] MODELS WITHOUT AIR CONDITIONER MBWA1476E EC-1136 DTC P1217 ENGINE OVER TEMPERATURE [HR (WITH EURO-OBD)] Diagnostic Procedure BBS004V8 A PROCEDURE FOR MODELS WITH AIR CONDITIONER 1. INSPECTION START EC Do you have CONSULT-II? Yes or No Yes >> GO TO 2. No >> GO TO 4. C 2. CHECK COOLING FAN LOW SPEED OPERATION D With CONSULT-II 1. Turn ignition switch ON. 2. Perform “COOLING FAN” in “ACTIVE TEST” mode with CONSULT-II and touch “LOW” on the CONSULT-II screen. 3. Make sure that cooling fan operates at low speed. OK or NG OK >> GO TO 3. NG >> Check cooling fan control circuit. (Go to EC-1139, "PROCEDURE A" .) E F G SEF784Z H 3. CHECK COOLING FAN HIGH SPEED OPERATION I With CONSULT-II 1. Touch “HIGH” on the CONSULT-II screen. 2. Make sure that cooling fan operates at higher speed than low speed. OK or NG OK >> GO TO 6. NG >> Check cooling fan control circuit. (Go to EC-1139, "PROCEDURE A" .) J K L SEF785Z M EC-1137 DTC P1217 ENGINE OVER TEMPERATURE [HR (WITH EURO-OBD)] 4. CHECK COOLING FAN LOW SPEED OPERATION Without CONSULT-II 1. Start engine and let it idle. 2. Turn air conditioner switch ON. 3. Turn blower fan switch ON. 4. Make sure that cooling fan operates at low speed. OK or NG OK >> GO TO 5. NG >> Check cooling fan low speed control circuit. (Go to EC1139, "PROCEDURE A" .) MBIB0651E 5. CHECK COOLING FAN HIGH SPEED OPERATION Without CONSULT-II Turn ignition switch OFF. Turn air conditioner switch and blower fan switch OFF. Disconnect engine coolant temperature sensor harness connector. Connect 150Ω resistor to engine coolant temperature sensor harness connector. Restart engine and make sure that cooling fan operates at higher speed than low speed. OK or NG OK >> GO TO 6. NG >> Check cooling fan high speed control circuit. (Go to EC1139, "PROCEDURE A" .) 1. 2. 3. 4. 5. SEF023R 6. CHECK COOLING SYSTEM FOR LEAK Refer to CO-27, "ENGINE COOLANT" . OK or NG OK >> GO TO 8. NG >> GO TO 7. 7. DETECT MALFUNCTIONING PART Check the following for leak. ● Hose ● Radiator ● Water pump (Refer to CO-36, "WATER PUMP" .) ● Reservoir tank >> Repair or replace. EC-1138 DTC P1217 ENGINE OVER TEMPERATURE [HR (WITH EURO-OBD)] 8. CHECK RESERVOIR TANK CAP (M/T MODELS) OR RADIATOR CAP (A/T MODELS) A Refer to CO-35, "Checking Reservoir Tank Cap (M/T with A/C Models)" or CO-34, "Checking Radiator Cap (All Models Except M/T with A/C)" . EC OK or NG OK >> GO TO 9. NG >> Replace reservoir tank cap (M/T models) or radiator cap (A/T models). C CHECK THERMOSTAT 9. Refer to CO-38, "THERMOSTAT" . OK or NG OK >> GO TO 10. NG >> Replace thermostat. D E 10. CHECK ENGINE COOLANT TEMPERATURE SENSOR Refer to EC-951, "Component Inspection" . OK or NG OK >> GO TO 11. NG >> Replace engine coolant temperature sensor. F G 11. CHECK MAIN 12 CAUSES H If the cause cannot be isolated, go to EC-1144, "Main 12 Causes of Overheating" . >> INSPECTION END I PROCEDURE A 1. CHECK POWER SUPPLY CIRCUIT 1. 2. 3. J Turn ignition switch OFF. Disconnect IPDM E/R harness connector E6. Check voltage between IPDM E/R terminal 14 and ground with CONSULT-II or tester. K Voltage: Battery voltage L OK or NG OK >> GO TO 3. NG >> GO TO 2. M MBIB1307E 2. DETECT MALFUNCTIONING PART Check the following. ● 40A fusible link ● Harness for open or short between IPDM E/R and battery >> Repair open circuit or short to ground or short to power in harness or connectors. EC-1139 DTC P1217 ENGINE OVER TEMPERATURE [HR (WITH EURO-OBD)] 3. CHECK COOLING FAN MOTOR CIRCUIT 1. Disconnect cooling fan motor harness connector (1). – : Vehicle front Disconnect IPDM E/R harness connectors E11 and E12. Check harness continuity between cooling fan motor terminal 1 and IPDM E/R terminal 10, cooling fan motor terminal 2 and ground. Refer to wiring diagram. 2. 3. Continuity should exist. 4. 5. Also check harness for short to ground and short to power. Check harness continuity between IPDM E/R terminal 12 and cooling fan motor terminal 1. Refer to wiring diagram. MBIB1549E Continuity should exist. 6. 7. Also check harness for short to ground and short to power. Check harness continuity between IPDM E/R terminals 3, 53 and ground. Refer to Wiring Diagram. Continuity should exist. 8. Also check harness for short to ground and short to power. OK or NG OK >> GO TO 5. NG >> GO TO 4. 4. DETECT MALFUNCTIONING PART Check the following. ● Harness for open or short between cooling fan motor and IPDM E/R ● Harness for open or short between cooling fan motor and ground ● Harness for open or short between resistor and IPDM E/R ● Harness for open or short between resistor and cooling fan motor ● Resistor E62 >> Repair open circuit or short to ground or short to power in harness or connectors. 5. CHECK COOLING FAN MOTOR Refer to EC-1145, "Component Inspection" . OK or NG OK >> GO TO 6. NG >> Replace cooling fan motor. 6. CHECK INTERMITTENT INCIDENT Perform EC-917, "TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT" . OK or NG OK >> Replace IPDM E/R. Refer to PG-18, "IPDM E/R (INTELLIGENT POWER DISTRIBUTION MODULE ENGINE ROOM)" . NG >> Repair or replace harness or connector. EC-1140 DTC P1217 ENGINE OVER TEMPERATURE [HR (WITH EURO-OBD)] PROCEDURE FOR MODELS WITHOUT AIR CONDITIONER A 1. INSPECTION START Do you have CONSULT-II? Yes or No Yes >> GO TO 2. No >> GO TO 3. EC C 2. CHECK COOLING FAN OPERATION With CONSULT-II 1. Turn ignition switch ON. 2. Perform “COOLING FAN” in “ACTIVE TEST” mode with CONSULT-II and touch “LOW” on the CONSULT-II screen. 3. Make sure that cooling fan operates. OK or NG OK >> GO TO4. NG >> Check cooling fan control circuit. (Go to EC-1142, "PROCEDURE B" .) D E F G SEF784Z H 3. CHECK COOLING FAN OPERATION Without CONSULT-II 1. Turn ignition switch OFF. 2. Disconnect engine coolant temperature sensor harness connector. 3. Connect 150Ω resistor to engine coolant temperature sensor harness connector. 4. Restart engine and make sure that cooling fan operates. OK or NG OK >> GO TO 4. NG >> Check cooling fan speed control circuit. (Go to EC-1142, "PROCEDURE B" .) I J K L M SEF023R 4. CHECK COOLING SYSTEM FOR LEAK Refer to CO-27, "ENGINE COOLANT" . OK or NG OK >> GO TO 6. NG >> GO TO 5. EC-1141 DTC P1217 ENGINE OVER TEMPERATURE [HR (WITH EURO-OBD)] 5. DETECT MALFUNCTIONING PART Check the following for leak. ● Hose ● Radiator ● Water pump (Refer to CO-36, "WATER PUMP" .) >> Repair or replace. 6. CHECK RADIATOR CAP Refer to CO-34, "Checking Radiator Cap (All Models Except M/T with A/C)" . OK or NG OK >> GO TO 7. NG >> Replace radiator cap. 7. CHECK THERMOSTAT Refer to CO-38, "THERMOSTAT" . OK or NG OK >> GO TO 8. NG >> Replace thermostat. 8. CHECK ENGINE COOLANT TEMPERATURE SENSOR Refer to EC-170, "Component Inspection" . OK or NG OK >> GO TO 9. NG >> Replace engine coolant temperature sensor. 9. CHECK MAIN 12 CAUSES If the cause cannot be isolated, go to EC-1144, "Main 12 Causes of Overheating" . >> INSPECTION END PROCEDURE B 1. CHECK POWER SUPPLY CIRCUIT 1. 2. 3. Turn ignition switch OFF. Disconnect IPDM E/R harness connector E6. Check voltage between IPDM E/R terminal 14 and ground with CONSULT-II or tester. Voltage: Battery voltage OK or NG OK >> GO TO 3. NG >> GO TO 2. MBIB1307E EC-1142 DTC P1217 ENGINE OVER TEMPERATURE [HR (WITH EURO-OBD)] 2. DETECT MALFUNCTIONING PART A Check the following. ● 40A fusible link ● Harness for open or short between IPDM E/R and battery EC >> Repair open circuit or short to ground or short to power in harness or connectors. C 3. CHECK COOLING FAN MOTORS CIRCUIT 1. Disconnect cooling fan motor harness connector (1). – : Vehicle front Disconnect IPDM E/R harness connectors E11 and E12. Check harness continuity between cooling fan motor terminal 1 and IPDM E/R terminal 10, cooling fan motor terminal 2 and ground. Refer to wiring diagram. 2. 3. D E F Continuity should exist. 4. 5. Also check harness for short to ground and short to power. Check harness continuity between IPDM E/R terminals 3, 53 and ground. Refer to Wiring Diagram. MBIB1549E G H Continuity should exist. 6. Also check harness for short to ground and short to power. OK or NG OK >> GO TO 5. NG >> GO TO 4. 4. DETECT MALFUNCTIONING PART Check the following. ● Harness for open or short between cooling fan motor and IPDM E/R ● Harness for open or short between cooling fan motor and ground I J K L >> Repair open circuit or short to ground or short to power in harness or connectors. 5. CHECK COOLING FAN MOTOR M Refer to EC-1145, "Component Inspection" . OK or NG OK >> GO TO 6. NG >> Replace cooling fan motor. 6. CHECK INTERMITTENT INCIDENT Perform EC-917, "TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT" . OK or NG OK >> Replace IPDM E/R. Refer to PG-18, "IPDM E/R (INTELLIGENT POWER DISTRIBUTION MODULE ENGINE ROOM)" . NG >> Repair or replace harness or connector. EC-1143 DTC P1217 ENGINE OVER TEMPERATURE [HR (WITH EURO-OBD)] Main 12 Causes of Overheating Engine Step OFF 1 Inspection item ● Blocked radiator ● Blocked condenser ● Blocked radiator grille ● Blocked bumper 2 ● 3 4*5 BBS004V9 Equipment Standard Reference page ● Visual No blocking Coolant mixture ● Coolant tester 50 - 50% coolant mixture See MA-26, "Engine Coolant Mixture Ratio" . ● Coolant level ● Visual Coolant up to MAX level in reservoir tank and radiator filler neck See CO-27, "LEVEL CHECK" . ● Radiator cap ● Pressure tester 59 - 98 kPa (0.59 - 0.98 bar, 0.6 - 1.0 See CO-34, "Checking Radiator Cap (All Models Except M/T with A/C)" . kg/cm2 , 9 - 14 psi) (Limit) 88 kPa (0.88 bar, 0.90 kg/ — See CO-35, "Checking Reservoir Tank Cap (M/T with A/C Models)" . 4*6 ● Reservoir tank cap ● Pressure tester ON*2 5 ● Coolant leaks ● Visual No leaks See CO-27, "LEAK CHECK" . ON*2 6 ● Thermostat ● Touch the upper and lower radiator hoses Both hoses should be hot See CO-38, "THERMOSTAT" , and CO-31, "RADIATOR" . ON*1 7 ● Cooling fan ● CONSULT-II Operating See trouble diagnosis for DTC P1217 (EC-1137, "Diagnostic Procedure" ). OFF 8 ● Combustion gas leak ● Color checker chemical tester 4 Gas analyzer Negative — ON*3 9 ● Coolant temperature gauge ● Visual Gauge less than 3/4 when driving — ● Coolant overflow to reservoir tank ● Visual No overflow during driving and idling See MA-39, "Changing Engine Coolant" . cm2 , 12.8psi) OFF*4 10 ● Coolant return from reservoir tank to radiator ● Visual Should be initial level in reservoir tank See CO-27, "LEVEL CHECK" . OFF 11 ● Cylinder head ● Straight gauge feeler gauge 0.1 mm (0.004 in) Maximum distortion (warping) See EM-173, "CYLINDER HEAD" . 12 ● Cylinder block and pistons ● Visual No scuffing on cylinder walls or piston See EM-189, "CYLINDER BLOCK" . *1: Turn the ignition switch ON. *2: Engine running at 3,000 rpm for 10 minutes. *3: Drive at 90 km/h (55 MPH) for 30 minutes and then let idle for 10 minutes. *4: After 60 minutes of cool down time. *5: M/T models without A/C and A/T models. *6: M/T models with A/C. For more information, refer to CO-24, "OVERHEATING CAUSE ANALYSIS" . EC-1144 DTC P1217 ENGINE OVER TEMPERATURE [HR (WITH EURO-OBD)] Component Inspection BBS004VA A COOLING FAN MOTOR 1. 2. Disconnect cooling fan motor harness connectors. Supply cooling fan motor terminals with battery voltage and check operation. EC Terminals Cooling fan motor (+) (-) 1 2 C D MBIB0607E E F G H I J K L M EC-1145 DTC P1225 TP SENSOR [HR (WITH EURO-OBD)] DTC P1225 TP SENSOR Component Description PFP:16119 BBS004H9 Electric throttle control actuator consists of throttle control motor, throttle position sensor, etc. The throttle position sensor responds to the throttle valve movement. The throttle position sensor has the two sensors. These sensors are a kind of potentiometers which transform the throttle valve position into output voltage, and emit the voltage signal to the ECM. In addition, these sensors detect the opening and closing speed of the throttle valve and feed the voltage signals to the ECM. The ECM judges the current opening angle of the throttle valve from these signals and the ECM controls the throttle control motor to make the throttle valve opening angle properly in response to driving condition. PBIB0145E On Board Diagnosis Logic BBS004HA The MI will not light up for this diagnosis. DTC No. P1225 1225 Trouble diagnosis name DTC detecting condition Closed throttle position learning performance Closed throttle position learning value is excessively low. DTC Confirmation Procedure Possible cause ● Electric throttle control actuator (TP sensor 1 and 2) BBS004HB NOTE: If DTC Confirmation Procedure has been previously conducted, always turn ignition switch OFF and wait at least 10 seconds before conducting the next test. TESTING CONDITION: Before performing the following procedure, confirm that battery voltage is more than 10V at idle. WITH CONSULT-II 1. 2. 3. 4. 5. Turn ignition switch ON. Select “DATA MONITOR” mode with CONSULT-II. Turn ignition switch OFF and wait at least 10 seconds. Turn ignition switch ON. If 1st trip DTC is detected, go to EC-1147, "Diagnostic Procedure" . SEF058Y WITH GST Follow the procedure “WITH CONSULT-II” above. EC-1146 DTC P1225 TP SENSOR [HR (WITH EURO-OBD)] Diagnostic Procedure BBS004HC 1. CHECK ELECTRIC THROTTLE CONTROL ACTUATOR VISUALLY 1. 2. 3. A Turn ignition switch OFF. Remove the intake air duct. Check if foreign matter is caught between the throttle valve (1) and the housing. EC C : Vehicle front – Illustration shows the view with intake air duct removed. OK or NG OK >> GO TO 2. NG >> Remove the foreign matter and clean the electric throttle control actuator inside. – D E PBIB2974E 2. REPLACE ELECTRIC THROTTLE CONTROL ACTUATOR F 1. 2. 3. G Replace the electric throttle control actuator. Perform EC-857, "Throttle Valve Closed Position Learning" . Perform EC-858, "Idle Air Volume Learning" . H >> INSPECTION END Removal and Installation BBS004HD ELECTRIC THROTTLE CONTROL ACTUATOR Refer to EM-120, "INTAKE MANIFOLD" . I J K L M EC-1147 DTC P1226 TP SENSOR [HR (WITH EURO-OBD)] DTC P1226 TP SENSOR Component Description PFP:16119 BBS004HE Electric throttle control actuator consists of throttle control motor, throttle position sensor, etc. The throttle position sensor responds to the throttle valve movement. The throttle position sensor has the two sensors. These sensors are a kind of potentiometers which transform the throttle valve position into output voltage, and emit the voltage signal to the ECM. In addition, these sensors detect the opening and closing speed of the throttle valve and feed the voltage signals to the ECM. The ECM judges the current opening angle of the throttle valve from these signals and the ECM controls the throttle control motor to make the throttle valve opening angle properly in response to driving condition. PBIB0145E On Board Diagnosis Logic BBS004HF The MI will not light up for this diagnosis. DTC No. P1226 1226 Trouble diagnosis name Closed throttle position learning performance DTC detecting condition Closed throttle position learning is not performed successfully, repeatedly. DTC Confirmation Procedure Possible cause ● Electric throttle control actuator (TP sensor 1 and 2) BBS004HG NOTE: If DTC Confirmation Procedure has been previously conducted, always turn ignition switch OFF and wait at least 10 seconds before conducting the next test. TESTING CONDITION: Before performing the following procedure, confirm that battery voltage is more than 10V at idle. WITH CONSULT-II 1. 2. 3. 4. 5. 6. Turn ignition switch ON. Select “DATA MONITOR” mode with CONSULT-II. Turn ignition switch OFF and wait at least 10 seconds. Turn ignition switch ON. Repeat steps 3 and 4 for 32 times. If 1st trip DTC is detected, go to EC-1149, "Diagnostic Procedure" . SEF058Y WITH GST Follow the procedure “WITH CONSULT-II” above. EC-1148 DTC P1226 TP SENSOR [HR (WITH EURO-OBD)] Diagnostic Procedure BBS004HH 1. CHECK ELECTRIC THROTTLE CONTROL ACTUATOR VISUALLY 1. 2. 3. A Turn ignition switch OFF. Remove the intake air duct. Check if foreign matter is caught between the throttle valve (1) and the housing. EC C : Vehicle front – Illustration shows the view with intake air duct removed. OK or NG OK >> GO TO 2. NG >> Remove the foreign matter and clean the electric throttle control actuator inside. – D E PBIB2974E 2. REPLACE ELECTRIC THROTTLE CONTROL ACTUATOR F 1. 2. 3. G Replace the electric throttle control actuator. Perform EC-857, "Throttle Valve Closed Position Learning" . Perform EC-858, "Idle Air Volume Learning" . H >> INSPECTION END Removal and Installation BBS004HI ELECTRIC THROTTLE CONTROL ACTUATOR Refer to EM-120, "INTAKE MANIFOLD" . I J K L M EC-1149 DTC P1229 SENSOR POWER SUPPLY [HR (WITH EURO-OBD)] DTC P1229 SENSOR POWER SUPPLY On Board Diagnosis Logic PFP:16119 BBS004HJ This self-diagnosis has the one trip detection logic. DTC No. P1229 1229 Trouble diagnosis name Sensor power supply circuit short DTC detecting condition Possible cause ● Harness or connectors (APP sensor 1 circuit is shorted.) (Throttle position sensor circuit is shorted.) [Camshaft position sensor (PHASE) circuit is shorted.] ● Accelerator pedal position sensor ● Throttle position sensor ● Camshaft position sensor (PHASE) ECM detects a voltage of power source for sensor is excessively low or high. FAIL-SAFE MODE When the malfunction is detected, ECM enters fail-safe mode and the MI lights up. Engine operation condition in fail-safe mode ECM stops the electric throttle control actuator control, throttle valve is maintained at a fixed opening (approx. 5 degrees) by the return spring. DTC Confirmation Procedure BBS004HK NOTE: If DTC Confirmation Procedure has been previously conducted, always turn ignition switch OFF and wait at least 10 seconds before conducting the next test. TESTING CONDITION: Before performing the following procedure, confirm that battery voltage is more than 10V at idle. WITH CONSULT-II 1. 2. 3. 4. Turn ignition switch ON. Select “DATA MONITOR” mode with CONSULT-II. Start engine and let it idle for 1 second. If DTC is detected, go to EC-1155, "Diagnostic Procedure" . SEF058Y WITH GST Follow the procedure “WITH CONSULT-II” above. EC-1150 DTC P1229 SENSOR POWER SUPPLY [HR (WITH EURO-OBD)] Wiring Diagram BBS004HL A LHD MODELS EC C D E F G H I J K L M MBWA1477E EC-1151 DTC P1229 SENSOR POWER SUPPLY [HR (WITH EURO-OBD)] Specification data are reference values and are measured between each terminal and ground. CAUTION: Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM's transistor. Use a ground other than ECM terminals, such as the ground. TERMINAL NO. WIRE COLOR ITEM CONDITION DATA (DC Voltage) 72 L Sensor power supply (Throttle position sensor) [Ignition switch: ON] Approximately 5V 78 O Sensor power supply [Camshaft position sensor (PHASE)] [Ignition switch: ON] Approximately 5V 102 BR Sensor power supply (APP sensor 2) [Ignition switch: ON] Approximately 5V [Ignition switch: ON] 103 G Accelerator pedal position sensor 2 ● Engine stopped ● Accelerator pedal: Fully released 0.3 - 0.6V [Ignition switch: ON] ● Engine stopped ● Accelerator pedal: Fully depressed 1.95 - 2.4V [Engine is running] 104 106 B Sensor ground (APP sensor 2) O Sensor power supply (APP sensor 1) ● Warm-up condition ● Idle speed [Ignition switch: ON] Approximately 0V Approximately 5V [Ignition switch: ON] 110 W Accelerator pedal position sensor 1 ● Engine stopped ● Accelerator pedal: Fully released 0.6 - 0.9V [Ignition switch: ON] ● Engine stopped ● Accelerator pedal: Fully depressed 3.9 - 4.7V [Engine is running] 111 B Sensor ground (APP sensor 1) ● Warm-up condition ● Idle speed EC-1152 Approximately 0V DTC P1229 SENSOR POWER SUPPLY [HR (WITH EURO-OBD)] RHD MODELS A EC C D E F G H I J K L M MBWA1478E EC-1153 DTC P1229 SENSOR POWER SUPPLY [HR (WITH EURO-OBD)] Specification data are reference values and are measured between each terminal and ground. CAUTION: Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM's transistor. Use a ground other than ECM terminals, such as the ground. TERMINAL NO. WIRE COLOR ITEM CONDITION DATA (DC Voltage) 72 L Sensor power supply (Throttle position sensor) [Ignition switch: ON] Approximately 5V 78 O Sensor power supply [Camshaft position sensor (PHASE)] [Ignition switch: ON] Approximately 5V 102 BR Sensor power supply (APP sensor 2) [Ignition switch: ON] Approximately 5V [Ignition switch: ON] 103 G Accelerator pedal position sensor 2 ● Engine stopped ● Accelerator pedal: Fully released 0.3 - 0.6V [Ignition switch: ON] ● Engine stopped ● Accelerator pedal: Fully depressed 1.95 - 2.4V [Engine is running] 104 106 B Sensor ground (APP sensor 2) O Sensor power supply (APP sensor 1) ● Warm-up condition ● Idle speed [Ignition switch: ON] Approximately 0V Approximately 5V [Ignition switch: ON] 110 W Accelerator pedal position sensor 1 ● Engine stopped ● Accelerator pedal: Fully released 0.6 - 0.9V [Ignition switch: ON] ● Engine stopped ● Accelerator pedal: Fully depressed 3.9 - 4.7V [Engine is running] 111 B Sensor ground (APP sensor 1) ● Warm-up condition ● Idle speed EC-1154 Approximately 0V DTC P1229 SENSOR POWER SUPPLY [HR (WITH EURO-OBD)] Diagnostic Procedure BBS004HM 1. CHECK GROUND CONNECTIONS 1. 2. A Turn ignition switch OFF. Loosen and retighten ground screws on the body. Refer to EC-924, "Ground Inspection" . EC C D E MBIB1550E 1. IPDM E/R 2. Body ground 3. F Body ground OK or NG OK >> GO TO 2. NG >> Repair or replace ground connections. G 2. CHECK ACCELERATOR PEDAL POSITION SENSOR 1 POWER SUPPLY CIRCUIT 1. – – 2. H Disconnect accelerator pedal position (APP) sensor harness connector (1). Accelerator pedal position sensor (2) Accelerator pedal (3) Turn ignition switch ON. I J K PBIB2975E 3. L Check voltage between APP sensor terminal 4 and ground with CONSULT-II or tester. Voltage: Approximately 5V M OK or NG OK >> GO TO 7. NG >> GO TO 3. PBIA9606J EC-1155 DTC P1229 SENSOR POWER SUPPLY [HR (WITH EURO-OBD)] 3. CHECK ACCELERATOR PEDAL POSITION SENSOR 1 POWER SUPPLY CIRCUIT-II 1. 2. 3. Turn ignition switch OFF. Disconnect ECM harness connector. Check harness continuity between APP sensor terminal 4 and ECM terminal 106. Refer to Wiring Diagram. Continuity should exist. OK or NG OK >> GO TO 5. NG >> GO TO 4. 4. DETECT MALFUNCTIONING PART Check the following. ● Harness connectors M201, M8 (RHD models) ● Harness connectors M1, E101 (RHD models) ● Harness for open or short between APP sensor and ECM >> Repair open circuit. 5. CHECK SENSOR POWER SUPPLY CIRCUITS Check harness for short to power and short to ground, between the following terminals. ECM terminal Sensor terminal Reference Wiring Diagram 72 Throttle position sensor terminal 1 EC-1193, "Wiring Diagram" 78 Camshaft position sensor (PHASE) terminal 1 EC-1051, "Wiring Diagram" 106 APP sensor terminal 4 EC-1151, "Wiring Diagram" OK or NG OK >> GO TO 6. NG >> Repair short to ground or short to power in harness or connectors. 6. CHECK COMPONENTS Check the following. ● Throttle position sensor (Refer to EC-1196, "Component Inspection" .) ● Camshaft position sensor (PHASE) (Refer to EC-1054, "Component Inspection" .) OK or NG OK >> GO TO 7. NG >> Replace malfunctioning component. 7. CHECK APP SENSOR Refer to EC-1206, "Component Inspection" . OK or NG OK >> GO TO 9. NG >> GO TO 8. EC-1156 DTC P1229 SENSOR POWER SUPPLY [HR (WITH EURO-OBD)] 8. REPLACE ACCELERATOR PEDAL ASSEMBLY 1. 2. 3. 4. Replace accelerator pedal assembly. Perform EC-857, "Accelerator Pedal Released Position Learning" . Perform EC-857, "Throttle Valve Closed Position Learning" . Perform EC-858, "Idle Air Volume Learning" . A EC C >> INSPECTION END 9. CHECK INTERMITTENT INCIDENT D Refer to EC-917, "TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT" . E >> INSPECTION END F G H I J K L M EC-1157 DTC P1706 PNP SWITCH [HR (WITH EURO-OBD)] DTC P1706 PNP SWITCH Component Description PFP:32006 BBS004HN When the shift lever position is P or N (A/T), Neutral (M/T), park/neutral position (PNP) switch is ON. ECM detects the position because the continuity of the line (the ON signal) exists. CONSULT-II Reference Value in Data Monitor Mode BBS004HO Specification data are reference values. MONITOR ITEM P/N POSI SW CONDITION ● Ignition switch: ON SPECIFICATION Shift lever: P or N (A/T), Neutral (M/T) ON Shift lever: Except above OFF On Board Diagnosis Logic DTC No. P1706 1706 BBS004HP Trouble diagnosis name DTC detecting condition Park/neutral position switch The signal of the park/neutral position (PNP) switch is not changed in the process of engine starting and driving. DTC Confirmation Procedure Possible cause ● Harness or connectors (PNP switch circuit is open or shorted.) ● Park/neutral position (PNP) switch BBS004HQ CAUTION: Always drive vehicle at a safe speed. NOTE: If DTC Confirmation Procedure has been previously conducted, always turn ignition switch OFF and wait at least 10 seconds before conducting the next test. WITH CONSULT-II 1. 2. Turn ignition switch ON. Select “P/N POSI SW” in “DATA MONITOR” mode with CONSULT-II. Then check the “P/N POSI SW” signal under the following conditions. Position (Shift lever) Known-good signal N or P position (A/T) Neutral position (M/T) ON Except above position OFF 3. 4. 5. If NG, go to EC-1163, "Diagnostic Procedure" . If OK, go to following step. Select “DATA MONITOR” mode with CONSULT-II. Start engine and warm it up to normal operating temperature. Maintain the following conditions for at least 60 consecutive seconds. ENG SPEED A/T: 1,650 - 6,375 rpm M/T: 1,925 - 6,375 rpm COOLAN TEMP/S More than 70°C (158°F) B/FUEL SCHDL A/T: 3.5 - 31.8 msec M/T: 2.5 - 31.8 msec VHCL SPEED SE More than 64km/h (29 MPH) Shift lever Suitable position SEF212Y SEF213Y 6. If 1st trip DTC is detected, go to EC-1163, "Diagnostic Procedure" . EC-1158 DTC P1706 PNP SWITCH [HR (WITH EURO-OBD)] Overall Function Check BBS004HR Use this procedure to check the overall function of the park/neutral position (PNP) switch circuit. During this check, a 1st trip DTC might not be confirmed. WITH GST 1. 2. EC Turn ignition switch ON. Check voltage between ECM terminal 70 (PNP switch signal) and ground under the following conditions. Condition (Shift lever) C Voltage V (Known-good data) P or N position (A/T) Neutral position (M/T) Approx. 0 Except above position BATTERY VOLTAGE (11 - 14V) 3. A D E If NG, go to EC-1163, "Diagnostic Procedure" . MBIB1397E F G H I J K L M EC-1159 DTC P1706 PNP SWITCH [HR (WITH EURO-OBD)] Wiring Diagram BBS004HS A/T MODELS MBWA1479E EC-1160 DTC P1706 PNP SWITCH [HR (WITH EURO-OBD)] Specification data are reference values and are measured between each terminal and ground. CAUTION: Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM's transistor. Use a ground other than ECM terminals, such as the ground. TERMINAL NO. WIRE COLOR EC ITEM CONDITION DATA (DC Voltage) [Ignition switch: ON] 70 GR A Park/Neutral position (PNP) switch ● Shift lever: P or N (A/T models) ● Shift lever: Neutral (M/T models) [Ignition switch: ON] ● Except above position C Approximately 0V BATTERY VOLTAGE (11 - 14V) D E F G H I J K L M EC-1161 DTC P1706 PNP SWITCH [HR (WITH EURO-OBD)] M/T MODELS MBWA1480E EC-1162 DTC P1706 PNP SWITCH [HR (WITH EURO-OBD)] Specification data are reference values and are measured between each terminal and ground. CAUTION: Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM's transistor. Use a ground other than ECM terminals, such as the ground. TERMINAL NO. EC WIRE COLOR ITEM CONDITION DATA (DC Voltage) [Ignition switch: ON] 70 GR Park/Neutral position (PNP) switch ● Shift lever: P or N (A/T models) ● Shift lever: Neutral (M/T models) [Ignition switch: ON] ● Except above position Diagnostic Procedure C Approximately 0V D BATTERY VOLTAGE (11 - 14V) BBS004HT 1. CHECK PNP SWITCH CIRCUIT 1. 2. A Turn ignition switch ON. Check voltage between IPDM E/R terminal 31 and ground under following condition. Shift lever position F G Voltage P or N (A/T models) Neutral (M/T models) Battery voltage (11- 14V) Except above position Approximately 0V OK or NG OK >> GO TO 8. NG >> GO TO 2. E H I MBIB0652E J K L M EC-1163 DTC P1706 PNP SWITCH [HR (WITH EURO-OBD)] 2. CHECK PNP SWITCH POWER SUPPLY CIRCUIT 1. 2. 3. 4. Turn ignition switch OFF. Disconnect PNP switch harness connector. Turn ignition switch ON. Check voltage between PNP switch terminal 1 (A/T models), 2 (M/T models) and ground with CONSULT-II or tester. MBIB0654E MBIB0653E Voltage: Battery voltage OK or NG OK >> GO TO 4. NG >> GO TO 3. 3. DETECT MALFUNCTIONING PARTS Check the following. ● 10A fuse ● Harness connectors E59, F1 ● IPDM E/R connector E7 ● Harness for short or open between PNP switch and fuse >> Repair or replace harness or connectors. EC-1164 DTC P1706 PNP SWITCH [HR (WITH EURO-OBD)] 4. CHECK HARNESS CONTINUTY BETWEEN PNP SWITCH AND IPDM E/R 1. 2. 3. A Turn ignition switch OFF. Disconnect IPDM E/R harness connector E7. Check harness continuity between IPDM E/R terminal 31 and PNP switch terminal 2 (A/T models), 3 (M/T EC models).Refer to Wiring Diagram. Continuity should exist. C 4. Also check harness for short to ground and short to power. OK or NG OK >> GO TO 6. NG >> GO TO 5. 5. DETECT MALFUNCTIONING PART D E Check the following. ● Harness connectors E59, F1 ● Harness for open or short between IPDM E/R and PNP switch >> Repair open circuit or short to ground or short to power in harness or connectors. F G 6. CHECK PNP SWITCH Refer to AT-109, "Component Inspection" (A/T models) or MT-16, "Park/Neutral Position Switch" (M/T models). OK or NG OK >> GO TO 7. NG >> Replace PNP switch. 7. CHECK INTERMITTENT INCIDENT H I J Refer to EC-917, "TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT" . K >> INSPECTION END 8. CHECK PNP SWITCH GROUND CIRCUIT FOR OPEN AND SHORT 1. 2. 3. Turn ignition switch OFF. Disconnect IPDM E/R harness connectors E11 and E12. Check harness continuity between IPDM E/R terminal 3, 54 and ground. Refer to Wiring Diagram. Continuity should exist. 4. Also check harness for short to power. OK or NG OK >> GO TO 9. NG >> Repair open circuit or short to power in harness or connectors. EC-1165 L M DTC P1706 PNP SWITCH [HR (WITH EURO-OBD)] 9. CHECK PNP SWITCH INPUT SIGNAL CIRCUIT FOR OPEN AND SHORT 1. 2. 3. Disconnect IPDM E/R harness connector E5 Disconnect ECM harness connector. Check harness continuity between ECM terminal 70 and IPDM E/R terminal 64. Refer to Wiring Diagram. Continuity should exist. 4. Also check harness for short to ground and short to power. OK or NG OK >> GO TO 10. NG >> Repair open circuit or short to ground or short to power in harness or connectors. 10. CHECK INTERMITTENT INCIDENT Refer to EC-917, "TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT" . OK or NG OK >> Replace IPDM E/R. Refer to PG-18, "IPDM E/R (INTELLIGENT POWER DISTRIBUTION MODULE ENGINE ROOM)" . NG >> Repair or replace. EC-1166 DTC P1805 BRAKE SWITCH [HR (WITH EURO-OBD)] DTC P1805 BRAKE SWITCH Description PFP:25320 A BBS004HU Brake switch signal is applied to the ECM through the stop lamp switch when the brake pedal is depressed. This signal is used mainly to decrease the engine speed when the vehicle is driving. EC CONSULT-II Reference Value in Data Monitor Mode BBS004HV Specification data are reference values. C MONITOR ITEM BRAKE SW CONDITION ● Ignition switch: ON SPECIFICATION Brake pedal: Fully released OFF Brake pedal: Slightly depressed ON On Board Diagnosis Logic D BBS004HW E The MI will not light up for this self-diagnosis. DTC No. Trouble diagnosis name P1805 1805 Brake switch DTC detecting condition A brake switch signal is not sent to ECM for extremely long time while the vehicle is driving. Possible cause ● Harness or connectors (Stop lamp switch circuit is open or shorted.) ● Stop lamp switch FAIL-SAFE MODE BBS004HX F G When the malfunction is detected, the ECM enters in fail-safe mode. H Engine operation condition in fail-fail safe mode ECM controls the electric throttle control actuator by regulating the throttle opening to a small range. Therefore, acceleration will be poor. Vehicle condition Driving condition When engine is idling Normal When accelerating Poor acceleration DTC Confirmation Procedure I J BBS004HY WITH CONSULT-II 1. 2. 3. 4. 5. K Turn ignition switch ON. Fully depress the brake pedal for at least 5 seconds. Erase the DTC with CONSULT-II. Select “DATA MONITOR” mode with CONSULT-II. If 1st trip DTC is detected, go to EC-1169, "Diagnostic Procedure" . L M PBIB1952E WITH GST Follow the procedure “WITH CONSULT-II” above. EC-1167 DTC P1805 BRAKE SWITCH [HR (WITH EURO-OBD)] Wiring Diagram BBS004HZ MBWA1481E EC-1168 DTC P1805 BRAKE SWITCH [HR (WITH EURO-OBD)] Specification data are reference values and are measured between each terminal and ground. CAUTION: Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM's transistor. Use a ground other than ECM terminals, such as the ground. TERMINAL NO. EC WIRE COLOR ITEM CONDITION [Ignition switch: OFF] ● 99 R Stop lamp switch Brake pedal: Fully released [Ignition switch: OFF] ● Brake pedal: Slightly depressed DATA (DC Voltage) C Approximately 0V BATTERY VOLTAGE (11 - 14V) Diagnostic Procedure D BBS004I0 1. CHECK STOP LAMP SWITCH CIRCUIT 1. 2. E Turn ignition switch OFF. Check the stop lamp when depressing and releasing the brake pedal. Brake pedal Stop lamp Fully released Not illuminated Slightly depressed Illuminated F G OK or NG OK >> GO TO 4. NG >> GO TO 2. H 2. CHECK STOP LAMP SWITCH POWER SUPPLY CIRCUIT 1. – A I Disconnect stop lamp switch (1) harness connector. Brake pedal (2) J K L PBIB2976E 2. M Check voltage between stop lamp switch terminal 1 and ground with CONSULT-II or tester. PBIB2284E Voltage: Battery voltage OK or NG OK >> GO TO 4. NG >> GO TO 3. EC-1169 DTC P1805 BRAKE SWITCH [HR (WITH EURO-OBD)] 3. DETECT MALFUNCTIONING PART Check the following. ● Harness connectors M1, E101 (LHD models) ● Harness connectors M8, M201 (RHD models) ● 10A fuse ● Harness for open and short between stop lamp switch and battery >> Repair open circuit or short to ground or short to power in harness or connectors. 4. CHECK STOP LAMP SWITCH INPUT SIGNAL CIRCUIT FOR OPEN AND SHORT 1. – 2. 3. Disconnect stop lamp switch (1) harness connector. Brake pedal (2) Disconnect ECM harness connector. Check harness continuity between stop lamp switch terminal 2 and ECM terminal 99. Refer to Wiring Diagram. Continuity should exist. 4. Also check harness for short to ground and short to power. OK or NG OK >> GO TO 6. NG >> GO TO 5. 5. DETECT MALFUNCTIONING PART Check the following. ● Harness connectors M8, M201 (RHD models) ● Harness connectors M1, E101 (RHD models) ● Harness for open and short between stop lamp switch and ECM >> Repair open circuit or short to ground or short to power in harness connectors. 6. CHECK STOP LAMP SWITCH Refer to EC-1171, "Component Inspection" . OK or NG OK >> GO TO 7. NG >> Replace stop lamp switch. 7. CHECK INTERMITTENT INCIDENT Refer to EC-917, "TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT" . >> INSPECTION END EC-1170 PBIB2976E DTC P1805 BRAKE SWITCH [HR (WITH EURO-OBD)] Component Inspection BBS004I1 A STOP LAMP SWITCH 1. 2. 3. Turn ignition switch OFF. Disconnect stop lamp switch harness connector. Check continuity between stop lamp switch terminals 1 and 2 under the following conditions. EC C D E PBIB2285E Condition Brake pedal: Fully released. Brake pedal: Slightly depressed. Continuity F Should not exist. Should exist. G If NG, adjust stop lamp switch installation, refer to BR-6, "BRAKE PEDAL" , and perform step 3 again. H I J K L M EC-1171 DTC P2122, P2123 APP SENSOR [HR (WITH EURO-OBD)] DTC P2122, P2123 APP SENSOR Component Description PFP:18002 BBS004I2 The accelerator pedal position sensor is installed on the upper end of the accelerator pedal assembly. The sensor detects the accelerator position and sends a signal to the ECM. Accelerator pedal position sensor has two sensors. These sensors are a kind of potentiometers which transform the accelerator pedal position into output voltage, and emit the voltage signal to the ECM. In addition, these sensors detect the opening and closing speed of the accelerator pedal and feed the voltage signals to the ECM. The ECM judges the current opening angle of the accelerator pedal from these signals and controls the throttle control motor based on these signals. PBIB1741E Idle position of the accelerator pedal is determined by the ECM receiving the signal from the accelerator pedal position sensor. The ECM uses this signal for the engine operation such as fuel cut. CONSULT-II Reference Value in Data Monitor Mode BBS004I3 Specification data are reference values. MONITOR ITEM ACCEL SEN 1 ACCEL SEN 2* CLSD THL POS CONDITION ● ● ● SPECIFICATION Ignition switch: ON (Engine stopped) Accelerator pedal: Fully released 0.6 - 0.9V Accelerator pedal: Fully depressed 4.0 - 4.8V Ignition switch: ON (Engine stopped) Accelerator pedal: Fully released 0.6 - 0.9V Accelerator pedal: Fully depressed 3.9 - 4.8V Ignition switch: ON (Engine stopped) Accelerator pedal: Fully released ON Accelerator pedal: Slightly depressed OFF *: Accelerator pedal position sensor 2 signal is converted by ECM internally. Thus, it differs from ECM terminal voltage. On Board Diagnosis Logic BBS004I4 These self-diagnoses have the one trip detection logic. NOTE: If DTC P2122 or P2123 is displayed with DTC P1229, first perform the trouble diagnosis for DTC P1229. Refer to EC-1150, "DTC P1229 SENSOR POWER SUPPLY" . DTC No. Trouble diagnosis name DTC detecting condition P2122 2122 Accelerator pedal position sensor 1 circuit low input An excessively low voltage from the APP sensor 1 is sent to ECM. P2123 2123 Accelerator pedal position sensor 1 circuit high input An excessively high voltage from the APP sensor 1 is sent to ECM. Possible cause ● Harness or connectors (APP sensor 1 circuit is open or shorted.) ● Accelerator pedal position sensor (APP sensor 1) FAIL-SAFE MODE When the malfunction is detected, ECM enters fail-safe mode and the MI lights up. Engine operating condition in fail-safe mode The ECM controls the electric throttle control actuator in regulating the throttle opening in order for the idle position to be within +10 degrees. The ECM regulates the opening speed of the throttle valve to be slower than the normal condition. So, the acceleration will be poor. EC-1172 DTC P2122, P2123 APP SENSOR [HR (WITH EURO-OBD)] DTC Confirmation Procedure BBS004I5 A NOTE: If DTC Confirmation Procedure has been previously conducted, always turn ignition switch OFF and wait at least 10 seconds before conducting the next test. EC TESTING CONDITION: Before performing the following procedure, confirm that battery voltage is more than 10V at idle. WITH CONSULT-II 1. 2. 3. 4. C Turn ignition switch ON. Select “DATA MONITOR” mode with CONSULT-II. Start engine and let it idle for 1 second. If DTC is detected, go to EC-1177, "Diagnostic Procedure" . D E F SEF058Y WITH GST G Follow the procedure “WITH CONSULT-II” above. H I J K L M EC-1173 DTC P2122, P2123 APP SENSOR [HR (WITH EURO-OBD)] Wiring Diagram BBS004I6 LHD MODELS MBWA1482E EC-1174 DTC P2122, P2123 APP SENSOR [HR (WITH EURO-OBD)] Specification data are reference values and are measured between each terminal and ground. CAUTION: Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM's transistor. Use a ground other than ECM terminals, such as the ground. TERMINAL NO. 102 WIRE COLOR BR A EC ITEM Sensor power supply (APP sensor 2) CONDITION [Ignition switch: ON] DATA (DC Voltage) Approximately 5V C 0.3 - 0.6V D 1.95 - 2.4V E Approximately 0V F Approximately 5V G [Ignition switch: ON] 103 G Accelerator pedal position sensor 2 ● Engine stopped ● Accelerator pedal: Fully released [Ignition switch: ON] ● Engine stopped ● Accelerator pedal: Fully depressed [Engine is running] 104 106 B O Sensor ground (APP sensor 2) Sensor power supply (APP sensor 1) ● Warm-up condition ● Idle speed [Ignition switch: ON] [Ignition switch: ON] 110 W Accelerator pedal position sensor 1 ● Engine stopped ● Accelerator pedal: Fully released 0.6 - 0.9V H [Ignition switch: ON] ● Engine stopped ● Accelerator pedal: Fully depressed 3.9 - 4.7V I Approximately 0V J [Engine is running] 111 B Sensor ground (APP sensor 1) ● Warm-up condition ● Idle speed K L M EC-1175 DTC P2122, P2123 APP SENSOR [HR (WITH EURO-OBD)] RHD MODELS MBWA1483E EC-1176 DTC P2122, P2123 APP SENSOR [HR (WITH EURO-OBD)] Specification data are reference values and are measured between each terminal and ground. CAUTION: Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM's transistor. Use a ground other than ECM terminals, such as the ground. TERMINAL NO. 102 WIRE COLOR BR A EC ITEM CONDITION Sensor power supply (APP sensor 2) DATA (DC Voltage) [Ignition switch: ON] Approximately 5V C 0.3 - 0.6V D 1.95 - 2.4V E Approximately 0V F Approximately 5V G [Ignition switch: ON] 103 G Accelerator pedal position sensor 2 ● Engine stopped ● Accelerator pedal: Fully released [Ignition switch: ON] ● Engine stopped ● Accelerator pedal: Fully depressed [Engine is running] 104 106 B O Sensor ground (APP sensor 2) Sensor power supply (APP sensor 1) ● Warm-up condition ● Idle speed [Ignition switch: ON] [Ignition switch: ON] 110 W Accelerator pedal position sensor 1 ● Engine stopped ● Accelerator pedal: Fully released 0.6 - 0.9V H [Ignition switch: ON] ● Engine stopped ● Accelerator pedal: Fully depressed 3.9 - 4.7V I Approximately 0V J [Engine is running] 111 B Sensor ground (APP sensor 1) ● Warm-up condition ● Idle speed Diagnostic Procedure BBS004I7 1. CHECK GROUND CONNECTIONS 1. 2. Turn ignition switch OFF. Loosen and retighten ground screws on the body. Refer to EC-924, "Ground Inspection" . K L M MBIB1550E 1. IPDM E/R 2. Body ground OK or NG OK >> GO TO 2. NG >> Repair or replace ground connections. EC-1177 3. Body ground DTC P2122, P2123 APP SENSOR [HR (WITH EURO-OBD)] 2. CHECK APP SENSOR 1 POWER SUPPLY CIRCUIT 1. – – 2. Disconnect accelerator pedal position (APP) sensor harness connector (1). Accelerator pedal position sensor (2) Accelerator pedal (3) Turn ignition switch ON. PBIB2975E 3. Check voltage between APP sensor terminal 4 and ground with CONSULT-II or tester. Voltage: Approximately 5V OK or NG OK >> GO TO 4. NG >> GO TO 3. PBIA9606J 3. DETECT MALFUNCTIONING PART Check the following. ● Harness connectors M201, M8 (RHD models) ● Harness connectors M1, E101 (RHD models) ● Harness for open or short between APP sensor and ECM >> Repair open circuit or short to ground or short to power in harness or connectors. 4. CHECK APP SENSOR 1 GROUND CIRCUIT FOR OPEN AND SHORT 1. 2. 3. Turn ignition switch OFF. Disconnect ECM harness connector. Check harness continuity between ECM terminal 111 and APP sensor terminal 2. Refer to Wiring Diagram. Continuity should exist. 4. Also check harness for short to ground and short to power. OK or NG OK >> GO TO 6. NG >> GO TO 5. 5. DETECT MALFUNCTIONING PART Check the following. Harness connectors M201, M8 (RHD models) ● Harness connectors M1, E101 (RHD models) ● Harness for open or short between APP sensor and ECM ● >> Repair open circuit or short to ground or short to power in harness or connectors. EC-1178 DTC P2122, P2123 APP SENSOR [HR (WITH EURO-OBD)] 6. CHECK APP SENSOR 1 INPUT SIGNAL CIRCUIT FOR OPEN AND SHORT 1. A Check harness continuity between ECM terminal 110 and APP sensor terminal 3. Refer to Wiring Diagram. EC Continuity should exist. 2. Also check harness for short to ground and short to power. OK or NG OK >> GO TO 8. NG >> GO TO 7. C 7. DETECT MALFUNCTIONING PART D Check the following. ● Harness connectors M201, M8 (RHD models) ● Harness connectors M1, E101 (RHD models) ● Harness for open or short between APP sensor and ECM E F >> Repair open circuit or short to ground or short to power in harness or connectors. 8. CHECK APP SENSOR G Refer to EC-1180, "Component Inspection" . OK or NG OK >> GO TO 10. NG >> GO TO 9. H 9. REPLACE ACCELERATOR PEDAL ASSEMBLY 1. 2. 3. 4. Replace accelerator pedal assembly. Perform EC-857, "Accelerator Pedal Released Position Learning" . Perform EC-857, "Throttle Valve Closed Position Learning" . Perform EC-858, "Idle Air Volume Learning" . I J K >> INSPECTION END L 10. CHECK INTERMITTENT INCIDENT Refer to EC-917, "TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT" . M >> INSPECTION END EC-1179 DTC P2122, P2123 APP SENSOR [HR (WITH EURO-OBD)] Component Inspection BBS004I8 ACCELERATOR PEDAL POSITION SENSOR 1. 2. 3. Reconnect all harness connectors disconnected. Turn ignition switch ON. Check voltage between ECM terminals 110 (APP sensor 1 signal), 103 (APP sensor 2 signal) and ground under the following conditions. Terminal Accelerator pedal Voltage 110 (Accelerator pedal position sensor 1) Fully released 0.6 - 0.9V Fully depressed 3.9 - 4.7V Fully released 0.3 - 0.6V Fully depressed 1.95 - 2.4V 103 (Accelerator pedal position sensor 2) 4. 5. 6. 7. PBIA9572J If NG, replace accelerator pedal assembly and go to next step. Perform EC-857, "Accelerator Pedal Released Position Learning" . Perform EC-857, "Throttle Valve Closed Position Learning" . Perform EC-858, "Idle Air Volume Learning" . Removal and Installation BBS004I9 ACCELERATOR PEDAL Refer to ACC-2, "ACCELERATOR CONTROL SYSTEM" . EC-1180 DTC P2127, P2128 APP SENSOR [HR (WITH EURO-OBD)] DTC P2127, P2128 APP SENSOR Component Description PFP:18002 A BBS004IA The accelerator pedal position sensor is installed on the upper end of the accelerator pedal assembly. The sensor detects the acceleraEC tor position and sends a signal to the ECM. Accelerator pedal position sensor has two sensors. These sensors are a kind of potentiometers which transform the accelerator pedal C position into output voltage, and emit the voltage signal to the ECM. In addition, these sensors detect the opening and closing speed of the accelerator pedal and feed the voltage signals to the ECM. The ECM judges the current opening angle of the accelerator pedal from D these signals and controls the throttle control motor based on these signals. PBIB1741E Idle position of the accelerator pedal is determined by the ECM E receiving the signal from the accelerator pedal position sensor. The ECM uses this signal for the engine operation such as fuel cut. CONSULT-II Reference Value in Data Monitor Mode BBS004IB F Specification data are reference values. MONITOR ITEM ACCEL SEN 1 ACCEL SEN 2* CLSD THL POS CONDITION ● ● ● SPECIFICATION Ignition switch: ON (Engine stopped) Accelerator pedal: Fully released 0.6 - 0.9V Accelerator pedal: Fully depressed 4.0 - 4.8V Ignition switch: ON (Engine stopped) Accelerator pedal: Fully released 0.6 - 0.9V Accelerator pedal: Fully depressed 3.9 - 4.8V Ignition switch: ON (Engine stopped) Accelerator pedal: Fully released ON Accelerator pedal: Slightly depressed OFF G H I *: Accelerator pedal position sensor 2 signal is converted by ECM internally. Thus, it differs from ECM terminal voltage. On Board Diagnosis Logic BBS004IC J These self-diagnoses have the one trip detection logic. DTC No. P2127 2127 P2128 2128 Trouble diagnosis name Accelerator pedal position sensor 2 circuit low input Accelerator pedal position sensor 2 circuit high input DTC detecting condition An excessively low voltage from the APP sensor 2 is sent to ECM. An excessively high voltage from the APP sensor 2 is sent to ECM. Possible cause ● Harness or connectors (APP sensor 2 circuit is open or shorted.) [Crankshaft position sensor (POS) circuit is shorted.] (Refrigerant pressure sensor circuit is shorted.) ● Accelerator pedal position sensor (APP sensor 2) ● Crankshaft position sensor (POS) ● Refrigerant pressure sensor FAIL-SAFE MODE When the malfunction is detected, ECM enters fail-safe mode and the MI lights up. Engine operating condition in fail-safe mode The ECM controls the electric throttle control actuator in regulating the throttle opening in order for the idle position to be within +10 degrees. The ECM regulates the opening speed of the throttle valve to be slower than the normal condition. So, the acceleration will be poor. EC-1181 K L M DTC P2127, P2128 APP SENSOR [HR (WITH EURO-OBD)] DTC Confirmation Procedure BBS004ID NOTE: If DTC Confirmation Procedure has been previously conducted, always turn ignition switch OFF and wait at least 10 seconds before conducting the next test. TESTING CONDITION: Before performing the following procedure, confirm that battery voltage is more than 10V at idle. WITH CONSULT-II 1. 2. 3. 4. Turn ignition switch ON. Select “DATA MONITOR” mode with CONSULT-II. Start engine and let it idle for 1 second. If DTC is detected, go to EC-1187, "Diagnostic Procedure" . SEF058Y WITH GST Follow the procedure “WITH CONSULT-II” above. EC-1182 DTC P2127, P2128 APP SENSOR [HR (WITH EURO-OBD)] Wiring Diagram BBS004IE A LHD MODELS EC C D E F G H I J K L M MBWA1484E EC-1183 DTC P2127, P2128 APP SENSOR [HR (WITH EURO-OBD)] Specification data are reference values and are measured between each terminal and ground. CAUTION: Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM's transistor. Use a ground other than ECM terminals, such as the ground. TERMINAL NO. WIRE COLOR ITEM CONDITION DATA (DC Voltage) 74 W Sensor power supply (Refrigerant pressure sensor) [Ignition switch: ON] Approximately 5V 75 G Sensor power supply [Crankshaft position sensor (POS)] [Ignition switch: ON] Approximately 5V 102 B Sensor power supply (APP sensor 2) [Ignition switch: ON] Approximately 5V [Ignition switch: ON] 103 G Accelerator pedal position sensor 2 ● Engine stopped ● Accelerator pedal: Fully released 0.3 - 0.6V [Ignition switch: ON] ● Engine stopped ● Accelerator pedal: Fully depressed 1.95 - 2.4V [Engine is running] 104 106 B O Sensor ground (APP sensor 2) Sensor power supply (APP sensor 1) ● Warm-up condition ● Idle speed [Ignition switch: ON] Approximately 0V Approximately 5V [Ignition switch: ON] 110 W Accelerator pedal position sensor 1 ● Engine stopped ● Accelerator pedal: Fully released 0.6 - 0.9V [Ignition switch: ON] ● Engine stopped ● Accelerator pedal: Fully depressed 3.9 - 4.7V [Engine is running] 111 B Sensor ground (APP sensor 1) ● Warm-up condition ● Idle speed EC-1184 Approximately 0V DTC P2127, P2128 APP SENSOR [HR (WITH EURO-OBD)] RHD MODELS A EC C D E F G H I J K L M MBWA1485E EC-1185 DTC P2127, P2128 APP SENSOR [HR (WITH EURO-OBD)] Specification data are reference values and are measured between each terminal and ground. CAUTION: Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM's transistor. Use a ground other than ECM terminals, such as the ground. TERMINAL NO. WIRE COLOR ITEM CONDITION DATA (DC Voltage) 74 W Sensor power supply (Refrigerant pressure sensor) [Ignition switch: ON] Approximately 5V 75 G Sensor power supply [Crankshaft position sensor (POS)] [Ignition switch: ON] Approximately 5V 102 B Sensor power supply (APP sensor 2) [Ignition switch: ON] Approximately 5V [Ignition switch: ON] 103 G Accelerator pedal position sensor 2 ● Engine stopped ● Accelerator pedal: Fully released 0.3 - 0.6V [Ignition switch: ON] ● Engine stopped ● Accelerator pedal: Fully depressed 1.95 - 2.4V [Engine is running] 104 106 B O Sensor ground (APP sensor 2) Sensor power supply (APP sensor 1) ● Warm-up condition ● Idle speed [Ignition switch: ON] Approximately 0V Approximately 5V [Ignition switch: ON] 110 W Accelerator pedal position sensor 1 ● Engine stopped ● Accelerator pedal: Fully released 0.6 - 0.9V [Ignition switch: ON] ● Engine stopped ● Accelerator pedal: Fully depressed 3.9 - 4.7V [Engine is running] 111 B Sensor ground (APP sensor 1) ● Warm-up condition ● Idle speed EC-1186 Approximately 0V DTC P2127, P2128 APP SENSOR [HR (WITH EURO-OBD)] Diagnostic Procedure BBS004IF 1. CHECK GROUND CONNECTIONS 1. 2. A Turn ignition switch OFF. Loosen and retighten ground screws on the body. Refer to EC-924, "Ground Inspection" . EC C D E MBIB1550E 1. IPDM E/R 2. Body ground 3. F Body ground OK or NG OK >> GO TO 2. NG >> Repair or replace ground connections. G 2. CHECK APP SENSOR 2 POWER SUPPLY CIRCUIT-I 1. – – 2. H Disconnect accelerator pedal position (APP) sensor harness connector (1). Accelerator pedal position sensor (2) Accelerator pedal (3) Turn ignition switch ON. I J K PBIB2975E 3. Check voltage between APP sensor terminal 5 and ground with CONSULT-II or tester. L Voltage: Approximately 5V M OK or NG OK >> GO TO 7. NG >> GO TO 3. PBIA9607J EC-1187 DTC P2127, P2128 APP SENSOR [HR (WITH EURO-OBD)] 3. CHECK APP SENSOR 2 POWER SUPPLY CIRCUIT-II 1. 2. 3. Turn ignition switch OFF. Disconnect ECM harness connector. Check harness continuity between APP sensor terminal 5 and ECM terminal 102. Refer to Wiring Diagram. Continuity should exist. OK or NG OK >> GO TO 5. NG >> GO TO 4. 4. DETECT MALFUNCTIONING PART Check the following. ● Harness connectors M201, M8 (RHD models) ● Harness connectors M1, E101 (RHD models) ● Harness for open or short between APP sensor and ECM >> Repair open circuit in harness or connectors. 5. CHECK APP SENSOR 2 POWER SUPPLY CIRCUIT-III Check harness for short to power and short to ground, between the following terminals. ECM terminal Sensor terminal Reference Wiring Diagram 74 Refrigerant pressure sensor terminal 3 EC-1232, "Wiring Diagram" 75 Crankshaft position sensor (POS) terminal 1 EC-1044, "Wiring Diagram" 102 APP sensor terminal 5 EC-1183, "Wiring Diagram" OK or NG OK >> GO TO 6. NG >> Repair short to ground or short to power in harness or connectors. 6. CHECK COMPONENTS Check the following. ● Crankshaft position sensor (POS) (Refer to EC-1048, "Component Inspection" .) ● Refrigerant pressure sensor (Refer to ATC-85, "Refrigerant Pressure Sensor" .) OK or NG OK >> GO TO 13. NG >> Replace malfunctioning component. 7. CHECK APP SENSOR 2 GROUND CIRCUIT FOR OPEN AND SHORT 1. 2. 3. Turn ignition switch OFF. Disconnect ECM harness connector. Check harness continuity between ECM terminal 104 and APP sensor terminal 1. Refer to Wiring Diagram. Continuity should exist. 4. Also check harness for short to ground and short to power. OK or NG OK >> GO TO 9. NG >> GO TO 8. EC-1188 DTC P2127, P2128 APP SENSOR [HR (WITH EURO-OBD)] 8. DETECT MALFUNCTIONING PART A Check the following. ● Harness connectors M201, M8 (RHD models) ● Harness connectors M1, E101 (RHD models) ● Harness for open or short between APP sensor and ECM >> Repair open circuit or short to ground or short to power in harness or connectors. 9. CHECK APP SENSOR 2 INPUT SIGNAL CIRCUIT FOR OPEN AND SHORT 1. EC C D Check harness continuity between ECM terminal 103 and APP sensor terminal 6. Refer to Wiring Diagram. E Continuity should exist. 2. Also check harness for short to ground and short to power. OK or NG OK >> GO TO 11. NG >> GO TO 10. F 10. DETECT MALFUNCTIONING PART G Check the following. ● Harness connectors M201, M8 (RHD models) ● Harness connectors M1, E101 (RHD models) ● Harness for open or short between APP sensor and ECM H I >> Repair open circuit or short to ground or short to power in harness or connectors. 11. CHECK APP SENSOR J Refer to EC-1190, "Component Inspection" . OK or NG OK >> GO TO 13. NG >> GO TO 12. K 12. REPLACE ACCELERATOR PEDAL ASSEMBLY 1. 2. 3. 4. Replace accelerator pedal assembly. Perform EC-857, "Accelerator Pedal Released Position Learning" . Perform EC-857, "Throttle Valve Closed Position Learning" . Perform EC-858, "Idle Air Volume Learning" . >> INSPECTION END 13. CHECK INTERMITTENT INCIDENT Refer to EC-917, "TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT" . >> INSPECTION END EC-1189 L M DTC P2127, P2128 APP SENSOR [HR (WITH EURO-OBD)] Component Inspection BBS004IG ACCELERATOR PEDAL POSITION SENSOR 1. 2. 3. Reconnect all harness connectors disconnected. Turn ignition switch ON. Check voltage between ECM terminals 110 (APP sensor 1 signal), 103 (APP sensor 2 signal) and ground under the following conditions. Terminal Accelerator pedal Voltage 110 (Accelerator pedal position sensor 1) Fully released 0.6 - 0.9V Fully depressed 3.9 - 4.7V Fully released 0.3 - 0.6V Fully depressed 1.95 - 2.4V 103 (Accelerator pedal position sensor 2) 4. 5. 6. 7. PBIA9572J If NG, replace accelerator pedal assembly and go to next step. Perform EC-857, "Accelerator Pedal Released Position Learning" . Perform EC-857, "Throttle Valve Closed Position Learning" . Perform EC-858, "Idle Air Volume Learning" . Removal and Installation BBS004IH ACCELERATOR PEDAL Refer to ACC-2, "ACCELERATOR CONTROL SYSTEM" . EC-1190 DTC P2135 TP SENSOR [HR (WITH EURO-OBD)] DTC P2135 TP SENSOR Component Description PFP:16119 A BBS004II Electric throttle control actuator consists of throttle control motor, throttle position sensor, etc. The throttle position sensor responds to the throttle valve movement. The throttle position sensor has the two sensors. These sensors are a kind of potentiometers which transform the throttle valve position into output voltage, and emit the voltage signal to the ECM. In addition, these sensors detect the opening and closing speed of the throttle valve and feed the voltage signals to the ECM. The ECM judges the current opening angle of the throttle valve from these signals and the ECM controls the throttle control motor to make the throttle valve opening angle properly in response to driving condition. EC C D PBIB0145E E CONSULT-II Reference Value in Data Monitor Mode BBS004IJ Specification data are reference values. MONITOR ITEM CONDITION ● Ignition switch: ON (Engine stopped) Accelerator pedal: Fully released More than 0.36V ● Shift lever: D (A/T), 1st (M/T) Accelerator pedal: Fully depressed Less than 4.75V THRTL SEN 1 THRTL SEN 2* F SPECIFICATION G *: Throttle position sensor 2 signal is converted by ECM internally. Thus, it differs from ECM terminal voltage signal. On Board Diagnosis Logic BBS004IK This self-diagnosis has the one trip detection logic. NOTE: If DTC P2135 is displayed with DTC P1229, first perform the trouble diagnosis for DTC P1229. Refer to EC-1150, "DTC P1229 SENSOR POWER SUPPLY" . DTC No. P2135 2135 Trouble diagnosis name DTC detecting condition Throttle position sensor circuit range/performance Rationally incorrect voltage is sent to ECM compared with the signals from TP sensor 1 and TP sensor 2. Possible cause ● Harness or connector (TP sensor 1 and 2 circuit is open or shorted.) ● Electric throttle control actuator (TP sensor 1 and 2) H I J K L FAIL-SAFE MODE When the malfunction is detected, the ECM enters fail-safe mode and the MI lights up. Engine operation condition in fail-safe mode The ECM controls the electric throttle control actuator in regulating the throttle opening in order for the idle position to be within +10 degrees. The ECM regulates the opening speed of the throttle valve to be slower than the normal condition. So, the acceleration will be poor. EC-1191 M DTC P2135 TP SENSOR [HR (WITH EURO-OBD)] DTC Confirmation Procedure BBS004IL NOTE: If DTC Confirmation Procedure has been previously conducted, always turn ignition switch OFF and wait at least 10 seconds before conducting the next test. TESTING CONDITION: Before performing the following procedure, confirm that battery voltage is more than 10V at idle. WITH CONSULT-II 1. 2. 3. 4. Turn ignition switch ON. Select “DATA MONITOR” mode with CONSULT-II. Start engine and let it idle for 1 second. If DTC is detected, go to EC-1194, "Diagnostic Procedure" . SEF058Y WITH GST Follow the procedure “WITH CONSULT-II” above. EC-1192 DTC P2135 TP SENSOR [HR (WITH EURO-OBD)] Wiring Diagram BBS004IM A EC C D E F G H I J K L M MBWA1486E EC-1193 DTC P2135 TP SENSOR [HR (WITH EURO-OBD)] Specification data are reference values and are measured between each terminal and ground. CAUTION: Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM's transistor. Use a ground other than ECM terminals, such as the ground. TERMINAL NO. WIRE COLOR ITEM CONDITION DATA (DC Voltage) [Ignition switch: ON] 33 Y ● Engine stopped ● Shift lever: D (A/T), 1st (M/T) ● Accelerator pedal: Fully released Throttle position sensor 1 More than 0.36V [Ignition switch: ON] ● Engine stopped ● Shift lever: D (A/T), 1st (M/T) ● Accelerator pedal: Fully depressed Less than 4.75V [Ignition switch: ON] 34 R Throttle position sensor 2 ● Engine stopped ● Shift lever: D (A/T), 1st (M/T) ● Accelerator pedal: Fully released Less than 4.75V [Ignition switch: ON] ● Engine stopped ● Shift lever: D (A/T), 1st (M/T) ● Accelerator pedal: Fully depressed More than 0.36V [Engine is running] 36 72 BR L Sensor ground (Throttle position sensor) Sensor power supply (Throttle position sensor) ● Warm-up condition ● Idle speed Approximately 0V [Ignition switch: ON] Approximately 5V Diagnostic Procedure BBS004IN 1. CHECK GROUND CONNECTIONS 1. 2. Turn ignition switch OFF. Loosen and retighten ground screws on the body. Refer to EC-924, "Ground Inspection" . MBIB1550E 1. IPDM E/R 2. Body ground OK or NG OK >> GO TO 2. NG >> Repair or replace ground connections. EC-1194 3. Body ground DTC P2135 TP SENSOR [HR (WITH EURO-OBD)] 2. CHECK THROTTLE POSITION SENSOR POWER SUPPLY CIRCUIT 1. 2. A Disconnect electric throttle control actuator (1) harness connector. : Vehicle front Turn ignition switch ON. EC C D PBIB2965E 3. Check voltage between electric throttle control actuator terminal 1 and ground with CONSULT-II or tester. E Voltage: Approximately 5V F OK or NG OK >> GO TO 3. NG >> Repair open circuit or short to ground or short to power in harness or connectors. G PBIA9580J H 3. CHECK THROTTLE POSITION SENSOR GROUND CIRCUIT FOR OPEN AND SHORT 1. 2. 3. Turn ignition switch OFF. Disconnect ECM harness connector. Check harness continuity between electric throttle control actuator terminal 4 and ECM terminal 36. Refer to Wiring Diagram. I J Continuity should exist. 4. Also check harness for short to ground and short to power. OK or NG OK >> GO TO 4. NG >> Repair open circuit or short to ground or short to power in harness or connectors. K L 4. CHECK THROTTLE POSITION SENSOR INPUT SIGNAL CIRCUIT FOR OPEN AND SHORT 1. Check harness continuity between electric throttle control actuator terminal 2 and ECM terminal 33, electric throttle control actuator terminal 3 and ECM terminal 34. Refer to Wiring Diagram. Continuity should exist. 2. Also check harness for short to ground and short to power. OK or NG OK >> GO TO 5. NG >> Repair open circuit or short to ground or short to power in harness or connectors. 5. CHECK THROTTLE POSITION SENSOR Refer to EC-1196, "Component Inspection" . OK or NG OK >> GO TO 7. NG >> GO TO 6. EC-1195 M DTC P2135 TP SENSOR [HR (WITH EURO-OBD)] 6. REPLACE ELECTRIC THROTTLE CONTROL ACTUATOR 1. 2. 3. Replace the electric throttle control actuator. Perform EC-857, "Throttle Valve Closed Position Learning" . Perform EC-858, "Idle Air Volume Learning" . >> INSPECTION END 7. CHECK INTERMITTENT INCIDENT Refer to EC-917, "TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT" . >> INSPECTION END Component Inspection BBS004IO THROTTLE POSITION SENSOR 1. 2. 3. 4. 5. Reconnect all harness connectors disconnected. Perform EC-857, "Throttle Valve Closed Position Learning" . Turn ignition switch ON. Set shift lever to D position (A/T) or 1st position (M/T). Check voltage between ECM terminals 33 (TP sensor 1 signal), 34 (TP sensor 2 signal) and ground under the following conditions. Terminal Accelerator pedal Voltage 33 (Throttle position sensor 1) Fully released More than 0.36V Fully depressed Less than 4.75V Fully released Less than 4.75V Fully depressed More than 0.36V 34 (Throttle position sensor 2) 6. 7. 8. If NG, replace electric throttle control actuator and go to the next step. Perform EC-857, "Throttle Valve Closed Position Learning" . Perform EC-858, "Idle Air Volume Learning" . Removal and Installation PBIB3038E BBS004IP ELECTRIC THROTTLE CONTROL ACTUATOR Refer to EM-120, "INTAKE MANIFOLD" . EC-1196 DTC P2138 APP SENSOR [HR (WITH EURO-OBD)] DTC P2138 APP SENSOR Component Description PFP:18002 A BBS004IQ The accelerator pedal position sensor is installed on the upper end of the accelerator pedal assembly. The sensor detects the acceleraEC tor position and sends a signal to the ECM. Accelerator pedal position sensor has two sensors. These sensors are a kind of potentiometers which transform the accelerator pedal C position into output voltage, and emit the voltage signal to the ECM. In addition, these sensors detect the opening and closing speed of the accelerator pedal and feed the voltage signals to the ECM. The ECM judges the current opening angle of the accelerator pedal from D these signals and controls the throttle control motor based on these signals. PBIB1741E Idle position of the accelerator pedal is determined by the ECM E receiving the signal from the accelerator pedal position sensor. The ECM uses this signal for the engine operation such as fuel cut. CONSULT-II Reference Value in Data Monitor Mode BBS004IR F Specification data are reference values. MONITOR ITEM ACCEL SEN 1 ACCEL SEN 2* CLSD THL POS CONDITION ● ● ● SPECIFICATION Ignition switch: ON (Engine stopped) Accelerator pedal: Fully released 0.6 - 0.9V Accelerator pedal: Fully depressed 4.0 - 4.8V Ignition switch: ON (Engine stopped) Accelerator pedal: Fully released 0.6 - 0.9V Accelerator pedal: Fully depressed 3.9 - 4.8V Ignition switch: ON (Engine stopped) Accelerator pedal: Fully released ON Accelerator pedal: Slightly depressed OFF G H I *: Accelerator pedal position sensor 2 signal is converted by ECM internally. Thus, it differs from ECM terminal voltage. On Board Diagnosis Logic BBS004IS This self-diagnosis has the one trip detection logic. NOTE: If DTC P2138 is displayed with DTC P1229, first perform the trouble diagnosis for DTC P1229. Refer to EC-1150, "DTC P1229 SENSOR POWER SUPPLY" . DTC No. Trouble diagnosis name DTC detecting condition Possible cause ● P2138 2138 Accelerator pedal position sensor circuit range/performance Rationally incorrect voltage is sent to ECM compared with the signals from APP sensor 1 and APP sensor 2. EC-1197 Harness or connector (APP sensor 1 and 2 circuit is open or shorted.) [Crankshaft position sensor (POS) circuit is shorted.] (Refrigerant pressure sensor circuit is shorted.) ● Accelerator pedal position sensor (APP sensor 1 and 2) ● Crankshaft position sensor (POS) ● Refrigerant pressure sensor J K L M DTC P2138 APP SENSOR [HR (WITH EURO-OBD)] FAIL-SAFE MODE When the malfunction is detected, ECM enters fail-safe mode and the MI lights up. Engine operating condition in fail-safe mode The ECM controls the electric throttle control actuator in regulating the throttle opening in order for the idle position to be within +10 degrees. The ECM regulates the opening speed of the throttle valve to be slower than the normal condition. So, the acceleration will be poor. DTC Confirmation Procedure BBS004IT NOTE: If DTC Confirmation Procedure has been previously conducted, always turn ignition switch OFF and wait at least 10 seconds before conducting the next test. TESTING CONDITION: Before performing the following procedure, confirm that battery voltage is more than 10V at idle. WITH CONSULT-II 1. 2. 3. 4. Turn ignition switch ON. Select “DATA MONITOR” mode with CONSULT-II. Start engine and let it idle for 1 second. If DTC is detected, go to EC-1203, "Diagnostic Procedure" . SEF058Y WITH GST Follow the procedure “WITH CONSULT-II” above. EC-1198 DTC P2138 APP SENSOR [HR (WITH EURO-OBD)] Wiring Diagram BBS004IU A LHD MODELS EC C D E F G H I J K L M MBWA1487E EC-1199 DTC P2138 APP SENSOR [HR (WITH EURO-OBD)] Specification data are reference values and are measured between each terminal and ground. CAUTION: Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM's transistor. Use a ground other than ECM terminals, such as the ground. TERMINAL NO. WIRE COLOR ITEM CONDITION DATA (DC Voltage) 74 W Sensor power supply (Refrigerant pressure sensor) [Ignition switch: ON] Approximately 5V 75 G Sensor power supply [Crankshaft position sensor (POS)] [Ignition switch: ON] Approximately 5V 102 BR Sensor power supply (APP sensor 2) [Ignition switch: ON] Approximately 5V [Ignition switch: ON] 103 G Accelerator pedal position sensor 2 ● Engine stopped ● Accelerator pedal: Fully released 0.3 - 0.6V [Ignition switch: ON] ● Engine stopped ● Accelerator pedal: Fully depressed 1.95 - 2.4V [Engine is running] 104 106 B O Sensor ground (APP sensor 2) Sensor power supply (APP sensor 1) ● Warm-up condition ● Idle speed [Ignition switch: ON] Approximately 0V Approximately 5V [Ignition switch: ON] 110 W Accelerator pedal position sensor 1 ● Engine stopped ● Accelerator pedal: Fully released 0.6 - 0.9V [Ignition switch: ON] ● Engine stopped ● Accelerator pedal: Fully depressed 3.9 - 4.7V [Engine is running] 111 B Sensor ground (APP sensor 1) ● Warm-up condition ● Idle speed EC-1200 Approximately 0V DTC P2138 APP SENSOR [HR (WITH EURO-OBD)] RHD MODELS A EC C D E F G H I J K L M MBWA1488E EC-1201 DTC P2138 APP SENSOR [HR (WITH EURO-OBD)] Specification data are reference values and are measured between each terminal and ground. CAUTION: Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM's transistor. Use a ground other than ECM terminals, such as the ground. TERMINAL NO. WIRE COLOR ITEM CONDITION DATA (DC Voltage) 74 W Sensor power supply (Refrigerant pressure sensor) [Ignition switch: ON] Approximately 5V 75 G Sensor power supply [Crankshaft position sensor (POS)] [Ignition switch: ON] Approximately 5V 102 BR Sensor power supply (APP sensor 2) [Ignition switch: ON] Approximately 5V [Ignition switch: ON] 103 G Accelerator pedal position sensor 2 ● Engine stopped ● Accelerator pedal: Fully released 0.3 - 0.6V [Ignition switch: ON] ● Engine stopped ● Accelerator pedal: Fully depressed 1.95 - 2.4V [Engine is running] 104 106 B O Sensor ground (APP sensor 2) Sensor power supply (APP sensor 1) ● Warm-up condition ● Idle speed [Ignition switch: ON] Approximately 0V Approximately 5V [Ignition switch: ON] 110 W Accelerator pedal position sensor 1 ● Engine stopped ● Accelerator pedal: Fully released 0.6 - 0.9V [Ignition switch: ON] ● Engine stopped ● Accelerator pedal: Fully depressed 3.9 - 4.7V [Engine is running] 111 B Sensor ground (APP sensor 1) ● Warm-up condition ● Idle speed EC-1202 Approximately 0V DTC P2138 APP SENSOR [HR (WITH EURO-OBD)] Diagnostic Procedure BBS004IV 1. CHECK GROUND CONNECTIONS 1. 2. A Turn ignition switch OFF. Loosen and retighten ground screws on the body. Refer to EC-924, "Ground Inspection" . EC C D E MBIB1550E 1. IPDM E/R 2. Body ground 3. F Body ground OK or NG OK >> GO TO 2. NG >> Repair or replace ground connections. G 2. CHECK APP SENSOR 1 POWER SUPPLY CIRCUIT 1. – – 2. H Disconnect accelerator pedal position (APP) sensor harness connector (1). Accelerator pedal position sensor (2) Accelerator pedal (3) Turn ignition switch ON. I J K PBIB2975E 3. Check voltage between APP sensor terminal 4 and ground with CONSULT-II or tester. L Voltage: Approximately 5V M OK or NG OK >> GO TO 4. NG >> GO TO 3. PBIA9606J 3. DETECT MALFUNCTIONING PART Check the following. ● Harness connectors M201, M8 (RHD models) ● Harness connectors M1, E101 (RHD models) ● Harness for open or short between APP sensor and ECM >> Repair open circuit or short to ground or short to power in harness or connectors. EC-1203 DTC P2138 APP SENSOR [HR (WITH EURO-OBD)] 4. CHECK APP SENSOR 2 POWER SUPPLY CIRCUIT-I 1. 2. Turn ignition switch ON. Check voltage between APP sensor terminal 5 and ground with CONSULT-II or tester. Voltage: Approximately 5V OK or NG OK >> GO TO 9. NG >> GO TO 5. PBIA9607J 5. CHECK APP SENSOR 2 POWER SUPPLY CIRCUIT-II 1. 2. 3. Turn ignition switch OFF. Disconnect ECM harness connector. Check harness continuity between APP sensor terminal 5 and ECM terminal 102. Refer to Wiring Diagram. Continuity should exist. OK or NG OK >> GO TO 7. NG >> GO TO 6. 6. DETECT MALFUNCTIONING PART Check the following. ● Harness connectors M201, M8 (RHD models) ● Harness connectors M1, E101 (RHD models) ● Harness for open between APP sensor and ECM >> Repair open circuit in harness or connectors. 7. CHECK APP SENSOR 2 POWER SUPPLY CIRCUIT-III Check harness for short to power and short to ground, between the following terminals. ECM terminal Sensor terminal Reference Wiring Diagram 74 Refrigerant pressure sensor terminal 3 EC-1232, "Wiring Diagram" 75 Crankshaft position sensor (POS) terminal 1 EC-1044, "Wiring Diagram" 102 APP sensor terminal 5 EC-1199, "Wiring Diagram" OK or NG OK >> GO TO 8. NG >> Repair short to ground or short to power in harness or connectors. 8. CHECK COMPONENTS Check the following. Crankshaft position sensor (POS) (Refer to EC-1048, "Component Inspection" .) ● Refrigerant pressure sensor (Refer to ATC-85, "Refrigerant Pressure Sensor" .) OK or NG OK >> GO TO 15. NG >> Replace malfunctioning component. ● EC-1204 DTC P2138 APP SENSOR [HR (WITH EURO-OBD)] 9. CHECK APP SENSOR GROUND CIRCUIT FOR OPEN AND SHORT 1. 2. 3. A Turn ignition switch OFF. Disconnect ECM harness connector. Check harness continuity between ECM terminal 111 and APP sensor terminal 2, ECM terminal 104 and EC APP sensor terminal 1. Refer to Wiring Diagram. C Continuity should exist. 4. Also check harness for short to ground and short to power. OK or NG OK >> GO TO 11. NG >> GO TO 10. D E 10. DETECT MALFUNCTIONING PART Check the following. Harness connectors M201, M8 (RHD models) ● Harness connectors M1, E101 (RHD models) ● Harness for open between APP sensor and ECM ● F G >> Repair open circuit in harness or connectors. 11. CHECK APP SENSOR INPUT SIGNAL CIRCUIT FOR OPEN AND SHORT 1. Check harness continuity between ECM terminal 110 and APP sensor terminal 3, ECM terminal 103 and APP sensor terminal 6. Refer to Wiring Diagram. H I Continuity should exist. 2. Also check harness for short to ground and short to power. OK or NG OK >> GO TO 13. NG >> GO TO 12. 12. DETECT MALFUNCTIONING PART J K L Check the following. ● Harness connectors M201, M8 (RHD models) ● Harness connectors M1, E101 (RHD models) ● Harness for open between APP sensor and ECM >> Repair open circuit in harness or connectors. 13. CHECK APP SENSOR Refer to EC-1206, "Component Inspection" . OK or NG OK >> GO TO 15. NG >> GO TO 14. EC-1205 M DTC P2138 APP SENSOR [HR (WITH EURO-OBD)] 14. REPLACE ACCELERATOR PEDAL ASSEMBLY 1. 2. 3. 4. Replace accelerator pedal assembly. Perform EC-857, "Accelerator Pedal Released Position Learning" . Perform EC-857, "Throttle Valve Closed Position Learning" . Perform EC-858, "Idle Air Volume Learning" . >> INSPECTION END 15. CHECK INTERMITTENT INCIDENT Refer to EC-917, "TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT" . >> INSPECTION END Component Inspection BBS004IW ACCELERATOR PEDAL POSITION SENSOR 1. 2. 3. Reconnect all harness connectors disconnected. Turn ignition switch ON. Check voltage between ECM terminals 110 (APP sensor 1 signal), 103 (APP sensor 2 signal) and ground under the following conditions. Terminal Accelerator pedal Voltage 110 (Accelerator pedal position sensor 1) Fully released 0.6 - 0.9V Fully depressed 3.9 - 4.7V Fully released 0.3 - 0.6V Fully depressed 1.95 - 2.4V 103 (Accelerator pedal position sensor 2) 4. 5. 6. 7. PBIA9572J If NG, replace accelerator pedal assembly and go to next step. Perform EC-857, "Accelerator Pedal Released Position Learning" . Perform EC-857, "Throttle Valve Closed Position Learning" . Perform EC-858, "Idle Air Volume Learning" . Removal and Installation BBS004IX ACCELERATOR PEDAL Refer to ACC-2, "ACCELERATOR CONTROL SYSTEM" . EC-1206 ELECTRICAL LOAD SIGNAL [HR (WITH EURO-OBD)] ELECTRICAL LOAD SIGNAL CONSULT-II Reference Value in Data Monitor Mode PFP:25350 A BBS004J1 Specification data are reference values. MONITOR ITEM LOAD SIGNAL CONDITION ● HEATER FAN SW ● Ignition switch: ON Ignition switch: ON SPECIFICATION Rear window defogger switch is ON and/or lighting switch is in 2nd position. ON Rear window defogger switch is OFF and lighting switch is OFF. OFF Heater fan is operating. ON Heater fan is not operating. OFF Diagnostic Procedure C D BBS004J2 1. CHECK LOAD SIGNAL CIRCUIT OVERALL FUNCITION-I 1. 2. E Turn ignition switch ON. Check “LOAD SIGNAL” in “DATA MONITOR” mode with CONSULT-II under the following conditions. Condition EC F LOAD SIGNAL Lighting switch: ON at 2nd position ON Lighting switch: OFF OFF G OK or NG OK >> GO TO 2. NG >> GO TO 4. H PBIB0103E I 2. CHECK LOAD SIGNAL CIRCUIT OVERALL FUNCTION-II J Check “LOAD SIGNAL” in “DATA MONITOR” mode with CONSULTII under the following conditions. Condition LOAD SIGNAL Rear window defogger switch: ON ON Rear window defogger switch: OFF OFF K L OK or NG OK >> GO TO 3. NG >> GO TO 5. M PBIB0103E 3. CHECK HEATER FAN SIGNAL CIRCUIT OVERALL FUNCTION Check “HEATER FAN SW” in “DATA MONITOR” mode with CONSULT-II under the following conditions. Condition HEATER FAN SW Heater fan control switch: ON ON Heater fan control switch: OFF OFF OK or NG OK >> INSPECTION END. NG >> GO TO 6. PBIB1995E EC-1207 ELECTRICAL LOAD SIGNAL [HR (WITH EURO-OBD)] 4. CHECK HEADLAMP SYSTEM Refer to LT-7, "HEADLAMP -CONVENTIONAL TYPE-" or LT-35, "HEADLAMP - DAYTIME LIGHT SYSTEM ". >> INSPECTION END 5. CHECK REAR WINDOW DEFOGGER SYSTEM Refer to GW-12, "REAR WINDOW DEFOGGER" . >> INSPECTION END 6. CHECK HEATER FAN CONTROL SYSTEM Refer to ATC-26, "TROUBLE DIAGNOSIS" (models with automatic air conditioner), MTC-23, "TROUBLE DIAGNOSIS" (models with manual air conditioner). >> INSPECTION END EC-1208 FUEL INJECTOR [HR (WITH EURO-OBD)] FUEL INJECTOR Component Description PFP:16600 A BBS004J3 The fuel injector is a small, precise solenoid valve. When the ECM supplies a ground to the fuel injector circuit, the coil in the fuel injector is energized. The energized coil pulls the ball valve back and allows fuel to flow through the fuel injector into the intake manifold. The amount of fuel injected depends upon the injection pulse duration. Pulse duration is the length of time the fuel injector remains open. The ECM controls the injection pulse duration based on engine fuel needs. EC C D SEF375Z E CONSULT-II Reference Value in Data Monitor Mode BBS004J4 Specification data are reference values. MONITOR ITEM B/FUEL SCHDL INJ PULSE-B1 CONDITION SPECIFICATION F See EC-907, "TROUBLE DIAGNOSIS - SPECIFICATION VALUE" . ● Engine: After warming up ● Air conditioner switch: OFF ● Shift lever: P or N (A/T), Neutral (M/T) ● No load Idle 2.0 - 3.0 msec 2,000 rpm 1.9 - 2.9 msec G H I J K L M EC-1209 FUEL INJECTOR [HR (WITH EURO-OBD)] Wiring Diagram BBS004J5 MBWA1489E EC-1210 FUEL INJECTOR [HR (WITH EURO-OBD)] Specification data are reference values and are measured between each terminal and ground. Pulse signal is measured by CONSULT-II. A CAUTION: Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM's transistor. Use a ground other than ECM terminals, such as the ground. EC TERMINAL NO. WIRE COLOR ITEM CONDITION DATA (DC Voltage) C BATTERY VOLTAGE [Engine is running] 25 29 30 31 R O GR L ● Warm-up condition ● Idle speed (11 - 14V) D NOTE: The pulse cycle changes depending on rpm at idle Fuel injector No. 4 Fuel injector No. 3 Fuel injector No. 2 Fuel injector No. 1 E PBIB0529E BATTERY VOLTAGE F (11 - 14V) [Engine is running] ● Warm-up condition ● Engine speed: 2,000 rpm G H PBIA4943J : Average voltage for pulse signal (Actual pulse signal can be confirmed by oscilloscope.) I Diagnostic Procedure BBS004J6 1. INSPECTION START J Turn ignition switch to START. Is any cylinder ignited? Yes or No Yes >> GO TO 2. No >> GO TO 3. K L M EC-1211 FUEL INJECTOR [HR (WITH EURO-OBD)] 2. CHECK OVERALL FUNCTION With CONSULT-II Start engine. Perform “POWER BALANCE” in “ACTIVE TEST” mode with CONSULT-II. 3. Make sure that each circuit produces a momentary engine speed drop. 1. 2. PBIB0133E Without CONSULT-II 1. Start engine. 2. Listen to each fuel injector operating sound. Clicking noise should be heard. PBIB1986E OK or NG OK >> INSPECTION END NG >> GO TO 3. EC-1212 FUEL INJECTOR [HR (WITH EURO-OBD)] 3. CHECK FUEL INJECTOR POWER SUPPLY CIRCUIT 1. 2. – 3. A Turn ignition switch OFF. Disconnect fuel injector (2) harness connector. Ignition coil (1) Turn ignition switch ON. EC C D PBIB2968E E 4. Check voltage between fuel injector terminal 1 and ground with CONSULT-II or tester. F Voltage: Battery voltage OK or NG OK >> GO TO 5. NG >> GO TO 4. G H PBIB0582E 4. DETECT MALFUNCTIONING PART I Check the following. ● Harness connectors E59, F1 ● IPDM E/R harness connector E10 ● 10A fuse ● Harness for open or short between fuel injector and fuse J K >> Repair open circuit or short to ground or short to power in harness or connectors. 5. CHECK FUEL INJECTOR OUTPUT SIGNAL CIRCUIT FOR OPEN AND SHORT 1. 2. 3. Turn ignition switch OFF. Disconnect ECM harness connector. Check harness continuity between fuel injector terminal 2 and ECM terminals 25, 29, 30, 31. Refer to Wiring Diagram. Continuity should exist. 4. Also check harness for short to ground and short to power. OK or NG OK >> GO TO 6. NG >> Repair open circuit or short to ground or short to power in harness or connectors. 6. CHECK FUEL INJECTOR Refer to EC-1214, "Component Inspection" . OK or NG OK >> GO TO 7. NG >> Replace fuel injector. EC-1213 L M FUEL INJECTOR [HR (WITH EURO-OBD)] 7. CHECK INTERMITTENT INCIDENT Refer to EC-917, "TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT" . >> INSPECTION END Component Inspection BBS004J7 FUEL INJECTOR 1. 2. Disconnect fuel injector harness connector. Check resistance between terminals as shown in the figure. Resistance: 11.1 - 14.5Ω [at 10 - 60°C (50 - 140°F)] PBIB1727E Removal and Installation BBS004J8 FUEL INJECTOR Refer to EM-135, "FUEL INJECTOR AND FUEL TUBE" . EC-1214 FUEL PUMP [HR (WITH EURO-OBD)] FUEL PUMP Description PFP:17042 A BBS004J9 SYSTEM DESCRIPTION Sensor Input Signal to ECM Crankshaft position sensor (POS) Camshaft position sensor (PHASE) Engine speed* Battery Battery voltage* ECM Function Actuator Fuel pump control EC Fuel pump relay C *: ECM determines the start signal status by the signals of engine speed and battery voltage. The ECM activates the fuel pump for several seconds after the ignition switch is turned ON to improve engine startability. If the ECM receives a engine speed signal from the crankshaft position sensor (POS) and camshaft position sensor (PHASE), it knows that the engine is rotating, and causes the pump to operate. If the engine speed signal is not received when the ignition switch is ON, the engine stalls. The ECM stops pump operation and prevents battery discharging, thereby improving safety. The ECM does not directly drive the fuel pump. It controls the ON/OFF fuel pump relay, which in turn controls the fuel pump. Condition D E Fuel pump operation Ignition switch is turned to ON Operates for 1 second Engine running and cranking Operates When engine is stopped Stops in 1.5 seconds Except as shown above Stops F G COMPONENT DESCRIPTION H A turbine type design fuel pump is used in the fuel tank. I J K MBIB0291E CONSULT-II Reference Value in Data Monitor Mode BBS004JA L Specification data are reference values. MONITOR ITEM FUEL PUMP RLY CONDITION ● For 1 second after turning ignition switch ON ● Engine running or cranking ● Except above conditions SPECIFICATION ON OFF EC-1215 M FUEL PUMP [HR (WITH EURO-OBD)] Wiring Diagram BBS004JB MBWA1490E EC-1216 FUEL PUMP [HR (WITH EURO-OBD)] Specification data are reference values and are measured between each terminal and ground. CAUTION: Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM's transistor. Use a ground other than ECM terminals, such as the ground. TERMINAL NO. EC WIRE COLOR ITEM CONDITION DATA (DC Voltage) [Ignition switch: ON] ● 23 R A Fuel pump relay For 1 second after turning ignition switch ON C 0 - 1.0V [Engine is running] [Ignition switch: ON] ● More than 1 second after turning ignition switch ON D BATTERY VOLTAGE (11 - 14V) E Diagnostic Procedure BBS004JC 1. CHECK OVERALL FUNCTION 1. 2. – F Turn ignition switch ON. Pinch fuel feed hose (1) with two fingers. Illustration shows the view with intake air duct removed. G Fuel pressure pulsation should be felt on the fuel feed hose for 1 second after ignition switch is turned ON. H OK or NG OK >> INSPECTION END NG >> GO TO 2. I PBIB2978E 2. CHECK FUEL PUMP POWER SUPPLY CIRCUIT-I 1. 2. 3. 4. J Turn ignition switch OFF. Disconnect ECM harness connector. Turn ignition switch ON. Check voltage between ECM terminal 23 and ground with CONSULT-II or tester. K L Voltage: Battery voltage OK or NG OK >> GO TO 5. NG >> GO TO 3. M PBIA9573J EC-1217 FUEL PUMP [HR (WITH EURO-OBD)] 3. CHECK FUEL PUMP POWER SUPPLY CIRCUIT-II 1. 2. 3. Turn ignition switch OFF. Disconnect IPDM E/R harness connector E5. Check harness continuity between ECM terminal 23 and IPDM E/R terminal 69. Refer to Wiring Diagram. Continuity should exist. 4. Also check harness for short to ground and short to power. OK or NG OK >> GO TO 11. NG >> GO TO 4. 4. DETECT MALFUNCTIONING PART Check the following. ● Harness or connectors E59, F1 ● Harness for open or short between IPDM E/R and ECM >> Repair harness or connectors. 5. CHECK FUEL PUMP POWER SUPPLY CIRCUIT-III 1. 2. 3. 4. Turn ignition switch OFF. Reconnect all harness connectors disconnected. Disconnect “fuel level sensor unit and fuel pump” harness connector. Turn ignition switch ON. MBIB0288E 5. Check voltage between “fuel level sensor unit and fuel pump” terminal 1 and ground with CONSULT-II or tester. Voltage: Battery voltage should exist for 1 second after ignition switch is turned ON. OK or NG OK >> GO TO 9. NG >> GO TO 6. PBIB3004E EC-1218 FUEL PUMP [HR (WITH EURO-OBD)] 6. CHECK 15A FUSE A 1. Turn ignition switch OFF. 2. Disconnect 15A fuse. 3. Check 15A fuse. OK or NG OK >> GO TO 7. NG >> Replace fuse. EC C 7. CHECK FUEL PUMP POWER SUPPLY CIRCUIT-IV 1. 2. Disconnect IPDM E/R harness connector E10. Check harness continuity between IPDM E/R terminal 20 and “fuel level sensor unit and fuel pump” terminal 1. Refer to Wiring Diagram. D E Continuity should exist. 3. Also check harness for short to ground and short to power. OK or NG OK >> GO TO 11. NG >> GO TO 8. F G 8. DETECT MALFUNCTIONING PART H Check the following. ● Harness or connectors M1, E101 ● Harness or connectors M72, B21 ● Harness for open or short between IPDM E/R and “fuel level sensor unit and fuel pump” I J >> Repair harness or connectors. 9. CHECK FUEL PUMP GROUND CIRCUIT 1. Check harness continuity between “fuel level sensor unit and fuel pump” terminal 3 and ground. Refer to Wiring Diagram. Continuity should exist. K L 2. Also check harness for short to power. OK or NG OK >> GO TO 10. NG >> Repair or replace harness or connectors. 10. CHECK FUEL PUMP Refer to EC-1220, "Component Inspection" . OK or NG OK >> GO TO 11. NG >> Replace “fuel level sensor unit and fuel pump”. 11. CHECK INTERMITTENT INCIDENT Refer to EC-917, "TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT" . OK or NG OK >> Replace IPDM E/R. Refer to PG-18, "IPDM E/R (INTELLIGENT POWER DISTRIBUTION MODULE ENGINE ROOM)" NG >> Repair or replace harness or connectors. EC-1219 M FUEL PUMP [HR (WITH EURO-OBD)] Component Inspection BBS004JD FUEL PUMP 1. 2. Disconnect “fuel level sensor unit and fuel pump” harness connector. Check resistance between “fuel level sensor unit and fuel pump” terminals 1 and 3. Resistance: Approximately 0.2 - 5.0Ω [at 25°C (77°F)] MBIB0311E Removal and Installation BBS004JE FUEL PUMP Refer to FL-15, "FUEL LEVEL SENSOR UNIT, FUEL FILTER AND FUEL PUMP ASSEMBLY" . EC-1220 IGNITION SIGNAL [HR (WITH EURO-OBD)] IGNITION SIGNAL Component Description PFP:22448 A BBS004JF IGNITION COIL & POWER TRANSISTOR The ignition signal from the ECM is sent to and amplified by the power transistor. The power transistor turns ON and OFF the ignition coil (1) primary circuit. This ON/OFF operation induces the proper high voltage in the coil secondary circuit. ● Fuel injector (2) EC C D PBIB2968E E F G H I J K L M EC-1221 IGNITION SIGNAL [HR (WITH EURO-OBD)] Wiring Diagram BBS004JG MBWA1491E EC-1222 IGNITION SIGNAL [HR (WITH EURO-OBD)] Specification data are reference values and are measured between each terminal and ground. CAUTION: Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM's transistor. Use a ground other than ECM terminals, such as the ground. TERMINAL NO. WIRE COLOR EC ITEM CONDITION [Engine is running] [Ignition switch: OFF] ● 32 P ECM relay (Self shut-off) G Power supply for ECM For a few seconds after turning ignition switch OFF [Ignition switch: OFF] ● 105 A More than a few seconds after turning ignition switch OFF [Ignition switch: ON] DATA (DC Voltage) C 0 - 1.0V D BATTERY VOLTAGE (11 - 14V) E BATTERY VOLTAGE (11 - 14V) F G H I J K L M EC-1223 IGNITION SIGNAL [HR (WITH EURO-OBD)] MBWA1492E EC-1224 IGNITION SIGNAL [HR (WITH EURO-OBD)] Specification data are reference values and are measured between each terminal and ground. Pulse signal is measured by CONSULT-II. A CAUTION: Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM's transistor. Use a ground other than ECM terminals, such as the ground. EC TERMINAL NO. WIRE COLOR ITEM CONDITION C [Engine is running] 17 18 21 22 DATA (DC Voltage) V BR G Y ● Warm-up condition ● Idle speed 0 - 0.3V D NOTE: The pulse cycle changes depending on rpm at idle Ignition signal No. 1 Ignition signal No. 2 Ignition signal No. 4 Ignition signal No. 3 E PBIA9265J 0.2 - 0.5V F [Engine is running] ● Warm-up condition ● Engine speed: 2,000 rpm G PBIA9266J H : Average voltage for pulse signal (Actual pulse signal can be confirmed by oscilloscope.) Diagnostic Procedure BBS004JH I 1. CHECK ENGINE START Turn ignition switch OFF, and restart engine. Is engine running? Yes or No Yes (With CONSULT-II)>>GO TO 2. Yes (Without CONSULT-II)>>GO TO 3. No >> GO TO 4. J K 2. CHECK OVERALL FUNCTION L With CONSULT-II Perform “POWER BALANCE” in “ACTIVE TEST” mode with CONSULT-II. 2. Make sure that each circuit produces a momentary engine speed drop. OK or NG OK >> INSPECTION END NG >> GO TO 10. 1. M PBIB0133E EC-1225 IGNITION SIGNAL [HR (WITH EURO-OBD)] 3. CHECK OVERALL FUNCTION Without CONSULT-II Let engine idle. Read the voltage signal between ECM terminals 17, 18, 21, 22 and ground with an oscilloscope. 3. Verify that the oscilloscope screen shows the signal wave as shown below. NOTE: The pulse cycle changes depending on rpm at idle. 1. 2. PBIA9567J PBIA9265J OK or NG OK >> INSPECTION END NG >> GO TO 10. 4. CHECK IGNITION COIL POWER SUPPLY CIRCUIT-I 1. 2. Turn ignition switch OFF, wait at least 10 seconds and then turn ON. Check voltage between ECM terminal 105 and ground with CONSULT-II or tester. Voltage: Battery voltage OK or NG OK >> GO TO 5. NG >> Go to EC-918, "POWER SUPPLY AND GROUND CIRCUIT" . PBIA9575J EC-1226 IGNITION SIGNAL [HR (WITH EURO-OBD)] 5. CHECK IGNITION COIL POWER SUPPLY CIRCUIT-II 1. 2. Turn ignition switch OFF. Disconnect condenser (1) harness connector. – : Vehicle front Turn ignition switch ON. 3. A EC C D MBIB1548E E 4. Check voltage between condenser terminal 1 and ground with CONSULT-II or tester. F Voltage: Battery voltage OK or NG OK >> GO TO 8. NG >> GO TO 6. G H PBIB0624E 6. CHECK IGNITION COIL POWER SUPPLY CIRCUIT-III 1. 2. 3. Turn ignition switch OFF. Disconnect IPDM E/R harness connector E7. Check harness continuity between IPDM E/R terminal 33 and condenser terminal 1. Refer to Wiring Diagram. Continuity should exist. I J K 4. Also check harness for short to ground and short to power. OK or NG OK >> Go to EC-918, "POWER SUPPLY AND GROUND CIRCUIT" . NG >> GO TO 7. L 7. DETECT MALFUNCTIONING PART M Check the following. ● Harness connectors E59, F1 ● Harness for open or short between IPDM E/R and condenser >> Repair open circuit or short to ground or short to power in harness or connectors. EC-1227 IGNITION SIGNAL [HR (WITH EURO-OBD)] 8. CHECK CONDENSER GROUND CIRCUIT FOR OPEN AND SHORT 1. 2. Turn ignition switch OFF. Check harness continuity between condenser terminal 2 and ground. Refer to Wiring Diagram. Continuity should exist. 3. Also check harness for short to power. OK or NG OK >> GO TO 9. NG >> Repair open circuit or short to power in harness or connectors. 9. CHECK CONDENSER Refer to EC-1229, "Component Inspection" OK or NG OK >> GO TO 10. NG >> Replace condenser. 10. CHECK IGNITION COIL POWER SUPPLY CIRCUIT-IV 1. 2. 3. – 4. Turn ignition switch OFF. Reconnect all harness connectors disconnected. Disconnect ignition coil (1) harness connector. Fuel injector (2) Turn ignition switch ON. PBIB2968E 5. Check voltage between ignition coil terminal 1 and ground with CONSULT-II or tester. Voltage: Battery voltage OK or NG OK >> GO TO 12. NG >> GO TO 11. SEF107S 11. DETECT MALFUNCTIONING PART Check the following. ● Harness connector F1 ● Harness for open or short between ignition coil and harness connector F1 >> Repair or replace harness or connectors. EC-1228 IGNITION SIGNAL [HR (WITH EURO-OBD)] 12. CHECK IGNITION COIL GROUND CIRCUIT FOR OPEN AND SHORT 1. 2. A Turn ignition switch OFF. Check harness continuity between ignition coil terminal 2 and ground. Refer to Wiring Diagram. EC Continuity should exist. 3. Also check harness for short to power. OK or NG OK >> GO TO 13. NG >> Repair open circuit or short to power in harness or connectors. C D 13. CHECK IGNITION COIL OUTPUT SIGNAL CIRCUIT FOR OPEN AND SHORT 1. 2. E Disconnect ECM harness connector. Check harness continuity between ECM terminals 17, 18, 21, 22 and ignition coil terminal 3. Refer to Wiring Diagram. F Continuity should exist. 3. Also check harness for short to ground and short to power. OK or NG OK >> GO TO 14. NG >> Repair open circuit or short to ground or short to power in harness or connectors. G H 14. CHECK IGNITION COIL WITH POWER TRANSISTOR Refer to EC-1229, "Component Inspection" . OK or NG OK >> GO TO 15. NG >> Replace ignition coil with power transistor. I J 15. CHECK INTERMITTENT INCIDENT Refer to EC-917, "TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT" . K >> INSPECTION END L Component Inspection BBS004JI IGNITION COIL WITH POWER TRANSISTOR CAUTION: Do the following procedure in the place where ventilation is good without the combustible. 1. Turn ignition switch OFF. 2. Disconnect ignition coil harness connector. 3. Check resistance between ignition coil terminals as follows. Terminal No. (Polarity) Resistance Ω [at 25°C (77°F)] 1 and 2 Except 0 or ∞ M 1 and 3 2 and 3 4. 5. 6. Except 0 If NG, replace ignition coil with power transistor. If OK, go to next step. Turn ignition switch OFF. Reconnect all harness connectors disconnected. EC-1229 MBIB0032E IGNITION SIGNAL [HR (WITH EURO-OBD)] 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. Remove fuel pump fuse in IPDM E/R to release fuel pressure. NOTE: Do not use CONSULT-II to release fuel pressure, or fuel pressure applies again during the following procedure. Start engine. After engine stalls, crank it two or three times to release all fuel pressure. Turn ignition switch OFF. Remove all ignition coil harness connectors to avoid the electrical discharge from the ignition coils. Remove ignition coil and spark plug of the cylinder to be checked. Crank engine for 5 seconds or more to remove combustion gas in the cylinder. Connect spark plug and harness connector to ignition coil. Fix ignition coil using a rope etc. with gap of 13 - 17 mm between the edge of the spark plug and grounded metal portion as shown in the figure. Crank engine for about three seconds, and check whether spark is generated between the spark plug and the grounded metal portion. MBIB0277E Spark should be generated. CAUTION: Do not approach to the spark plug and the ignition coil within 50cm. Be careful not to get an electrical shock PBIB2325E while checking, because the electrical discharge voltage becomes 20kV or more. ● It might cause to damage the ignition coil if the gap of more than 17 mm is taken. NOTE: When the gap is less than 13 mm, the spark might be generated even if the coil is malfunctioning. 17. If NG, replace ignition coil with power transistor. ● CONDENSER 1. 2. 3. Turn ignition switch OFF. Disconnect condenser harness connector. Check resistance between condenser terminals 1 and 2. Resistance: Above 1 MΩ at 25°C (77°F) PBIB0794E Removal and Installation BBS004JJ IGNITION COIL WITH POWER TRANSISTOR Refer to EM-132, "IGNITION COIL" . EC-1230 REFRIGERANT PRESSURE SENSOR [HR (WITH EURO-OBD)] REFRIGERANT PRESSURE SENSOR Component Description PFP:92136 A BBS004JK The refrigerant pressure sensor (1) is installed at the condenser of the air conditioner system. The sensor uses an electrostatic volume pressure transducer to convert refrigerant pressure to voltage. The voltage signal is sent to ECM, and ECM controls cooling fan system. ● EC : Vehicle front C D PBIB2980E E F G H PBIB2657E I J K L M EC-1231 REFRIGERANT PRESSURE SENSOR [HR (WITH EURO-OBD)] Wiring Diagram BBS004JL MBWA1493E EC-1232 REFRIGERANT PRESSURE SENSOR [HR (WITH EURO-OBD)] Specification data are reference values and are measured between each terminal and ground. CAUTION: Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM's transistor. Use a ground other than ECM terminals, such as the ground. TERMINAL NO. EC WIRE COLOR ITEM CONDITION DATA (DC Voltage) [Engine is running] 41 BR A C ● Warm-up condition ● Both A/C switch and blower fan switch: ON Refrigerant pressure sensor 1.0 - 4.0V D (Compressor operates) [Engine is running] 48 74 Y W Sensor ground (Refrigerant pressure sensor) Sensor power supply (Refrigerant pressure sensor) ● Warm-up condition ● Idle speed Approximately 0V E [Ignition switch: ON] Approximately 5V F Diagnostic Procedure BBS004JM 1. CHECK REFRIGERANT PRESSURE SENSOR OVERALL FUNCTION 1. 2. 3. G Start engine and warm it up to normal operating temperature. Turn A/C switch and blower fan switch ON. Check voltage between ECM terminal 41 and ground with CONSULT-II or tester. H Voltage: 1.0 - 4.0V I OK or NG OK >> INSPECTION END NG >> GO TO 2. J PBIA9574J K 2. CHECK GROUND CONNECTIONS 1. 2. 3. L Turn A/C switch and blower fan switch OFF. Stop engine. Loosen and retighten ground screws on the body. Refer to EC-924, "Ground Inspection" . M MBIB1550E 1. IPDM E/R 2. Body ground OK or NG OK >> GO TO 3. NG >> Repair or replace ground connections. EC-1233 3. Body ground REFRIGERANT PRESSURE SENSOR [HR (WITH EURO-OBD)] 3. CHECK REFRIGERANT PRESSURE SENSOR POWER SUPPLY CIRCUIT 1. Disconnect refrigerant pressure sensor (1) harness connector. – : Vehicle front Turn ignition switch ON. 2. PBIB2980E 3. Check voltage between refrigerant pressure sensor terminal 3 and ground with CONSULT-II or tester. Voltage: Approximately 5V OK or NG OK >> GO TO 5. NG >> GO TO 4. SEF479Y 4. DETECT MALFUNCTIONING PART Check the following. ● Harness connectors E59, F1 ● Harness for open or short between refrigerant pressure sensor and ECM >> Repair open circuit or short to ground or short to power in harness or connectors. 5. CHECK REFRIGERANT PRESSURE SENSOR GROUND CIRCUIT FOR OPEN AND SHORT 1. 2. 3. Turn ignition switch OFF. Disconnect ECM harness connector. Check harness continuity between refrigerant pressure sensor terminal 1 and ECM terminal 48. Refer to Wiring Diagram. Continuity should exist. 4. Also check harness for short to ground and short to power. OK or NG OK >> GO TO 7. NG >> GO TO 6. 6. DETECT MALFUNCTIONING PART Check the following. ● Harness connectors E59, F1 ● Harness for open or short between refrigerant pressure sensor and ECM >> Repair open circuit or short to ground or short to power in harness or connectors. EC-1234 REFRIGERANT PRESSURE SENSOR [HR (WITH EURO-OBD)] 7. CHECK REFRIGERANT PRESSURE SENSOR INPUT SIGNAL CIRCUIT FOR OPEN AND SHORT 1. A Check harness continuity between refrigerant pressure sensor terminal 2 and ECM terminal 41. Refer to Wiring Diagram. EC Continuity should exist. 2. Also check harness for short to ground and short to power. OK or NG OK >> GO TO 9. NG >> GO TO 8. C 8. DETECT MALFUNCTIONING PART D Check the following. ● Harness connectors E59, F1 ● Harness for open or short between refrigerant pressure sensor and ECM E F >> Repair open circuit or short to ground or short to power in harness or connectors. 9. CHECK INTERMITTENT INCIDENT G Refer to EC-917, "TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT" . OK or NG OK >> Replace refrigerant pressure sensor. NG >> Repair or replace. Removal and Installation H BBS004JN REFRIGERANT PRESSURE SENSOR I Refer to ATC-135, "REFRIGERANT LINES" or MTC-81, "REFRIGERANT LINES" . J K L M EC-1235 MI & DATA LINK CONNECTORS [HR (WITH EURO-OBD)] MI & DATA LINK CONNECTORS Wiring Diagram PFP:24814 BBS004JO MBWA1494E EC-1236 SERVICE DATA AND SPECIFICATIONS (SDS) [HR (WITH EURO-OBD)] SERVICE DATA AND SPECIFICATIONS (SDS) Fuel Pressure PFP:00030 A BBS004JP Approximately 350 kPa (3.5 bar, 3.57 kg/cm2 , 51 psi) Fuel pressure at idle EC Idle Speed and Ignition Timing Target idle speed Air conditioner: ON Ignition timing BBS004JQ A/T No load* (in P or N position) 700 ± 50 rpm M/T No load* (in Neutral position) 650 ± 50 rpm A/T In P or N position 700 rpm or more M/T In Neutral position 750 rpm or more A/T In P or N position M/T In Neutral position C D 6 ± 5° BTDC E *: Under the following conditions: ● Air conditioner switch: OFF ● Electric load: OFF (Lights, heater fan & rear window defogger) ● Steering wheel: Kept in straight-ahead position F Calculated Load Value BBS004JR G Calculated load value% (Using CONSULT-II or GST) At idle 10 - 35 At 2,500 rpm 10 - 35 Mass Air Flow Sensor H BBS004JS Supply voltage Battery voltage (11 - 14V) Output voltage at idle I 1.0 - 1.3*V 1.0 - 4.0 g·m/sec at idle* 2.0 - 10.0 g·m/sec at 2,500 rpm* Mass air flow (Using CONSULT-II or GST) J *: Engine is warmed up to normal operating temperature and running under no load. Intake Air Temperature Sensor BBS004JT Temperature °C (°F) K Resistance kΩ 25 (77) 1.800 - 2.200 80 (176) 0.283 - 0.359 Engine Coolant Temperature Sensor Temperature °C (°F) L BBS004JU M Resistance kΩ 20 (68) 2.1 - 2.9 50 (122) 0.68 - 1.00 90 (194) 0.236 - 0.260 Knock Sensor BBS00584 Resistance [at 20°C (68°F)] Approximately 530 – 590kΩ Heated Oxygen Sensor 1 Heater BBS004JV Resistance [at 25°C (77°F)] 3.4 - 4.4Ω Heated Oxygen sensor 2 Heater BBS004JW Resistance [at 25°C (77°F)] 3.4 - 4.4Ω EC-1237 SERVICE DATA AND SPECIFICATIONS (SDS) [HR (WITH EURO-OBD)] Crankshaft Position Sensor (POS) BBS004JX Refer to EC-1048, "Component Inspection" . Camshaft Position Sensor (PHASE) BBS004JY Refer to EC-1054, "Component Inspection" . Intake Valve Timing Control Solenoid Valve Resistance [at 20°C (68°F)] BBS00585 6.7 – 7.7Ω Throttle Control Motor BBS004JZ Resistance [at 25°C (77°F)] Approximately 1 - 15Ω Fuel Injector BBS004K0 Resistance [at 10 - 60°C (50 - 140°F)] 11.1 - 14.5Ω Fuel Pump BBS004K1 Resistance [at 25°C (77°F)] Approximately 0.2 - 5.0Ω EC-1238 INDEX FOR DTC [HR (WITHOUT EURO-OBD)] INDEX FOR DTC DTC No. Index [HR (WITHOUT EURO-OBD)] PFP:00024 A BBS004K2 NOTE: ● If DTC U1000 or U1001 is displayed with other DTC, first perform the trouble diagnosis for DTC EC U1000, U1001. Refer to EC-1344, "DTC U1000, U1001 CAN COMMUNICATION LINE" . ● If DTC U1010 is displayed with other DTC, first perform the trouble diagnosis for DTC U1010. Refer to EC-1347, "DTC U1010 CAN COMMUNICATION" . C DTC*1 Items (CONSULT-II screen terms) Reference page CONSULT-II ECM*2 U1000 1000*3 CAN COMM CIRCUIT EC-1344 U1001 1001*3 CAN COMM CIRCUIT EC-1344 U1010 1010 CONTROL UNIT(CAN) EC-1347 P0000 Flashing*4 NO DTC IS DETECTED. FURTHER TESTING MAY BE REQUIRED. EC-1269 P0000 0000 NO DTC IS DETECTED. FURTHER TESTING MAY BE REQUIRED. — D F G P0011 0011 INT/V TIM CONT-B1 EC-1349 P0102 0102 MAF SEN/CIRCUIT EC-1354 P0103 0103 MAF SEN/CIRCUIT EC-1354 P0117 0117 ECT SEN/CIRC EC-1361 P0118 0118 ECT SEN/CIRC EC-1361 P0122 0122 TP SEN 2/CIRC EC-1367 P0123 0123 TP SEN 2/CIRC EC-1367 P0132 0132 HO2S1 (B1) EC-1373 P0134 0134 HO2S1 (B1) EC-1381 P0138 0138 HO2S2 (B1) EC-1388 P0222 0222 TP SEN 1/CIRC EC-1395 P0223 0223 TP SEN 1/CIRC EC-1395 P0327 0327 KNOCK SEN/CIRC-B1 EC-1401 P0328 0328 KNOCK SEN/CIRC-B1 EC-1401 P0335 0335 CKP SEN/CIRCUIT EC-1405 P0340 0340 CMP SEN/CIRC-B1 EC-1413 P0605 0605 ECM EC-1420 P1065 1065 ECM BACK UP/CIRCUIT*5 EC-1423 P1111 1111 INT/V TIM V/CIR-B1 EC-1425 P1121 1121 ETC ACTR EC-1430 P1122 1122 ETC FUNCTION/CIRC EC-1433 P1124 1124 ETC MOT PWR EC-1439 P1126 1126 ETC MOT PWR EC-1439 P1128 1128 ETC MOT EC-1445 P1212 1212 TCS/CIRC EC-1450 P1217 1217 ENG OVER TEMP EC-1451 P1225 1225 CTP LEARNING EC-1467 P1226 1226 CTP LEARNING EC-1469 EC-1239 E H I J K L M INDEX FOR DTC [HR (WITHOUT EURO-OBD)] DTC*1 Items (CONSULT-II screen terms) Reference page CONSULT-II ECM*2 P1229 1229 P1610 - P1615 1610 - 1615 NATS MALFUNCTION BL-215 P1706 1706 P-N POS SW/CIRCUIT EC-1479 P1805 1805 BRAKE SW/CIRCUIT EC-1487 P2122 2122 APP SEN 1/CIRC EC-1492 P2123 2123 APP SEN 1/CIRC EC-1492 P2127 2127 APP SEN 2/CIRC EC-1501 P2128 2128 APP SEN 2/CIRC EC-1501 P2135 2135 TP SENSOR EC-1511 P2138 2138 APP SENSOR EC-1517 SENSOR POWER/CIRC EC-1471 *1: 1st trip DTC No. is the same as DTC No. *2: In Diagnostic Test Mode II (Self-diagnostic results). *3: The troubleshooting for this DTC needs CONSULT-II. *4: When engine is running, MI may flash. For details, refer to EC-1269, "MI Flashing Without DTC" . *5: This self-diagnosis is not for ECM power supply circuit, even though “ECM BACK UP/CIRCUIT” is displayed on CONSULT-II screen. EC-1240 INDEX FOR DTC [HR (WITHOUT EURO-OBD)] Alphabetical Index BBS004K3 A NOTE: ● If DTC U1000 or U1001 is displayed with other DTC, first perform the trouble diagnosis for DTC U1000, U1001. Refer to EC-1344, "DTC U1000, U1001 CAN COMMUNICATION LINE" . ● If DTC U1010 is displayed with other DTC, first perform the trouble diagnosis for DTC U1010. Refer EC to EC-1347, "DTC U1010 CAN COMMUNICATION" . Items (CONSULT-II screen terms) DTC*1 Reference page ECM* APP SEN 1/CIRC P2122 2122 EC-1492 APP SEN 1/CIRC P2123 2123 EC-1492 APP SEN 2/CIRC P2127 2127 EC-1501 APP SEN 2/CIRC P2128 2128 EC-1501 APP SENSOR P2138 2138 EC-1517 BRAKE SW/CIRCUIT P1805 1805 EC-1487 3 CAN COMM CIRCUIT U1000 1000* EC-1344 CAN COMM CIRCUIT U1001 1001*3 EC-1344 CONTROL UNIT(CAN) U1010 1010 EC-1347 CKP SEN/CIRCUIT P0335 0335 EC-1405 CMP SEN/CIRC-B1 P0340 0340 EC-1413 CTP LEARNING P1225 1225 EC-1467 CTP LEARNING P1226 1226 EC-1469 ECM P0605 0605 EC-1420 P1065 1065 EC-1423 ECT SEN/CIRC P0117 0117 EC-1361 ECT SEN/CIRC P0118 0118 EC-1361 ENG OVER TEMP P1217 1217 EC-1451 ETC ACTR P1121 1121 EC-1430 ETC FUNCTION/CIRC P1122 1122 EC-1433 ECM BACK UP/CIRCUIT*5 ETC MOT P1128 1128 EC-1445 ETC MOT PWR P1124 1124 EC-1439 ETC MOT PWR P1126 1126 EC-1439 HO2S1 (B1) P0132 0132 EC-1373 HO2S1 (B1) P0134 0134 EC-1381 HO2S2 (B1) P0138 0138 EC-1388 INT/V TIM CONT-B1 P0011 0011 EC-1349 INT/V TIM V/CIR-B1 P1111 1111 EC-1425 KNOCK SEN/CIRC-B1 P0327 0327 EC-1401 KNOCK SEN/CIRC-B1 P0328 0328 EC-1401 MAF SEN/CIRCUIT P0102 0102 EC-1354 MAF SEN/CIRCUIT P0103 0103 EC-1354 P1610 - P1615 1610 - 1615 BL-215 No DTC Flashing*4 EC-1269 NATS MALFUNCTION NO DTC IS DETECTED. FURTHER TESTING MAY BE REQUIRED. EC-1241 C 2 CONSULT-II D E F G H I J K L M INDEX FOR DTC [HR (WITHOUT EURO-OBD)] Items (CONSULT-II screen terms) DTC*1 Reference page CONSULT-II ECM*2 NO DTC IS DETECTED. FURTHER TESTING MAY BE REQUIRED. P0000 0000 — P-N POS SW/CIRCUIT P1706 1706 EC-1479 SENSOR POWER/CIRC P1229 1229 EC-1471 TCS/CIRC P1212 1212 EC-1450 TP SEN 1/CIRC P0222 0222 EC-1395 TP SEN 1/CIRC P0223 0223 EC-1395 TP SEN 2/CIRC P0122 0122 EC-1367 TP SEN 2/CIRC P0123 0123 EC-1367 TP SENSOR P2135 2135 EC-1511 *1: 1st trip DTC No. is the same as DTC No. *2: In Diagnostic Test Mode II (Self-diagnostic results). *3: The troubleshooting for this DTC needs CONSULT-II. *4: When engine is running, MI may flash. For details, refer to EC-1269, "MI Flashing Without DTC" . *5: This self-diagnosis is not for ECM power supply circuit, even though “ECM BACK UP/CIRCUIT” is displayed on CONSULT-II screen. EC-1242 PRECAUTIONS [HR (WITHOUT EURO-OBD)] PRECAUTIONS PFP:00001 Precautions for Supplemental Restraint System (SRS) “AIR BAG” and “SEAT BELT PRE-TENSIONER” A BBS004K4 The Supplemental Restraint System such as “AIR BAG” and “SEAT BELT PRE-TENSIONER”, used along EC with a front seat belt, helps to reduce the risk or severity of injury to the driver and front passenger for certain types of collision. Information necessary to service the system safely is included in the SRS and SB section of this Service Manual. C WARNING: ● To avoid rendering the SRS inoperative, which could increase the risk of personal injury or death in the event of a collision which would result in air bag inflation, all maintenance must be perD formed by an authorized NISSAN/INFINITI dealer. ● Improper maintenance, including incorrect removal and installation of the SRS, can lead to personal injury caused by unintentional activation of the system. For removal of Spiral Cable and Air E Bag Module, see the SRS section. ● Do not use electrical test equipment on any circuit related to the SRS unless instructed to in this Service Manual. SRS wiring harnesses can be identified by yellow and/or orange harnesses or harness connectors. F Maintenance Information BBS005AT If any of following part is replaced, always replace with new* one. If it's not (or fail to do so), the electrical system may not be operated properly. *: New one means a virgin control unit that has never been energized on-board. G RHD MODELS H ● ● ● ● ● ● BCM (Models without Intelligent Key system) Intelligent Key unit (Models with Intelligent Key system) ECM IPDM E/R Combination meter EPS control unit I J LHD MODELS ● ● ● BCM (Models without Intelligent Key system) Intelligent Key unit (Models with Intelligent Key system) ECM Precautions for Procedures without Cowl Top Cover K L BBS00586 When performing the procedure after removing cowl top cover, cover the lower end of windshield with urethane, etc. M PIIB3706J On Board Diagnostic (OBD) System of Engine BBS004K6 The ECM has an on board diagnostic system. It will light up the malfunction indicator (MI) to warn the driver of a malfunction causing emission deterioration. CAUTION: ● Be sure to turn the ignition switch OFF and disconnect the negative battery cable before any repair or inspection work. The open/short circuit of related switches, sensors, solenoid valves, etc. will cause the MI to light up. EC-1243 PRECAUTIONS [HR (WITHOUT EURO-OBD)] ● ● ● ● Be sure to connect and lock the connectors securely after work. A loose (unlocked) connector will cause the MI to light up due to the open circuit. (Be sure the connector is free from water, grease, dirt, bent terminals, etc.) Certain systems and components, especially those related to OBD, may use a new style slidelocking type harness connector. For description and how to disconnect, refer to PG-88, "HARNESS CONNECTOR" . Be sure to route and secure the harnesses properly after work. The interference of the harness with a bracket, etc. may cause the MI to light up due to the short circuit. Be sure to erase the unnecessary malfunction information (repairs completed) from the ECM before returning the vehicle to the customer. Precaution ● ● ● ● BBS004K7 Always use a 12 volt battery as power source. Do not attempt to disconnect battery cables while engine is running. Before connecting or disconnecting the ECM harness connector, turn ignition switch OFF and disconnect negative battery cable. Failure to do so may damage the ECM because battery voltage is applied to ECM even if ignition switch is turned OFF. Before removing parts, turn ignition switch OFF and then disconnect negative battery cable. SEF289H ● ● ● – – – – ● – – Do not disassemble ECM. If a battery cable is disconnected, the memory will return to the ECM value. The ECM will now start to self-control at its initial value. Engine operation can vary slightly when the terminal is disconnected. However, this is not an indication of a malfunction. Do not replace parts because of a slight variation. If the battery is disconnected, the following emissionrelated diagnostic information will be lost within 24 hours. Diagnostic trouble codes 1st trip diagnostic trouble codes Freeze frame data 1st trip freeze frame data When connecting ECM harness connector, fasten (B) it securely with a lever (1) as far as it will go as shown in the figure. ECM (2) Loosen (A) PBIA9222J PBIB2947E EC-1244 PRECAUTIONS [HR (WITHOUT EURO-OBD)] ● ● ● ● ● ● ● ● ● ● ● When connecting or disconnecting pin connectors into or from ECM, take care not to damage pin terminals (bend or break). Make sure that there are not any bends or breaks on ECM pin terminal, when connecting pin connectors. Securely connect ECM harness connectors. A poor connection can cause an extremely high (surge) voltage to develop in coil and condenser, thus resulting in damage to ICs. Keep engine control system harness at least 10 cm (4 in) away from adjacent harness, to prevent engine control system malfunctions due to receiving external noise, degraded operation of ICs, etc. Keep engine control system parts and harness dry. Before replacing ECM, perform ECM Terminals and Reference Value inspection and make sure ECM functions properly. Refer to EC-1304, "ECM Terminals and Reference Value" . Handle mass air flow sensor carefully to avoid damage. Do not clean mass air flow sensor with any type of detergent. Do not disassemble electric throttle control actuator. Even a slight leak in the air intake system can cause serious incidents. Do not shock or jar the camshaft position sensor (PHASE), crankshaft position sensor (POS). After performing each TROUBLE DIAGNOSIS, perform DTC Confirmation Procedure or Overall Function Check. The DTC should not be displayed in the DTC Confirmation Procedure if the repair is completed. The Overall Function Check should be a good result if the repair is completed. A EC C PBIB0090E D E F G MEF040D H I J K SAT652J L M EC-1245 PRECAUTIONS [HR (WITHOUT EURO-OBD)] ● ● When measuring ECM signals with a circuit tester, never allow the two tester probes to contact. Accidental contact of probes will cause a short circuit and damage the ECM power transistor. Do not use ECM ground terminals when measuring input/ output voltage. Doing so may result in damage to the ECM's transistor. Use a ground other than ECM terminals, such as the ground. SEF348N ● ● Do not operate fuel pump when there is no fuel in lines. Tighten fuel hose clamps to the specified torque. MBIB0291E ● ● ● Do not depress accelerator pedal when starting. Immediately after starting, do not rev up engine unnecessarily. Do not rev up engine just prior to shutdown. SEF709Y ● – – – When installing C.B. ham radio or a mobile phone, be sure to observe the following as it may adversely affect electronic control systems depending on installation location. Keep the antenna as far as possible from the electronic control units. Keep the antenna feeder line more than 20 cm (8 in) away from the harness of electronic controls. Do not let them run parallel for a long distance. Adjust the antenna and feeder line so that the standingwave radio can be kept smaller. SEF708Y EC-1246 PRECAUTIONS [HR (WITHOUT EURO-OBD)] – Be sure to ground the radio to vehicle body. A EC C D E F G H I J K L M EC-1247 PREPARATION [HR (WITHOUT EURO-OBD)] PREPARATION Special Service Tools PFP:00002 BBS004K8 Tool number Tool name Description KV10117100 Heated oxygen sensor wrench Loosening or tightening heated oxygen sensor with 22 mm (0.87 in) hexagon nut S-NT379 KV10114400 Heated oxygen sensor wrench Loosening or tightening heated oxygen sensor a: 22 mm (0.87 in) S-NT636 EG17650301 Radiator cap tester adapter Adapting radiator cap tester to radiator cap and radiator filler neck a: 28 (1.10) dia. b: 31.4 (1.236) dia. c: 41.3 (1.626) dia. Unit: mm (in) S-NT564 EG17550000 Break-out box Measuring ECM signals with a circuit tester ZZA1194D EG17680000 Y-cable adapter Measuring ECM signals with a circuit tester PBIA9379J KV10118400 Fuel tube adapter Measuring fuel pressure PBIB3043E EC-1248 PREPARATION [HR (WITHOUT EURO-OBD)] Commercial Service Tools BBS004K9 A Tool name Description Quick connector release Removing fuel tube quick connectors in engine room (Available in SEC. 164 of PARTS CATALOG: Part No. 16441 6N210) EC C PBIC0198E Fuel filler cap adapter Checking fuel tank vacuum relief valve opening pressure D E S-NT653 Socket wrench Removing and installing engine coolant temperature sensor F G H S-NT705 Oxygen sensor thread cleaner Reconditioning the exhaust system threads before installing a new oxygen sensor. Use with anti-seize lubricant shown below. a: 18 mm diameter with pitch 1.5 mm for Zirconia Oxygen Sensor b: 12 mm diameter with pitch 1.25 mm for Titania Oxygen Sensor J Lubricating oxygen sensor thread cleaning tool when reconditioning exhaust system threads. K I AEM488 Anti-seize lubricant i.e.: (PermatexTM 133AR or equivalent meeting MIL specification MIL-A907) L S-NT779 M EC-1249 ENGINE CONTROL SYSTEM [HR (WITHOUT EURO-OBD)] ENGINE CONTROL SYSTEM System Diagram PFP:23710 BBS004KA MBIB1449E EC-1250 ENGINE CONTROL SYSTEM [HR (WITHOUT EURO-OBD)] Multiport Fuel Injection (MFI) System BBS004KB A INPUT/OUTPUT SIGNAL CHART Sensor Crankshaft position sensor (POS) Input Signal to ECM Camshaft position sensor (PHASE) Engine speed*3 Piston position Mass air flow sensor Amount of intake air Engine coolant temperature sensor Engine coolant temperature Heated oxygen sensor 1 Density of oxygen in exhaust gas Throttle position sensor Throttle position Accelerator pedal position sensor Accelerator pedal position Park/neutral position (PNP) switch Gear position Battery Battery voltage*3 Knock sensor Engine knocking condition EPS control unit Power steering operation*2 Heated oxygen sensor 2*1 Density of oxygen in exhaust gas Air conditioner switch Air conditioner operation*2 Wheel sensor Vehicle speed*2 ECM function Actuator EC C D Fuel injection & mixture ratio control Fuel injector *1: This sensor is not used to control the engine system under normal conditions. *2: This signal is sent to the ECM through CAN communication line. *3: ECM determines the start signal status by the signals of engine speed and battery voltage. E F G H SYSTEM DESCRIPTION The amount of fuel injected from the fuel injector is determined by the ECM. The ECM controls the length of time the valve remains open (injection pulse duration). The amount of fuel injected is a program value in the ECM memory. The program value is preset by engine operating conditions. These conditions are determined by input signals (for engine speed and intake air) from the crankshaft position sensor (POS), camshaft position sensor (PHASE) and the mass air flow sensor. I J VARIOUS FUEL INJECTION INCREASE/DECREASE COMPENSATION In addition, the amount of fuel injected is compensated to improve engine performance under various operating conditions as listed below. ● During warm-up ● When starting the engine ● During acceleration ● Hot-engine operation ● When shift lever is changed from N to D (A/T models) ● High-load, high-speed operation ● During deceleration ● During high engine speed operation EC-1251 K L M ENGINE CONTROL SYSTEM [HR (WITHOUT EURO-OBD)] MIXTURE RATIO FEEDBACK CONTROL (CLOSED LOOP CONTROL) PBIB2953E The mixture ratio feedback system provides the best air-fuel mixture ratio for driveability and emission control. The three way catalyst (manifold) can then better reduce CO, HC and NOx emissions. This system uses heated oxygen sensor 1 in the exhaust manifold to monitor whether the engine operation is rich or lean. The ECM adjusts the injection pulse width according to the sensor voltage signal. For more information about heated oxygen sensor 1, refer to EC-1373, "DTC P0132 HO2S1" . This maintains the mixture ratio within the range of stoichiometric (ideal air-fuel mixture). This stage is referred to as the closed loop control condition. Heated oxygen sensor 2 is located downstream of the three way catalyst (manifold). Even if the switching characteristics of heated oxygen sensor 1 shift, the air-fuel ratio is controlled to stoichiometric by the signal from heated oxygen sensor 2. Open Loop Control The open loop system condition refers to when the ECM detects any of the following conditions. Feedback control stops in order to maintain stabilized fuel combustion. ● Deceleration and acceleration ● High-load, high-speed operation ● Malfunction of heated oxygen sensor 1 or its circuit ● Insufficient activation of heated oxygen sensor 1 at low engine coolant temperature ● High engine coolant temperature ● During warm-up ● After shifting from N to D (A/T models) ● When starting the engine MIXTURE RATIO SELF-LEARNING CONTROL The mixture ratio feedback control system monitors the mixture ratio signal transmitted from heated oxygen sensor 1. This feedback signal is then sent to the ECM. The ECM controls the basic mixture ratio as close to the theoretical mixture ratio as possible. However, the basic mixture ratio is not necessarily controlled as originally designed. Both manufacturing differences (i.e., mass air flow sensor hot wire) and characteristic changes during operation (i.e., fuel injector clogging) directly affect mixture ratio. Accordingly, the difference between the basic and theoretical mixture ratios is monitored in this system. This is then computed in terms of “injection pulse duration” to automatically compensate for the difference between the two ratios. “Fuel trim” refers to the feedback compensation value compared against the basic injection duration. Fuel trim includes short term fuel trim and long term fuel trim. “Short term fuel trim” is the short-term fuel compensation used to maintain the mixture ratio at its theoretical value. The signal from heated oxygen sensor 1 indicates whether the mixture ratio is RICH or LEAN compared to the theoretical value. The signal then triggers a reduction in fuel volume if the mixture ratio is rich, and an increase in fuel volume if it is lean. “Long term fuel trim” is overall fuel compensation carried out long-term to compensate for continual deviation of the short term fuel trim from the central value. Such deviation will occur due to individual engine differences, wear over time and changes in the usage environment. EC-1252 ENGINE CONTROL SYSTEM [HR (WITHOUT EURO-OBD)] FUEL INJECTION TIMING A EC C SEF337W D Two types of systems are used. Sequential Multiport Fuel Injection System Fuel is injected into each cylinder during each engine cycle according to the firing order. This system is used when the engine is running. Simultaneous Multiport Fuel Injection System Fuel is injected simultaneously into all four cylinders twice each engine cycle. In other words, pulse signals of the same width are simultaneously transmitted from the ECM. The four fuel injectors will then receive the signals two times for each engine cycle. This system is used when the engine is being started and/or if the fail-safe system (CPU) is operating. E F G FUEL SHUT-OFF Fuel to each cylinder is cut off during deceleration, operation of the engine at excessively high speeds or operation of the vehicle at excessively high speeds. Electronic Ignition (EI) System BBS004KC INPUT/OUTPUT SIGNAL CHART Sensor Crankshaft position sensor (POS) I Input Signal to ECM Camshaft position sensor (PHASE) Engine speed*2 Piston position Mass air flow sensor Amount of intake air Engine coolant temperature sensor Engine coolant temperature Throttle position sensor Throttle position Accelerator pedal position sensor Accelerator pedal position Battery Battery voltage*2 Knock sensor Engine knocking Park/neutral position (PNP) switch Gear position Wheel sensor H ECM function Actuator J K Ignition timing control Power transistor L M 1 Vehicle speed* *1: This signal is sent to the ECM through CAN communication line. *2: ECM determines the start signal status by the signals of engine speed and battery voltage. SYSTEM DESCRIPTION Firing order: 1 - 3 - 4 - 2 The ignition timing is controlled by the ECM to maintain the best air-fuel ratio for every running condition of the engine. The ignition timing data is stored in the ECM. The ECM receives information such as the injection pulse width and camshaft position sensor (PHASE) signal. Computing this information, ignition signals are transmitted to the power transistor. During the following conditions, the ignition timing is revised by the ECM according to the other data stored in the ECM. ● At starting ● During warm-up ● At idle ● At low battery voltage EC-1253 ENGINE CONTROL SYSTEM [HR (WITHOUT EURO-OBD)] ● During acceleration The knock sensor retard system is designed only for emergencies. The basic ignition timing is programmed within the anti-knocking zone, if recommended fuel is used under dry conditions. The retard system does not operate under normal driving conditions. If engine knocking occurs, the knock sensor monitors the condition. The signal is transmitted to the ECM. The ECM retards the ignition timing to eliminate the knocking condition. Fuel Cut Control (at No Load and High Engine Speed) BBS004KD INPUT/OUTPUT SIGNAL CHART Sensor Input Signal to ECM Park/neutral position (PNP) switch Neutral position Accelerator pedal position sensor Accelerator pedal position Engine coolant temperature sensor Engine coolant temperature Crankshaft position sensor (POS) Camshaft position sensor (PHASE) Engine speed Wheel sensor Vehicle speed* ECM function Fuel cut control Actuator Fuel injector *: This signal is sent to the ECM through CAN communication line. SYSTEM DESCRIPTION If the engine speed is above 2,500 rpm under no load (for example, the shift lever position is neutral and engine speed is over 2,500 rpm) fuel will be cut off after some time. The exact time when the fuel is cut off varies based on engine speed. Fuel cut will be operated until the engine speed reaches 2,000 rpm, then fuel cut will be cancelled. NOTE: This function is different from deceleration control listed under EC-1251, "Multiport Fuel Injection (MFI) System" . EC-1254 AIR CONDITIONING CUT CONTROL [HR (WITHOUT EURO-OBD)] AIR CONDITIONING CUT CONTROL Input/Output Signal Chart Sensor PFP:23710 A BBS004KE Input Signal to ECM Air conditioner switch Air conditioner ON signal* Accelerator pedal position sensor Accelerator pedal position Crankshaft position sensor (POS) Camshaft position sensor (PHASE) Engine speed*2 Engine coolant temperature sensor Engine coolant temperature Battery Battery voltage*2 Refrigerant pressure sensor Refrigerant pressure EPS control unit Power steering operation*1 Wheel sensor ECM function Actuator EC 1 C Air conditioner cut control Air conditioner relay D E 1 Vehicle speed* *1: This signal is sent to the ECM through CAN communication line. *2: ECM determines the start signal status by the signals of engine speed and battery voltage. System Description F BBS004KF This system improves engine operation when the air conditioner is used. Under the following conditions, the air conditioner is turned OFF. ● When the accelerator pedal is fully depressed. ● When cranking the engine. ● At high engine speeds. ● When the engine coolant temperature becomes excessively high. ● When operating power steering during low engine speed or low vehicle speed. ● When engine speed is excessively low. ● When refrigerant pressure is excessively low or high. G H I J K L M EC-1255 CAN COMMUNICATION [HR (WITHOUT EURO-OBD)] CAN COMMUNICATION System Description PFP:23710 BBS004KG CAN (Controller Area Network) is a serial communication line for real time application. It is an on-vehicle multiplex communication line with high data communication speed and excellent error detection ability. Many electronic control units are equipped onto a vehicle, and each control unit shares information and links with other control units during operation (not independent). In CAN communication, control units are connected with 2 communication lines (CAN H line, CAN L line) allowing a high rate of information transmission with less wiring. Each control unit transmits/receives data but selectively reads required data only. Refer to LAN-21, "CAN COMMUNICATION" , about CAN communication for detail. EC-1256 EVAPORATIVE EMISSION SYSTEM [HR (WITHOUT EURO-OBD)] EVAPORATIVE EMISSION SYSTEM Description PFP:14950 A BBS004KH SYSTEM DESCRIPTION EC C D E F G PBIB3039E The evaporative emission system is used to reduce hydrocarbons emitted into the atmosphere from the fuel system. This reduction of hydrocarbons is accomplished by activated charcoals in the EVAP canister. The fuel vapor in the sealed fuel tank is led into the EVAP canister which contains activated carbon and the vapor is stored there when the engine is not operating or when refueling to the fuel tank. The vapor in the EVAP canister is purged by the air through the purge line to the intake manifold when the engine is operating. EVAP canister purge volume control solenoid valve is controlled by ECM. When the engine operates, the flow rate of vapor controlled by EVAP canister purge volume control solenoid valve is proportionally regulated as the air flow increases. EVAP canister purge volume control solenoid valve also shuts off the vapor purge line during decelerating. H I J K L M EC-1257 EVAPORATIVE EMISSION SYSTEM [HR (WITHOUT EURO-OBD)] EVAPORATIVE EMISSION LINE DRAWING PBIB2946E : Vehicle front 1. Intake manifold : From next page 2. EVAP canister purge volume control solenoid valve 3. EVAP purge resonator NOTE: Do not use soapy water or any type of solvent while installing vacuum hose or purge hoses. EC-1258 EVAPORATIVE EMISSION SYSTEM [HR (WITHOUT EURO-OBD)] A EC C D E F G H MBIB1450E : Vehicle front 1. : To previous page I EVAP canister J K L M EC-1259 EVAPORATIVE EMISSION SYSTEM [HR (WITHOUT EURO-OBD)] Component Inspection BBS004KI EVAP CANISTER Check EVAP canister as follows: 1. Block port (B). 2. Blow air into port (A) and check that it flows freely out of port (C). 3. Release blocked port (B). 4. Apply vacuum pressure to port (B) and check that vacuum pressure exists at the ports (A) and (C). 5. Block port (A) and (B). 6. Apply pressure to port (C) and check that there is no leakage. PBIB2961E FUEL TANK VACUUM RELIEF VALVE (BUILT INTO FUEL FILLER CAP) 1. Wipe clean valve housing. SEF989X 2. Check valve opening pressure and vacuum. Pressure: Vacuum: 3. 15.3 - 20.0 kPa (0.153 - 0.200 bar, 0.156 - 0.204 kg/cm2 , 2.22 - 2.90 psi) −6.0 to −3.3 kPa (−0.060 to −0.034 bar, −0.061 to −0.035 kg/cm2 , −0.87 to −0.49 psi) If out of specification, replace fuel filler cap as an assembly. SEF943S EVAP CANISTER PURGE VOLUME CONTROL SOLENOID VALVE Refer to EC-1530, "EVAP CANISTER PURGE VOLUME CONTROL SOLENOID VALVE" . EC-1260 NATS (NISSAN ANTI-THEFT SYSTEM) [HR (WITHOUT EURO-OBD)] NATS (NISSAN ANTI-THEFT SYSTEM) Description ● ● ● PFP:25386 A BBS004KJ If the security indicator lights up with the ignition switch in the ON position or “NATS MALFUNCTION” is displayed on EC “SELF-DIAG RESULTS” screen, perform self-diagnostic results mode with CONSULT-II using NATS program card. Refer to BL-215, "NATS (Nissan Anti-Theft System)" . C Confirm no self-diagnostic results of NATS is displayed before touching “ERASE” in “SELF-DIAG RESULTS” mode with CONSULT-II. D When replacing ECM, initialization of NATS system and registration of all NATS ignition key IDs must be carried out SEF515Y with CONSULT-II using NATS program card. Therefore, be sure to receive all keys from vehicle owner. E Regarding the procedures of NATS initialization and all NATS ignition key ID registration, refer to CONSULT-II operation manual, NATS. F G H I J K L M EC-1261 POSITIVE CRANKCASE VENTILATION [HR (WITHOUT EURO-OBD)] POSITIVE CRANKCASE VENTILATION Description PFP:11810 BBS004KK SYSTEM DESCRIPTION PBIB2962E This system returns blow-by gas to the intake manifold. The positive crankcase ventilation (PCV) valve is provided to conduct crankcase blow-by gas to the intake manifold. During partial throttle operation of the engine, the intake manifold sucks the blow-by gas through the PCV valve. Normally, the capacity of the valve is sufficient to handle any blow-by and a small amount of ventilating air. The ventilating air is then drawn from the air inlet tubes into the crankcase. In this process the air passes through the hose connecting air inlet tubes to rocker cover. Under full-throttle condition, the manifold vacuum is insufficient to draw the blow-by flow through the valve. The flow goes through the hose connection in the reverse direction. On vehicles with an excessively high blow-by, the valve does not meet the requirement. This is because some of the flow will go through the hose connection to the air inlet tubes under all conditions. PBIB1588E Component Inspection BBS004KL PCV (POSITIVE CRANKCASE VENTILATION) VALVE With engine running at idle, remove PCV valve from rocker cover. A properly working valve makes a hissing noise as air passes through it. A strong vacuum should be felt immediately when a finger is placed over valve inlet. PBIB1589E EC-1262 POSITIVE CRANKCASE VENTILATION [HR (WITHOUT EURO-OBD)] PCV VALVE VENTILATION HOSE 1. 2. A Check hoses and hose connections for leaks. Disconnect all hoses and clean with compressed air. If any hose cannot be freed of obstructions, replace. EC C S-ET277 D E F G H I J K L M EC-1263 ON BOARD DIAGNOSTIC (OBD) SYSTEM [HR (WITHOUT EURO-OBD)] ON BOARD DIAGNOSTIC (OBD) SYSTEM Introduction PFP:00028 BBS004KM The ECM has an on board diagnostic system, which detects malfunctions related to engine sensors or actuators. The ECM also records various emission-related diagnostic information including: Emission-related diagnostic information Diagnostic Trouble Code (DTC) Freeze Frame data 1st Trip Diagnostic Trouble Code (1st Trip DTC) 1st Trip Freeze Frame data The above information can be checked using procedures listed in the table below. ×: Applicable —: Not applicable DTC 1st trip DTC Freeze Frame data 1st trip Freeze Frame data CONSULT-II × × × × ECM × ×* — — *: When DTC and 1st trip DTC simultaneously appear on the display, they cannot be clearly distinguished from each other. The malfunction indicator (MI) on the instrument panel lights up when the same malfunction is detected in two consecutive trips (Two trip detection logic), or when the ECM enters fail-safe mode. (Refer to EC-1291, "FailSafe Chart" .) Two Trip Detection Logic BBS004KN When a malfunction is detected for the first time, 1st trip DTC and 1st trip Freeze Frame data are stored in the ECM memory. The MI will not light up at this stage. <1st trip> If the same malfunction is detected again during the next drive, the DTC and Freeze Frame data are stored in the ECM memory, and the MI lights up. The MI lights up at the same time when the DTC is stored. <2nd trip> The “trip” in the “Two Trip Detection Logic” means a driving mode in which self-diagnosis is performed during vehicle operation. When there is an open circuit on MI circuit, the ECM cannot warn the driver by lighting up MI when there is malfunction on engine control system. Therefore, when electrical controlled throttle and part of ECM related diagnoses are continuously detected as NG for 5 trips, ECM warns the driver that engine control system malfunctions and MI circuit is open by means of operating fail-safe function. The fail-safe function also operates when above diagnoses except MI circuit are detected and demands the driver to repair the malfunction. Engine operating condition in fail-safe mode Engine speed will not rise more than 2,500 rpm due to the fuel cut Emission-related Diagnostic Information BBS004KO EMISSION-RELATED DIAGNOSTIC INFORMATION ITEMS Items (CONSULT-II screen terms) ×:Applicable —: Not applicable DTC*1 Trip MI Reference page 2 CONSULT-II ECM* CAN COMM CIRCUIT U1000 1000*3 2 — EC-1344 CAN COMM CIRCUIT U1001 1001*3 2 — EC-1344 CONTROL UNIT(CAN) U1010 1010 2 — EC-1347 NO DTC IS DETECTED. FURTHER TESTING MAY BE REQUIRED. P0000 0000 — Flashing*4 EC-1269 INT/V TIM CONT-B1 P0011 0011 2 — EC-1349 MAF SEN/CIRCUIT P0102 0102 1 × EC-1354 MAF SEN/CIRCUIT P0103 0103 1 × EC-1354 ECT SEN/CIRC P0117 0117 2 × EC-1361 EC-1264 ON BOARD DIAGNOSTIC (OBD) SYSTEM [HR (WITHOUT EURO-OBD)] DTC*1 Trip MI Reference page 0118 2 × EC-1361 P0122 0122 1 × EC-1367 TP SEN 2/CIRC P0123 0123 1 × EC-1367 HO2S1 (B1) P0132 0132 2 × EC-1373 HO2S1 (B1) P0134 0134 2 × EC-1381 Items (CONSULT-II screen terms) CONSULT-II ECM*2 ECT SEN/CIRC P0118 TP SEN 2/CIRC HO2S2 (B1) P0138 0138 2 × EC-1388 TP SEN 1/CIRC P0222 0222 1 × EC-1395 TP SEN 1/CIRC P0223 0223 1 × EC-1395 KNOCK SEN/CIRC-B1 P0327 0327 2 — EC-1401 KNOCK SEN/CIRC-B1 P0328 0328 2 — EC-1401 CKP SEN/CIRCUIT P0335 0335 2 × EC-1405 CMP SEN/CIRC-B1 P0340 0340 2 × EC-1413 ECM P0605 0605 1 or 2 × or — EC-1420 ECM BACK UP/CIRCUIT*5 P1065 1065 2 × EC-1423 INT/V TIM V/CIR-B1 P1111 1111 2 × EC-1425 ETC ACTR P1121 1121 1 × EC-1430 ETC FUNCTION/CIRC P1122 1122 1 × EC-1433 ETC MOT PWR P1124 1124 1 × EC-1439 ETC MOT PWR P1126 1126 1 × EC-1439 ETC MOT P1128 1128 1 × EC-1445 TCS/CIRC P1212 1212 2 — EC-1450 ENG OVER TEMP P1217 1217 1 × EC-1451 CTP LEARNING P1225 1225 2 — EC-1467 CTP LEARNING P1226 1226 2 — EC-1469 SENSOR POWER/CIRC P1229 1229 1 × EC-1471 NATS MALFUNCTION P1610 - P1615 1610 - 1615 2 — BL-215 P-N POS SW/CIRCUIT P1706 1706 2 × EC-1479 BRAKE SW/CIRCUIT P1805 1805 1 × EC-1487 APP SEN 1/CIRC P2122 2122 1 × EC-1492 APP SEN 1/CIRC P2123 2123 1 × EC-1492 APP SEN 2/CIRC P2127 2127 1 × EC-1501 APP SEN 2/CIRC P2128 2128 1 × EC-1501 TP SENSOR P2135 2135 1 × EC-1511 APP SENSOR P2138 2138 1 × EC-1517 *1: 1st trip DTC No. is the same as DTC No. *2: In Diagnostic Test Mode II (Self-diagnostic results), this number is controlled by NISSAN. *3: The troubleshooting for this DTC needs CONSULT-II. *4: When engine is running, MI may flash. For details, refer to EC-1269, "MI Flashing Without DTC" . *5: This self-diagnosis is not for ECM power supply circuit, even though “ECM BACK UP/CIRCUIT” is displayed on CONSULT-II screen. DTC AND 1ST TRIP DTC The 1st trip DTC (whose number is the same as the DTC number) is displayed for the latest self-diagnostic result obtained. If the ECM memory was cleared previously, and the 1st trip DTC did not reoccur, the 1st trip DTC will not be displayed. If a malfunction is detected during the 1st trip, the 1st trip DTC is stored in the ECM memory. The MI will not light up (two trip detection logic). If the same malfunction is not detected in the 2nd trip (meeting the required EC-1265 A EC C D E F G H I J K L M ON BOARD DIAGNOSTIC (OBD) SYSTEM [HR (WITHOUT EURO-OBD)] driving pattern), the 1st trip DTC is cleared from the ECM memory. If the same malfunction is detected in the 2nd trip, both the 1st trip DTC and DTC are stored in the ECM memory and the MI lights up. In other words, the DTC is stored in the ECM memory and the MI lights up when the same malfunction occurs in two consecutive trips. If a 1st trip DTC is stored and a non-diagnostic operation is performed between the 1st and 2nd trips, only the 1st trip DTC will continue to be stored. For malfunctions that blink or light up the MI during the 1st trip, the DTC and 1st trip DTC are stored in the ECM memory. Procedures for clearing the DTC and the 1st trip DTC from the ECM memory are described in EC-1267, "HOW TO ERASE EMISSION-RELATED DIAGNOSTIC INFORMATION" . When a 1st trip DTC is detected, check, print out or write down and erase (1st trip) DTC and Freeze Frame data as specified in Work Flow procedure Step 2, refer to EC-1285, "WORK FLOW" . Then perform DTC Confirmation Procedure or Overall Function Check to try to duplicate the malfunction. If the malfunction is duplicated, the item requires repair. How to Read DTC and 1st Trip DTC DTC and 1st trip DTC can be read by the following methods. With CONSULT-II CONSULT-II displays the DTC in “SELF-DIAG RESULTS” mode. Examples: P0117, P0340, P1217, etc. (CONSULT-II also displays the malfunctioning component or system.) Without CONSULT-II The number of blinks of the MI in the Diagnostic Test Mode II (Self-Diagnostic Results) indicates the DTC. Example: 0117, 0340, 1217, etc. ● 1st trip DTC No. is the same as DTC No. ● Output of a DTC indicates a malfunction. However, the Diagnostic Test Mode II do not indicate whether the malfunction is still occurring or has occurred in the past and has returned to normal. CONSULT-II can identify malfunction status as shown below. Therefore, using CONSULT-II (if available) is recommended. A sample of CONSULT-II display for DTC and 1st trip DTC is shown below. DTC or 1st trip DTC of a malfunction is displayed in SELF-DIAGNOSTIC RESULTS mode of CONSULT-II. Time data indicates how many times the vehicle was driven after the last detection of a DTC. If the DTC is being detected currently, the time data will be [0]. If a 1st trip DTC is stored in the ECM, the time data will be [1t]. PBIB0911E FREEZE FRAME DATA AND 1ST TRIP FREEZE FRAME DATA The ECM records the driving conditions such as fuel system status, calculated load value, engine coolant temperature, short term fuel trim, long term fuel trim, engine speed, vehicle speed, base fuel schedule and intake air temperature at the moment a malfunction is detected. Data which are stored in the ECM memory, along with the 1st trip DTC, are called 1st trip freeze frame data. The data, stored together with the DTC data, are called freeze frame data and displayed on CONSULT-II. For details, see EC-1314, "Freeze Frame Data and 1st Trip Freeze Frame Data" . Only one set of freeze frame data (either 1st trip freeze frame data or freeze frame data) can be stored in the ECM. 1st trip freeze frame data is stored in the ECM memory along with the 1st trip DTC. There is no priority for 1st trip freeze frame data and it is updated each time a different 1st trip DTC is detected. However, once freeze frame data (2nd trip detection/MI on) is stored in the ECM memory, 1st trip freeze frame data is no longer stored. Remember, only one set of freeze frame data can be stored in the ECM. Both 1st trip freeze frame data and freeze frame data (along with the DTCs) are cleared when the ECM memory is erased. Procedures for clearing the ECM memory are described in EC-1267, "HOW TO ERASE EMISSION-RELATED DIAGNOSTIC INFORMATION" . EC-1266 ON BOARD DIAGNOSTIC (OBD) SYSTEM [HR (WITHOUT EURO-OBD)] HOW TO ERASE EMISSION-RELATED DIAGNOSTIC INFORMATION How to Erase DTC A WITH CONSULT-II The emission related diagnostic information in the ECM can be erased by selecting “ERASE” in the “SELFEC DIAG RESULTS” mode with CONSULT-II. 1. If the ignition switch stays ON after repair work, be sure to turn ignition switch OFF once. Wait at least 10 seconds and then turn it ON (engine stopped) again. C 2. Touch “ENGINE”. 3. Touch “SELF-DIAG RESULTS”. 4. Touch “ERASE”. (The DTC in the ECM will be erased.) D E F G H I PBIB2454E Without CONSULT-II 1. If the ignition switch stays ON after repair work, be sure to turn ignition switch OFF once. 2. Wait at least 10 seconds and then turn it ON (engine stopped) again. 3. Change the diagnostic test mode from Mode II to Mode I by depressing the accelerator pedal. Refer to EC-1269, "HOW TO SWITCH DIAGNOSTIC TEST MODE" . ● If the battery is disconnected, the emission-related diagnostic information will be lost within 24 hours. ● The following data are cleared when the ECM memory is erased. – Diagnostic trouble codes – 1st trip diagnostic trouble codes – Freeze frame data – 1st trip freeze frame data Actual work procedures are explained using a DTC as an example. Be careful so that not only the DTC, but all of the data listed above, are cleared from the ECM memory during work procedures. EC-1267 J K L M ON BOARD DIAGNOSTIC (OBD) SYSTEM [HR (WITHOUT EURO-OBD)] Malfunction Indicator (MI) BBS004KP DESCRIPTION The MI is located on the instrument panel. 1. The MI will light up when the ignition switch is turned ON without the engine running. This is a bulb check. If the MI does not light up, refer to DI-32, "WARNING LAMPS" , or see EC-1596, "MI & DATA LINK CONNECTORS" . 2. When the engine is started, the MI should go off. If the MI remains on, the on board diagnostic system has detected an engine system malfunction. SAT652J ON BOARD DIAGNOSTIC SYSTEM FUNCTION The on board diagnostic system has the following four functions. Diagnostic Test Mode KEY and ENG. Status Function Explanation of Function Mode I Ignition switch in ON position BULB CHECK This function checks the MI bulb for damage (blown, open circuit, etc.). If the MI does not come on, check MI circuit. Engine running MALFUNCTION WARNING This is a usual driving condition. When a malfunction is detected twice in two consecutive driving cycles (two trip detection logic), the MI will light up to inform the driver that a malfunction has been detected. One trip detection diagnoses will light up the MI in the 1st trip. Ignition switch in ON position SELF-DIAGNOSTIC RESULTS This function allows DTCs and 1st trip DTCs to be read. HEATED OXYGEN SENSOR 1 MONITOR This function allows the fuel mixture condition (lean or rich), monitored by heated oxygen sensor 1, to be read. Engine stopped Mode II Engine stopped Engine running When there is an open circuit on MI circuit, the ECM cannot warn the driver by lighting up MI when there is malfunction on engine control system. Therefore, when electrical controlled throttle and part of ECM related diagnoses are continuously detected as NG for 5 trips, ECM warns the driver that engine control system malfunctions and MI circuit is open by means of operating fail-safe function. The fail-safe function also operates when above diagnoses except MI circuit are detected and demands the driver to repair the malfunction. Engine operating condition in fail-safe mode Engine speed will not rise more than 2,500 rpm due to the fuel cut EC-1268 ON BOARD DIAGNOSTIC (OBD) SYSTEM [HR (WITHOUT EURO-OBD)] MI Flashing Without DTC If the ECM is in Diagnostic Test Mode II, MI may flash when engine is running. In this case, check ECM diag- A nostic test mode. Refer to EC-1269, "HOW TO SWITCH DIAGNOSTIC TEST MODE" . How to switch the diagnostic test (function) modes, and details of the above functions are described later. Refer to EC-1269, "HOW TO SWITCH DIAGNOSTIC TEST MODE" . EC The following emission-related diagnostic information is cleared when the ECM memory is erased. ● Diagnostic trouble codes ● 1st trip diagnostic trouble codes C ● Freeze frame data ● 1st trip freeze frame data D HOW TO SWITCH DIAGNOSTIC TEST MODE NOTE: ● It is better to count the time accurately with a clock. ● It is impossible to switch the diagnostic mode when an accelerator pedal position sensor circuit has a malfunction. ● Always ECM returns to Diagnostic Test Mode I after ignition switch is turned OFF. E F How to Set Diagnostic Test Mode II (Self-diagnostic Results) 1. 2. a. b. 3. 4. Confirm that accelerator pedal is fully released, turn ignition switch ON and wait 3 seconds. Repeat the following procedure quickly five times within 5 seconds. Fully depress the accelerator pedal. Fully release the accelerator pedal. Wait 7 seconds, fully depress the accelerator pedal and keep it for approx. 10 seconds until the MI starts blinking. Fully release the accelerator pedal. ECM has entered to Diagnostic Test Mode II (Self-diagnostic results). NOTE: Wait until the same DTC (or 1st trip DTC) appears to confirm all DTCs certainly. G H I J K L PBIB0092E How to Set Diagnostic Test Mode II (Heated Oxygen Sensor 1 Monitor) 1. 2. Set the ECM in Diagnostic Test Mode II (Self-diagnostic results). Refer to EC-1269, "How to Set Diagnostic Test Mode II (Self-diagnostic Results)" . Start Engine. ECM has entered to Diagnostic Test Mode II (Heated oxygen sensor 1 monitor). How to Erase Diagnostic Test Mode II (Self-diagnostic Results) 1. 2. 3. Set ECM in Diagnostic Test Mode II (Self-diagnostic results). Refer to EC-1269, "How to Set Diagnostic Test Mode II (Self-diagnostic Results)" . Fully depress the accelerator pedal and keep it for more than 10 seconds. The emission-related diagnostic information has been erased from the backup memory in the ECM. Fully release the accelerator pedal, and confirm the DTC 0000 is displayed. DIAGNOSTIC TEST MODE I — BULB CHECK In this mode, the MI on the instrument panel should stay ON. If it remains OFF, check the bulb. Refer to DI-32, "WARNING LAMPS" or see EC-1596, "MI & DATA LINK CONNECTORS" . EC-1269 M ON BOARD DIAGNOSTIC (OBD) SYSTEM [HR (WITHOUT EURO-OBD)] DIAGNOSTIC TEST MODE I — MALFUNCTION WARNING MI Condition ON When the malfunction is detected. OFF No malfunction. This DTC number is clarified in Diagnostic Test Mode II (SELF-DIAGNOSTIC RESULTS) DIAGNOSTIC TEST MODE II — SELF-DIAGNOSTIC RESULTS In this mode, the DTC and 1st trip DTC are indicated by the number of blinks of the MI as shown below. The DTC and 1st trip DTC are displayed at the same time. If the MI does not illuminate in diagnostic test mode I (Malfunction warning), all displayed items are 1st trip DTCs. If only one code is displayed when the MI illuminates in diagnostic test mode II (SELF-DIAGNOSTIC RESULTS), it is a DTC; if two or more codes are displayed, they may be either DTCs or 1st trip DTCs. DTC No. is same as that of 1st trip DTC. These unidentified codes can be identified by using CONSULT-II. A DTC will be used as an example for how to read a code. PBIA3905E A particular trouble code can be identified by the number of four-digit numeral flashes. The “zero” is indicated by the number of ten flashes. The length of time the 1,000th-digit numeral flashes on and off is 1.2 seconds consisting of an ON (0.6-second) - OFF (0.6-second) cycle. The 100th-digit numeral and lower digit numerals consist of a 0.3-second ON and 0.3-second OFF cycle. A change from one digit numeral to another occurs at an interval of 1.0-second OFF. In other words, the later numeral appears on the display 1.3 seconds after the former numeral has disappeared. A change from one trouble code to another occurs at an interval of 1.8-second OFF. In this way, all the detected malfunctions are classified by their DTC numbers. The DTC 0000 refers to no malfunction. (See EC-1239, "INDEX FOR DTC" ) How to Erase Diagnostic Test Mode II (Self-diagnostic Results) The DTC can be erased from the back up memory in the ECM by depressing accelerator pedal. Refer to EC1269, "How to Erase Diagnostic Test Mode II (Self-diagnostic Results)" . ● If the battery is disconnected, the DTC will be lost from the backup memory within 24 hours. ● Be careful not to erase the stored memory before starting trouble diagnoses. EC-1270 ON BOARD DIAGNOSTIC (OBD) SYSTEM [HR (WITHOUT EURO-OBD)] DIAGNOSTIC TEST MODE II — HEATED OXYGEN SENSOR 1 MONITOR In this mode, the MI displays the condition of the fuel mixture (lean or rich) which is monitored by the heated oxygen sensor 1. MI Fuel mixture condition in the exhaust gas ON Lean OFF Rich *Remains ON or OFF Any condition A Air fuel ratio feedback control condition EC Closed loop system Open loop system C *: Maintains conditions just before switching to open loop. To check the heated oxygen sensor 1 function, start engine in the Diagnostic Test Mode II and warm it up until engine coolant temperature indicator points to the middle of the gauge. Next run engine at about 2,000 rpm for about 2 minutes under no load conditions. Then make sure that the MI comes ON more than 5 times within 10 seconds with engine running at 2,000 rpm under no load. D E F G H I J K L M EC-1271 BASIC SERVICE PROCEDURE [HR (WITHOUT EURO-OBD)] BASIC SERVICE PROCEDURE Basic Inspection PFP:00018 BBS004KQ 1. INSPECTION START 1. 2. – – – – – – 3. – – – – 4. Check service records for any recent repairs that may indicate a related malfunction, or a current need for scheduled maintenance. Open engine hood and check the following: Harness connectors for improper connections Wiring harness for improper connections, pinches and cut Vacuum hoses for splits, kinks and improper connections Hoses and ducts for leaks Air cleaner clogging Gasket Confirm that electrical or mechanical loads are not applied. Headlamp switch is OFF. SEF983U Air conditioner switch is OFF. Rear window defogger switch is OFF. Steering wheel is in the straight-ahead position, etc. Start engine and warm it up until engine coolant temperature indicator points the middle of gauge. Ensure engine stays below 1,000 rpm. SEF976U 5. Run engine at about 2,000 rpm for about 2 minutes under no load. 6. Make sure that no DTC is displayed with CONSULT-II. OK or NG OK >> GO TO 3. NG >> GO TO 2. SEF977U 2. REPAIR OR REPLACE Repair or replace components as necessary according to corresponding Diagnostic Procedure. >> GO TO 3 EC-1272 BASIC SERVICE PROCEDURE [HR (WITHOUT EURO-OBD)] 3. CHECK TARGET IDLE SPEED 1. 2. A With CONSULT-II Run engine at about 2,000 rpm for about 2 minutes under no load. Rev engine (2,000 to 3,000 rpm) two or three times under no load, then run engine at idle speed for about 1 minute. EC C D E PBIA8513J 3. Read idle speed in “DATA MONITOR” mode with CONSULT-II. Refer to EC-1277, "IDLE SPEED" . A/T: M/T: F 700 ± 50 rpm (in P or N position) 650 ± 50 rpm (in Neutral position) G H SEF058Y I Without CONSULT-II 1. Run engine at about 2,000 rpm for about 2 minutes under no load. 2. Rev engine (2,000 to 3,000 rpm) two or three times under no load, then run engine at idle speed for about 1 minute. 3. Check idle speed. Refer to EC-1277, "IDLE SPEED" . A/T: M/T: 700 ± 50 rpm (in P or N position) 650 ± 50 rpm (in Neutral position) OK or NG OK >> GO TO 10. NG >> GO TO 4. K L M 4. PERFORM ACCELERATOR PEDAL RELEASED POSITION LEARNING 1. 2. J Stop engine. Perform EC-1278, "Accelerator Pedal Released Position Learning" . >> GO TO 5. 5. PERFORM THROTTLE VALVE CLOSED POSITION LEARNING Perform EC-1279, "Throttle Valve Closed Position Learning" . >> GO TO 6. EC-1273 BASIC SERVICE PROCEDURE [HR (WITHOUT EURO-OBD)] 6. PERFORM IDLE AIR VOLUME LEARNING Refer to EC-1279, "Idle Air Volume Learning" . Is Idle Air Volume Learning carried out successfully? Yes or No Yes >> GO TO 7. No >> 1. Follow the instruction of Idle Air Volume Learning. 2. GO TO 4. 7. CHECK TARGET IDLE SPEED AGAIN 1. 2. With CONSULT-II Start engine and warm it up to normal operating temperature. Read idle speed in “DATA MONITOR” mode with CONSULT-II. Refer to EC-1277, "IDLE SPEED" . A/T: M/T: 700 ± 50 rpm (in P or N position) 650 ± 50 rpm (in Neutral position) Without CONSULT-II 1. Start engine and warm it up to normal operating temperature. 2. Check idle speed. Refer to EC-1277, "IDLE SPEED" . A/T: M/T: 700 ± 50 rpm (in P or N position) 650 ± 50 rpm (in Neutral position) SEF174Y OK or NG OK >> GO TO 10. NG >> GO TO 8. 8. DETECT MALFUNCTIONING PART Check the Following. ● Check camshaft position sensor (PHASE) and circuit. Refer to EC-1413, "DTC P0340 CMP SENSOR (PHASE)" . ● Check crankshaft position sensor (POS) and circuit. Refer to EC-1405, "DTC P0335 CKP SENSOR (POS)" . OK or NG OK >> GO TO 9. NG >> 1. Repair or replace. 2. GO TO 4. 9. CHECK ECM FUNCTION 1. 2. Substitute another known-good ECM to check ECM function. (ECM may be the cause of an incident, but this is a rare case.) Perform initialization of NATS system and registration of all NATS ignition key IDs. Refer to BL-218, "ECM Re-communicating Function" . >> GO TO 4. EC-1274 BASIC SERVICE PROCEDURE [HR (WITHOUT EURO-OBD)] 10. CHECK IGNITION TIMING 1. 2. – A Run engine at idle. Check ignition timing with a timing light. Refer to EC-1277, "IGNITION TIMING" . Timing indicator (1) A/T: M/T: EC 6 ± 5° BTDC (in P or N position) 6 ± 5° BTDC (in Neutral position) C OK or NG OK >> INSPECTION END NG >> GO TO 11. D MBIB1331E E 11. PERFORM ACCELERATOR PEDAL RELEASED POSITION LEARNING 1. 2. Stop engine. Perform EC-1278, "Accelerator Pedal Released Position Learning" . F >> GO TO 12. G 12. PERFORM THROTTLE VALVE CLOSED POSITION LEARNING H Perform EC-1279, "Throttle Valve Closed Position Learning" . >> GO TO 13. I 13. PERFORM IDLE AIR VOLUME LEARNING Refer to EC-1279, "Idle Air Volume Learning" . Is Idle Air Volume Learning carried out successfully? Yes or No Yes >> GO TO 14. No >> 1. Follow the instruction of Idle Air Volume Learning. 2. GO TO 4. J K L 14. CHECK TARGET IDLE SPEED AGAIN With CONSULT-II 1. Start engine and warm it up to normal operating temperature. 2. Read idle speed in “DATA MONITOR” mode with CONSULT-II. Refer to EC-1277, "IDLE SPEED" . A/T: M/T: M 700 ± 50 rpm (in P or N position) 650 ± 50 rpm (in Neutral position) Without CONSULT-II 1. Start engine and warm it up to normal operating temperature. 2. Check idle speed. Refer to EC-1277, "IDLE SPEED" . A/T: M/T: 700 ± 50 rpm (in P or N position) 650 ± 50 rpm (in Neutral position) OK or NG OK >> GO TO 15. NG >> GO TO 17. EC-1275 SEF174Y BASIC SERVICE PROCEDURE [HR (WITHOUT EURO-OBD)] 15. CHECK IGNITION TIMING AGAIN 1. 2. – Run engine at idle. Check ignition timing with a timing light. Refer to EC-1277, "IGNITION TIMING" . Timing indicator (1) A/T: M/T: 6 ± 5° BTDC (in P or N position) 6 ± 5° BTDC (in Neutral position) OK or NG OK >> INSPECTION END NG >> GO TO 16. MBIB1331E 16. CHECK TIMING CHAIN INSTALLATION Check timing chain installation. Refer to EM-142, "TIMING CHAIN" . OK or NG OK >> GO TO 17. NG >> 1. Repair the timing chain installation. 2. GO TO 4. 17. DETECT MALFUNCTIONING PART Check the following. ● Check camshaft position sensor (PHASE) and circuit. Refer to EC-1413, "DTC P0340 CMP SENSOR (PHASE)" . ● Check crankshaft position sensor (POS) and circuit. Refer to EC-1405, "DTC P0335 CKP SENSOR (POS)" . OK or NG OK >> GO TO 18. NG >> 1. Repair or replace. 2. GO TO 4. 18. CHECK ECM FUNCTION 1. 2. Substitute another known-good ECM to check ECM function. (ECM may be the cause of an incident, but this is a rare case.) Perform initialization of NATS system and registration of all NATS ignition key IDs. Refer to BL-218, "ECM Re-communicating Function" . >> GO TO 4. EC-1276 BASIC SERVICE PROCEDURE [HR (WITHOUT EURO-OBD)] Idle Speed and Ignition Timing Check BBS004KR A IDLE SPEED With CONSULT-II Check idle speed in “DATA MONITOR” mode with CONSULT-II. EC C D SEF058Y E Without CONSULT-II Check the idle speed by installing the pulse type tachometer clamp on the loop wire or on suitable high-tension wire which installed between ignition coil No.4 and spark plug No.4. NOTE: For the method of installing the tachometer, refer to EC-1277, "IGNITION TIMING" . F IGNITION TIMING G Any of following two methods may be used. Method A 1. H Attach timing light A to loop wire (1) as shown. ● : Vehicle front I J K PBIB2955E 2. Check ignition timing. ● Timing indicator (1) L M MBIB1331E EC-1277 BASIC SERVICE PROCEDURE [HR (WITHOUT EURO-OBD)] Method B 1. Remove ignition coil No. 4 (1). ● : Vehicle front MBIB1457E 2. Connect ignition coil No. 4 (1) and spark plug No. 4 with suitable high-tension wire A as shown, and attach timing light clamp B to this wire. MBIB1541E SEF166Y 3. Check ignition timing. ● Timing indicator (1) MBIB1331E Accelerator Pedal Released Position Learning BBS004KS DESCRIPTION Accelerator Pedal Released Position Learning is an operation to learn the fully released position of the accelerator pedal by monitoring the accelerator pedal position sensor output signal. It must be performed each time harness connector of accelerator pedal position sensor or ECM is disconnected. OPERATION PROCEDURE 1. 2. 3. Make sure that accelerator pedal is fully released. Turn ignition switch ON and wait at least 2 seconds. Turn ignition switch OFF and wait at least 10 seconds. EC-1278 BASIC SERVICE PROCEDURE [HR (WITHOUT EURO-OBD)] 4. 5. Turn ignition switch ON and wait at least 2 seconds. Turn ignition switch OFF and wait at least 10 seconds. Throttle Valve Closed Position Learning A BBS004KT DESCRIPTION Throttle Valve Closed Position Learning is an operation to learn the fully closed position of the throttle valve by monitoring the throttle position sensor output signal. It must be performed each time harness connector of electric throttle control actuator or ECM is disconnected. OPERATION PROCEDURE 1. 2. 3. Make sure that accelerator pedal is fully released. Turn ignition switch ON. Turn ignition switch OFF and wait at least 10 seconds. Make sure that throttle valve moves during above 10 seconds by confirming the operating sound. Idle Air Volume Learning EC C D BBS004KU E DESCRIPTION Idle Air Volume Learning is an operation to learn the idle air volume that keeps each engine within the specific range. It must be performed under any of the following conditions: ● Each time electric throttle control actuator or ECM is replaced. ● Idle speed or ignition timing is out of specification. G PREPARATION Before performing Idle Air Volume Learning, make sure that all of the following conditions are satisfied. Learning will be cancelled if any of the following conditions are missed for even a moment. ● Battery voltage: More than 12.9V (At idle) ● Engine coolant temperature: 70 - 95°C (158 - 203°F) ● PNP switch: ON ● Electric load switch: OFF (Air conditioner, headlamp, rear window defogger) On vehicles equipped with daytime light systems, set lighting switch to the 1st position to light only small lamps. ● Steering wheel: Neutral (Straight-ahead position) ● Vehicle speed: Stopped ● Transmission: Warmed-up – A/T models • With CONSULT-II: Drive vehicle until “FLUID TEMP SE” in “DATA MONITOR” mode of “A/T” system indicates less than 0.9V. • Without CONSULT-II: Drive vehicle for 10 minutes. – M/T models • Drive vehicle for 10 minutes. OPERATION PROCEDURE With CONSULT-II 1. 2. 3. 4. F Perform EC-1278, "Accelerator Pedal Released Position Learning" . Perform EC-1279, "Throttle Valve Closed Position Learning" . Start engine and warm it up to normal operating temperature. Check that all items listed under the topic PREPARATION (previously mentioned) are in good order. EC-1279 H I J K L M BASIC SERVICE PROCEDURE [HR (WITHOUT EURO-OBD)] 5. Select “IDLE AIR VOL LEARN” in “WORK SUPPORT” mode. SEF217Z 6. Touch “START” and wait 20 seconds. SEF454Y 7. 8. Make sure that “CMPLT” is displayed on CONSULT-II screen. If “CMPLT” is not displayed, Idle Air Volume Learning will not be carried out successfully. In this case, find the cause of the incident by referring to the DIAGNOSTIC PROCEDURE below. Rev up the engine two or three times and make sure that idle speed and ignition timing are within the specifications. ITEM SPECIFICATION Idle speed A/T: 700 ± 50 rpm (in P or N position) M/T: 650 ± 50 rpm (in Neutral position) Ignition timing A/T: 6 ± 5° BTDC (in P or N position) M/T: 6 ± 5° BTDC (in Neutral position) MBIB0238E Without CONSULT-II NOTE: ● It is better to count the time accurately with a clock. ● It is impossible to switch the diagnostic mode when an accelerator pedal position sensor circuit has a malfunction. 1. Perform EC-1278, "Accelerator Pedal Released Position Learning" . 2. Perform EC-1279, "Throttle Valve Closed Position Learning" . 3. Start engine and warm it up to normal operating temperature. 4. Check that all items listed under the topic PREPARATION (previously mentioned) are in good order. 5. Turn ignition switch OFF and wait at least 10 seconds. 6. Confirm that accelerator pedal is fully released, turn ignition switch ON and wait 3 seconds. 7. Repeat the following procedure quickly five times within 5 seconds. a. Fully depress the accelerator pedal. b. Fully release the accelerator pedal. 8. Wait 7 seconds, fully depress the accelerator pedal and keep it for approx. 20 seconds until the MI stops blinking and turned ON. 9. Fully release the accelerator pedal within 3 seconds after the MI turned ON. 10. Start engine and let it idle. EC-1280 BASIC SERVICE PROCEDURE [HR (WITHOUT EURO-OBD)] 11. Wait 20 seconds. A EC C PBIB0665E D 12. Rev up the engine two or three times and make sure that idle speed and ignition timing are within the specifications. E ITEM SPECIFICATION Idle speed A/T: 700 ± 50 rpm (in P or N position) M/T: 650 ± 50 rpm (in Neutral position) Ignition timing A/T: 6 ± 5° BTDC (in P or N position) M/T: 6 ± 5° BTDC (in Neutral position) F 13. If idle speed and ignition timing are not within the specification, Idle Air Volume Learning will not be carried out successfully. In this case, find the cause of the incident by referring to the Diagnostic Procedure below. G DIAGNOSTIC PROCEDURE If idle air volume learning cannot be performed successfully, proceed as follows: 1. Check that throttle valve is fully closed. 2. Check PCV valve operation. 3. Check that downstream of throttle valve is free from air leakage. 4. When the above three items check out OK, engine component parts and their installation condition are questionable. Check and eliminate the cause of the incident. It is useful to perform EC-1597, "SERVICE DATA AND SPECIFICATIONS (SDS)" . 5. If any of the following conditions occur after the engine has started, eliminate the cause of the incident and perform Idle Air Volume Learning all over again: ● Engine stalls. ● Erroneous idle. H Fuel Pressure Check L BBS004KV I J K FUEL PRESSURE RELEASE With CONSULT-II 1. 2. 3. 4. 5. Turn ignition switch ON. Perform “FUEL PRESSURE RELEASE” in “WORK SUPPORT” mode with CONSULT-II. Start engine. After engine stalls, crank it two or three times to release all fuel pressure. Turn ignition switch OFF. M SEF214Y EC-1281 BASIC SERVICE PROCEDURE [HR (WITHOUT EURO-OBD)] Without CONSULT-II 1. 2. 3. 4. 5. Remove fuel pump fuse located in IPDM E/R. Start engine. After engine stalls, crank it 2 or 3 times to release all fuel pressure. Turn ignition switch OFF. Reinstall fuel pump fuse after servicing fuel system. MBIB0277E FUEL PRESSURE CHECK CAUTION: ● Before disconnecting fuel line, release fuel pressure from fuel line to eliminate danger. ● The fuel hose connection method used when taking fuel pressure check must not be used for other purposes. ● Be careful not to scratch or put debris around connection area when servicing, so that the quick connector maintains sealability with O-rings inside. ● Do not perform fuel pressure check with electrical systems operating (i.e. lights, rear defogger, A/ C, etc.) Fuel pressure gauge may indicate false readings due to varying engine load and changes in manifold vacuum. NOTE: Prepare pans or saucers under the disconnected fuel line because the fuel may spill out. The fuel pressure cannot be completely released because E11 models do not have fuel return system. 1. Release fuel pressure to zero. Refer to EC-1281, "FUEL PRESSURE RELEASE" . 2. Prepare fuel hose for fuel pressure check B and fuel tube adapter (KV10118400) D, then connect fuel pressure gauge A. ● : To quick connector : To fuel tube (engine side) ● C: Clamp ● Use suitable fuel hose for fuel pressure check (genuine NISSAN fuel hose without quick connector). ● To avoid unnecessary force or tension to hose, use moderately long fuel hose for fuel pressure check. ● Do not use the fuel hose for checking fuel pressure with damage or cracks on it. ● Use Pressure Gauge to check fuel pressure. Remove fuel hose. Refer to EM-120, "INTAKE MANIFOLD" . ● Do not twist or kink fuel hose because it is plastic hose. Connect fuel hose for fuel pressure check (1) to fuel tube (engine side) with clamp (2) as shown in the figure. ● No.2 spool (5) ● Wipe off oil or dirt from hose insertion part using cloth moistened with gasoline. ● Apply proper amount of gasoline between top of the fuel tube (3) and No.1 spool (4). ● Insert fuel hose for fuel pressure check until it touches the No.1 spool on fuel tube. ● Use NISSAN genuine hose clamp (part number: 16439 N4710 or 16439 40U00). ● When reconnecting fuel line, always use new clamps. ● Use a torque driver to tighten clamps. ● 3. 4. EC-1282 PBIB2982E PBIB2983E BASIC SERVICE PROCEDURE [HR (WITHOUT EURO-OBD)] ● Install hose clamp to the position within 1 - 2 mm (0.04 - 0.08 in). Tightening torque: A 1 - 1.5 N·m (0.1 - 0.15 kg-m, 9 - 13 in-lb) Make sure that clamp screw does not contact adjacent parts. Connect fuel tube adapter to quick connector. ● A: Fuel pressure gauge ● B: Fuel hose for fuel pressure check After connecting fuel hose for fuel pressure check, pull the hose with a force of approximately 98 N (10 kg, 22 lb) to confirm fuel tube does not come off. Turn ignition switch ON and check for fuel leakage. Start engine and check for fuel leakage. Read the indication of fuel pressure gauge. ● Do not perform fuel pressure check with system operating. Fuel pressure gauge may indicate false readings. ● During fuel pressure check, confirm for fuel leakage from fuel connection every 3 minutes. ● 5. 6. 7. 8. 9. EC C D PBIB2984E E F At idling: Approximately 350 kPa (3.5 bar, 3.57 kg/cm2 , 51 psi) 10. If result is unsatisfactory, go to next step. 11. Check the following. ● Fuel hoses and fuel tubes for clogging ● Fuel filter for clogging ● Fuel pump ● Fuel pressure regulator for clogging If OK, replace fuel pressure regulator. If NG, repair or replace. G H I J K L M EC-1283 TROUBLE DIAGNOSIS [HR (WITHOUT EURO-OBD)] TROUBLE DIAGNOSIS Trouble Diagnosis Introduction PFP:00004 BBS004KW INTRODUCTION The engine has an ECM to control major systems such as fuel control, ignition control, idle air control system, etc. The ECM accepts input signals from sensors and instantly drives actuators. It is essential that both input and output signals are proper and stable. At the same time, it is important that there are no malfunctions such as vacuum leaks, fouled spark plugs, or other malfunctions with the engine. MEF036D It is much more difficult to diagnose an incident that occurs intermittently rather than continuously. Most intermittent incidents are caused by poor electric connections or improper wiring. In this case, careful checking of suspected circuits may help prevent the replacement of good parts. SEF233G A visual check only may not find the cause of the incidents. A road test with CONSULT-II or a circuit tester connected should be performed. Follow the Work Flow on EC-1285, "WORK FLOW" . Before undertaking actual checks, take a few minutes to talk with a customer who approaches with a driveability complaint. The customer can supply good information about such incidents, especially intermittent ones. Find out what symptoms are present and under what conditions they occur. A Diagnostic Worksheet like the example on EC-1289, "Worksheet Sample" should be used. Start your diagnosis by looking for conventional malfunctions first. This will help troubleshoot driveability malfunctions on an electronically controlled engine vehicle. EC-1284 SEF234G TROUBLE DIAGNOSIS [HR (WITHOUT EURO-OBD)] WORK FLOW Overall Sequence A EC C D E F G H I J K L M PBIB2267E EC-1285 TROUBLE DIAGNOSIS [HR (WITHOUT EURO-OBD)] Detailed Flow 1. GET INFORMATION FOR SYMPTOM Get the detailed information from the customer about the symptom (the condition and the environment when the incident/malfunction occurred) using the EC-1288, "DIAGNOSTIC WORKSHEET" . >> GO TO 2. 2. CHECK DTC*1 1. Check DTC*1 . 2. Perform the following procedure if DTC*1 is displayed. – Record DTC*1 and freeze frame data*2 . (Print them out with CONSULT-II.) – Erase DTC*1 . (Refer to EC-1267, "HOW TO ERASE EMISSION-RELATED DIAGNOSTIC INFORMATION" .) Study the relationship between the cause detected by DTC*1 and the symptom described by the customer. (Symptom Matrix Chart is useful. Refer to EC-1292, "Symptom Matrix Chart" .) 3. Check related service bulletins for information. Is any symptom described and any DTC detected? – Symptom is described, DTC*1 is displayed>>GO TO 3. Symptom is described, DTC*1 is not displayed>>GO TO 4. Symptom is not described, DTC*1 is displayed>>GO TO 5. 3. CONFIRM THE SYMPTOM Try to confirm the symptom described by the customer (except MI ON). DIAGNOSIS WORK SHEET is useful to verify the incident. Connect CONSULT-II to the vehicle in “DATA MONITOR (AUTO TRIG)” mode and check real time diagnosis results. Verify relation between the symptom and the condition when the symptom is detected. >> GO TO 5. 4. CONFIRM THE SYMPTOM Try to confirm the symptom described by the customer. DIAGNOSIS WORK SHEET is useful to verify the incident. Connect CONSULT-II to the vehicle in “DATA MONITOR (AUTO TRIG)” mode and check real time diagnosis results. Verify relation between the symptom and the condition when the symptom is detected. >> GO TO 6. EC-1286 TROUBLE DIAGNOSIS [HR (WITHOUT EURO-OBD)] 5. PERFORM DTC CONFIRMATION PROCEDURE A 1 1 Perform DTC Confirmation Procedure for the displayed DTC* , and then make sure that DTC* is detected again. At this time, always connect CONSULT-II to the vehicle, and check diagnostic results in real time on “DATA EC MONITOR (AUTO TRIG)”. If two or more DTCs*1 are detected, refer to EC-1290, "DTC Inspection Priority Chart" and determine trouble diagnosis order. C NOTE: ● Freeze frame data*2 is useful if the DTC*1 is not detected. ● Perform Overall Function Check if DTC Confirmation Procedure is not included on Service Manual. This D simplified check procedure is an effective alternative though DTC*1 cannot be detected during this check. If the result of Overall Function Check is NG, it is the same as the detection of DTC*1 by DTC Confirma- E tion Procedure. Is DTC*1 detected? Yes >> GO TO 10. No >> Check according to EC-1336, "TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT" . F 6. PERFORM BASIC INSPECTION G Perform EC-1272, "Basic Inspection" . H With CONSULT-II>>GO TO 7. Without CONSULT-II>>GO TO 9. 7. PERFORM DATA MONITOR (SPEC) MODE I With CONSULT-II Make sure that “MAS A/F SE-B1”, “B/FUEL SCHDL”, and “A/F ALPHA-B1” are within the SP value using CONSULT-II “DATA MONITOR (SPEC)” mode. Refer to EC-1326, "Inspection Procedure" . Are they within the SP value? Yes >> GO TO 9. No >> GO TO 8. J K L SEF601Z 8. DETECT MALFUNCTIONING PART BY TROUBLE DIAGNOSIS - SPECIFICATION VALUE Detect malfunctioning part according to EC-1327, "Diagnostic Procedure" . Is malfunctioning part detected? Yes >> GO TO 11. No >> GO TO 9. 9. DETECT MALFUNCTIONING SYSTEM BY SYMPTOM MATRIX CHART Detect malfunctioning system according to EC-1292, "Symptom Matrix Chart" based on the confirmed symptom in step 4, and determine the trouble diagnosis order based on possible causes and symptom. >> GO TO 10. EC-1287 M TROUBLE DIAGNOSIS [HR (WITHOUT EURO-OBD)] 10. DETECT MALFUNCTIONING PART BY DIAGNOSTIC PROCEDURE Inspect according to Diagnostic Procedure of the system. NOTE: The Diagnostic Procedure in EC section described based on open circuit inspection. A short circuit inspection is also required for the circuit check in the Diagnostic Procedure. For details, refer to Circuit Inspection in GI25, "How to Perform Efficient Diagnosis for an Electrical Incident" . Is malfunctioning part detected? Yes >> GO TO 11. No >> Monitor input data from related sensors or check voltage of related ECM terminals using CONSULT-II. Refer to EC-1304, "ECM Terminals and Reference Value" , EC-1321, "CONSULT-II Reference Value in Data Monitor" . 11. REPAIR OR REPLACE THE MALFUNCTIONING PART 1. 2. 3. Repair or replace the malfunctioning part. Reconnect parts or connectors disconnected during Diagnostic Procedure again after repair and replacement. Check DTC. If DTC is displayed, erase it, refer to EC-1267, "HOW TO ERASE EMISSION-RELATED DIAGNOSTIC INFORMATION" . >> GO TO 12. 12. FINAL CHECK When DTC was detected in step 2, perform DTC Confirmation Procedure or Overall Function Check again, and then make sure that the malfunction have been repaired securely. When symptom was described from the customer, refer to confirmed symptom in step 3 or 4, and make sure that the symptom is not detected. OK or NG NG (DTC*1 is detected)>>GO TO 10. NG (Symptom remains)>>GO TO 6. OK >> 1. Before returning the vehicle to the customer, make sure to erase unnecessary DTC*1 in ECM. (Refer to EC-1267, "HOW TO ERASE EMISSION-RELATED DIAGNOSTIC INFORMATION" .) 2. INSPECTION END *1: Include 1st trip DTC. *2: Include 1st trip freeze frame data. DIAGNOSTIC WORKSHEET Description There are many operating conditions that lead to the malfunction of engine components. A good grasp of such conditions can make troubleshooting faster and more accurate. In general, each customer feels differently about a incident. It is important to fully understand the symptoms or conditions for a customer complaint. Utilize a diagnostic worksheet like the one on the next page in order to organize all the information for troubleshooting. SEF907L EC-1288 TROUBLE DIAGNOSIS [HR (WITHOUT EURO-OBD)] Worksheet Sample A EC C D E F G H I J K L M MTBL0017 EC-1289 TROUBLE DIAGNOSIS [HR (WITHOUT EURO-OBD)] DTC Inspection Priority Chart BBS004KX If some DTCs are displayed at the same time, perform inspections one by one based on the following priority chart. NOTE: ● If DTC U1000 or U1001 is displayed with other DTC, first perform the trouble diagnosis for DTC U1000, U1001. Refer to EC-1344, "DTC U1000, U1001 CAN COMMUNICATION LINE" . ● If DTC U1010 is displayed with other DTC, first perform the trouble diagnosis for DTC U1010. Refer to EC-1347, "DTC U1010 CAN COMMUNICATION" . Priority 1 2 3 Detected items (DTC) ● U1000 U1001 CAN communication line ● U1010 CAN communication ● P0102 P0103 Mass air flow sensor ● P0117 P0118 Engine coolant temperature sensor ● P0122 P0123 P0222 P0223 P1225 P1226 P2135 Throttle position sensor ● P0327 P0328 Knock sensor ● P0335 Crankshaft position sensor (POS) ● P0340 Camshaft position sensor (PHASE) ● P0605 ECM ● P1229 Sensor power supply ● P1610 - P1615 NATS ● P1706 Park/Neutral position (PNP) switch ● P2122 P2123 P2127 P2128 P2138 Accelerator pedal position sensor ● P0132 P0134 Heated oxygen sensor 1 ● P0138 Heated oxygen sensor 2 ● P1065 ECM ● P1111 Intake valve timing control solenoid valve ● P1122 Electric throttle control function ● P1124 P1126 Throttle control motor relay ● P1128 Throttle control motor ● P1217 Engine over temperature (OVERHEAT) ● P1805 Brake switch ● P0011 Intake valve timing control ● P1121 Electric throttle control actuator ● P1212 ESP communication line EC-1290 TROUBLE DIAGNOSIS [HR (WITHOUT EURO-OBD)] Fail-Safe Chart BBS004KY When the DTC listed below is detected, the ECM enters fail-safe mode and the MI lights up. DTC No. Detected items Engine operating condition in fail-safe mode P0102 P0103 Mass air flow sensor circuit Engine speed will not rise more than 2,400 rpm due to the fuel cut. P0122 P0123 P0222 P0223 P2135 Throttle position sensor The ECM controls the electric throttle control actuator in regulating the throttle opening in order for the idle position to be within +10 degrees. The ECM regulates the opening speed of the throttle valve to be slower than the normal condition. So, the acceleration will be poor. P1121 Electric throttle control actuator (When electric throttle control actuator does not function properly due to the return spring malfunction:) ECM controls the electric throttle actuator by regulating the throttle opening around the idle position. The engine speed will not rise more than 2,000 rpm. A EC C D E (When throttle valve opening angle in fail-safe mode is not in specified range:) ECM controls the electric throttle control actuator by regulating the throttle opening to 20 degrees or less. (When ECM detects the throttle valve is stuck open:) While the vehicle is driving, it slows down gradually by fuel cut. After the vehicle stops, the engine stalls. The engine can restart in N or P (A/T), Neutral (M/T) position, and engine speed will not exceed 1,000 rpm or more. P1122 Electric throttle control function ECM stops the electric throttle control actuator control, throttle valve is maintained at a fixed opening (approx. 5 degrees) by the return spring. P1124 P1126 Throttle control relay ECM stops the electric throttle control actuator control, throttle valve is maintained at a fixed opening (approx. 5 degrees) by the return spring. P1128 Throttle control motor ECM stops the electric throttle control actuator control, throttle valve is maintained at a fixed opening (approx. 5 degrees) by the return spring. P1229 Sensor power supply ECM stops the electric throttle control actuator control, throttle valve is maintained at a fixed opening (approx. 5 degrees) by the return spring. P1805 Brake switch ECM controls the electric throttle control actuator by regulating the throttle opening to a small range. Therefore, acceleration will be poor. P2122 P2123 P2127 P2128 P2138 ● Accelerator pedal position sensor Vehicle condition Driving condition When engine is idling Normal When accelerating Poor acceleration The ECM controls the electric throttle control actuator in regulating the throttle opening in order for the idle position to be within +10 degrees. The ECM regulates the opening speed of the throttle valve to be slower than the normal condition. So, the acceleration will be poor. When there is an open circuit on MI circuit, the ECM cannot warn the driver by lighting up MI when there is malfunction on engine control system. Therefore, when electrical controlled throttle and part of ECM related diagnoses are continuously detected as NG for 5 trips, ECM warns the driver that engine control system malfunctions and MI circuit is open by means of operating fail-safe function. The fail-safe function also operates when above diagnoses except MI circuit are detected and demands the driver to repair the malfunction. Engine operating condition in fail-safe mode Engine speed will not rise more than 2,500 rpm due to the fuel cut EC-1291 F G H I J K L M TROUBLE DIAGNOSIS [HR (WITHOUT EURO-OBD)] Symptom Matrix Chart BBS004KZ SYSTEM — BASIC ENGINE CONTROL SYSTEM 1 1 2 3 2 Fuel pressure regulator system 3 3 4 4 4 Fuel injector circuit 1 1 2 3 2 Evaporative emission system 3 3 4 4 4 Air Positive crankcase ventilation system 4 4 4 3 3 Incorrect idle speed adjustment Ignition BATTERY DEAD (UNDER CHARGE) Fuel pump circuit EXCESSIVE OIL CONSUMPTION Fuel EXCESSIVE FUEL CONSUMPTION AE OVERHEATS/WATER TEMPERATURE HIGH LACK OF POWER/POOR ACCELERATION AD SLOW/NO RETURN TO IDLE SPARK KNOCK/DETONATION AC IDLING VIBRATION HESITATION/SURGING/FLAT SPOT AB ROUGH IDLE/HUNTING ENGINE STALL AA Warranty symptom code HIGH IDLE/LOW IDLE HARD/NO START/RESTART (EXCP. HA) SYMPTOM AF AG AH AJ AK AL AM HA 2 2 4 4 2 2 4 4 4 4 4 1 2 4 3 4 2 Reference page EC-1543 4 EC-1282 2 EC-1537 4 4 EC-1257 4 4 4 1 1 1 1 2 2 2 2 1 EC-1262 EC-1272 1 1 2 3 3 Incorrect ignition timing adjustment 3 3 1 1 1 1 1 1 EC-1272 Ignition circuit 1 1 2 2 2 2 2 2 EC-1580 2 2 3 3 3 3 3 Main power supply and ground circuit Mass air flow sensor circuit Engine coolant temperature sensor circuit 2 3 2 3 3 EC-1361 3 Heated oxygen sensor 1 circuit 2 2 2 2 2 2 3 Knock sensor circuit 2 2 EC-1373, EC-1381 , EC-1549 EC-1367, EC-1395 , EC-1467 , EC-1469 , EC-1511 Throttle position sensor circuit Accelerator pedal position sensor circuit EC-1337 EC-1354 1 1 2 EC-1430, EC-1433 Electric throttle control actuator 2 EC-1471, EC-1492 , EC-1501 , EC-1517 1 3 EC-1401 Crankshaft position sensor (POS) circuit 2 2 EC-1405 Camshaft position sensor (PHASE) circuit 3 2 EC-1413 Vehicle speed signal circuit ECM Intake valve timing control solenoid valve circuit 2 2 3 2 3 3 2 3 3 3 3 3 3 3 1 3 2 2 3 EC-1292 3 3 EC-1595 3 EC-1420, EC-1423 3 EC-1425 TROUBLE DIAGNOSIS [HR (WITHOUT EURO-OBD)] SYMPTOM HARD/NO START/RESTART (EXCP. HA) ENGINE STALL HESITATION/SURGING/FLAT SPOT SPARK KNOCK/DETONATION LACK OF POWER/POOR ACCELERATION HIGH IDLE/LOW IDLE ROUGH IDLE/HUNTING IDLING VIBRATION SLOW/NO RETURN TO IDLE OVERHEATS/WATER TEMPERATURE HIGH EXCESSIVE FUEL CONSUMPTION EXCESSIVE OIL CONSUMPTION BATTERY DEAD (UNDER CHARGE) Warranty symptom code AA AB AC AD AE AF AG AH AJ AK AL AM HA PNP switch circuit 3 Refrigerant pressure sensor circuit 3 2 2 2 ABS actuator and electric unit (control unit) 3 3 3 Electrical load signal circuit Air conditioner circuit A 3 3 3 3 3 EC Reference page D E 3 EC-1479 4 EC-1590 3 EC-1528 3 ATC-20, MTC-20 3 3 3 2 BRC-8, BRC-49 4 C 1 - 6: The numbers refer to the order of inspection. (continued on next page) F G H I SYSTEM — ENGINE MECHANICAL & OTHER SYMPTOM Fuel Fuel tank HARD/NO START/RESTART (EXCP. HA) ENGINE STALL HESITATION/SURGING/FLAT SPOT SPARK KNOCK/DETONATION LACK OF POWER/POOR ACCELERATION HIGH IDLE/LOW IDLE ROUGH IDLE/HUNTING IDLING VIBRATION SLOW/NO RETURN TO IDLE OVERHEATS/WATER TEMPERATURE HIGH EXCESSIVE FUEL CONSUMPTION EXCESSIVE OIL CONSUMPTION BATTERY DEAD (UNDER CHARGE) Warranty symptom code J AA AB AC AD AE AF AG AH AJ AK AL AM HA Fuel piping 5 5 5 5 5 5 FL-14 — 5 5 5 5 5 5 5 — EC-1293 L M — 5 Valve deposit Poor fuel (Heavy weight gasoline, Low octane) Reference page FL-19 5 Vapor lock K TROUBLE DIAGNOSIS [HR (WITHOUT EURO-OBD)] Air ENGINE STALL HESITATION/SURGING/FLAT SPOT SPARK KNOCK/DETONATION LACK OF POWER/POOR ACCELERATION HIGH IDLE/LOW IDLE ROUGH IDLE/HUNTING IDLING VIBRATION SLOW/NO RETURN TO IDLE OVERHEATS/WATER TEMPERATURE HIGH EXCESSIVE FUEL CONSUMPTION EXCESSIVE OIL CONSUMPTION BATTERY DEAD (UNDER CHARGE) Warranty symptom code HARD/NO START/RESTART (EXCP. HA) SYMPTOM AA AB AC AD AE AF AG AH AJ AK AL AM HA Air duct EM-118 Air cleaner EM-118 Air leakage from air duct (Mass air flow sensor — electric throttle control actuator) Electric throttle control actuator 5 5 5 5 5 5 5 5 EM-118 5 5 EM-120 Air leakage from intake manifold/ Collector/Gasket Cranking EM-120 Battery Generator circuit SC-5 1 Starter circuit 3 Signal plate 6 PNP switch Engine Reference page 1 1 1 1 1 1 SC-15 SC-45 EM-189 1 MT-16, MT46 , AT105 , AT293 4 Cylinder head Cylinder head gasket 5 5 5 5 5 5 5 4 5 3 EM-173 Cylinder block Piston 4 Piston ring Connecting rod 6 6 6 6 6 6 6 6 EM-189 Bearing Crankshaft Valve mechanism Timing chain EM-142 Camshaft EM-151 Intake valve timing control 5 5 5 5 5 5 5 EM-151 5 Intake valve 3 Exhaust valve Exhaust Exhaust manifold/Tube/Muffler/ Gasket 5 5 5 5 5 Three way catalyst EC-1294 5 5 5 EM-173 EX-3, EM124 TROUBLE DIAGNOSIS [HR (WITHOUT EURO-OBD)] SYMPTOM Lubrication Oil pan/Oil strainer/Oil pump/Oil filter/Oil gallery HARD/NO START/RESTART (EXCP. HA) ENGINE STALL HESITATION/SURGING/FLAT SPOT SPARK KNOCK/DETONATION LACK OF POWER/POOR ACCELERATION HIGH IDLE/LOW IDLE ROUGH IDLE/HUNTING IDLING VIBRATION SLOW/NO RETURN TO IDLE OVERHEATS/WATER TEMPERATURE HIGH EXCESSIVE FUEL CONSUMPTION EXCESSIVE OIL CONSUMPTION BATTERY DEAD (UNDER CHARGE) Warranty symptom code A AA AB AC AD AE AF AG AH AJ AK AL AM HA 5 5 5 5 5 5 5 5 Oil level (Low)/Filthy oil Cooling Radiator/Hose/Radiator filler cap C D E EM-127, LU-16 , LU-19 F G CO-31 5 CO-38 Water pump H CO-36 5 5 5 5 5 5 5 4 Cooling fan 5 CO-26 CO-31 5 Coolant level (Low)/Contaminated coolant NATS (Nissan Anti-Theft System) Reference page LU-16 Thermostat Water gallery EC 1 1 I CO-27 BL-215 J 1 - 6: The numbers refer to the order of inspection. K L M EC-1295 TROUBLE DIAGNOSIS [HR (WITHOUT EURO-OBD)] Engine Control Component Parts Location BBS004L0 MBIB1542E 1. Ignition coil (with power transistor) and spark plug 2. Intake valve timing control solenoid valve 3. Refrigerant pressure sensor 4. Knock sensor 5. Fuel injector 6. Cooling fan motor 7. Camshaft position sensor (PHASE) 8. IPDM E/R 9. ECM 11. Engine coolant temperature sensor 12. Electric throttle control actuator (with built-in throttle position sensor, throttle control motor) 10. Mass air flow sensor (with intake air temperature sensor) 13. EVAP canister purge volume control solenoid valve EC-1296 TROUBLE DIAGNOSIS [HR (WITHOUT EURO-OBD)] A EC C D E F G H I J K L M PBIB2940E : Vehicle front 1. Mass air flow sensor (with intake air temperature sensor) 2. Engine coolant temperature sensor 3. Electric throttle control actuator 4. Camshaft position sensor (PHASE) 5. Ignition coil (with power transistor) 6. Fuel injector 7. EVAP canister purge volume control solenoid valve EC-1297 TROUBLE DIAGNOSIS [HR (WITHOUT EURO-OBD)] MBIB1543E : Vehicle front 1. ECM harness connectors 2. ECM 3. IPDM E/R 4. Fuel pump fuse (15A) 5. Intake valve timing control solenoid valve 6. Knock sensor 7. Refrigerant pressure sensor 8. PCV valve EC-1298 TROUBLE DIAGNOSIS [HR (WITHOUT EURO-OBD)] A EC C D E PBIB2942E F G H I PBIB2943E : Vehicle front 1. Exhaust manifold 4. Heated oxygen sensor 2 harness connector 2. Heated oxygen sensor 1 3. Heated oxygen sensor 2 J K L M EC-1299 TROUBLE DIAGNOSIS [HR (WITHOUT EURO-OBD)] MBIB1544E 1. Cooling fan motor 2. Crankshaft position sensor (POS) 3. Stop lamp switch 4. Brake pedal 5. Accelerator pedal position sensor harness connector 6. Accelerator pedal position sensor 7. Accelerator pedal 8. Fuel level sensor unit and fuel pump harness connector 9. Fuel pump and fuel filter 10. Fuel pressure regulator 11. Fuel level sensor unit EC-1300 TROUBLE DIAGNOSIS [HR (WITHOUT EURO-OBD)] Vacuum Hose Drawing BBS004L1 A EC C D E F G H I J K L M PBIB2946E : Vehicle front 1. Intake manifold : To EVAP canister 2. EVAP canister purge volume control solenoid valve 3. EVAP purge resonator NOTE: Do not use soapy water or any type of solvent while installing vacuum hoses or purge hoses. Refer to EC-1250, "System Diagram" for Vacuum Control System. EC-1301 TROUBLE DIAGNOSIS [HR (WITHOUT EURO-OBD)] Circuit Diagram BBS004L2 MBWA1453E EC-1302 TROUBLE DIAGNOSIS [HR (WITHOUT EURO-OBD)] A EC C D E F G H I J K L M MBWA1454E EC-1303 TROUBLE DIAGNOSIS [HR (WITHOUT EURO-OBD)] ECM Harness Connector Terminal Layout BBS004L3 PBIA9221J ECM Terminals and Reference Value BBS004L4 PREPARATION 1. ECM (1) is located in the engine room left side near battery. ● : Vehicle front PBIB2959E 2. 3. Disconnect ECM harness connector. ● When disconnecting ECM harness connector, loosen (A) it with levers (1) as far as they will go as shown in the figure. – ECM (2) – Fasten (B) Connect a break-out box (SST) and Y-cable adapter (SST) between the ECM and ECM harness connector. ● Use extreme care not to touch 2 pins at one time. ● Data is for comparison and may not be exact. PBIB2947E ECM INSPECTION TABLE Specification data are reference values and are measured between each terminal and ground. Pulse signal is measured by CONSULT-II. CAUTION: Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECMs transistor. Use a ground other than ECM terminals, such as the ground. TERMINAL NO. WIRE COLOR ITEM CONDITION DATA (DC Voltage) Approximately 3.2V [Ignition switch: ON] 1 P Throttle control motor (Open) ● Engine stopped ● Shift lever: D (A/T), 1st (M/T) ● Accelerator pedal: Fully depressed PBIA8150J 2 LG Throttle control motor power supply [Ignition switch: ON] EC-1304 BATTERY VOLTAGE (11 - 14V) TROUBLE DIAGNOSIS [HR (WITHOUT EURO-OBD)] TERMINAL NO. WIRE COLOR ITEM CONDITION DATA (DC Voltage) A Approximately 10V EC [Engine is running] 3 Y ● Warm-up condition ● Engine speed: Below 3,600 rpm C Heated oxygen sensor 1 heater PBIA8148J D [Ignition switch: ON] ● Engine stopped [Engine is running] ● BATTERY VOLTAGE (11 - 14V) E Engine speed: Above 3,600 rpm Approximately 1.8V F [Ignition switch: ON] 4 L Throttle control motor (Close) ● Engine stopped ● Shift lever: D (A/T), 1st (M/T) ● Accelerator pedal: Fully released G PBIA8149J [Engine is running] 5 GR ● Below 3,600 rpm after the following conditions are met. – Engine: After warming up – Keeping the engine speed between 3,500 and 4,000 rpm for 1 minute and at idle for 1 minute under no load Heated oxygen sensor 2 heater H Approximately 10V I PBIA8148J J [Ignition switch: ON] ● Engine stopped [Engine is running] ● BATTERY VOLTAGE (11 - 14V) K BATTERY VOLTAGE L Engine speed: Above 3,600 rpm (11 - 14V) [Engine is running] ● 9 LG M Idle speed EVAP canister purge volume control solenoid valve PBIB0050E Approximately 10V [Engine is running] ● Engine speed: About 2,000 rpm (More than 100 seconds after starting engine) PBIB0520E 10 11 B B/W ECM ground [Engine is running] ● Idle speed EC-1305 Body ground TROUBLE DIAGNOSIS [HR (WITHOUT EURO-OBD)] TERMINAL NO. WIRE COLOR ITEM CONDITION [Engine is running] ● Warm-up condition ● Idle speed DATA (DC Voltage) 3 - 5V NOTE: The pulse cycle changes depending on rpm at idle. PBIA8164J 13 L Tachometer signal 3 - 5V [Engine is running] ● ● Warm-up condition Engine speed: 2,000 rpm PBIA8165J 15 G [Ignition switch: OFF] BATTERY VOLTAGE (11 - 14V) [Ignition switch: ON] 0 - 1.0V Throttle control motor relay [Engine is running] 17 18 21 22 V BR G Y ● Warm-up condition ● Idle speed 0 - 0.3V NOTE: The pulse cycle changes depending on rpm at idle. Ignition signal No. 1 Ignition signal No. 2 Ignition signal No. 4 Ignition signal No. 3 PBIA9265J 0.2 - 0.5V [Engine is running] ● ● Warm-up condition Engine speed: 2,500 rpm PBIA9266J [Ignition switch: ON] ● 23 R Fuel pump relay For 1 second after turning ignition switch ON 0 - 1.0V [Engine is running] [Ignition switch: ON] ● More than 1 second after turning ignition switch ON EC-1306 BATTERY VOLTAGE (11 - 14V) TROUBLE DIAGNOSIS [HR (WITHOUT EURO-OBD)] TERMINAL NO. WIRE COLOR ITEM CONDITION DATA (DC Voltage) A BATTERY VOLTAGE [Engine is running] 25 29 30 31 R O GR L ● Warm-up condition ● Idle speed EC (11 - 14V) C NOTE: The pulse cycle changes depending on rpm at idle. Fuel injector No. 4 Fuel injector No. 3 Fuel injector No. 2 Fuel injector No. 1 PBIB0529E D BATTERY VOLTAGE (11 - 14V) E [Engine is running] ● Warm-up condition ● Engine speed: 2,000 rpm F PBIA4943J [Engine is running] [Ignition switch: OFF] ● 32 P ECM relay (Self shut-off) For a few seconds after turning ignition switch OFF [Ignition switch: OFF] ● More than a few seconds after turning ignition switch OFF G 0 - 1.0V H BATTERY VOLTAGE (11 - 14V) I [Ignition switch: ON] 33 Y ● Engine stopped ● Shift lever: D (A/T), 1st (M/T) ● Accelerator pedal: Fully released More than 0.36V J Throttle position sensor 1 [Ignition switch: ON] ● Engine stopped ● Shift lever: D (A/T), 1st (M/T) ● Accelerator pedal: Fully depressed K Less than 4.75V L [Ignition switch: ON] 34 R ● Engine stopped ● Shift lever: D (A/T), 1st (M/T) ● Accelerator pedal: Fully released Throttle position sensor 2 Less than 4.75V [Ignition switch: ON] ● Engine stopped ● Shift lever: D (A/T), 1st (M/T) ● Accelerator pedal: Fully depressed More than 0.36V [Engine is running] 36 37 BR W Sensor ground (Throttle position sensor) Knock sensor ● Warm-up condition ● Idle speed [Engine is running] ● 38 P Engine coolant temperature sensor Idle speed [Engine is running] EC-1307 Approximately 0V Approximately 2.5V Approximately 0 - 4.8V Output voltage varies with engine coolant temperature. M TROUBLE DIAGNOSIS [HR (WITHOUT EURO-OBD)] TERMINAL NO. WIRE COLOR ITEM CONDITION DATA (DC Voltage) [Engine is running] 40 — Sensor ground (Knock sensor) ● Warm-up condition ● Idle speed Approximately 0V [Engine is running] 41 44 BR Refrigerant pressure sensor B Sensor ground (Engine coolant temperature sensor) ● Warm-up condition ● Both A/C switch and blower fan switch: ON (Compressor operates.) 1.0 - 4.0V [Engine is running] ● Warm-up condition ● Idle speed [Ignition switch: ON] ● Engine stopped Approximately 0V Approximately 0.4V [Engine is running] 45 G Mass air flow sensor ● Warm-up condition ● Idle speed [Engine is running] 46 V Intake air temperature sensor 48 Y Sensor ground (Refrigerant pressure sensor) ● Warm-up condition ● Engine is revving from idle to about 4,000 rpm [Engine is running] 1.0 - 1.3V 1.0 - 1.3 to Approximately 2.4V (Check for linear voltage rise in response to engine being increased to about 4,000 rpm.) Approximately 0 - 4.8V Output voltage varies with intake air temperature. [Engine is running] ● Warm-up condition ● Idle speed Approximately 0V [Engine is running] 49 BR Heated oxygen sensor 1 ● Warm-up condition ● Engine speed: 2,000 rpm 0 - Approximately 1.0V (Periodically change) [Engine is running] 50 B Heated oxygen sensor 2 ● Revving engine from idle to 3,000 rpm quickly after the following conditions are met. – Engine: After warming up – Keeping the engine speed between 3,500 and 4,000 rpm for 1 minute and at idle for 1 minute under no load. 0 - Approximately 1.0V [Engine is running] 52 55 LG O Sensor ground (Mass air flow sensor) Sensor ground (Intake air temperature sensor) ● Warm-up condition ● Idle speed Approximately 0V [Engine is running] ● Warm-up condition ● Idle speed Approximately 0V [Engine is running] 56 R Sensor ground (Heated oxygen sensor 1) ● Warm-up condition ● Idle speed Approximately 0V [Engine is running] 59 LG Sensor ground (Heated oxygen sensor 2) ● Warm-up condition ● Idle speed EC-1308 Approximately 0V TROUBLE DIAGNOSIS [HR (WITHOUT EURO-OBD)] TERMINAL NO. WIRE COLOR ITEM CONDITION [Engine is running] ● Warm-up condition ● Idle speed DATA (DC Voltage) 0 - 1.0V EC NOTE: The pulse cycle changes depending on rpm at idle. 61 Y A C MBIB1453E Crankshaft position sensor (POS) D 0 - 1.0V E [Engine is running] ● Engine speed: 2,000 rpm F MBIB1454E 62 63 W B Sensor ground [Crankshaft position sensor (POS)] [Engine is running] Sensor ground [Camshaft position sensor (PHASE)] [Engine is running] ● Warm-up condition ● Idle speed ● Warm-up condition ● Idle speed [Engine is running] ● Warm-up condition ● Idle speed Approximately 0V G Approximately 0V H 0 - 1.0V I J NOTE: The pulse cycle changes depending on rpm at idle. 65 R MBIB1455E Camshaft position sensor (PHASE) K 0 - 1.0V L [Engine is running] ● Engine speed: 2,000 rpm M MBIB1456E [Ignition switch: ON] 70 GR Park/Neutral position (PNP) switch ● Shift lever: P or N (A/T models) ● Shift lever: Neutral (M/T models) [Ignition switch: ON] ● 72 L Sensor power supply (Throttle position sensor) Except above position [Ignition switch: ON] EC-1309 Approximately 0V BATTERY VOLTAGE (11 - 14V) Approximately 5V TROUBLE DIAGNOSIS [HR (WITHOUT EURO-OBD)] TERMINAL NO. WIRE COLOR ITEM CONDITION DATA (DC Voltage) [Engine is running] ● Warm-up condition ● Idle speed BATTERY VOLTAGE (11 - 14V) 7 - 10V 73 LG Intake valve timing control solenoid valve [Engine is running] ● Warm-up condition ● Engine speed: 2,000 rpm PBIA4937J 74 W Sensor power supply (Refrigerant pressure sensor) [Ignition switch: ON] Approximately 5V 75 G Sensor power supply [Crankshaft position sensor (POS)] [Ignition switch: ON] Approximately 5V 78 O Sensor power supply [Camshaft position sensor (PHASE)] [Ignition switch: ON] Approximately 5V 83 Y CAN communication line [Ignition switch: ON] Approximately 1.7 - 2.3V 84 L CAN communication line [Ignition switch: ON] Approximately 2.6 - 3.2V 88 LG DATA link connector [Ignition switch: ON] ● 93 O CONSULT-II: Disconnected. [Ignition switch: OFF] 0V [Ignition switch: ON] BATTERY VOLTAGE (11 - 14V) Ignition switch [Ignition switch: OFF] ● 99 R Stop lamp switch Brake pedal: Fully released [Ignition switch: OFF] ● 102 BR Sensor power supply (Accelerator pedal position sensor 2) Approximately 2.7V Brake pedal: Slightly depressed [Ignition switch: ON] Approximately 0V BATTERY VOLTAGE (11 - 14V) Approximately 5V [Ignition switch: ON] 103 104 G B Accelerator pedal position sensor 2 ● Engine stopped ● Accelerator pedal: Fully released 0.3 - 0.6V [Ignition switch: ON] ● Engine stopped ● Accelerator pedal: Fully depressed Sensor ground (Accelerator pedal position sensor 2) [Engine is running] ● Warm-up condition ● Idle speed 1.95 - 2.4V Approximately 0V 105 G Power supply for ECM [Ignition switch: ON] BATTERY VOLTAGE (11 - 14V) 106 O Sensor power supply (Accelerator pedal position sensor 1) [Ignition switch: ON] Approximately 5V 108 B ECM ground [Engine is running] ● Idle speed EC-1310 Body ground TROUBLE DIAGNOSIS [HR (WITHOUT EURO-OBD)] TERMINAL NO. WIRE COLOR ITEM CONDITION DATA (DC Voltage) A [Ignition switch: ON] 110 111 W B Accelerator pedal position sensor 1 Sensor ground (Accelerator pedal position sensor 1) ● Engine stopped ● Accelerator pedal: Fully released 0.6 - 0.9V EC 3.9 - 4.7V C [Ignition switch: ON] ● Engine stopped ● Accelerator pedal: Fully depressed [Engine is running] ● Warm-up condition ● Idle speed : Average voltage for pulse signal (Actual pulse signal can be confirmed by oscilloscope.) Approximately 0V D E F G H I J K L M EC-1311 TROUBLE DIAGNOSIS [HR (WITHOUT EURO-OBD)] CONSULT-II Function (ENGINE) BBS004L5 FUNCTION Diagnostic test mode Function Work support This mode enables a technician to adjust some devices faster and more accurately by following the indications on the CONSULT-II unit. Self-diagnostic results Self-diagnostic results such as 1st trip DTC, DTCs and 1st trip freeze frame data or freeze frame data can be read and erased quickly.* Data monitor Input/Output data in the ECM can be read. Data monitor (SPEC) Input/Output of the specification for Basic fuel schedule, AFM, A/F feedback control value and the other data monitor items can be read. CAN diagnostic support monitor The results of transmit/receive diagnosis of CAN communication can be read. Active test Diagnostic Test Mode in which CONSULT-II drives some actuators apart from the ECMs and also shifts some parameters in a specified range. Function test This mode is used to inform customers when their vehicle condition requires periodic maintenance. ECM part number ECM part number can be read. *: The following emission-related diagnostic information is cleared when the ECM memory is erased. ● Diagnostic trouble codes ● 1st trip diagnostic trouble codes ● Freeze frame data ● 1st trip freeze frame data ENGINE CONTROL COMPONENT PARTS/CONTROL SYSTEMS APPLICATION DIAGNOSTIC TEST MODE SELF-DIAGNOSTIC RESULTS Item WORK SUPPORT 1 DTC* FREEZE FRAME DATA MONITOR DATA MONITOR (SPEC) ACTIVE TEST INPUT ENGINE CONTROL COMPONENT PARTS DATA*2 Crankshaft position sensor (POS) × × × × Camshaft position sensor (PHASE) × × × × Mass air flow sensor × × × Engine coolant temperature sensor × × × Heated oxygen sensor 1 × × × Heated oxygen sensor 2 × × × Wheel sensor × × × Accelerator pedal position sensor × × × Throttle position sensor × × × Intake air temperature sensor × × × Knock sensor × EPS control unit × × Refrigerant pressure sensor × × Closed throttle position switch (accelerator pedal position sensor signal) × × Air conditioner switch × × × × × Park/neutral position (PNP) switch × × × Stop lamp switch × × × Battery voltage × × Load signal × × EC-1312 × TROUBLE DIAGNOSIS [HR (WITHOUT EURO-OBD)] DIAGNOSTIC TEST MODE SELF-DIAGNOSTIC RESULTS A DATA MONITOR DATA MONITOR (SPEC) ACTIVE TEST EC Fuel injector × × × C Power transistor (Ignition timing) × × × × × Item WORK SUPPORT DTC* 1 FREEZE FRAME OUTPUT ENGINE CONTROL COMPONENT PARTS DATA*2 Throttle control motor relay × Throttle control motor × EVAP canister purge volume control solenoid valve × Air conditioner relay × Fuel pump relay D × × × × × × × × Cooling fan relay × × × Heated oxygen sensor 1 heater × × × Heated oxygen sensor 2 heater × × × Intake valve timing control solenoid valve × × × × E × X: Applicable *1: This item includes 1st trip DTCs. *2: This mode includes 1st trip freeze frame data or freeze frame data. The items appear on CONSULT-II screen in freeze frame data mode only if a 1st trip DTC or DTC is detected. For details, refer to EC-1266 . F G H INSPECTION PROCEDURE Refer to GI-36, "CONSULT-II Start Procedure" . I WORK SUPPORT MODE Work Item J WORK ITEM FUEL PRESSURE RELEASE IDLE AIR VOL LEARN SELF-LEARNING CONT CONDITION ● ● ● USAGE FUEL PUMP WILL STOP BY TOUCHING “START” DURING IDLING. CRANK A FEW TIMES AFTER ENGINE STALLS. When releasing fuel pressure from fuel line THE IDLE AIR VOLUME THAT KEEPS THE ENGINE WITHIN THE SPECIFIED RANGE IS MEMORIZED IN ECM. When learning the idle air volume THE COEFFICIENT OF SELF-LEARNING CONTROL MIXTURE RATIO RETURNS TO THE ORIGINAL COEFFICIENT. When clearing the coefficient of self-learning control value L TARGET IDLE RPM ADJ* ● IDLE CONDITION When setting target idle speed TARGET IGN TIM ADJ* ● IDLE CONDITION When adjusting target ignition timing *: This function is not necessary in the usual service procedure. SELF-DIAG RESULTS MODE Self Diagnostic Item Regarding items of DTC and 1st trip DTC, refer to EC-1264, "EMISSION-RELATED DIAGNOSTIC INFORMATION ITEMS" . EC-1313 K M TROUBLE DIAGNOSIS [HR (WITHOUT EURO-OBD)] Freeze Frame Data and 1st Trip Freeze Frame Data Freeze frame data item* DIAG TROUBLE CODE [PXXXX] Description ● The engine control component part/control system has a trouble code, it is displayed as PXXXX. (Refer to EC-1239, "INDEX FOR DTC" .) ● “Fuel injection system status” at the moment a malfunction is detected is displayed. ● One mode in the following is displayed. Mode2: Open loop due to detected system malfunction Mode3: Open loop due to driving conditions (power enrichment, deceleration enleanment) Mode4: Closed loop - using oxygen sensor(s) as feedback for fuel control Mode5: Open loop - has not yet satisfied condition to go to closed loop CAL/LD VALUE [%] ● The calculated load value at the moment a malfunction is detected is displayed. COOLANT TEMP [°C] or [°F] ● The engine coolant temperature at the moment a malfunction is detected is displayed. ● “Long-term fuel trim” at the moment a malfunction is detected is displayed. ● The long-term fuel trim indicates much more gradual feedback compensation to the base fuel schedule than short-term fuel trim. ● “Short-term fuel trim” at the moment a malfunction is detected is displayed. S-FUEL TRM-B1 [%] ● The short-term fuel trim indicates dynamic or instantaneous feedback compensation to the base fuel schedule. ENGINE SPEED [rpm] ● The engine speed at the moment a malfunction is detected is displayed. VEHICL SPEED [km/h] or [mph] ● The vehicle speed at the moment a malfunction is detected is displayed. B/FUEL SCHDL [msec] ● The base fuel schedule at the moment a malfunction is detected is displayed. INT/A TEMP SE [°C] or [°F] ● The intake air temperature at the moment a malfunction is detected is displayed. FUEL SYS-B1 L-FUEL TRM-B1 [%] *: The items are the same as those of 1st trip freeze frame data. DATA MONITOR MODE Monitored Item Monitored item [Unit] ECM INPUT SIGNALS ×: Applicable MAIN SIGNALS Description ● ENG SPEED [rpm] × × MAS A/F SE-B1 [V] × × B/FUEL SCHDL [msec] A/F ALPHA-B1 [%] ● The signal voltage of the mass air flow sensor is displayed. ● “Base fuel schedule” indicates the fuel injection pulse width programmed into ECM, prior to any learned on board correction. × × Indicates the engine speed computed from the signals of the crankshaft position sensor (POS) and camshaft position sensor (PHASE). ● The mean value of the air-fuel ratio feedback correction factor per cycle is indicated. EC-1314 Remarks ● Accuracy becomes poor if engine speed drops below the idle rpm. ● If the signal is interrupted while the engine is running, an abnormal value may be indicated. ● When the engine is stopped, a certain value is indicated. ● When the engine is stopped, a certain value is indicated. ● This data also includes the data for the air-fuel ratio learning control. TROUBLE DIAGNOSIS [HR (WITHOUT EURO-OBD)] Monitored item [Unit] ECM INPUT SIGNALS MAIN SIGNALS Description Remarks ● COOLAN TEMP/S [°C] or [°F] ● × HO2S1 (B1) [V] × HO2S2 (B1) [V] × × × The engine coolant temperature (determined by the signal voltage of the engine coolant temperature sensor) is displayed. ● The signal voltage of the heated oxygen sensor 1 is displayed. ● The signal voltage of the heated oxygen sensor 2 is displayed. ● Display of heated oxygen sensor 1 signal during air-fuel ratio feedback control: RICH: means the mixture became “rich”, and control is being affected toward a leaner mixture. LEAN: means the mixture became “lean”, and control is being affected toward a rich mixture. × × ● Display of heated oxygen sensor 2 signal: RICH: means the amount of oxygen after three way catalyst is relatively small. LEAN: means the amount of oxygen after three way catalyst is relatively large. HO2S2 MNTR (B1) [RICH/LEAN] × VHCL SPEED SE [km/h] or [mph] × × ● BATTERY VOLT [V] × × ● The power supply voltage of ECM is displayed. ACCEL SEN 1 [V] × × ● The accelerator pedal position sensor signal voltage is displayed. ACCEL SEN 2 [V] × THRTL SEN 1 [V] × THRTL SEN 2 [V] × INT/A TEMP SE [°C] or [°F] × START SIGNAL [ON/OFF] × × CLSD THL POS [ON/OFF] × × AIR COND SIG [ON/OFF] × × P/N POSI SW [ON/OFF] × × PW/ST SIGNAL [ON/OFF] × × ● ● × ● ● After turning ON the ignition switch, “RICH” is displayed until air-fuel mixture ratio feedback control begins. When the air-fuel ratio feedback is clamped, the value just before the clamping is displayed continuously. When the engine is stopped, a certain value is indicated. The vehicle speed computed from the vehicle speed signal is displayed. × ● ACCEL SEN 2 signal is converted by ECM internally. Thus, it differs from ECM terminal voltage signal. ● THRTL SEN 2 signal is converted by ECM internally. Thus, it differs from ECM terminal voltage signal. The intake air temperature (determined by the signal voltage of the intake air temperature sensor) is indicated. Indicates start signal status [ON/OFF] computed by the ECM according to the signals of engine speed and battery voltage. ● Indicates idle position [ON/OFF] computed by the ECM according to the accelerator pedal position sensor signal. ● Indicates [ON/OFF] condition of the air conditioner switch as determined by the air conditioner signal. ● Indicates [ON/OFF] condition from the park/ neutral position (PNP) switch signal. ● [ON/OFF] condition of the power steering system (determined by the signal sent from EPS control unit) is indicated. EC-1315 C E F G H I The throttle position sensor signal voltage is displayed. ● EC D ● HO2S1 MNTR (B1) [RICH/LEAN] When the engine coolant temperature sensor is open or shortcircuited, ECM enters fail-safe mode. The engine coolant temperature determined by the ECM is displayed. A J K L M ● After starting the engine, [OFF] is displayed regardless of the starter signal. TROUBLE DIAGNOSIS [HR (WITHOUT EURO-OBD)] Monitored item [Unit] ECM INPUT SIGNALS MAIN SIGNALS Description ● Indicates [ON/OFF] condition from the electrical load signal. ON: Rear window defogger switch is ON and/ or lighting switch is in 2nd position. OFF: Both rear window defogger switch and lighting switch are OFF. Remarks LOAD SIGNAL [ON/OFF] × IGNITION SW [ON/OFF] × ● Indicates [ON/OFF] condition from ignition switch. HEATER FAN SW [ON/OFF] × ● Indicates [ON/OFF] condition from the heater fan switch signal. BRAKE SW [ON/OFF] × ● Indicates [ON/OFF] condition from the stop lamp switch signal. ● Indicates the actual fuel injection pulse width compensated by ECM according to the input signals. ● When the engine is stopped, a certain computed value is indicated. ● Indicates the ignition timing computed by ECM according to the input signals. ● When the engine is stopped, a certain value is indicated. ● Indicates the EVAP canister purge volume control solenoid valve control value computed by the ECM according to the input signals. ● The opening becomes larger as the value increases. ● Indicates [°CA] of intake camshaft advanced angle. ● The control value of the intake valve timing control solenoid valve (determined by ECM according to the input signal) is indicated. ● The advance angle becomes larger as the value increases ● The air conditioner relay control condition (determined by ECM according to the input signals) is indicated. ● Indicates the fuel pump relay control condition determined by ECM according to the input signals. ● Indicates the throttle control motor relay control condition determined by the ECM according to the input signals. ● Indicates the condition of the cooling fan (determined by ECM according to the input signals). HI: High speed operation LOW: Low speed operation OFF: Stop ● Indicates [ON/OFF] condition of heated oxygen sensor 1 heater determined by ECM according to the input signals. ● Indicates [ON/OFF] condition of heated oxygen sensor 2 heater determined by ECM according to the input signals. × INJ PULSE-B1 [msec] × IGN TIMING [BTDC] × PURG VOL C/V [%] INT/V TIM (B1) [°CA] INT/V SOL (B1) [%] AIR COND RLY [ON/OFF] × FUEL PUMP RLY [ON/OFF] × THRTL RELAY [ON/OFF] × COOLING FAN [HI/LOW/OFF] HO2S1 HTR (B1) [ON/OFF] HO2S2 HTR (B1) [ON/OFF] EC-1316 TROUBLE DIAGNOSIS [HR (WITHOUT EURO-OBD)] Monitored item [Unit] ECM INPUT SIGNALS MAIN SIGNALS Description ● IDL A/V LEARN [YET/CMPLT] O2SEN HTR DTY [%] Remarks Display the condition of idle air volume learning YET: Idle Air Volume Learning has not been performed yet. CMPLT: Idle Air Volume Learning has already been performed successfully. ● Indicates the heated oxygen sensor 1 heater control value computed by the ECM according to the input signals. Indicates the engine speed computed from the furbine revolution sensor signal. The signal voltage from the refrigerant pressure sensor is displayed. I/P PULLY SPD [km/h] or [MPH] × ● AC PRESS SEN [V] × ● A EC C D E Voltage [V] Frequency [msec], [Hz] or [%] ● DUTY-HI DUTY-LOW Voltage, frequency, duty cycle or pulse width measured by the probe. PLS WIDTH-HI ● Only “#” is displayed if item is unable to be measured. ● Figures with “#”s are temporary ones. They are the same figures as an actual piece of data which was just previously measured. PLS WIDTH-LOW F G H NOTE: Any monitored item that does not match the vehicle being diagnosed is deleted from the display automatically. I DATA MONITOR (SPEC) MODE Monitored Item Monitored item [Unit] ENG SPEED [rpm] MAS A/F SE-B1 [V] B/FUEL SCHDL [msec] ECM INPUT SIGNALS × × J MAIN SIGNALS Description ● Indicates the engine speed computed from the signal of the crankshaft position sensor (POS) and camshaft position sensor (PHASE). ● The signal voltage of the mass air flow sensor specification is displayed. ● “Base fuel schedule” indicates the fuel injection pulse width programmed into ECM, prior to any learned on board correction. × × × ● A/F ALPHA-B1 [%] × The mean value of the air-fuel ratio feedback correction factor per cycle is indicated. Remarks K L ● When engine is running specification range is indicated. ● When engine is running specification range is indicated. ● When engine is running specification range is indicated. ● This data also includes the data for the air-fuel ratio learning control. M NOTE: Any monitored item that does not match the vehicle being diagnosed is deleted from the display automatically. EC-1317 TROUBLE DIAGNOSIS [HR (WITHOUT EURO-OBD)] ACTIVE TEST MODE Test Item TEST ITEM CONDITION ● FUEL INJECTION ● IGNITION TIMING POWER BALANCE COOLING FAN* Engine: Return to the original trouble condition ● Timing light: Set ● Retard the ignition timing using CONSULT-II. ● Engine: After warming up, idle the engine. ● A/C switch OFF ● Shift lever: P or N (A/T), Neutral (M/T) Ignition switch: ON ● Turn the cooling fan “LOW”, “MID”, “HI” and “OFF” with CONSULT-II. FUEL PUMP RELAY PURG VOL CONT/V ● Engine: Return to the original trouble condition ● Change the engine coolant temperature using CONSULT-II. ● Ignition switch: ON (Engine stopped) ● Turn the fuel pump relay ON and OFF using CONSULT-II and listen to operating sound. ● Engine: After warming up, run engine at 1,500 rpm. ● Change the EVAP canister purge volume control solenoid valve opening percent using CONSULT-II. ● V/T ASSIGN ANGLE ● Engine: Return to the original trouble condition Change intake valve timing using CONSULT-II. CHECK ITEM (REMEDY) ● Harness and connectors ● Fuel injector ● Air fuel ratio (A/F) sensor 1 ● Perform Idle Air Volume Learning. ● Harness and connectors ● Compression ● Fuel injector ● Power transistor ● Spark plug ● Ignition coil ● Harness and connectors ● Cooling fan relay ● Cooling fan motor ● Harness and connectors ● Engine coolant temperature sensor ● Fuel injector Fuel pump relay makes the operating sound. ● Harness and connectors ● Fuel pump relay Engine speed changes according to the opening percent. ● Harness and connectors ● Solenoid valve ● Harness and connectors ● Intake valve timing control solenoid valve If trouble symptom disappears, see CHECK ITEM. If trouble symptom disappears, see CHECK ITEM. Engine runs rough or dies. Cut off each fuel injector signal one at a time using CONSULT-II. ● , *2 , *3 ENG COOLANT TEMP Change the amount of fuel injection using CONSULT-II. ● ● 1 Engine: Return to the original trouble condition JUDGEMENT Cooling fan moves and stops. If trouble symptom disappears, see CHECK ITEM. If trouble symptom disappears, see CHECK ITEM. *1: Leaving cooling fan OFF with CONSULT-II while engine is running may cause the engine to overheat. *2: With A/C: “OFF”, “LOW”, “MID” or “HI” is displayed on CONSULT-II screen. But cooling fan operates at the same speed when “MID” or “HI” is displayed. *3: Without A/C: “OFF”, “LOW”, “MID” or “HI” is displayed on CONSULT-II screen. But cooling fan operates at the same speed when an item other than “OFF” is displayed. EC-1318 TROUBLE DIAGNOSIS [HR (WITHOUT EURO-OBD)] REAL TIME DIAGNOSIS IN DATA MONITOR MODE (RECORDING VEHICLE DATA) Description A CONSULT-II has two kinds of triggers and they can be selected by touching “SETTING” in “DATA MONITOR” mode. EC 1. “AUTO TRIG” (Automatic trigger): ● The malfunction will be identified on the CONSULT-II screen in real time. C In other words, DTC/1st trip DTC and malfunction item will be displayed if the malfunction is detected by ECM. At the moment a malfunction is detected by ECM, “MONITOR” in “DATA MONITOR” screen is changed to “Recording D Data ... xx%” as shown at right, and the data after the malfunction detection is recorded. Then when the percentage reached 100%, “REAL-TIME DIAG” screen is displayed. If E “STOP” is touched on the screen during “Recording Data ... PBIB1593E xx%”, “REAL-TIME DIAG” screen is also displayed. The recording time after the malfunction detection and the recording speed can be changed by “TRIGGER POINT” and F “Recording Speed”. Refer to CONSULT-II OPERATION MANUAL. 2. “MANU TRIG” (Manual trigger): G ● DTC/1st trip DTC and malfunction item will not be displayed automatically on CONSULT-II screen even though a malfunction is detected by ECM. H DATA MONITOR can be performed continuously even though a malfunction is detected. SEF707X I J K L M EC-1319 TROUBLE DIAGNOSIS [HR (WITHOUT EURO-OBD)] Operation 1. 2. “AUTO TRIG” ● While trying to detect the DTC/1st trip DTC by performing the “DTC Confirmation Procedure”, be sure to select to “DATA MONITOR (AUTO TRIG)” mode. You can confirm the malfunction at the moment it is detected. ● While narrowing down the possible causes, CONSULT-II should be set in “DATA MONITOR (AUTO TRIG)” mode, especially in case the incident is intermittent. When you are inspecting the circuit by gently shaking (or twisting) the suspicious connectors, components and harness in the “DTC Confirmation Procedure”, the moment a malfunction is found the DTC/ 1st trip DTC will be displayed. (Refer to “INCIDENT SIMULATION TESTS” in GI-25, "How to Perform Efficient Diagnosis for an Electrical Incident" .) “MANU TRIG” ● If the malfunction is displayed as soon as “DATA MONITOR” is selected, reset CONSULT-II to “MANU TRIG”. By selecting “MANU TRIG” you can monitor and store the data. The data can be utilized for further diagnosis, such as a comparison with the value for the normal operating condition. PBIB0197E EC-1320 TROUBLE DIAGNOSIS [HR (WITHOUT EURO-OBD)] CONSULT-II Reference Value in Data Monitor BBS004L6 Remarks: ● Specification data are reference values. ● Specification data are output/input values which are detected or supplied by the ECM at the connector. * Specification data may not be directly related to their components signals/values/operations. i.e. Adjust ignition timing with a timing light before monitoring IGN TIMING, because the monitor may show the specification data in spite of the ignition timing not being adjusted to the specification data. This IGN TIMING monitors the data calculated by the ECM according to the signals input from the camshaft position sensor and other ignition timing related sensors. MONITOR ITEM CONDITION SPECIFICATION ● ENG SPEED Run engine and compare CONSULT-II value with the tachometer indication. MAS A/F SE-B1 See EC-1326, "TROUBLE DIAGNOSIS - SPECIFICATION VALUE" . B/FUEL SCHDL See EC-1326, "TROUBLE DIAGNOSIS - SPECIFICATION VALUE" . A/F ALPHA-B1 See EC-1326, "TROUBLE DIAGNOSIS - SPECIFICATION VALUE" . COOLAN TEMP/S ● Almost the same speed as the tachometer indication. More than 70°C (158°F) ● Engine: After warming up 0 - 0.3V ←→ Approx. 0.6 1.0V ● Revving engine from idle to 3,000 rpm quickly after the following conditions are met. – Engine: After warming up. – Keep the engine speed between 3,500 rpm and 4,000 rpm for 1 minute and idle for 1 minute under no load. ● Engine: After warming up ● Revving engine from idle to 3,000 rpm quickly after the following conditions are met. – Engine: After warming up. – Keep the engine speed between 3,500 rpm and 4,000 rpm for 1 minute and idle for 1 minute under no load. ● Turn drive wheels and compare CONSULT-II value with the speedometer indication. Almost the same speed as the speedometer indication. ● Ignition switch: ON (Engine stopped) 11 - 14V ● Ignition switch: ON (Engine stopped) Accelerator pedal: Fully released 0.6 - 0.9V Accelerator pedal: Fully depressed 4.0 - 4.8V Ignition switch: ON (Engine stopped) Accelerator pedal: Fully released 0.6 - 0.9V Accelerator pedal: Fully depressed 3.9 - 4.8V Ignition switch: ON (Engine stopped) Accelerator pedal: Fully released More than 0.36V ● Shift lever: D (A/T), 1st (M/T) Accelerator pedal: Fully depressed Less than 4.75V START SIGNAL ● Ignition switch: ON → START → ON CLSD THL POS ● Ignition switch: ON HO2S2 (B1) HO2S1 MNTR (B1) HO2S2 MNTR (B1) VHCL SPEED SE BATTERY VOLT ACCEL SEN 1 ACCEL SEN 2*1 ● THRTL SEN 1 THRTL SEN 2* ● 1 AIR COND SIG P/N POSI SW PW/ST SIGNAL ● ● ● Engine: After warming up, idle the engine Ignition switch: ON Engine: After warming up, idle the engine Maintaining engine speed at 2,000 rpm Maintaining engine speed at 2,000 rpm C E F 0 - 0.3V ←→ Approx. 0.6 1.0V G LEAN ←→ RICH Changes more than 5 times during 10 seconds. LEAN ←→ RICH OFF → ON → OFF Accelerator pedal: Fully released ON Accelerator pedal: Slightly depressed OFF Air conditioner switch: OFF OFF Air conditioner switch: ON (Compressor operates.) ON Shift lever: P or N (A/T), Neutral (M/T) ON Shift lever: Except above OFF Steering wheel: Not being turned. OFF Steering wheel: Being turned. ON EC-1321 EC D Engine: After warming up HO2S1 (B1) A H I J K L M TROUBLE DIAGNOSIS [HR (WITHOUT EURO-OBD)] MONITOR ITEM LOAD SIGNAL CONDITION ● Ignition switch: ON IGNITION SW ● Ignition switch: ON → OFF → ON HEATER FAN SW ● Ignition switch: ON Rear window defogger switch: ON and/or Lighting switch: 2nd ON Rear window defogger switch and lighting switch: OFF OFF ON → OFF → ON Heater fan: Operating. BRAKE SW INJ PULSE-B1 IGN TIMING PURG VOL C/V INT/V TIM (B1) INT/V SOL (B1) AIR COND RLY FUEL PUMP RLY THRTL RELAY ● Ignition switch: ON ● Engine: After warming up ● Air conditioner switch: OFF ● Shift lever: P or N (A/T), Neutral (M/T) ● No load ● Engine: After warming up ● Air conditioner switch: OFF ● Shift lever: P or N (A/T), Neutral (M/T) ● No load ● Engine: After warming up ● Air conditioner switch: OFF ● Shift lever: P or N (A/T), Neutral (M/T) ● No load ● Engine: After warming up ● Air conditioner switch: OFF ● Shift lever: P or N (A/T), Neutral (M/T) ● No load ● Engine: After warming up ● Air conditioner switch: OFF ● Shift lever: P or N (A/T), Neutral (M/T) ● No load ● Engine: After warming up, idle the engine SPECIFICATION ON Heater fan: Not operating OFF Brake pedal: Fully released OFF Brake pedal: Slightly depressed ON Idle 2.0 - 3.0 msec 2,000 rpm 1.9 - 2.9 msec Idle 1° - 11° BTDC 2,000 rpm 25° - 45° BTDC Idle 0% 2,000 rpm 0 - 50% Idle −5° - 5°CA 2,500 rpm Approx. 0° - 40°CA Idle 0% - 2% 2,500 rpm Approx. 0% - 90% Air conditioner switch: OFF OFF Air conditioner switch: ON (Compressor operates) ON ● For 1 second after turning ignition switch ON ● Engine running or cranking ● Except above conditions OFF ● Ignition switch: ON ON ● COOLING FAN ● Engine: After warming up, idle the engine Air conditioner switch: OFF ON Engine coolant temperature is 94°C (201°F) or less OFF Engine coolant temperature is between 95°C (203°F) and 99°C (210°F) LOW*2 Engine coolant temperature is 100°C (212°F) or more HIGH*2 EC-1322 TROUBLE DIAGNOSIS [HR (WITHOUT EURO-OBD)] MONITOR ITEM CONDITION ● HO2S1 HTR (B1) HO2S2 HTR (B1) I/P PULLY SPD SPECIFICATION A Engine: After warming up ON ● Engine speed: Below 3,600 rpm ● Engine speed: Above 3,600 rpm ● Below 3,600 rpm after the following conditions are met. – Engine: After warming up – Keeping the engine speed between 3,500 and 4,000 rpm for 1 minute and at idle for 1 minute under no load ● Engine speed: Above 3,600 rpm OFF ● Vehicle speed: More than 20 km/h (12 MPH) Almost the same speed as the tachometer indication D ● Engine coolant temperature when engine started: More than 80°C (176°F) Engine speed: below 3,600 rpm Approx. 30% ● E ● Engine: Idle ● Air conditioner switch: ON (Compressor operates) O2SEN HTR DTY AC PRESS SEN OFF EC ON C 1.0 - 4.0V *1: Accelerator pedal position sensor 2 signal and throttle position sensor 2 signal are converted by ECM internally. Thus, they differ from ECM terminals voltage signal. *2: Models without air conditioner, cooling fan operates only ON and OFF operation, but CONSULT-II display will change OFF, LOW and HI depends on engine coolant temperature. F G H I J K L M EC-1323 TROUBLE DIAGNOSIS [HR (WITHOUT EURO-OBD)] Major Sensor Reference Graph in Data Monitor Mode BBS004L7 The following are the major sensor reference graphs in “DATA MONITOR” mode. CLSD THL POS, ACCEL SEN 1, THRTL SEN 1 Below is the data for “CLSD THL POS”, “ACCEL SEN 1” and “THRTL SEN 1” when depressing the accelerator pedal with the ignition switch ON and with shift lever in D position (A/T), 1st position (M/T). The signal of “ACCEL SEN 1” and “THRTL SEN 1” should rise gradually without any intermittent drop or rise after “CLSD THL POS” is changed from “ON” to “OFF”. PBIB0198E ENG SPEED, MAS A/F SE-B1, THRTL SEN 1, HO2S2 (B1), INJ PULSE-B1 Below is the data for “ENG SPEED”, “MAS A/F SE-B1”, “THRTL SEN 1”, “HO2S2 (B1)” and “INJ PULSE-B1” when revving engine quickly up to 4,800 rpm under no load after warming up engine sufficiently. Each value is for reference, the exact value may vary. PBIB2445E EC-1324 TROUBLE DIAGNOSIS [HR (WITHOUT EURO-OBD)] A EC C D E F G H I J K L M PBIB0668E EC-1325 TROUBLE DIAGNOSIS - SPECIFICATION VALUE [HR (WITHOUT EURO-OBD)] TROUBLE DIAGNOSIS - SPECIFICATION VALUE Description PFP:00031 BBS004L8 The specification (SP) value indicates the tolerance of the value that is displayed in “DATA MONITOR (SPEC)” mode of CONSULT-II during normal operation of the Engine Control System. When the value in “DATA MONITOR (SPEC)” mode is within the SP value, the Engine Control System is confirmed OK. When the value in “DATA MONITOR (SPEC)” mode is NOT within the SP value, the Engine Control System may have one or more malfunctions. The SP value is used to detect malfunctions that may affect the Engine Control System, but will not light the MI. The SP value will be displayed for the following three items: ● B/FUEL SCHDL (The fuel injection pulse width programmed into ECM prior to any learned on board correction) ● A/F ALPHA-B1 (The mean value of air-fuel ratio feedback correction factor per cycle) ● MAS A/F SE-B1 (The signal voltage of the mass air flow sensor) Testing Condition ● ● ● ● ● ● – – ● – BBS004L9 Vehicle driven distance: More than 5,000 km (3,107 miles) Barometric pressure: 98.3 - 104.3 kPa (0.983 - 1.043 bar, 1.003 - 1.064 kg/cm2 , 14.25 - 15.12 psi) Atmospheric temperature: 20 - 30°C (68 - 86°F) Engine coolant temperature: 75 - 95°C (167 - 203°F) Engine speed: Idle Transmission: Warmed-up A/T models: After the engine is warmed up to normal operating temperature, drive vehicle until “FLUID TEMP SE” (A/T fluid temperature sensor signal) indicates more than 60°C (140°F). M/T models: After the engine is warmed up to normal operating temperature, drive vehicle for 5 minutes. Electrical load: Not applied Rear window defogger switch, air conditioner switch, lighting switch are OFF. Steering wheel is straight ahead. Inspection Procedure BBS004LA NOTE: Perform “DATA MONITOR (SPEC)” mode in maximum scale display. 1. Perform EC-1272, "Basic Inspection" . 2. Confirm that the testing conditions indicated above are met. 3. Select “B/FUEL SCHDL”, “A/F ALPHA-B1” and “MAS A/F SEB1” in “DATA MONITOR (SPEC)” mode with CONSULT-II. 4. Make sure that monitor items are within the SP value. 5. If NG, go to EC-1327, "Diagnostic Procedure" . SEF601Z EC-1326 TROUBLE DIAGNOSIS - SPECIFICATION VALUE [HR (WITHOUT EURO-OBD)] Diagnostic Procedure BBS004LB A OVERALL SEQUENCE EC C D E F G H I J K L M PBIB2384E EC-1327 TROUBLE DIAGNOSIS - SPECIFICATION VALUE [HR (WITHOUT EURO-OBD)] PBIB3213E EC-1328 TROUBLE DIAGNOSIS - SPECIFICATION VALUE [HR (WITHOUT EURO-OBD)] DETAILED PROCEDURE A 1. CHECK “A/F ALPHA-B1” 1. 2. 3. Start engine. Confirm that the testing conditions are met. Refer to EC-1326, "Testing Condition" . Select “A/F ALPHA-B1” in “DATA MONITOR (SPEC)” mode, and make sure that the each indication is within the SP value. NOTE: Check “A/F ALPHA-B1” for approximately 1 minute because they may fluctuate. It is NG if the indication is out of the SP value even a little. OK or NG OK >> GO TO 17. NG (Less than the SP value)>>GO TO 2. NG (More than the SP value)>>GO TO 3. EC C D E PBIB2369E 2. CHECK “B/FUEL SCHDL” F Select “B/FUEL SCHDL” in “DATA MONITOR (SPEC)” mode, and make sure that the indication is within the SP value. OK or NG OK >> GO TO 4. NG (More than the SP value)>>GO TO 19. G H I PBIB2332E J 3. CHECK “B/FUEL SCHDL” Select “B/FUEL SCHDL” in “DATA MONITOR (SPEC)” mode, and make sure that the indication is within the SP value. OK or NG OK >> GO TO 6. NG (More than the SP value)>>GO TO 6. NG (Less than the SP value)>>GO TO 25. K L M PBIB2332E 4. CHECK “A/F ALPHA-B1” 1. 2. 3. 4. Stop the engine. Disconnect PCV hose, and then plug it. Start engine. Select “A/F ALPHA-B1” in “DATA MONITOR (SPEC)” mode, and make sure that the each indication is within the SP value. OK or NG OK >> GO TO 5. NG >> GO TO 6. EC-1329 TROUBLE DIAGNOSIS - SPECIFICATION VALUE [HR (WITHOUT EURO-OBD)] 5. CHANGE ENGINE OIL 1. 2. Stop the engine. Change engine oil. NOTE: This symptom may occur when a large amount of gasoline is mixed with engine oil because of driving conditions (such as when engine oil temperature does not rise enough since a journey distance is too short during winter). The symptom will not be detected after changing engine oil or changing driving condition. >> INSPECTION END 6. CHECK FUEL PRESSURE Check fuel pressure. (Refer to EC-1282, "FUEL PRESSURE CHECK" .) OK or NG OK >> GO TO 9. NG (Fuel pressure is too high)>>Replace fuel pressure regulator, refer to EC-1282, "FUEL PRESSURE CHECK" . GO TO 8. NG (Fuel pressure is too low)>>GO TO 7. 7. DETECT MALFUNCTIONING PART 1. – – – 2. Check the following. Clogged and bent fuel hose and fuel tube Clogged fuel filter Fuel pump and its circuit (Refer to EC-1543, "FUEL PUMP" .) If NG, repair or replace the malfunctioning part. (Refer to EC-1282, "FUEL PRESSURE CHECK" .) If OK, replace fuel pressure regulator. >> GO TO 8. 8. CHECK “A/F ALPHA-B1” 1. 2. Start engine. Select “A/F ALPHA-B1” in “DATA MONITOR (SPEC)” mode, and make sure that the each indication is within the SP value. OK or NG OK >> INSPECTION END NG >> GO TO 9. 9. PERFORM POWER BALANCE TEST 1. 2. Perform “POWER BALANCE” in “ACTIVE TEST” mode. Make sure that the each cylinder produces a momentary engine speed drop. OK or NG OK >> GO TO 12. NG >> GO TO 10. PBIB0133E EC-1330 TROUBLE DIAGNOSIS - SPECIFICATION VALUE [HR (WITHOUT EURO-OBD)] 10. DETECT MALFUNCTIONING PART 1. – – – – 2. A Check the following. Ignition coil and its circuit (Refer to EC-1580, "IGNITION SIGNAL" .) Fuel injector and its circuit (Refer to EC-1537, "FUEL INJECTOR" .) Intake air leakage Low compression pressure (Refer to EM-173, "CHECKING COMPRESSION PRESSURE" .) If NG, repair or replace the malfunctioning part. If OK, replace fuel injector. (It may be caused by leakage from fuel injector or clogging.) EC C D >> GO TO 11. 11. CHECK “A/F ALPHA-B1” E 1. 2. Start engine. Select “A/F ALPHA-B1” in “DATA MONITOR (SPEC)” mode, and make sure that the each indication is within the SP value. OK or NG OK >> INSPECTION END NG >> GO TO 12. F G 12. CHECK HEATED OXYGEN SENSOR 1 FUNCTION 1. 2. 3. H Run engine at about 2,000 rpm for about 2 minutes under no load. Select “HO2S1 MNTR (B1)”, in “DATA MONITOR” mode. Running engine at 2,000 rpm under no load (The engine is warmed up to normal operating temperature.), check that the monitor fluctuates between LEAN and RICH more than 5 times during 10 seconds. 1 time 2 times I J : RICH → LEAN → RICH : RICH → LEAN → RICH → LEAN → RICH K OK or NG OK >> GO TO 15. NG >> GO TO 13. SEF820Y L 13. CHECK HEATED OXYGEN SENSOR 1 CIRCUIT Check heated oxygen sensor 1 and its circuit. Refer to EC-1381, "DTC P0134 HO2S1" . >> GO TO 14. 14. CHECK “A/F ALPHA-B1” 1. 2. Start engine. Select “A/F ALPHA-B1” in “DATA MONITOR (SPEC)” mode, and make sure that the each indication is within the SP value. OK or NG OK >> INSPECTION END NG >> GO TO 15. EC-1331 M TROUBLE DIAGNOSIS - SPECIFICATION VALUE [HR (WITHOUT EURO-OBD)] 15. DISCONNECT AND RECONNECT ECM HARNESS CONNECTOR 1. 2. Stop the engine. Disconnect ECM harness connector. Check pin terminal and connector for damage, and then reconnect it. >> GO TO 16. 16. CHECK “A/F ALPHA-B1” 1. 2. Start engine. Select “A/F ALPHA-B1” in “DATA MONITOR (SPEC)” mode, and make sure that the each indication is within the SP value. OK or NG OK >> INSPECTION END NG >> Detect malfunctioning part according to EC-1292, "Symptom Matrix Chart" 17. CHECK “B/FUEL SCHDL” Select “B/FUEL SCHDL” in “DATA MONITOR (SPEC)” mode, and make sure that the indication is within the SP value. OK or NG OK >> INSPECTION END NG (More than the SP value)>>GO TO 18. NG (Less than the SP value)>>GO TO 25. PBIB2332E 18. DETECT MALFUNCTIONING PART 1. – – – – – 2. – – – Check for the cause of large engine friction. Refer to the following. Engine oil level is too high Engine oil viscosity Belt tension of power steering, alternator, A/C compressor, etc. is excessive Noise from engine Noise from transmission, etc. Check for the cause of insufficient combustion. Refer to the following. Valve clearance malfunction Intake valve timing control function malfunction Camshaft sprocket installation malfunction, etc. >> Repair or replace malfunctioning part, and then GO TO 30. 19. CHECK INTAKE SYSTEM Check for the cause of uneven air flow through mass air flow sensor. Refer to the following. ● Crushed air ducts ● Malfunctioning seal of air cleaner element ● Uneven dirt of air cleaner element ● Improper specification of intake air system OK or NG OK >> GO TO 21. NG >> Repair or replace malfunctioning part, and then GO TO 20. EC-1332 TROUBLE DIAGNOSIS - SPECIFICATION VALUE [HR (WITHOUT EURO-OBD)] 20. CHECK “A/F ALPHA-B1” AND “B/FUEL SCHDL” A Select “A/F ALPHA-B1” and “B/FUEL SCHDL” in “DATA MONITOR (SPEC)” mode, and make sure that the each indication is within the SP value. EC OK or NG OK >> INSPECTION END NG (“B/FUEL SCHDL” is more, “A/F ALPHA-B1” is less than the SP value)>>GO TO 21. C DISCONNECT AND RECONNECT MASS AIR FLOW SENSOR HARNESS CONNECTOR 21. 1. 2. Stop the engine. Disconnect mass air flow sensor harness connector. Check pin terminal and connector for damage and then reconnect it again. D E >> GO TO 22. 22. CHECK “A/F ALPHA-B1” F 1. 2. Start engine. Select “A/F ALPHA-B1” in “DATA MONITOR (SPEC)” mode, and make sure that the each indication is within the SP value. OK or NG OK >> 1. Detect malfunctioning part of mass air flow sensor circuit and repair it. Refer to EC-1354, "DTC P0102, P0103 MAF SENSOR" . 2. GO TO 29. NG >> GO TO 23. G H I 23. CHECK “MAS A/F SE-B1” Select “MAS A/F SE-B1” in “DATA MONITOR (SPEC)” mode, and make sure that the indication is within the SP value. OK or NG OK >> GO TO 24. NG (More than the SP value)>>Replace mass air flow sensor, and then GO TO 29. J K L PBIB2370E 24. REPLACE ECM 1. 2. 3. 4. 5. Replace ECM. Perform initialization of NATS system and registration of all NATS ignition key IDs. Refer to BL-218, "ECM Re-communicating Function" . Perform EC-1278, "Accelerator Pedal Released Position Learning" . Perform EC-1279, "Throttle Valve Closed Position Learning" . Perform EC-1279, "Idle Air Volume Learning" . >> GO TO 29. EC-1333 M TROUBLE DIAGNOSIS - SPECIFICATION VALUE [HR (WITHOUT EURO-OBD)] 25. CHECK INTAKE SYSTEM Check for the cause of uneven air flow through mass air flow sensor. Refer to the following. ● Crushed air ducts ● Malfunctioning seal of air cleaner element ● Uneven dirt of air cleaner element ● Improper specification of intake air system OK or NG OK >> GO TO 27. NG >> Repair or replace malfunctioning part, and then GO TO 26. 26. CHECK “B/FUEL SCHDL” Select “B/FUEL SCHDL” in “DATA MONITOR (SPEC)” mode, and make sure that the indication is within the SP value. OK or NG OK >> INSPECTION END NG (Less than the SP value)>>GO TO 27. 27. CHECK “MAS A/F SE-B1” Select “MAS A/F SE-B1” in “DATA MONITOR (SPEC)” mode, and make sure that the indication is within the SP value. OK or NG OK >> GO TO 28. NG (Less than the SP value)>>Replace mass air flow sensor, and then GO TO 30. PBIB2370E 28. CHECK INTAKE SYSTEM Check for the cause of air leak after the mass air flow sensor. Refer to the following. ● Disconnection, looseness, and cracks in air duct ● Looseness of oil filler cap ● Disconnection of oil level gauge ● Open stuck, breakage, hose disconnection, or cracks of PCV valve ● Disconnection or cracks of EVAP purge hose, open stuck of EVAP canister purge volume control solenoid valve ● Malfunctioning seal of rocker cover gasket ● Disconnection, looseness, or cracks of hoses, such as vacuum hose, connecting to intake air system parts ● Malfunctioning seal of intake air system, etc. >> GO TO 30. 29. CHECK “A/F ALPHA-B1” AND “B/FUEL SCHDL” Select “A/F ALPHA-B1” and “B/FUEL SCHDL” in “DATA MONITOR (SPEC)” mode, and make sure that the each indication is within the SP value. OK or NG OK >> INSPECTION END NG >> Detect malfunctioning part according to EC-1292, "Symptom Matrix Chart" . EC-1334 TROUBLE DIAGNOSIS - SPECIFICATION VALUE [HR (WITHOUT EURO-OBD)] 30. CHECK “B/FUEL SCHDL” A Select “B/FUEL SCHDL” in “DATA MONITOR (SPEC)” mode, and then make sure that the indication is within the SP value. EC OK or NG OK >> INSPECTION END NG >> Detect malfunctioning part according to EC-1292, "Symptom Matrix Chart" . C D E F G H I J K L M EC-1335 TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT [HR (WITHOUT EURO-OBD)] TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT Description PFP:00006 BBS004LC Intermittent incidents may occur. In many cases, the malfunction resolves itself (the part or circuit function returns to normal without intervention). It is important to realize that the symptoms described in the customer's complaint often do not recur on (1st trip) DTC visits. Realize also that the most frequent cause of intermittent incidents occurrences is poor electrical connections. Because of this, the conditions under which the incident occurred may not be clear. Therefore, circuit checks made as part of the standard diagnostic procedure may not indicate the specific malfunctioning area. Common Intermittent Incidents Report Situations STEP in Work Flow 2 3 or 4 Situation The CONSULT-II is used. The SELF-DIAG RESULTS screen shows time data other than [0] or [1t]. The symptom described by the customer does not recur. 5 (1st trip) DTC does not appear during the DTC Confirmation Procedure. 10 The Diagnostic Procedure for PXXXX does not indicate the malfunctioning area. Diagnostic Procedure BBS004LD 1. INSPECTION START Erase (1st trip) DTCs. Refer to EC-1267, "HOW TO ERASE EMISSION-RELATED DIAGNOSTIC INFORMATION" . >> GO TO 2. 2. CHECK GROUND TERMINALS Check ground terminals for corroding or loose connection. Refer to EC-1342, "Ground Inspection" . OK or NG OK >> GO TO 3. NG >> Repair or replace. 3. SEARCH FOR ELECTRICAL INCIDENT Perform GI-25, "How to Perform Efficient Diagnosis for an Electrical Incident" , “INCIDENT SIMULATION TESTS”. OK or NG OK >> INSPECTION END NG >> Repair or replace. EC-1336 POWER SUPPLY AND GROUND CIRCUIT [HR (WITHOUT EURO-OBD)] POWER SUPPLY AND GROUND CIRCUIT Wiring Diagram PFP:24110 A BBS004LE EC C D E F G H I J K L M MBWA1455E EC-1337 POWER SUPPLY AND GROUND CIRCUIT [HR (WITHOUT EURO-OBD)] Specification data are reference values and are measured between each terminal and ground. CAUTION: Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM's transistor. Use a ground other than ECM terminals, such as the ground. TERMINAL NO. 10 11 WIRE COLOR B B/W ITEM ECM ground CONDITION [Engine is running] ● Idle speed [Engine is running] [Ignition switch: OFF] ● 32 P ECM relay (Self shut-off) For a few seconds after turning ignition switch OFF [Ignition switch: OFF] ● 93 O Ignition switch 105 G Power supply for ECM 108 B ECM ground More than a few seconds after turning ignition switch OFF DATA (DC Voltage) Body ground 0 - 1.0V BATTERY VOLTAGE (11 - 14V) [Ignition switch: OFF] 0V [Ignition switch: ON] BATTERY VOLTAGE (11 - 14V) [Ignition switch: ON] BATTERY VOLTAGE (11 - 14V) [Engine is running] ● Idle speed Diagnostic Procedure Body ground BBS004LF 1. INSPECTION START Start engine. Is engine running? Yes or No Yes >> GO TO 8. No >> GO TO 2. 2. CHECK ECM POWER SUPPLY CIRCUIT-I 1. 2. Turn ignition switch OFF and then ON. Check voltage between ECM terminal 93 and ground with CONSULT-II or tester. Voltage: Battery voltage OK or NG OK >> GO TO 4. NG >> GO TO 3. PBIA9561J EC-1338 POWER SUPPLY AND GROUND CIRCUIT [HR (WITHOUT EURO-OBD)] 3. DETECT MALFUNCTIONING PART A Check the following. ● Harness connectors M1, E101 ● Fuse block (J/B) connector M7 ● 10A fuse ● Harness for open or short between ECM and fuse EC C >> Repair open circuit or short to ground or short to power in harness or connectors. 4. CHECK GROUND CONNECTIONS-1 1. 2. D Turn ignition switch OFF. Loosen and retighten ground screws on the body. Refer to EC-1342, "Ground Inspection" . E F G H MBIB1550E 1. IPDM E/R 2. Body ground 3. Body ground OK or NG OK >> GO TO 5. NG >> Repair or replace ground connections. 5. CHECK ECM GROUND CIRCUIT FOR OPEN AND SHORT-I 1. 2. Disconnect ECM harness connector. Check harness continuity between ECM terminals 10, 11, 108 and ground. Refer to Wiring Diagram. I J K L Continuity should exist. 3. Also check harness for short to power. OK or NG OK >> GO TO 7. NG >> GO TO 6. M 6. DETECT MALFUNCTIONING PART Check the following. ● Harness connectors F1, E59 ● Harness for open or short between ECM and ground >> Repair open circuit or short to power in harness or connectors. EC-1339 POWER SUPPLY AND GROUND CIRCUIT [HR (WITHOUT EURO-OBD)] 7. CHECK ECM POWER SUPPLY CIRCUIT-II 1. 2. 3. Reconnect ECM harness connector. Turn ignition switch ON. Check voltage between IPDM E/R terminal 33 and ground with CONSULT-II or tester. Voltage: Battery voltage OK or NG OK >> Go to EC-1580, "IGNITION SIGNAL" . NG >> GO TO 8. MBIB1353E 8. CHECK ECM POWER SUPPLY CIRCUIT-III 1. 2. 3. Turn ignition switch OFF and wait at least 10 seconds. Turn ignition switch ON and then OFF. Check voltage between ECM terminal 105 and ground with CONSULT-II or tester. Voltage: After turning ignition switch OFF, battery voltage will exist for a few seconds, then drop approximately 0V. OK or NG OK >> GO TO 14. NG (Battery voltage does not exist.)>>GO TO 9. NG (Battery voltage exists for more than a few seconds.)>>GO TO 11. PBIB3037E 9. CHECK ECM POWER SUPPLY CIRCUIT-IV 1. 2. Turn ignition switch OFF and wait at least 10 seconds. Check voltage between ECM terminal 32 and ground with CONSULT-II or tester. Voltage: Battery voltage OK or NG OK >> GO TO 10. NG >> GO TO 11. PBIA9562J EC-1340 POWER SUPPLY AND GROUND CIRCUIT [HR (WITHOUT EURO-OBD)] 10. CHECK ECM POWER SUPPLY CIRCUIT-V 1. 2. 3. Disconnect ECM harness connector. Disconnect IPDM E/R harness connector E7. Check harness continuity between ECM terminal 105 and IPDM E/R terminal 32. Refer to Wiring Diagram. Continuity should exist. EC C 4. Also check harness for short to ground and short to power. OK or NG OK >> GO TO 17. NG >> Repair open circuit or short to ground or short to power in harness or connectors. 11. CHECK ECM POWER SUPPLY CIRCUIT-VI 1. 2. 3. A Disconnect ECM harness connector. Disconnect IPDM E/R harness connector E7. Check harness continuity between ECM terminal 32 and IPDM E/R terminal 29. Refer to Wiring Diagram. Continuity should exist. D E F G 4. Also check harness for short to ground and short to power. OK or NG OK >> GO TO 13. NG >> GO TO 12. H 12. DETECT MALFUNCTIONING PART I Check the following. Harness or connectors E59, F1 ● Harness for open or short between ECM and IPDM E/R J ● >> Repair open circuit or short to ground or short to power in harness or connectors. K 13. CHECK 20A FUSE L 1. Disconnect 20A fuse from IPDM E/R. 2. Check 20A fuse. OK or NG OK >> GO TO 17. NG >> Replace 20A fuse. M EC-1341 POWER SUPPLY AND GROUND CIRCUIT [HR (WITHOUT EURO-OBD)] 14. CHECK GROUND CONNECTIONS-II 1. Loosen and retighten ground screws on the body. Refer to EC-1342, "Ground Inspection" . MBIB1550E 1. IPDM E/R 2. Body ground 3. Body ground OK or NG OK >> GO TO 15. NG >> Repair or replace ground connections. 15. CHECK ECM GROUND CIRCUIT FOR OPEN AND SHORT-II 1. 2. Disconnect ECM harness connector. Check harness continuity between ECM terminals 10, 11, 108 and ground. Refer to Wiring Diagram. Continuity should exist. 3. Also check harness for short to power. OK or NG OK >> GO TO 17. NG >> GO TO 16. 16. DETECT MALFUNCTIONING PART Check the following. ● Harness or connectors F1, E59 ● Harness for open or short between ECM and ground >> Repair open circuit or short to power in harness or connectors. 17. CHECK INTERMITTENT INCIDENT Refer to EC-1336, "TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT" . OK or NG OK >> Replace IPDM E/R. Refer to PG-18, "IPDM E/R (INTELLIGENT POWER DISTRIBUTION MODULE ENGINE ROOM)" . NG >> Repair open circuit or short to power in harness or connectors. Ground Inspection BBS004LG Ground connections are very important to the proper operation of electrical and electronic circuits. Ground connections are often exposed to moisture, dirt and other corrosive elements. The corrosion (rust) can become an unwanted resistance. This unwanted resistance can change the way a circuit works. Electronically controlled circuits are very sensitive to proper grounding. A loose or corroded ground can drastically affect an electronically controlled circuit. A poor or corroded ground can easily affect the circuit. Even when the ground connection looks clean, there can be a thin film of rust on the surface. When inspecting a ground connection follow these rules: EC-1342 POWER SUPPLY AND GROUND CIRCUIT [HR (WITHOUT EURO-OBD)] Remove the ground bolt or screw. A Inspect all mating surfaces for tarnish, dirt, rust, etc. ● Clean as required to assure good contact. ● Reinstall bolt or screw securely. EC ● Inspect for “add-on” accessories which may be interfering with the ground circuit. ● If several wires are crimped into one ground eyelet terminal, check for proper crimps. Make sure all of the wires are clean, securely fastened and providing a good ground path. If multiple wires are cased in one C eyelet make sure no ground wires have excess wire insulation. For detailed ground distribution information, refer to PG-38, "Ground Distribution" . ● ● D E F G H I PBIB1870E J K L M EC-1343 DTC U1000, U1001 CAN COMMUNICATION LINE [HR (WITHOUT EURO-OBD)] DTC U1000, U1001 CAN COMMUNICATION LINE Description PFP:23710 BBS004LH CAN (Controller Area Network) is a serial communication line for real time application. It is an on-vehicle multiplex communication line with high data communication speed and excellent error detection ability. Many electronic control units are equipped onto a vehicle, and each control unit shares information and links with other control units during operation (not independent). In CAN communication, control units are connected with 2 communication lines (CAN H line, CAN L line) allowing a high rate of information transmission with less wiring. Each control unit transmits/receives data but selectively reads required data only. On Board Diagnosis Logic BBS004LI The MI will not light up for these self-diagnoses. DTC No. U1000 1000 U1001 1001 Trouble diagnosis name DTC detecting condition ● CAN communication line ● ECM cannot communicate to other control units. ECM cannot communicate for more than the specified time. DTC Confirmation Procedure 1. 2. 3. Possible cause ● Harness or connectors (CAN communication line is open or shorted.) BBS004LJ Turn ignition switch ON and wait at least 3 seconds. Select “DATA MONITOR” mode with CONSULT-II. If 1st trip DTC is detected, go to EC-1346, "Diagnostic Procedure" . EC-1344 DTC U1000, U1001 CAN COMMUNICATION LINE [HR (WITHOUT EURO-OBD)] Wiring Diagram BBS004LK A EC C D E F G H I J K L M MBWA1456E EC-1345 DTC U1000, U1001 CAN COMMUNICATION LINE [HR (WITHOUT EURO-OBD)] Diagnostic Procedure BBS004LL Go to LAN-3, "Precautions When Using CONSULT-II" . EC-1346 DTC U1010 CAN COMMUNICATION [HR (WITHOUT EURO-OBD)] DTC U1010 CAN COMMUNICATION Description PFP:23710 A BBS004LM CAN (Controller Area Network) is a serial communication line for real time application. It is an on-vehicle multiplex communication line with high data communication speed and excellent error detection ability. Many elec- EC tronic control units are equipped onto a vehicle, and each control unit shares information and links with other control units during operation (not independent). In CAN communication, control units are connected with 2 communication lines (CAN H line, CAN L line) allowing a high rate of information transmission with less wiring. C Each control unit transmits/receives data but selectively reads required data only. On Board Diagnosis Logic BBS004LN D The MI will not light up for this self-diagnosis. DTC No. U1010 1010 Trouble diagnosis name CAN communication bus DTC detecting condition Initializing CAN communication bus is malfunctioning. DTC Confirmation Procedure Possible cause ● E ECM BBS004LO WITH CONSULT-II 1. 2. 3. F Turn ignition switch ON. Select “DATA MONITOR” mode with CONSULT-II. If 1st trip DTC is detected, go to EC-1348, "Diagnostic Procedure" . G H I SEF058Y J WITHOUT CONSULT-II 1. 2. 3. 4. Turn ignition switch ON. Turn ignition switch OFF, wait at least 10 seconds and then turn ON. Perform Diagnostic Test Mode II (Self-diagnostic results) with ECM. If 1st trip DTC is detected, go to EC-1348, "Diagnostic Procedure" . K L M EC-1347 DTC U1010 CAN COMMUNICATION [HR (WITHOUT EURO-OBD)] Diagnostic Procedure BBS004LP 1. INSPECTION START 1. 2. 3. 4. 5. With CONSULT-II Turn ignition switch ON. Select “SELF-DIAG RESULTS” mode with CONSULT-II. Touch “ERASE”. Perform DTC Confirmation Procedure. See EC-1347, "DTC Confirmation Procedure" . Is the 1st trip DTC U1010 displayed again? Without CONSULT-II 1. Turn ignition switch ON. 2. Erase the Diagnostic Test Mode II (Self-diagnostic results) memory. Refer to EC-1267, "HOW TO ERASE EMISSION-RELATED DIAGNOSTIC INFORMATION" . 3. Perform DTC Confirmation Procedure. See EC-1347, "DTC Confirmation Procedure" . 4. Is the 1st trip DTC 1010 displayed again? Yes or No Yes >> GO TO 2. No >> INSPECTION END 2. REPLACE ECM 1. 2. 3. 4. 5. Replace ECM. Perform initialization of NATS system and registration of all NATS ignition key IDs. Refer to BL-218, "ECM Re-communicating Function" . Perform EC-1278, "Accelerator Pedal Released Position Learning" . Perform EC-1279, "Throttle Valve Closed Position Learning" . Perform EC-1279, "Idle Air Volume Learning" . >> INSPECTION END EC-1348 DTC P0011 IVT CONTROL [HR (WITHOUT EURO-OBD)] DTC P0011 IVT CONTROL Description PFP:23796 A BBS004LQ SYSTEM DESCRIPTION Sensor Input signal to ECM Crankshaft position sensor (POS) Camshaft position sensor (PHASE) Engine speed and piston position Engine coolant temperature sensor Engine coolant temperature Wheel sensor Vehicle speed* ECM function Intake valve timing control Actuator EC Intake valve timing control solenoid valve C *: This signal is sent to the ECM through CAN communication line. D E F G H I MBIB1560E This mechanism hydraulically controls cam phases continuously with the fixed operating angle of the intake valve. The ECM receives signals such as crankshaft position, camshaft position, engine speed, and engine coolant temperature. Then, the ECM sends ON/OFF pulse duty signals to the intake valve timing control solenoid valve depending on driving status. This makes it possible to control the shut/open timing of the intake valve to increase engine torque in low/mid speed range and output in high-speed range. CONSULT-II Reference Value in Data Monitor Mode BBS004LR J K L Specification data are reference values. MONITOR ITEM INT/V TIM (B1) INT/V SOL (B1) CONDITION ● Engine: After warming up ● Air conditioner switch: OFF ● Shift lever: P or N (A/T), Neutral (M/T) ● No load ● Engine: After warming up ● Air conditioner switch: OFF ● Shift lever: P or N (A/T), Neutral (M/T) ● No load SPECIFICATION Idle −5° - 5°CA 2,500 rpm Approx. 0° - 40°CA Idle 0% - 2% 2,500 rpm Approx. 0% - 90% EC-1349 M DTC P0011 IVT CONTROL [HR (WITHOUT EURO-OBD)] On Board Diagnosis Logic BBS004LS The MI will not light up for this self-diagnosis. Trouble diagnosis name DTC No. P0011 0011 Intake valve timing control performance Detecting condition There is a gap between angle of target and phase-control angle degree. Possible cause ● Crankshaft position sensor (POS) ● Camshaft position sensor (PHASE) ● Intake valve timing control solenoid valve ● Accumulation of debris to the signal pick-up portion of the camshaft ● Timing chain installation ● Foreign matter caught in the oil groove for intake valve timing control FAIL-SAFE MODE ECM enters in fail-safe mode when the malfunction is detected. Detected items Engine operating condition in fail-safe mode Intake valve timing control The signal is not energized to the solenoid valve and the valve control does not function DTC Confirmation Procedure BBS004LT CAUTION: Always drive at a safe speed. NOTE: ● If DTC P0011 is displayed with DTC P1111, first perform trouble diagnosis for DTC P1111. See EC1425, "DTC P1111 IVT CONTROL SOLENOID VALVE" . ● If DTC Confirmation Procedure has been previously conducted, always turn ignition switch OFF and wait at least 10 seconds before conducting the next test. TESTING CONDITION: Before performing the following procedure, confirm that battery voltage is between 10V and 16V at idle. WITH CONSULT-II 1. 2. 3. Turn ignition switch ON and select “DATA MONITOR” mode with CONSULT-II. Start engine and warm it up to the normal operating temperature. Maintain the following conditions for at least 6 consecutive seconds. Hold the accelerator pedal as steady as possible. ENG SPEED 1,200 - 2,000 rpm (A constant rotation is maintained.) COOLANT TEMPS 60 - 120°C (140 - 248°F) B/FUEL SCHDL More than 3.5 msec Shift lever A/T: P or N position M/T: Neutral position 4. 5. 6. SEF174Y Let engine idle for 10 seconds. If the 1st trip DTC is detected, go to EC-1352, "Diagnostic Procedure" . If the 1st trip DTC is not detected, go to next step. Maintain the following conditions for at least 20 consecutive seconds. ENG SPEED 1,700 - 3,175 rpm (A constant rotation is maintained.) COOLANT TEMPS 70 - 105°C (158 - 221°F) EC-1350 DTC P0011 IVT CONTROL [HR (WITHOUT EURO-OBD)] Shift lever 1st or 2nd position Driving location uphill Driving vehicle uphill (Increased engine load will help maintain the driving conditions required for this test.) 7. A EC If 1st trip DTC is detected, go to EC-1352, "Diagnostic Procedure" . Overall Function Check BBS004LU Use this procedure to check the overall function of the intake valve timing control system. During this check, a 1st trip DTC might not be confirmed. WITHOUT CONSULT-II 1. 2. 3. 4. 5. 6. D Start engine and warm it up to normal operating temperature. Turn ignition switch OFF and wait at least 10 seconds. Turn ignition switch ON. Set the tester probe between ECM terminal 73 (IVT control solenoid valve signal) and ground. Start engine and let it idle. Check the voltage under the following conditions. Verify that the oscilloscope screen shows the signal wave as shown below. Conditions At idle C E F G Voltage BATTERY VOLTAGE (11 - 14V) H 7V - 10V I Engine speed: 2,000 rpm PBIB3036E J PBIA4937J : Average voltage for pulse signal (Actual pulse signal can be confirmed by oscilloscope.) 7. If NG, go to EC-1352, "Diagnostic Procedure" . K L M EC-1351 DTC P0011 IVT CONTROL [HR (WITHOUT EURO-OBD)] Diagnostic Procedure BBS004LV 1. CHECK OIL PRESSURE WARNING LAMP 1. 2. Start engine. Check oil pressure warning lamp and confirm it is not illuminated. OK or NG OK >> GO TO 2. KG >> Go to LU-16, "OIL PRESSURE CHECK" . PBIA8559J 2. CHECK INTAKE VALVE TIMING CONTROL SOLENOID VALVE Refer to EC-1353, "Component Inspection" . OK or NG OK >> GO TO 3. NG >> Replace intake valve timing control solenoid valve. 3. CHECK CRANKSHAFT POSITION SENSOR (POS) Refer to EC-1412, "Component Inspection" . OK or NG OK >> GO TO 4. NG >> Replace crankshaft position sensor (POS). 4. CHECK CAMSHAFT POSITION SENSOR (PHASE) Refer to EC-1418, "Component Inspection" . OK or NG OK >> GO TO 5. NG >> Replace camshaft position sensor (PHASE). 5. CHECK CAMSHAFT (INTAKE) Check the following. ● Accumulation of debris to the signal plate of camshaft (1) rear end ● Chipping signal plate of camshaft rear end OK or NG OK >> GO TO 6. NG >> Remove debris and clean the signal plate of camshaft rear end or replace camshaft. PBIA9557J 6. CHECK TIMING CHAIN INSTALLATION Check service records for any recent repairs that may cause timing chain misaligned. Are there any service records that may cause timing chain misaligned? Yes or No Yes >> Check timing chain installation. Refer to EM-142, "TIMING CHAIN" . No >> GO TO 7. EC-1352 DTC P0011 IVT CONTROL [HR (WITHOUT EURO-OBD)] 7. CHECK LUBRICATION CIRCUIT A Refer to EM-166, "Inspection of Camshaft Sprocket (INT) Oil Groove" . OK or NG OK >> GO TO 8. NG >> Clean lubrication line. EC 8. CHECK INTERMITTENT INCIDENT C Refer to EC-1336, "TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT" . For Wiring Diagram, refer to EC-1407, "Wiring Diagram" for CKP sensor (POS) and EC-1415, "Wiring Diagram" for CMP sensor (PHASE). D >> INSPECTION END E Component Inspection BBS004LW INTAKE VALVE TIMING CONTROL SOLENOID VALVE 1. 2. 3. 4. Disconnect intake valve timing control solenoid valve harness connector. Check resistance between intake valve timing control solenoid valve as follows. F G Terminal Resistance 1 and 2 6.7 - 7.7Ω [at 20°C (68°F)] 1 or 2 and ground ∞Ω (Continuity should not exist.) If NG, replace intake valve timing control solenoid valve. If OK, go to next step. Remove intake valve timing control solenoid valve. Provide 12V DC between intake valve timing control solenoid valve terminals and then interrupt it. Make sure that the plunger moves as shown in the figure. CAUTION: Do not apply 12V DC continuously for 5 seconds or more. Doing so may result in damage to the coil in intake valve timing control solenoid valve. If NG, replace intake valve timing control solenoid valve. NOTE: Always replace O-ring when intake valve timing control solenoid valve is removed. Removal and Installation H I PBIB0193E J K L PBIB2275E BBS004LX INTAKE VALVE TIMING CONTROL SOLENOID VALVE Refer to EM-142, "TIMING CHAIN" . EC-1353 M DTC P0102, P0103 MAF SENSOR [HR (WITHOUT EURO-OBD)] DTC P0102, P0103 MAF SENSOR Component Description PFP:22680 BBS004LY The mass air flow sensor (1) is placed in the stream of intake air. It measures the intake flow rate by measuring a part of the entire intake flow. The mass air flow sensor controls the temperature of the hot wire to a certain amount. The heat generated by the hot wire is reduced as the intake air flows around it. The more air, the greater the heat loss. Therefore, the electric current supplied to hot wire is changed to maintain the temperature of the hot wire as air flow increases. The ECM detects the air flow by means of this current change. PBIA9559J CONSULT-II Reference Value in Data Monitor Mode BBS004LZ Specification data are reference values. MONITOR ITEM MAS A/F SE-B1 CONDITION SPECIFICATION See EC-1326, "TROUBLE DIAGNOSIS - SPECIFICATION VALUE" . On Board Diagnosis Logic BBS004M0 These self-diagnoses have the one trip detection logic. DTC No. P0102 0102 P0103 0103 Trouble diagnosis name Mass air flow sensor circuit low input Mass air flow sensor circuit high input DTC detecting condition An excessively low voltage from the sensor is sent to ECM. Possible cause ● Harness or connectors (The sensor circuit is open or shorted.) ● Intake air leaks ● Mass air flow sensor ● Harness or connectors (The sensor circuit is open or shorted.) ● Mass air flow sensor An excessively high voltage from the sensor is sent to ECM. FAIL-SAFE MODE When the malfunction is detected, the ECM enters fail-safe mode and the MI lights up. Detected items Mass air flow sensor circuit Engine operating condition in fail-safe mode Engine speed will not rise more than 2,400 rpm due to the fuel cut. EC-1354 DTC P0102, P0103 MAF SENSOR [HR (WITHOUT EURO-OBD)] DTC Confirmation Procedure BBS004M1 NOTE: If DTC Confirmation Procedure has been previously conducted, always turn ignition switch OFF and wait at least 10 seconds before conducting the next test. EC PROCEDURE FOR DTC P0102 With CONSULT-II 1. 2. 3. 4. A Turn ignition switch ON. Select “DATA MONITOR” mode with CONSULT-II. Start engine and wait at least 5 seconds. If DTC is detected, go to EC-1357, "Diagnostic Procedure" . C D E F SEF058Y Without CONSULT-II 1. 2. 3. 4. G Start engine and wait at least 5 seconds. Turn ignition switch OFF, wait at least 10 seconds and then turn ON. Perform Diagnostic Test Mode II (Self-diagnostic results) with ECM. If DTC is detected, go to EC-1357, "Diagnostic Procedure" . H PROCEDURE FOR DTC P0103 With CONSULT-II 1. 2. 3. 4. 5. 6. I Turn ignition switch ON. Select “DATA MONITOR” mode with CONSULT-II. Wait at least 5 seconds. If DTC is detected, go to EC-1357, "Diagnostic Procedure" . If DTC is not detected, go to next step. Start engine and wait at least 5 seconds. If DTC is detected, go to EC-1357, "Diagnostic Procedure" . J K L SEF058Y M Without CONSULT-II 1. 2. 3. 4. 5. 6. 7. 8. 9. Turn ignition switch ON and wait at least 5 seconds. Turn ignition switch OFF, wait at least 10 seconds and then turn ON. Perform Diagnostic Test Mode II (Self-diagnostic results) with ECM. If DTC is detected, go to EC-1357, "Diagnostic Procedure" . If DTC is not detected, go to next step. Turn ignition switch OFF and wait at least 10 seconds. Start engine and wait at least 5 seconds. Turn ignition switch OFF, wait at least 10 seconds and then turn ON. Perform Diagnostic Test Mode II (Self-diagnostic results) with ECM. If DTC is detected, go to EC-1357, "Diagnostic Procedure" . EC-1355 DTC P0102, P0103 MAF SENSOR [HR (WITHOUT EURO-OBD)] Wiring Diagram BBS004M2 MBWA1457E EC-1356 DTC P0102, P0103 MAF SENSOR [HR (WITHOUT EURO-OBD)] Specification data are reference values and are measured between each terminal and ground. CAUTION: Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM's transistor. Use a ground other than ECM terminals, such as the ground. TERMINAL NO. EC WIRE COLOR ITEM CONDITION [Engine is running] [Ignition switch: OFF] ● 32 P ECM relay (Self shut-off) For a few seconds after turning ignition switch OFF [Ignition switch: OFF] ● More than a few seconds after turning ignition switch OFF [Ignition switch: ON] ● Engine stopped DATA (DC Voltage) C 0 - 1.0V D BATTERY VOLTAGE (11 - 14V) E Approximately 0.4V [Engine is running] 45 G A Mass air flow sensor ● Warm-up condition ● Idle speed [Engine is running] ● Warm-up condition ● Engine is revving from idle to about 4,000 rpm F 1.0 - 1.3V 1.0 - 1.3 to Approximately 2.4V (Check for linear voltage rise in response to engine being increased to about 4,000 rpm.) G H [Engine is running] 52 105 LG G Sensor ground (Mass air flow sensor) Power supply for ECM ● Warm-up condition ● Idle speed [Ignition switch: ON] Approximately 0V I BATTERY VOLTAGE (11 - 14V) J Diagnostic Procedure BBS004M3 1. INSPECTION START K Which malfunction (P0102 or P0103) is duplicated? P0102 or P0103 P0102 >> GO TO 2. P0103 >> GO TO 3. 2. CHECK INTAKE SYSTEM L M Check the following for connection. ● Air duct ● Vacuum hoses ● Intake air passage between air duct to intake manifold OK or NG OK >> GO TO 3. NG >> Reconnect the parts. EC-1357 DTC P0102, P0103 MAF SENSOR [HR (WITHOUT EURO-OBD)] 3. CHECK GROUND CONNECTIONS 1. 2. Turn ignition switch OFF. Loosen and retighten ground screws on the body. Refer to EC-1342, "Ground Inspection" . MBIB1550E 1. IPDM E/R 2. Body ground 3. Body ground OK or NG OK >> GO TO 4. NG >> Repair or replace ground connections. 4. CHECK MAF SENSOR POWER SUPPLY CIRCUIT 1. 2. Disconnect mass air flow (MAF) sensor (1) harness connector. Turn ignition switch ON. PBIB2948E 3. Check voltage between MAF sensor terminal 2 and ground with CONSULT-II or tester. Voltage: Battery voltage OK or NG OK >> GO TO 6. NG >> GO TO 5. PBIB1168E 5. DETECT MALFUNCTIONING PART Check the following. ● Harness connectors E59, F1 ● Harness for open or short between mass air flow sensor and ECM ● Harness for open or short between mass air flow sensor and IPDM E/R >> Repair open circuit or short to ground or short to power in harness or connectors. EC-1358 DTC P0102, P0103 MAF SENSOR [HR (WITHOUT EURO-OBD)] 6. CHECK MAF SENSOR GROUND CIRCUIT FOR OPEN AND SHORT 1. 2. 3. A Turn ignition switch OFF. Disconnect ECM harness connector. Check harness continuity between MAF sensor terminal 3 and ECM terminal 52. Refer to Wiring Diagram. EC Continuity should exist. C 4. Also check harness for short to ground and short to power. OK or NG OK >> GO TO 7. NG >> Repair open circuit or short to ground or short to power in harness or connectors. D 7. CHECK MAF SENSOR INPUT SIGNAL CIRCUIT FOR OPEN AND SHORT 1. E Check harness continuity between MAF sensor terminal 4 and ECM terminal 45. Refer to Wiring Diagram. F Continuity should exist. 2. Also check harness for short to ground and short to power. OK or NG OK >> GO TO 8. NG >> Repair open circuit or short to ground or short to power in harness or connectors. G H 8. CHECK MASS AIR FLOW SENSOR Refer to EC-1359, "Component Inspection" . OK or NG OK >> GO TO 9. NG >> Replace mass air flow sensor. I J 9. CHECK INTERMITTENT INCIDENT Refer to EC-1336, "TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT" . K >> INSPECTION END L Component Inspection BBS004M4 MASS AIR FLOW SENSOR With CONSULT-II 1. 2. 3. 4. M Reconnect all harness connectors disconnected. Start engine and warm it up to normal operating temperature. Connect CONSULT-II and select “DATA MONITOR” mode. Select “MAS A/F SE-B1” and check indication under the following conditions. Condition MAS A/F SE-B1 (V) Ignition switch ON (Engine stopped.) Approx. 0.4 Idle (Engine is warmed-up to normal operating temperature.) 1.0 - 1.3 Idle to about 4,000 rpm 1.0 - 1.3 to Approx. 2.4* *: Check for linear voltage rise in response to engine being increased to about 4,000 rpm. PBIB2371E 5. a. If the voltage is out of specification, proceed the following. Check for the cause of uneven air flow through mass air flow sensor. Refer to following. EC-1359 DTC P0102, P0103 MAF SENSOR [HR (WITHOUT EURO-OBD)] Crushed air ducts Malfunctioning seal of air cleaner element ● Uneven dirt of air cleaner element ● Improper specification of intake air system parts If NG, repair or replace malfunctioning part and perform step 2 to 4 again. If OK, go to next step. Turn ignition switch OFF. Disconnect mass air flow sensor harness connector and reconnect it again. Perform step 2 to 4 again. If NG, clean or replace mass air flow sensor. ● ● b. 6. 7. 8. 9. Without CONSULT-II 1. 2. 3. Reconnect all harness connectors disconnected. Start engine and warm it up to normal operating temperature. Check voltage between ECM terminal 45 (Mass air flow sensor signal) and ground. Condition Voltage V Ignition switch ON (Engine stopped.) Approx. 0.4 Idle (Engine is warmed-up to normal operating temperature.) 1.0 - 1.3 Idle to about 4,000 rpm 1.0 - 1.3 to Approx. 2.4* *: Check for linear voltage rise in response to engine being increased to about 4,000 rpm. PBIA9564J 4. a. b. 5. 6. 7. 8. If the voltage is out of specification, proceed the following. Check for the cause of uneven air flow through mass air flow sensor. Refer to following. ● Crushed air ducts ● Malfunctioning seal of air cleaner element ● Uneven dirt of air cleaner element ● Improper specification of intake air system parts If NG, repair or replace malfunctioning part and perform step 2 to 3 again. If OK, go to next step. Turn ignition switch OFF. Disconnect mass air flow sensor harness connector and reconnect it again. Perform step 2 and 3 again. If NG, clean or replace mass air flow sensor. Removal and Installation BBS004M5 MASS AIR FLOW SENSOR Refer to EM-118, "AIR CLEANER AND AIR DUCT" . EC-1360 DTC P0117, P0118 ECT SENSOR [HR (WITHOUT EURO-OBD)] DTC P0117, P0118 ECT SENSOR Component Description PFP:22630 A BBS004M6 The engine coolant temperature sensor is used to detect the engine coolant temperature. The sensor modifies a voltage signal from the ECM. The modified signal returns to the ECM as the engine coolant temperature input. The sensor uses a thermistor which is sensitive to the change in temperature. The electrical resistance of the thermistor decreases as temperature increases. EC C D SEF594K E Engine coolant temperature °C (°F) –10 (14) Voltage* V Resistance 4.4 F kΩ 7.0 - 11.4 20 (68) 3.5 2.1 - 2.9 50 (122) 2.2 0.68 - 1.00 90 (194) 0.9 0.236 - 0.260 G H *: This data is reference value and is measured between ECM terminal 38 (Engine coolant temperature sensor) and ground. SEF012P CAUTION: Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM's transistor. Use a ground other than ECM terminals, such as the ground. On Board Diagnosis Logic DTC No. Trouble Diagnosis Name BBS004M7 DTC Detecting Condition P0117 0117 Engine coolant temperature sensor circuit low input An excessively low voltage from the sensor is sent to ECM. P0118 0118 Engine coolant temperature sensor circuit high input An excessively high voltage from the sensor is sent to ECM. J Possible Cause K ● Harness or connectors (The sensor circuit is open or shorted.) ● Engine coolant temperature sensor L M FAIL-SAFE MODE ECM enters fail-safe mode when the malfunction is detected. Detected items Engine operating condition in fail-safe mode Engine coolant temperature will be determined by ECM based on the time after turning ignition switch ON or START. CONSULT-II displays the engine coolant temperature decided by ECM. Condition Engine coolant temperature sensor circuit I Engine coolant temperature decided (CONSULT-II display) Just as ignition switch is turned ON or START 40°C (104°F) More than approx. 4 minutes after ignition ON or START 80°C (176°F) 40 - 80°C (104 - 176°F) (Depends on the time) Except as shown above When the fail-safe system for engine coolant temperature sensor is activated, the cooling fan operates while engine is running. EC-1361 DTC P0117, P0118 ECT SENSOR [HR (WITHOUT EURO-OBD)] DTC Confirmation Procedure BBS004M8 NOTE: If DTC Confirmation Procedure has been previously conducted, always turn ignition switch OFF and wait at least 10 seconds before conducting the next test. WITH CONSULT-II 1. 2. 3. 4. Turn ignition switch ON. Select “DATA MONITOR” mode with CONSULT-II. Wait at least 5 seconds. If 1st trip DTC is detected, go to EC-1364, "Diagnostic Procedure" . SEF058Y WITHOUT CONSULT-II 1. 2. 3. 4. Turn ignition switch ON and wait at least 5 seconds. Turn ignition switch OFF, wait at least 10 seconds and then turn ON. Perform Diagnostic Test Mode II (Self-diagnostic results) with ECM. If 1st trip DTC is detected, go to EC-1364, "Diagnostic Procedure" . EC-1362 DTC P0117, P0118 ECT SENSOR [HR (WITHOUT EURO-OBD)] Wiring Diagram BBS004M9 A EC C D E F G H I J K L M MBWA1459E EC-1363 DTC P0117, P0118 ECT SENSOR [HR (WITHOUT EURO-OBD)] Diagnostic Procedure BBS004MA 1. CHECK GROUND CONNECTIONS 1. 2. Turn ignition switch OFF. Loosen and retighten ground screws on the body. Refer to EC-1342, "Ground Inspection" . MBIB1550E 1. IPDM E/R 2. Body ground 3. Body ground OK or NG OK >> GO TO 2. NG >> Repair or replace ground connections. 2. CHECK ECT SENSOR POWER SUPPLY CIRCUIT 1. Disconnect engine coolant temperature (ECT) sensor (1) harness connector. – : Vehicle front Turn ignition switch ON. 2. PBIB2964E 3. Check voltage between ECT sensor terminal 1 and ground with CONSULT-II or tester. Voltage: Approximately 5V OK or NG OK >> GO TO 3. NG >> Repair open circuit or short to ground or short to power in harness or connectors. PBIB0080E EC-1364 DTC P0117, P0118 ECT SENSOR [HR (WITHOUT EURO-OBD)] 3. CHECK ECT SENSOR GROUND CIRCUIT FOR OPEN AND SHORT 1. 2. 3. 4. A Turn ignition switch OFF. Disconnect ECM harness connector. Disconnect TCM harness connector. Check harness continuity between ECM terminal 44, TCM terminal 42 and ECT sensor terminal 2. Refer to Wiring Diagram. EC C Continuity should exist. 5. Also check harness for short to ground and short to power. OK or NG OK >> GO TO 5. NG >> GO TO 4. D E 4. DETECT MALFUNCTIONING PART Check the following. ● Harness connectors E59, F1 ● Harness for open or short between ECM and ECT sensor ● Harness for open or short between TCM and ECT sensor F G >> Repair open circuit or short to ground or short to power in harness or connectors. H 5. CHECK ENGINE COOLANT TEMPERATURE SENSOR Refer to EC-1365, "Component Inspection" . OK or NG OK >> GO TO 6. NG >> Replace engine coolant temperature sensor. I J 6. CHECK INTERMITTENT INCIDENT Refer to EC-1336, "TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT" . K >> INSPECTION END Component Inspection BBS004MB L ENGINE COOLANT TEMPERATURE SENSOR 1. Check resistance between engine coolant temperature sensor terminals 1 and 2 as shown in the figure. M PBIB2005E EC-1365 DTC P0117, P0118 ECT SENSOR [HR (WITHOUT EURO-OBD)] Temperature 2. °C (°F) Resistance kΩ 20 (68) 2.1 - 2.9 50 (122) 0.68 - 1.00 90 (194) 0.236 - 0.260 If NG, replace engine coolant temperature sensor. SEF012P Removal and Installation BBS004MC ENGINE COOLANT TEMPERATURE SENSOR Refer to EM-173, "CYLINDER HEAD" . EC-1366 DTC P0122, P0123 TP SENSOR [HR (WITHOUT EURO-OBD)] DTC P0122, P0123 TP SENSOR Component Description PFP:16119 A BBS004MD Electric throttle control actuator consists of throttle control motor, throttle position sensor, etc. The throttle position sensor responds to the throttle valve movement. The throttle position sensor has the two sensors. These sensors are a kind of potentiometers which transform the throttle valve position into output voltage, and emit the voltage signal to the ECM. In addition, these sensors detect the opening and closing speed of the throttle valve and feed the voltage signals to the ECM. The ECM judges the current opening angle of the throttle valve from these signals and the ECM controls the throttle control motor to make the throttle valve opening angle properly in response to driving condition. EC C D PBIB0145E E CONSULT-II Reference Value in Data Monitor Mode BBS004ME Specification data are reference values. MONITOR ITEM CONDITION ● Ignition switch: ON (Engine stopped) ● Shift lever: D (A/T), 1st (M/T) THRTL SEN 1 THRTL SEN 2* SPECIFICATION Accelerator pedal: Fully released More than 0.36V Accelerator pedal: Fully depressed Less than 4.75V F G *: Throttle position sensor 2 signal is converted by ECM internally. Thus, it differs from ECM terminal voltage signal. On Board Diagnosis Logic BBS004MF These self-diagnoses have the one trip detection logic. NOTE: If DTC P0122 or P0123 is displayed with DTC P1229, first perform the trouble diagnosis for DTC P1229. Refer to EC-1471, "DTC P1229 SENSOR POWER SUPPLY" . DTC No. Trouble diagnosis name DTC detecting condition Possible cause P0122 0122 Throttle position sensor 2 circuit low input An excessively low voltage from the TP sensor 2 is sent to ECM. ● Harness or connectors (TP sensor 2 circuit is open or shorted.) P0123 0123 Throttle position sensor 2 circuit high input An excessively high voltage from the TP sensor 2 is sent to ECM. ● Electric throttle control actuator (TP sensor 2) FAIL-SAFE MODE H I J K L When the malfunction is detected, ECM enters fail-safe mode and the MI lights up. Engine operation condition in fail-safe mode The ECM controls the electric throttle control actuator in regulating the throttle opening in order for the idle position to be within +10 degrees. The ECM regulates the opening speed of the throttle valve to be slower than the normal condition. So, the acceleration will be poor. EC-1367 M DTC P0122, P0123 TP SENSOR [HR (WITHOUT EURO-OBD)] DTC Confirmation Procedure BBS004MG NOTE: If DTC Confirmation Procedure has been previously conducted, always turn ignition switch OFF and wait at least 10 seconds before conducting the next test. TESTING CONDITION: Before performing the following procedure, confirm that battery voltage is more than 10V at idle. WITH CONSULT-II 1. 2. 3. 4. Turn ignition switch ON. Select “DATA MONITOR” mode with CONSULT-II. Start engine and let it idle for 1 second. If DTC is detected, go to EC-1370, "Diagnostic Procedure" . SEF058Y WITHOUT CONSULT-II 1. 2. 3. 4. Start engine and let it idle for 1 second. Turn ignition switch OFF, wait at least 10 seconds and then turn ON. Perform Diagnostic Test Mode II (Self-diagnostic results) with ECM. If DTC is detected, go to EC-1370, "Diagnostic Procedure" . EC-1368 DTC P0122, P0123 TP SENSOR [HR (WITHOUT EURO-OBD)] Wiring Diagram BBS004MH A EC C D E F G H I J K L M MBWA1460E EC-1369 DTC P0122, P0123 TP SENSOR [HR (WITHOUT EURO-OBD)] Specification data are reference values and are measured between each terminal and ground. CAUTION: Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM's transistor. Use a ground other than ECM terminals, such as the ground. TERMINAL NO. WIRE COLOR ITEM CONDITION DATA (DC Voltage) [Ignition switch: ON] 33 Y ● Engine stopped ● Shift lever: D (A/T), 1st (M/T) ● Accelerator pedal: Fully released Throttle position sensor 1 More than 0.36V [Ignition switch: ON] ● Engine stopped ● Shift lever: D (A/T), 1st (M/T) ● Accelerator pedal: Fully depressed Less than 4.75V [Ignition switch: ON] 34 R Throttle position sensor 2 ● Engine stopped ● Shift lever: D (A/T), 1st (M/T) ● Accelerator pedal: Fully released Less than 4.75V [Ignition switch: ON] ● Engine stopped ● Shift lever: D (A/T), 1st (M/T) ● Accelerator pedal: Fully depressed More than 0.36V [Engine is running] 36 72 BR L Sensor ground (Throttle position sensor) Sensor power supply (Throttle position sensor) ● Warm-up condition ● Idle speed Approximately 0V [Ignition switch: ON] Approximately 5V Diagnostic Procedure BBS004MI 1. CHECK GROUND CONNECTIONS 1. 2. Turn ignition switch OFF. Loosen and retighten ground screws on the body. Refer to EC-1342, "Ground Inspection" . MBIB1550E 1. IPDM E/R 2. Body ground OK or NG OK >> GO TO 2. NG >> Repair or replace ground connections. EC-1370 3. Body ground DTC P0122, P0123 TP SENSOR [HR (WITHOUT EURO-OBD)] 2. CHECK THROTTLE POSITION SENSOR 2 POWER SUPPLY CIRCUIT 1. Disconnect electric throttle control actuator (1) harness connector. – : Vehicle front Turn ignition switch ON. 2. A EC C D PBIB2965E 3. Check voltage between electric throttle control actuator terminal 1 and ground with CONSULT-II or tester. E Voltage: Approximately 5V F OK or NG OK >> GO TO 3. NG >> Repair open circuit or short to ground or short to power in harness or connectors. G PBIA9580J H 3. CHECK THROTTLE POSITION SENSOR 2 GROUND CIRCUIT FOR OPEN AND SHORT 1. 2. 3. Turn ignition switch OFF. Disconnect ECM harness connector. Check harness continuity between electric throttle control actuator terminal 4 and ECM terminal 36. Refer to Wiring Diagram. I J Continuity should exist. 4. Also check harness for short to ground and short to power. OK or NG OK >> GO TO 4. NG >> Repair open circuit or short to ground or short to power in harness or connectors. K L 4. CHECK THROTTLE POSITION SENSOR 2 INPUT SIGNAL CIRCUIT FOR OPEN AND SHORT 1. Check harness continuity between ECM terminal 34 and electric throttle control actuator terminal 3. Refer to Wiring Diagram. Continuity should exist. 2. Also check harness for short to ground and short to power. OK or NG OK >> GO TO 5. NG >> Repair open circuit or short to ground or short to power in harness or connectors. 5. CHECK THROTTLE POSITION SENSOR Refer to EC-1372, "Component Inspection" . OK or NG OK >> GO TO 7. NG >> GO TO 6. EC-1371 M DTC P0122, P0123 TP SENSOR [HR (WITHOUT EURO-OBD)] 6. REPLACE ELECTRIC THROTTLE CONTROL ACTUATOR 1. 2. 3. Replace the electric throttle control actuator. Perform EC-1279, "Throttle Valve Closed Position Learning" . Perform EC-1279, "Idle Air Volume Learning" . >> INSPECTION END 7. CHECK INTERMITTENT INCIDENT Refer to EC-1336, "TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT" . >> INSPECTION END Component Inspection BBS004MJ THROTTLE POSITION SENSOR 1. 2. 3. 4. 5. Reconnect all harness connectors disconnected. Perform EC-1279, "Throttle Valve Closed Position Learning" . Turn ignition switch ON. Set shift lever to D position (A/T) or 1st position (M/T). Check voltage between ECM terminals 33 (TP sensor 1 signal), 34 (TP sensor 2 signal) and ground under the following conditions. Terminal Accelerator pedal Voltage 33 (Throttle position sensor 1) Fully released More than 0.36V Fully depressed Less than 4.75V Fully released Less than 4.75V Fully depressed More than 0.36V 34 (Throttle position sensor 2) 6. 7. 8. If NG, replace electric throttle control actuator and go to the next step. Perform EC-1279, "Throttle Valve Closed Position Learning" . Perform EC-1279, "Idle Air Volume Learning" . Removal and Installation PBIB3038E BBS004MK ELECTRIC THROTTLE CONTROL ACTUATOR Refer to EM-120, "INTAKE MANIFOLD" . EC-1372 DTC P0132 HO2S1 [HR (WITHOUT EURO-OBD)] DTC P0132 HO2S1 Component Description PFP:22690 A BBS004ML The heated oxygen sensor 1 is placed into the exhaust manifold. It detects the amount of oxygen in the exhaust gas compared to the outside air. The heated oxygen sensor 1 has a closed-end tube made of ceramic zirconia. The zirconia generates voltage from approximately 1V in richer conditions to 0V in leaner conditions. The heated oxygen sensor 1 signal is sent to the ECM. The ECM adjusts the injection pulse duration to achieve the ideal air-fuel ratio. The ideal air-fuel ratio occurs near the radical change from 1V to 0V. EC C D SEF463R E F G H SEF288D CONSULT-II Reference Value in Data Monitor Mode BBS004MM I Specification data are reference values. MONITOR ITEM CONDITION SPECIFICATION J 0 - 0.3V ←→ Approx. 0.6 - 1.0V HO2S1 (B1) ● HO2S1 MNTR (B1) Engine: After warming up Maintaining engine speed at 2,000 rpm. LEAN ←→ RICH Changes more than 5 times during 10 seconds. On Board Diagnosis Logic K BBS004MN L To judge the malfunction, the diagnosis checks that the heated oxygen sensor 1 output is not inordinately high. M PBIB1848E DTC No. P0132 0132 Trouble diagnosis name Heated oxygen sensor 1 circuit high voltage DTC detecting condition Possible cause ● Harness or connectors (The sensor circuit is open or shorted.) ● Heated oxygen sensor 1 An excessively high voltage from the sensor is sent to ECM. EC-1373 DTC P0132 HO2S1 [HR (WITHOUT EURO-OBD)] DTC Confirmation Procedure BBS004MO NOTE: If DTC Confirmation Procedure has been previously conducted, always turn ignition switch OFF and wait at least 10 seconds before conducting the next test. WITH CONSULT-II 1. 2. 3. 4. 5. 6. Start engine and warm it up to normal operating temperature. Turn ignition switch OFF and wait at least 10 seconds. Turn ignition switch ON. Select “DATA MONITOR” mode with CONSULT-II. Restart engine and let it idle for 2 minutes. If 1st trip DTC is detected, go to EC-1376, "Diagnostic Procedure" . SEF174Y WITHOUT CONSULT-II 1. 2. 3. 4. 5. 6. Start engine and warm it up to normal operating temperature. Turn ignition switch OFF and wait at least 10 seconds. Restart engine and let it idle for 2 minutes. Turn ignition switch OFF and wait at least 10 seconds. Perform Diagnostic Test Mode II (Self-diagnostic results) with ECM. If 1st trip DTC is detected, go to EC-1376, "Diagnostic Procedure" . EC-1374 DTC P0132 HO2S1 [HR (WITHOUT EURO-OBD)] Wiring Diagram BBS004MP A EC C D E F G H I J K L M MBWA1461E EC-1375 DTC P0132 HO2S1 [HR (WITHOUT EURO-OBD)] Specification data are reference values and are measured between each terminal and ground. Pulse signal is measured by CONSULT-II. CAUTION: Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM's transistor. Use a ground other than ECM terminals, such as the ground. TERMINAL NO. WIRE COLOR ITEM CONDITION DATA (DC Voltage) Approximately 10V [Engine is running] 3 Y ● Warm-up condition ● Engine speed: Below 3,600 rpm Heated oxygen sensor 1 heater PBIA8148J [Ignition switch: ON] ● Engine stopped BATTERY VOLTAGE (11 - 14V) [Engine is running] ● Engine speed: Above 3,600 rpm [Engine is running] 49 56 BR R Heated oxygen sensor 1 Sensor ground (Heated oxygen sensor 1) ● Warm-up condition ● Engine speed: 2,000 rpm 0 - Approximately 1.0V (Periodically change) [Engine is running] ● Approximately 0V Idle speed : Average voltage for pulse signal (Actual pulse signal can be confirmed by oscilloscope.) Diagnostic Procedure BBS004MQ 1. CHECK GROUND CONNECTIONS 1. 2. Turn ignition switch OFF. Loosen and retighten ground screws on the body. Refer to EC-1342, "Ground Inspection" . MBIB1550E 1. IPDM E/R 2. Body ground OK or NG OK >> GO TO 2. NG >> Repair or replace ground connections. EC-1376 3. Body ground DTC P0132 HO2S1 [HR (WITHOUT EURO-OBD)] 2. RETIGHTEN HEATED OXYGEN SENSOR 1 A Loosen and retighten heated oxygen sensor 1 (1). ● ● : Vehicle front Exhaust manifold (2) EC Tightening torque: 50 N·m (5.1 kg-m, 37 ft-lb) C >> GO TO 3. D PBIB2966E 3. CHECK HO2S1 GROUND CIRCUIT FOR OPEN AND SHORT 1. Disconnect heated oxygen sensor 1 harness connector (1). – : Vehicle front Disconnect ECM harness connector. Check harness continuity between HO2S1 terminal 1 and ECM terminal 56. Refer to Wiring Diagram. 2. 3. E F G Continuity should exist. 4. Also check harness for short to ground and short to power. OK or NG OK >> GO TO 4. NG >> Repair open circuit or short to ground or short to power in harness or connectors. 4. CHECK HO2S1 INPUT SIGNAL CIRCUIT FOR OPEN AND SHORT 1. PBIB2967E I J Check harness continuity between HO2S1 terminal 4 and ECM terminal 49. Refer to Wiring Diagram. K Continuity should exist. 2. H Check harness continuity between ECM terminal 49 or HO2S1 terminal 4 and ground. Refer to Wiring Diagram. L Continuity should not exist. 3. Also check harness for short to power. OK or NG OK >> GO TO 5. NG >> Repair open circuit or short to ground or short to power in harness or connectors. 5. CHECK HO2S1 CONNECTOR FOR WATER Check heated oxygen sensor 1 connector for water. Water should not exist. OK or NG OK >> GO TO 6. NG >> Repair or replace harness or connectors. EC-1377 M DTC P0132 HO2S1 [HR (WITHOUT EURO-OBD)] 6. CHECK HEATED OXYGEN SENSOR 1 Refer to EC-1379, "Component Inspection" . OK or NG OK >> GO TO 7. NG >> Replace heated oxygen sensor 1. 7. CHECK INTERMITTENT INCIDENT Refer to EC-1336, "TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT" . >> INSPECTION END EC-1378 DTC P0132 HO2S1 [HR (WITHOUT EURO-OBD)] Component Inspection BBS004MR A HEATED OXYGEN SENSOR 1 With CONSULT-II 1. 2. 3. 4. 5. Start engine and warm it up to normal operating temperature. Select “MANU TRIG” and adjust “TRIGGER POINT” to 100% in “DATA MONITOR” mode with CONSULT- EC II. Select “HO2S1 (B1)” and “HO2S1 MNTR (B1)”. C Hold engine speed at 2,000 rpm under no load during the following steps. Touch “RECORD” on CONSULT-II screen. D E SEF646Y F 6. Check the following. ● “HO2S1 MNTR (B1)” in “DATA MONITOR” mode changes from “RICH” to “LEAN” to “RICH” more than 5 times in 10 seconds. 5 times (cycles) are counted as shown in the figure. ● “HO2S1 (B1)” voltage goes above 0.6V at least once. ● “HO2S1 (B1)” voltage goes below 0.3V at least once. ● “HO2S1 (B1)” voltage never exceeds 1.0V. G H I SEF217YA J K L SEF648Y CAUTION: Discard any heated oxygen sensor which has been dropped from a height of more than 0.5 m (19.7 in) onto a hard surface such as a concrete floor; use a new one. ● Before installing new oxygen sensor, clean exhaust system threads using Oxygen Sensor Thread Cleaner tool and approved anti-seize lubricant. ● Without CONSULT-II 1. 2. Start engine and warm it up to normal operating temperature. Set voltmeter probes between ECM terminal 49 (HO2S1 signal) and ground. EC-1379 M DTC P0132 HO2S1 [HR (WITHOUT EURO-OBD)] 3. Check the following with engine speed held at 2,000 rpm constant under no load. ● The voltage fluctuates between 0 to 0.3V and 0.6 to 1.0V more than 5 times within 10 seconds. ● The maximum voltage is over 0.6V at least 1 time. ● The minimum voltage is below 0.3V at least 1 time. ● The voltage never exceeds 1.0V. 1 time: 0 - 0.3V → 0.6 - 1.0V → 0 - 0.3V 2 times: 0 - 0.3V → 0.6 - 1.0V → 0 - 0.3V → 0.6 - 1.0V → 0 - 0.3V PBIA9566J CAUTION: ● Discard any heated oxygen sensor which has been dropped from a height of more than 0.5 m (19.7 in) onto a hard surface such as a concrete floor; use a new one. ● Before installing new oxygen sensor, clean exhaust system threads using Oxygen Sensor Thread Cleaner tool and approved anti-seize lubricant. Removal and Installation BBS004MS HEATED OXYGEN SENSOR 1 Refer to EM-124, "EXHAUST MANIFOLD" . EC-1380 DTC P0134 HO2S1 [HR (WITHOUT EURO-OBD)] DTC P0134 HO2S1 Component Description PFP:22690 A BBS004MT The heated oxygen sensor 1 is placed into the exhaust manifold. It detects the amount of oxygen in the exhaust gas compared to the outside air. The heated oxygen sensor 1 has a closed-end tube made of ceramic zirconia. The zirconia generates voltage from approximately 1V in richer conditions to 0V in leaner conditions. The heated oxygen sensor 1 signal is sent to the ECM. The ECM adjusts the injection pulse duration to achieve the ideal air-fuel ratio. The ideal air-fuel ratio occurs near the radical change from 1V to 0V. EC C D SEF463R E F G H SEF288D CONSULT-II Reference Value in Data Monitor Mode BBS004MU I Specification data are reference values. MONITOR ITEM CONDITION SPECIFICATION J 0 - 0.3V ←→ Approx. 0.6 - 1.0V HO2S1 (B1) ● HO2S1 MNTR (B1) Engine: After warming up Maintaining engine speed at 2,000 rpm. LEAN ←→ RICH Changes more than 5 times during 10 seconds. On Board Diagnosis Logic BBS004MV L Under the condition in which the heated oxygen sensor 1 signal is not input, the ECM circuits will read a continuous approximately 0.3V. Therefore, for this diagnosis, the time that output voltage is within 200 to 400 mV range is monitored, and the diagnosis checks that this time is not inordinately long. M SEF237U DTC No. P0134 0134 Trouble diagnosis name Heated oxygen sensor 1 circuit no activity detected K DTC detecting condition Possible cause ● Harness or connectors (The sensor circuit is open or shorted.) ● Heated oxygen sensor 1 The voltage from the sensor is constantly approx. 0.3V. EC-1381 DTC P0134 HO2S1 [HR (WITHOUT EURO-OBD)] Overall Function Check BBS004MW Use this procedure to check the overall function of the heated oxygen sensor 1 circuit. During this check, a 1st trip DTC might not be confirmed. WITH CONSULT-II 1. 2. 3. 4. 5. Start engine and warm it up to normal operating temperature. Select “MANU TRIG” in “DATA MONITOR” mode with CONSULT-II, and select “HO2S1 (B1)”. Hold engine speed at 2,000 rpm under no load. Make sure that the indications do not remain in the range between 0.2V to 0.4V. If NG, go to EC-1384, "Diagnostic Procedure" . SEF646Y WITHOUT CONSULT-II 1. 2. 3. ● 4. Start engine and warm it up to normal operating temperature. Set voltmeter probes between ECM terminal 49 (HO2S1 signal) and ground. Check the following with engine speed held at 2,000 rpm constant under no load. The voltage does not remain in the range of 0.2 to 0.4V. If NG, go to EC-1384, "Diagnostic Procedure" . PBIA9566J EC-1382 DTC P0134 HO2S1 [HR (WITHOUT EURO-OBD)] Wiring Diagram BBS004MX A EC C D E F G H I J K L M MBWA1461E EC-1383 DTC P0134 HO2S1 [HR (WITHOUT EURO-OBD)] Specification data are reference values and are measured between each terminal and ground. Pulse signal is measured by CONSULT-II. CAUTION: Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM's transistor. Use a ground other than ECM terminals, such as the ground. TERMINAL NO. WIRE COLOR ITEM CONDITION DATA (DC Voltage) Approximately 10V [Engine is running] 3 Y ● Warm-up condition ● Engine speed: Below 3,600 rpm Heated oxygen sensor 1 heater PBIA8148J [Ignition switch: ON] ● Engine stopped BATTERY VOLTAGE (11 - 14V) [Engine is running] ● Engine speed: Above 3,600 rpm [Engine is running] 49 BR Heated oxygen sensor 1 ● Warm-up condition ● Engine speed: 2,000 rpm 0 - Approximately 1.0V (Periodically change) [Engine is running] 56 R Sensor ground (Heated oxygen sensor 1) ● Warm-up condition ● Idle speed Approximately 0V : Average voltage for pulse signal (Actual pulse signal can be confirmed by oscilloscope.) Diagnostic Procedure BBS004MY 1. CHECK GROUND CONNECTIONS 1. 2. Turn ignition switch OFF. Loosen and retighten ground screws on the body. Refer to EC-1342, "Ground Inspection" . MBIB1550E 1. IPDM E/R 2. Body ground OK or NG OK >> GO TO 2. NG >> Repair or replace ground connections. EC-1384 3. Body ground DTC P0134 HO2S1 [HR (WITHOUT EURO-OBD)] 2. CHECK HO2S1 GROUND CIRCUIT FOR OPEN AND SHORT 1. Disconnect heated oxygen sensor 1 harness connector (1). – : Vehicle front Disconnect ECM harness connector. Check harness continuity between HO2S1 terminal 1 and ECM terminal 56. Refer to Wiring Diagram. 2. 3. A EC C Continuity should exist. 4. Also check harness for short to ground and short to power. OK or NG OK >> GO TO 3. NG >> Repair open circuit or short to ground or short to power in harness or connectors. D PBIB2967E E 3. CHECK HO2S1 INPUT SIGNAL CIRCUIT FOR OPEN AND SHORT 1. F Check harness continuity between HO2S1 terminal 4 and ECM terminal 49. Refer to Wiring Diagram. Continuity should exist. 2. G Check harness continuity between ECM terminal 49 or HO2S1 terminal 4 and ground. Refer to Wiring Diagram. H Continuity should not exist. 3. Also check harness for short to power. OK or NG OK >> GO TO 4. NG >> Repair open circuit or short to ground or short to power in harness or connectors. I J 4. CHECK HEATED OXYGEN SENSOR 1 Refer to EC-1385, "Component Inspection" . OK or NG OK >> GO TO 5. NG >> Replace heated oxygen sensor 1. K L 5. CHECK INTERMITTENT INCIDENT Refer to EC-1336, "TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT" . M >> INSPECTION END Component Inspection BBS004MZ HEATED OXYGEN SENSOR 1 With CONSULT-II 1. 2. Start engine and warm it up to normal operating temperature. Select “MANU TRIG” and adjust “TRIGGER POINT” to 100% in “DATA MONITOR” mode with CONSULTII. EC-1385 DTC P0134 HO2S1 [HR (WITHOUT EURO-OBD)] 3. 4. 5. Select “HO2S1 (B1)” and “HO2S1 MNTR (B1)”. Hold engine speed at 2,000 rpm under no load during the following steps. Touch “RECORD” on CONSULT-II screen. SEF646Y 6. Check the following. ● “HO2S1 MNTR (B1)” in “DATA MONITOR” mode changes from “RICH” to “LEAN” to “RICH” more than 5 times in 10 seconds. 5 times (cycles) are counted as shown in the figure. ● “HO2S1 (B1)” voltage goes above 0.6V at least once. ● “HO2S1 (B1)” voltage goes below 0.3V at least once. ● “HO2S1 (B1)” voltage never exceeds 1.0V. SEF217YA SEF648Y CAUTION: ● Discard any heated oxygen sensor which has been dropped from a height of more than 0.5 m (19.7 in) onto a hard surface such as a concrete floor; use a new one. ● Before installing new oxygen sensor, clean exhaust system threads using Oxygen Sensor Thread Cleaner tool and approved anti-seize lubricant. Without CONSULT-II 1. 2. 3. Start engine and warm it up to normal operating temperature. Set voltmeter probes between ECM terminal 49 (HO2S1 signal) and ground. Check the following with engine speed held at 2,000 rpm constant under no load. ● The voltage fluctuates between 0 to 0.3V and 0.6 to 1.0V more than 5 times within 10 seconds. ● The maximum voltage is over 0.6V at least 1 time. ● The minimum voltage is below 0.3V at least 1 time. ● The voltage never exceeds 1.0V. 1 time: 0 - 0.3V → 0.6 - 1.0V → 0 - 0.3V 2 times: 0 - 0.3V → 0.6 - 1.0V → 0 - 0.3V → 0.6 - 1.0V → 0 - 0.3V PBIA9566J CAUTION: ● Discard any heated oxygen sensor which has been dropped from a height of more than 0.5 m (19.7 in) onto a hard surface such as a concrete floor; use a new one. EC-1386 DTC P0134 HO2S1 [HR (WITHOUT EURO-OBD)] ● Before installing new oxygen sensor, clean exhaust system threads using Oxygen Sensor Thread Cleaner tool and approved anti-seize lubricant. Removal and Installation A BBS004N0 HEATED OXYGEN SENSOR 1 EC Refer to EM-124, "EXHAUST MANIFOLD" . C D E F G H I J K L M EC-1387 DTC P0138 HO2S2 [HR (WITHOUT EURO-OBD)] DTC P0138 HO2S2 Component Description PFP:226A0 BBS004N1 The heated oxygen sensor 2, after three way catalyst (manifold), monitors the oxygen level in the exhaust gas. Even if switching characteristics of the heated oxygen sensor 1 are shifted, the air-fuel ratio is controlled to stoichiometric, by the signal from the heated oxygen sensor 2. This sensor is made of ceramic zirconia. The zirconia generates voltage from approximately 1V in richer conditions to 0V in leaner conditions. Under normal conditions the heated oxygen sensor 2 is not used for engine control operation. SEF327R CONSULT-II Reference Value in Data Monitor Mode BBS004N2 Specification data are reference values. MONITOR ITEM HO2S2 (B1) HO2S2 MNTR (B1) CONDITION SPECIFICATION ● Revving engine from idle to 3,000 rpm quickly after the following conditions are met. 0 - 0.3V ←→ Approx. 0.6 - 1.0V – Engine: After warming up. – Keep the engine speed between 3,500 rpm and 4,000 rpm for 1 minute and idle for 1 minute under no load. LEAN ←→ RICH On Board Diagnosis Logic BBS004N3 The heated oxygen sensor 2 has a much longer switching time between rich and lean than the heated oxygen sensor 1. The oxygen storage capacity before the three way catalyst (manifold) causes the longer switching time. To judge the malfunctions of heated oxygen sensor 2, ECM monitors whether the voltage is unusually high during the various driving condition such as fuel-cut. PBIB1848E DTC No. P0138 0138 Trouble diagnosis name Heated oxygen sensor 2 circuit high voltage DTC detecting condition Possible cause ● Harness or connectors (The sensor circuit is open or shorted.) ● Heated oxygen sensor 2 An excessively high voltage from the sensor is sent to ECM. EC-1388 DTC P0138 HO2S2 [HR (WITHOUT EURO-OBD)] DTC Confirmation Procedure BBS004N4 A CAUTION: Always drive vehicle at a safe speed. NOTE: If DTC Confirmation Procedure has been previously conducted, always turn ignition switch OFF and wait at EC least 10 seconds before conducting the next test. WITH CONSULT-II 1. 2. 3. 4. 5. 6. C Turn ignition switch ON and select “DATA MONITOR” mode with CONSULT-II. Start engine and warm it up to the normal operating temperature. Turn ignition switch OFF and wait at least 10 seconds. Start engine and keep the engine speed between 3,500 and 4,000 rpm for at least 1 minute under no load. Let engine idle for 2 minutes. If 1st trip DTC is detected, go to EC-1391, "Diagnostic Procedure" . D E F G SEF174Y WITHOUT CONSULT-II 1. 2. 3. 4. 5. 6. 7. Start engine and warm it up to the normal operating temperature. Turn ignition switch OFF and wait at least 10 seconds. Start engine and keep the engine speed between 3,500 and 4,000 rpm for at least 1 minute under no load. Let engine idle for 2 minutes. Turn ignition switch OFF and wait at least 10 seconds and then turn ON. Perform Diagnostic Test Mode II (Self-diagnostic results) with ECM. If 1st trip DTC is detected, go to EC-1391, "Diagnostic Procedure" . H I J K L M EC-1389 DTC P0138 HO2S2 [HR (WITHOUT EURO-OBD)] Wiring Diagram BBS004N5 MBWA1463E EC-1390 DTC P0138 HO2S2 [HR (WITHOUT EURO-OBD)] Specification data are reference values and are measured between each terminal and ground. Pulse signal is measured by CONSULT-II. A CAUTION: Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM's transistor. Use a ground other than ECM terminals, such as the ground. EC TERMINAL NO. WIRE COLOR ITEM CONDITION DATA (DC Voltage) C Approximately 10V [Engine is running] 5 GR ● Below 3,600 rpm after the following conditions are met. – Engine: After warming up – Keeping the engine speed between 3,500 and 4,000 rpm for 1 minute and at idle for 1 minute under no load Heated oxygen sensor 2 heater D E PBIA8148J [Ignition switch: ON] ● Engine stopped ● F BATTERY VOLTAGE (11 - 14V) [Engine is running] Engine speed: Above 3,600 rpm G [Engine is running] 50 B Heated oxygen sensor 2 ● Revving engine from idle to 3,000 rpm quickly after the following conditions are met. – Engine: After warming up – Keeping the engine speed between 3,500 and 4,000 rpm for 1 minute and at idle for 1 minute under no load. H 0 - Approximately 1.0V I [Engine is running] 59 LG Sensor ground (Heated oxygen sensor 2) ● Warm-up condition ● Idle speed Approximately 0V J : Average voltage for pulse signal (Actual pulse signal can be confirmed by oscilloscope.) Diagnostic Procedure BBS004N6 K 1. CHECK GROUND CONNECTIONS 1. 2. L Turn ignition switch OFF. Loosen and retighten ground screws on the body. Refer to EC-1342, "Ground Inspection" . M MBIB1550E 1. IPDM E/R 2. Body ground OK or NG OK >> GO TO 2. NG >> Repair or replace ground connections. EC-1391 3. Body ground DTC P0138 HO2S2 [HR (WITHOUT EURO-OBD)] 2. CHECK HO2S2 GROUND CIRCUIT FOR OPEN AND SHORT 1. – 2. 3. Disconnect heated oxygen sensor 2 harness connector (2). Heated oxygen sensor 2 (1) Disconnect ECM harness connector. Check harness continuity between HO2S2 terminal 1 and ECM terminal 59. Refer to Wiring Diagram. Continuity should exist. 4. Also check harness for short to ground and short to power. OK or NG OK >> GO TO 3. NG >> Repair open circuit or short to ground or short to power in harness or connectors. PBIB2949E 3. CHECK HO2S2 INPUT SIGNAL CIRCUIT FOR OPEN AND SHORT 1. Check harness continuity between HO2S2 terminal 4 ECM terminal 50. Refer to Wiring Diagram. Continuity should exist. 2. Check harness continuity between ECM terminal 50 or HO2S2 terminal 4 and ground. Refer to Wiring Diagram. Continuity should not exist. 3. Also check harness for short to power. OK or NG OK >> GO TO 4. NG >> Repair open circuit or short to ground or short to power in harness or connectors. 4. CHECK HEATED OXYGEN SENSOR 2 Refer to EC-1392, "Component Inspection" . OK or NG OK >> GO TO 5. NG >> Replace heated oxygen sensor 2. 5. CHECK INTERMITTENT INCIDENT Refer to EC-1336, "TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT" . >> INSPECTION END Component Inspection BBS004N7 HEATED OXYGEN SENSOR 2 With CONSULT-II 1. 2. 3. 4. Start engine and warm it up to the normal operating temperature. Turn ignition switch OFF and wait at least 10 seconds. Start engine and keep the engine speed between 3,500 and 4,000 rpm for at least 1 minute under no load. Let engine idle for 1 minute. EC-1392 DTC P0138 HO2S2 [HR (WITHOUT EURO-OBD)] 5. Select “FUEL INJECTION” in “ACTIVE TEST” mode, and select “HO2S2 (B1)” as the monitor item with CONSULT-II. A EC C SEF662Y 6. D Check “HO2S2 (B1)” at idle speed when adjusting “FUEL INJECTION” to ±25%. E F G PBIB0551E “HO2S2 (B1)” should be above 0.68V at least once when the “FUEL INJECTION” is +25%. “HO2S2 (B1)” should be below 0.50V at least once when the “FUEL INJECTION” is −25%. CAUTION: ● Discard any heated oxygen sensor which has been dropped from a height of more than 0.5 m (19.7 in) onto a hard surface such as a concrete floor; use a new one. ● Before installing new oxygen sensor, clean exhaust system threads using Oxygen Sensor Thread Cleaner tool and approved anti-seize lubricant. H I J Without CONSULT-II 1. 2. 3. 4. 5. 6. Start engine and warm it up to the normal operating temperature. Turn ignition switch OFF and wait at least 10 seconds. Start engine and keep the engine speed between 3,500 and 4,000 rpm for at least 1 minute under no load. Let engine idle for 1 minute. Set voltmeter probes between ECM terminal 50 (HO2S2 signal) and ground. Check the voltage when revving up to 4,000 rpm under no load at least 10 times. (Depress and release accelerator pedal as soon as possible.) The voltage should be above 0.68V at least once during this procedure. If the voltage is above 0.68V at step 6, step 7 is not necessary. 7. Keep vehicle idling for 10 minutes, then check voltage. Or check the voltage when coasting from 80 km/h (50 MPH) in D position with “OD” OFF (A/T), 3rd gear position (M/T). The voltage should be below 0.50V at least once during this PBIB2996E procedure. 8. If NG, replace heated oxygen sensor 2. CAUTION: ● Discard any heated oxygen sensor which has been dropped from a height of more than 0.5 m (19.7 in) onto a hard surface such as a concrete floor; use a new one. ● Before installing new oxygen sensor, clean exhaust system threads using Oxygen Sensor Thread Cleaner tool and approved anti-seize lubricant. EC-1393 K L M DTC P0138 HO2S2 [HR (WITHOUT EURO-OBD)] Removal and Installation BBS004N8 HEATED OXYGEN SENSOR 2 Refer to EX-3, "EXHAUST SYSTEM" . EC-1394 DTC P0222, P0223 TP SENSOR [HR (WITHOUT EURO-OBD)] DTC P0222, P0223 TP SENSOR Component Description PFP:16119 A BBS004N9 Electric throttle control actuator consists of throttle control motor, throttle position sensor, etc. The throttle position sensor responds to the throttle valve movement. The throttle position sensor has the two sensors. These sensors are a kind of potentiometers which transform the throttle valve position into output voltage, and emit the voltage signal to the ECM. In addition, these sensors detect the opening and closing speed of the throttle valve and feed the voltage signals to the ECM. The ECM judges the current opening angle of the throttle valve from these signals and the ECM controls the throttle control motor to make the throttle valve opening angle properly in response to driving condition. EC C D PBIB0145E E CONSULT-II Reference Value in Data Monitor Mode BBS004NA Specification data are reference values. MONITOR ITEM CONDITION ● Ignition switch: ON (Engine stopped) ● Shift lever: D (A/T), 1st (M/T) THRTL SEN 1 THRTL SEN 2* SPECIFICATION Accelerator pedal: Fully released More than 0.36V Accelerator pedal: Fully depressed Less than 4.75V F G *: Throttle position sensor 2 signal is converted by ECM internally. Thus, it differs from ECM terminal voltage signal. On Board Diagnosis Logic BBS004NB These self-diagnoses have the one trip detection logic. NOTE: If DTC P0222 or P0223 is displayed with DTC P1229, first perform the trouble diagnosis for DTC P1229. Refer to EC-1471, "DTC P1229 SENSOR POWER SUPPLY" . DTC No. Trouble diagnosis name DTC detecting condition Possible cause P0222 0222 Throttle position sensor 1 circuit low input An excessively low voltage from the TP sensor 1 is sent to ECM. ● Harness or connectors (TP sensor 1 circuit is open or shorted.) P0223 0223 Throttle position sensor 1 circuit high input An excessively high voltage from the TP sensor 1 is sent to ECM. ● Electric throttle control actuator (TP sensor 1) FAIL-SAFE MODE H I J K L When the malfunction is detected, ECM enters fail-safe mode and the MI lights up. Engine operation condition in fail-safe mode The ECM controls the electric throttle control actuator in regulating the throttle opening in order for the idle position to be within +10 degrees. The ECM regulates the opening speed of the throttle valve to be slower than the normal condition. So, the acceleration will be poor. EC-1395 M DTC P0222, P0223 TP SENSOR [HR (WITHOUT EURO-OBD)] DTC Confirmation Procedure BBS004NC NOTE: If DTC Confirmation Procedure has been previously conducted, always turn ignition switch OFF and wait at least 10 seconds before conducting the next test. TESTING CONDITION: Before performing the following procedure, confirm that battery voltage is more than 10V at idle. WITH CONSULT-II 1. 2. 3. 4. Turn ignition switch ON. Select “DATA MONITOR” mode with CONSULT-II. Start engine and let it idle for 1 second. If DTC is detected, go to EC-1398, "Diagnostic Procedure" . SEF058Y WITHOUT CONSULT-II 1. 2. 3. 4. Start engine and let it idle for 1 second. Turn ignition switch OFF, wait at least 10 seconds and then turn ON. Perform Diagnostic Test Mode II (Self-diagnostic results) with ECM. If DTC is detected, go to EC-1398, "Diagnostic Procedure" . EC-1396 DTC P0222, P0223 TP SENSOR [HR (WITHOUT EURO-OBD)] Wiring Diagram BBS004ND A EC C D E F G H I J K L M MBWA1466E EC-1397 DTC P0222, P0223 TP SENSOR [HR (WITHOUT EURO-OBD)] Specification data are reference values and are measured between each terminal and ground. CAUTION: Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM's transistor. Use a ground other than ECM terminals, such as the ground. TERMINAL NO. WIRE COLOR ITEM CONDITION DATA (DC Voltage) [Ignition switch: ON] 33 Y ● Engine stopped ● Shift lever: D (A/T), 1st (M/T) ● Accelerator pedal: Fully released Throttle position sensor 1 More than 0.36V [Ignition switch: ON] ● Engine stopped ● Shift lever: D (A/T), 1st (M/T) ● Accelerator pedal: Fully depressed Less than 4.75V [Ignition switch: ON] 34 R Throttle position sensor 2 ● Engine stopped ● Shift lever: D (A/T), 1st (M/T) ● Accelerator pedal: Fully released Less than 4.75V [Ignition switch: ON] ● Engine stopped ● Shift lever: D (A/T), 1st (M/T) ● Accelerator pedal: Fully depressed More than 0.36V [Engine is running] 36 72 BR L Sensor ground (Throttle position sensor) Sensor power supply (Throttle position sensor) ● Warm-up condition ● Idle speed Approximately 0V [Ignition switch: ON] Approximately 5V Diagnostic Procedure BBS004NE 1. CHECK GROUND CONNECTIONS 1. 2. Turn ignition switch OFF. Loosen and retighten ground screws on the body. Refer to EC-1342, "Ground Inspection" . MBIB1550E 1. IPDM E/R 2. Body ground OK or NG OK >> GO TO 2. NG >> Repair or replace ground connections. EC-1398 3. Body ground DTC P0222, P0223 TP SENSOR [HR (WITHOUT EURO-OBD)] 2. CHECK THROTTLE POSITION SENSOR 1 POWER SUPPLY CIRCUIT-I 1. Disconnect electric throttle control actuator (1) harness connector. – : Vehicle front Turn ignition switch ON. 2. A EC C D PBIB2965E 3. Check voltage between electric throttle control actuator terminal 1 and ground with CONSULT-II or tester. E Voltage: Approximately 5V F OK or NG OK >> GO TO 3. NG >> Repair open circuit or short to ground or short to power in harness or connectors. G PBIA9580J H 3. CHECK THROTTLE POSITION SENSOR 1 GROUND CIRCUIT FOR OPEN AND SHORT 1. 2. 3. Turn ignition switch OFF. Disconnect ECM harness connector. Check harness continuity between electric throttle control actuator terminal 4 and ECM terminal 36. Refer to Wiring Diagram. I J Continuity should exist. 4. Also check harness for short to ground and short to power. OK or NG OK >> GO TO 4. NG >> Repair open circuit or short to ground or short to power in harness or connectors. K L 4. CHECK THROTTLE POSITION SENSOR 1 INPUT SIGNAL CIRCUIT FOR OPEN AND SHORT 1. Check harness continuity between ECM terminal 33 and electric throttle control actuator terminal 2. Refer to Wiring Diagram. Continuity should exist. 2. Also check harness for short to ground and short to power. OK or NG OK >> GO TO 5. NG >> Repair open circuit or short to ground or short to power in harness or connectors. 5. CHECK THROTTLE POSITION SENSOR Refer to EC-1400, "Component Inspection" . OK or NG OK >> GO TO 7. NG >> GO TO 6. EC-1399 M DTC P0222, P0223 TP SENSOR [HR (WITHOUT EURO-OBD)] 6. REPLACE ELECTRIC THROTTLE CONTROL ACTUATOR 1. 2. 3. Replace the electric throttle control actuator. Perform EC-1279, "Throttle Valve Closed Position Learning" . Perform EC-1279, "Idle Air Volume Learning" . >> INSPECTION END 7. CHECK INTERMITTENT INCIDENT Refer to EC-1336, "TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT" . >> INSPECTION END Component Inspection BBS004NF THROTTLE POSITION SENSOR 1. 2. 3. 4. 5. Reconnect all harness connectors disconnected. Perform EC-1279, "Throttle Valve Closed Position Learning" . Turn ignition switch ON. Set shift lever to D (A/T), 1st (M/T) position. Check voltage between ECM terminals 33 (TP sensor 1 signal), 34 (TP sensor 2 signal) and ground under the following conditions. Terminal Accelerator pedal Voltage 33 (Throttle position sensor 1) Fully released More than 0.36V Fully depressed Less than 4.75V Fully released Less than 4.75V Fully depressed More than 0.36V 34 (Throttle position sensor 2) 6. 7. 8. If NG, replace electric throttle control actuator and go to the next step. Perform EC-1279, "Throttle Valve Closed Position Learning" . Perform EC-1279, "Idle Air Volume Learning" . Removal and Installation PBIB3038E BBS004NG ELECTRIC THROTTLE CONTROL ACTUATOR Refer to EM-120, "INTAKE MANIFOLD" . EC-1400 DTC P0327, P0328 KS [HR (WITHOUT EURO-OBD)] DTC P0327, P0328 KS Component Description PFP:22060 A BBS004NH The knock sensor (1) is attached to the cylinder block. It senses engine knocking using a piezoelectric element. A knocking vibration from the cylinder block is sensed as vibrational pressure. This pressure is converted into a voltage signal and sent to the ECM. EC : Vehicle front ● C D PBIB2969E E On Board Diagnosis Logic BBS004NI The MI will not light up for these self-diagnoses. DTC No. Trouble Diagnosis Name DTC Detected Condition F Possible Cause P0327 0327 Knock sensor circuit low input An excessively low voltage from the sensor is sent to ECM. ● Harness or connectors (The sensor circuit is open or shorted.) P0328 0328 Knock sensor circuit high input An excessively high voltage from the sensor is sent to ECM. ● Knock sensor DTC Confirmation Procedure BBS004NJ NOTE: If DTC Confirmation Procedure has been previously conducted, always turn ignition switch OFF and wait at least 10 seconds before conducting the next test. TESTING CONDITION: Before performing the following procedure, confirm that battery voltage is more than 10V at idle. WITH CONSULT-II 1. 2. 3. G H I J Turn ignition switch ON and select “DATA MONITOR” mode with CONSULT-II. Start engine and run it for at least 5 seconds at idle speed. If 1st trip DTC is detected, go to EC-1403, "Diagnostic Procedure" . K L M SEF058Y WITHOUT CONSULT-II 1. 2. 3. 4. Start engine and run it for at least 5 seconds at idle speed. Turn ignition switch OFF, wait at least 10 seconds and then turn ON. Perform Diagnostic Test Mode II (Self-diagnostic results) with ECM. If 1st trip DTC is detected, go to EC-1403, "Diagnostic Procedure" . EC-1401 DTC P0327, P0328 KS [HR (WITHOUT EURO-OBD)] Wiring Diagram BBS004NK MBWA1467E EC-1402 DTC P0327, P0328 KS [HR (WITHOUT EURO-OBD)] Specification data are reference values and are measured between each terminal and ground. CAUTION: Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM's transistor. Use a ground other than ECM terminals, such as the ground. TERMINAL NO. 37 WIRE COLOR W A EC ITEM Knock sensor CONDITION [Engine is running] ● Idle speed DATA (DC Voltage) C Approximately 2.5V [Engine is running] 40 — Sensor ground (Knock sensor) ● Warm-up condition ● Idle speed D Approximately 0V Diagnostic Procedure BBS004NL 1. CHECK KNOCK SENSOR INPUT SIGNAL CIRCUIT-I 1. 2. 3. Turn ignition switch OFF. Disconnect ECM harness connector. Check resistance between ECM terminal 37 and ground. Refer to Wiring Diagram. NOTE: It is necessary to use an ohmmeter which can measure more than 10 MΩ. E F G Resistance: Approximately 530 - 590kΩ [at 20°C (68°F)] H 4. Also check harness for short to ground and short to power. OK or NG OK >> GO TO 4. NG >> GO TO 2. I 2. CHECK KNOCK SENSOR INPUT SIGNAL CIRCUIT-II 1. Disconnect knock sensor (1) harness connector. – : Vehicle front Check harness continuity between ECM terminal 37 and knock sensor terminal 1. Refer to Wiring Diagram. 2. J K L Continuity should exist. 3. Also check harness for short to ground and short to power. OK or NG OK >> GO TO 3. NG >> Repair open circuit or short to ground or short to power in harness or connectors. 3. CHECK KNOCK SENSOR Refer to EC-1404, "Component Inspection" . OK or NG OK >> GO TO 6. NG >> Replace knock sensor. EC-1403 M PBIB2969E DTC P0327, P0328 KS [HR (WITHOUT EURO-OBD)] 4. CHECK GROUND CONNECTIONS Loosen and retighten ground screws on the body. Refer to EC-1342, "Ground Inspection" . MBIB1550E 1. IPDM E/R 2. Body ground 3. Body ground OK or NG OK >> GO TO 5. NG >> Repair or replace ground connections. 5. CHECK KNOCK SENSOR SHIELD CIRCUIT FOR OPEN AND SHORT 1. 2. Reconnect knock sensor harness connector. Check harness continuity between ECM terminal 40 and knock sensor terminal 2. Continuity should exist 3. Also check harness for short to ground and short to power. OK or NG OK >> GO TO 6. NG >> Repair open circuit or short to ground or short to power in harness or connectors. 6. CHECK INTERMITTENT INCIDENT Refer to EC-1336, "TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT" . >> INSPECTION END Component Inspection BBS004NM KNOCK SENSOR Check resistance between knock sensor terminal 1 and ground. NOTE: It is necessary to use an ohmmeter which can measure more than 10 MΩ. Resistance: Approximately 530 - 590kΩ [at 20°C (68°F)] CAUTION: Do not use any knock sensors that have been dropped or physically damaged. Use only new ones. SEF227W Removal and Installation BBS004NN KNOCK SENSOR Refer to EM-189, "CYLINDER BLOCK" . EC-1404 DTC P0335 CKP SENSOR (POS) [HR (WITHOUT EURO-OBD)] DTC P0335 CKP SENSOR (POS) Component Description PFP:23731 A BBS004NO The crankshaft position sensor (POS) is located on the cylinder block rear housing facing the gear teeth (cogs) of the signal plate at the end of the crankshaft. It detects the fluctuation of the engine revolution. The sensor consists of a permanent magnet and Hall IC. When the engine is running, the high and low parts of the teeth cause the gap with the sensor to change. The changing gap causes the magnetic field near the sensor to change. Due to the changing magnetic field, the voltage from the sensor changes. The ECM receives the voltage signal and detects the fluctuation of the engine revolution. ECM receives the signals as shown in the figure. EC C D PBIA9209J E F G H PBIB2382E I CONSULT-II Reference Value in Data Monitor Mode BBS004NP Specification data are reference values. MONITOR ITEM ENG SPEED CONDITION ● J SPECIFICATION Run engine and compare CONSULT-II value with the tachometer indication. Almost the same speed as the tachometer indication. K On Board Diagnosis Logic DTC No. Trouble diagnosis name BBS004NQ DTC detecting condition Possible cause ● ● P0335 0335 Crankshaft position sensor (POS) circuit The crankshaft position sensor (POS) signal is not detected by the ECM during the first few seconds of engine cranking. ● The proper pulse signal from the crankshaft position sensor (POS) is not sent to ECM while the engine is running. ● The crankshaft position sensor (POS) signal is not in the normal pattern during engine running. EC-1405 Harness or connectors [Crankshaft position sensor (POS) circuit is open or shorted.] (Accelerator pedal position sensor circuit is shorted.) (Refrigerant pressure sensor circuit is shorted.) ● Crankshaft position sensor (POS) ● Accelerator pedal position sensor ● Refrigerant position sensor ● Signal plate L M DTC P0335 CKP SENSOR (POS) [HR (WITHOUT EURO-OBD)] DTC Confirmation Procedure BBS004NR NOTE: If DTC Confirmation Procedure has been previously conducted, always turn ignition switch OFF and wait at least 10 seconds before conducting the next test. TESTING CONDITION: Before performing the following procedure, confirm that battery voltage is more than 10.5V with ignition switch ON. WITH CONSULT-II 1. 2. 3. Turn ignition switch ON and select “DATA MONITOR” mode with CONSULT-II. Crank engine for at least 2 seconds and run it for at least 5 seconds at idle speed. If 1st trip DTC is detected, go to EC-1409, "Diagnostic Procedure" . SEF058Y WITHOUT CONSULT-II 1. 2. 3. 4. Crank engine for at least 2 seconds and run it for at least 5 seconds at idle speed. Turn ignition switch OFF, wait at least 10 seconds and then turn ON. Perform Diagnostic Test Mode II (Self-diagnostic results) with ECM. If 1st trip DTC is detected, go to EC-1409, "Diagnostic Procedure" . EC-1406 DTC P0335 CKP SENSOR (POS) [HR (WITHOUT EURO-OBD)] Wiring Diagram BBS004NS A EC C D E F G H I J K L M MBWA1468E EC-1407 DTC P0335 CKP SENSOR (POS) [HR (WITHOUT EURO-OBD)] Specification data are reference values and are measured between each terminal and ground. Pulse signal is measured by CONSULT-II. CAUTION: Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM's transistor. Use a ground other than ECM terminals, such as the ground. TERMINAL NO. WIRE COLOR ITEM CONDITION [Engine is running] ● Warm-up condition ● Idle speed DATA (DC Voltage) 0 - 1.0V NOTE: The pulse cycle changes depending on rpm at idle 61 Y MBIB1453E Crankshaft position sensor (POS) 0 - 1.0V [Engine is running] ● Engine speed: 2,000 rpm MBIB1454E 62 W [Engine is running] Sensor ground [Crankshaft position sensor (POS)] ● Warm-up condition ● Idle speed Approximately 0V 74 W Sensor power supply (Refrigerant pressure sensor) [Ignition switch: ON] Approximately 5V 75 G Sensor power supply [Crankshaft position sensor (POS)] [Ignition switch: ON] Approximately 5V 102 BR Sensor power supply (APP sensor 2) [Ignition switch: ON] Approximately 5V : Average voltage for pulse signal (Actual pulse signal can be confirmed by oscilloscope.) EC-1408 DTC P0335 CKP SENSOR (POS) [HR (WITHOUT EURO-OBD)] Diagnostic Procedure BBS004NT 1. CHECK GROUND CONNECTIONS 1. 2. A Turn ignition switch OFF. Loosen and retighten ground screws on the body. Refer to EC-1342, "Ground Inspection" . EC C D E MBIB1550E 1. IPDM E/R 2. Body ground 3. F Body ground OK or NG OK >> GO TO 2. NG >> Repair or replace ground connections. G 2. CHECK CRANKSHAFT POSITION (CKP) SENSOR (POS) POWER SUPPLY CIRCUIT-I 1. 2. H Disconnect crankshaft position (CKP) sensor (POS) (1) harness connector. Turn ignition switch ON. I J K PBIB2970E 3. Check voltage between CKP sensor (POS) terminal 1 and ground with CONSULT-II or tester. L Voltage: Approximately 5V M OK or NG OK >> GO TO 6. NG >> GO TO 3. PBIB2609E EC-1409 DTC P0335 CKP SENSOR (POS) [HR (WITHOUT EURO-OBD)] 3. CHECK CKP SENSOR (POS) POWER SUPPLY CIRCUIT-II 1. 2. 3. Turn ignition switch OFF. Disconnect ECM harness connector. Check harness continuity between CKP sensor (POS) terminal 1 and ECM terminal 75. Refer to Wiring Diagram. Continuity should exist. OK or NG OK >> GO TO 4. NG >> Repair open circuit 4. CHECK CKP SENSOR (POS) POWER SUPPLY CIRCUIT-III Check harness for short to power and short to ground, between the following terminals. ECM terminal Sensor terminal Reference Wiring Diagram 74 Refrigerant pressure sensor terminal 3 EC-1591, "Wiring Diagram" 75 Crankshaft position sensor (POS) terminal 1 EC-1407, "Wiring Diagram" 102 APP sensor terminal 5 EC-1503, "Wiring Diagram" OK or NG OK >> GO TO 5. NG >> Repair short to ground or short to power in harness or connectors. 5. CHECK COMPONENTS Check the following. Accelerator pedal position sensor (Refer to EC-1509, "Component Inspection" .) ● Refrigerant pressure sensor (Refer to ATC-85, "Refrigerant Pressure Sensor" .) OK or NG OK >> GO TO 10. NG >> Replace malfunctioning component. ● 6. CHECK CKP SENSOR (POS) GROUND CIRCUIT FOR OPEN AND SHORT 1. 2. 3. Turn ignition switch OFF. Disconnect ECM harness connector. Check harness continuity between CKP sensor (POS) terminal 2 and ECM terminal 62. Refer to Wiring Diagram. Continuity should exist. 4. Also check harness for short to ground and short to power. OK or NG OK >> GO TO 7. NG >> Repair open circuit or short to ground or short to power in harness or connectors. 7. CHECK CKP SENSOR (POS) INPUT SIGNAL CIRCUIT FOR OPEN AND SHORT 1. Check harness continuity between CKP sensor (POS) terminal 3 and ECM terminal 61. Refer to Wiring Diagram. Continuity should exist. 2. Also check harness for short to ground and short to power. OK or NG OK >> GO TO 8. NG >> Repair open circuit or short to ground or short to power in harness or connectors. EC-1410 DTC P0335 CKP SENSOR (POS) [HR (WITHOUT EURO-OBD)] 8. CHECK CRANKSHAFT POSITION SENSOR (POS) Refer to EC-1412, "Component Inspection" . OK or NG OK >> GO TO 9. NG >> Replace crankshaft position sensor (POS). A EC 9. CHECK GEAR TOOTH C Visually check for chipping signal plate gear tooth. OK or NG OK >> GO TO 10. NG >> Replace the signal plate. D 10. CHECK INTERMITTENT INCIDENT E Refer to EC-1336, "TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT" . F >> INSPECTION END G H I J K L M EC-1411 DTC P0335 CKP SENSOR (POS) [HR (WITHOUT EURO-OBD)] Component Inspection BBS004NU CRANKSHAFT POSITION SENSOR (POS) 1. 2. 3. 4. Loosen the fixing bolt of the sensor. Disconnect crankshaft position sensor (POS) harness connector. Remove the sensor. Visually check the sensor for chipping. PBIA9210J 5. Check resistance as shown in the figure. Terminal No. (Polarity) Resistance Ω [at 25°C (77°F)] 1 (+) - 2 (-) 1 (+) - 3 (-) Except 0 or ∞ 2 (+) - 3 (-) 6. If NG, replace crankshaft position sensor (POS). PBIA9584J Removal and Installation BBS004NV CRANKSHAFT POSITION SENSOR (POS) Refer to EM-189, "CYLINDER BLOCK" . EC-1412 DTC P0340 CMP SENSOR (PHASE) [HR (WITHOUT EURO-OBD)] DTC P0340 CMP SENSOR (PHASE) Component Description PFP:23731 A BBS004NW The camshaft position sensor (PHASE) senses the protrusion of camshaft (INT) to identify a particular cylinder. The camshaft position sensor (PHASE) senses the piston position. When the crankshaft position sensor (POS) system becomes inoperative, the camshaft position sensor (PHASE) provides various controls of engine parts instead, utilizing timing of cylinder identification signals. The sensor consists of a permanent magnet and Hall IC. When engine is running, the high and low parts of the teeth cause the gap with the sensor to change. The changing gap causes the magnetic field near the sensor to change. Due to the changing magnetic field, the voltage from the sensor changes. ECM receives the signals as shown in the figure. EC C D PBIA9209J E F G H PBIB2382E I On Board Diagnosis Logic BBS004NX NOTE: If DTC P0340 is displayed with DTC P1229, first perform the trouble diagnosis for DTC P1229. Refer to EC-1471, "DTC P1229 SENSOR POWER SUPPLY" . DTC No. Trouble diagnosis name DTC detecting condition ● P0340 0340 Camshaft position sensor (PHASE) circuit The cylinder No. signal is not sent to ECM for the first few seconds during engine cranking. Possible cause ● Harness or connectors (The sensor circuit is open or shorted.) ● Camshaft position sensor (PHASE) ● Camshaft (Intake) ● The cylinder No. signal is not set to ECM during engine running. ● Starter motor (Refer to SC-45, "STARTING SYSTEM" .) ● The cylinder No. signal is not in the normal pattern during engine running. ● Starting system circuit (Refer to SC-45, "STARTING SYSTEM" .) ● Dead (Weak) battery EC-1413 J K L M DTC P0340 CMP SENSOR (PHASE) [HR (WITHOUT EURO-OBD)] DTC Confirmation Procedure BBS004NY NOTE: If DTC Confirmation Procedure has been previously conducted, always turn ignition switch OFF and wait at least 10 seconds before conducting the next test. TESTING CONDITION: Before performing the following procedure, confirm that battery voltage is more than 10.5V with ignition switch ON. WITH CONSULT-II 1. 2. 3. 4. 5. 6. Turn ignition switch ON. Select “DATA MONITOR” mode with CONSULT-II. Crank engine for at least 2 seconds and run it for at least 5 seconds at idle speed. If 1st trip DTC is detected, go to EC-1416, "Diagnostic Procedure" . If 1st trip DTC is not detected, go to next step. Maintain engine speed at more than 800 rpm for at least 5 seconds. If 1st trip DTC is detected, go to EC-1416, "Diagnostic Procedure" . WITHOUT CONSULT-II 1. 2. 3. 4. 5. 6. 7. 8. Crank engine for at least 2 seconds and run it for at least 5 seconds at idle speed. Turn ignition switch OFF, wait at least 10 seconds and then turn ON. Perform Diagnostic Test Mode II (Self-diagnostic results) with ECM. If 1st trip DTC is detected, go to EC-1416, "Diagnostic Procedure" . If 1st trip DTC is not detected, go to next step. Start engine and maintaining engine speed at more than 800 rpm for at least 5 seconds. Turn ignition switch OFF, wait at least 10 seconds and then turn ON. Perform Diagnostic Test Mode II (Self-diagnostic results) with ECM. If 1st trip DTC is detected, go to EC-1416, "Diagnostic Procedure" . EC-1414 SEF058Y DTC P0340 CMP SENSOR (PHASE) [HR (WITHOUT EURO-OBD)] Wiring Diagram BBS004NZ A EC C D E F G H I J K L M MBWA1469E EC-1415 DTC P0340 CMP SENSOR (PHASE) [HR (WITHOUT EURO-OBD)] Specification data are reference values and are measured between each terminal and ground. Pulse signal is measured by CONSULT-II. CAUTION: Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM's transistor. Use a ground other than ECM terminals, such as the ground. TERMINAL NO. 63 WIRE COLOR B ITEM Sensor ground [Camshaft position sensor (PHASE)] CONDITION DATA (DC Voltage) [Engine is running] ● Warm-up condition ● Idle speed [Engine is running] ● Warm-up condition ● Idle speed Approximately 0V 0 - 1.0V NOTE: The pulse cycle changes depending on rpm at idle 65 R MBIB1455E Camshaft position sensor (PHASE) 0 - 1.0V [Engine is running] ● Engine speed: 2,000 rpm MBIB1456E 78 O Sensor power supply [Camshaft position sensor (PHASE)] [Ignition switch: ON] Approximately 5V : Average voltage for pulse signal (Actual pulse signal can be confirmed by oscilloscope.) Diagnostic Procedure BBS004O0 1. CHECK STARTING SYSTEM Turn ignition switch to START position. Does the engine turn over? Does the starter motor operate? Yes or No Yes >> GO TO 2. No >> Check starting system. (Refer to SC-45, "STARTING SYSTEM" .) EC-1416 DTC P0340 CMP SENSOR (PHASE) [HR (WITHOUT EURO-OBD)] 2. CHECK GROUND CONNECTIONS 1. 2. A Turn ignition switch OFF. Loosen and retighten ground screws on the body. Refer to EC-1342, "Ground Inspection" . EC C D E MBIB1550E 1. IPDM E/R 2. Body ground 3. Body ground F OK or NG OK >> GO TO 3. NG >> Repair or replace ground connections. G 3. CHECK CAMSHAFT POSITION (CMP) SENSOR (PHASE) POWER SUPPLY CIRCUIT 1. Disconnect camshaft position (CMP) sensor (PHASE) (1) harness connector. – : Vehicle front Turn ignition switch ON. 2. H I J PBIB2971E 3. Check voltage between CMP sensor (PHASE) terminal 1 and ground with CONSULT-II or tester. K L Voltage: Battery voltage OK or NG OK >> GO TO 4. NG >> Repair open circuit or short to ground or short to power in harness or connectors. M PBIB2609E EC-1417 DTC P0340 CMP SENSOR (PHASE) [HR (WITHOUT EURO-OBD)] 4. CHECK CMP SENSOR (PHASE) GROUND CIRCUIT FOR OPEN AND SHORT 1. 2. 3. Turn ignition switch OFF. Disconnect ECM harness connector. Check harness continuity between CMP sensor (PHASE) terminal 2 and ECM terminal 63. Refer to Wiring Diagram. Continuity should exist. 4. Also check harness for short to ground and short to power. OK or NG OK >> GO TO 5. NG >> Repair open circuit or short to ground or short to power in harness or connectors. 5. CHECK CMP SENSOR (PHASE) INPUT SIGNAL CIRCUIT FOR OPEN AND SHORT 1. Check harness continuity between CMP sensor (PHASE) terminal 3 and ECM terminal 65. Refer to Wiring Diagram. Continuity should exist. 2. Also check harness for short to ground and short to power. OK or NG OK >> GO TO 6. NG >> Repair open circuit or short to ground or short to power in harness or connectors. 6. CHECK CAMSHAFT POSITION SENSOR (PHASE) Refer to EC-1418, "Component Inspection" . OK or NG OK >> GO TO 7. NG >> Replace camshaft position sensor (PHASE). 7. CHECK CAMSHAFT (INTAKE) Check the following. Accumulation of debris to the signal plate of camshaft (1) rear end ● Chipping signal plate of camshaft rear end OK or NG OK >> GO TO 8. NG >> Remove debris and clean the signal plate of camshaft rear end or replace camshaft. ● PBIA9557J 8. CHECK INTERMITTENT INCIDENT Refer to EC-1336, "TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT" . >> INSPECTION END Component Inspection BBS004O1 CAMSHAFT POSITION SENSOR (PHASE) 1. 2. 3. Loosen the fixing bolt of the sensor. Disconnect camshaft position sensor (PHASE) harness connector. Remove the sensor. EC-1418 DTC P0340 CMP SENSOR (PHASE) [HR (WITHOUT EURO-OBD)] 4. Visually check the sensor for chipping. A EC C PBIA9210J D 5. Check resistance as shown in the figure. Terminal No. (Polarity) Resistance Ω [at 25°C (77°F)] E 1 (+) - 2 (-) 1 (+) - 3 (-) Except 0 or ∞ 2 (+) - 3 (-) F G PBIA9584J Removal and Installation BBS004O2 H CAMSHAFT POSITION SENSOR (PHASE) Refer to EM-151, "CAMSHAFT" . I J K L M EC-1419 DTC P0605 ECM [HR (WITHOUT EURO-OBD)] DTC P0605 ECM Component Description PFP:23710 BBS004O3 The ECM consists of a microcomputer and connectors for signal input and output and for power supply. The ECM controls the engine. PBIA9222J On Board Diagnosis Logic BBS004O4 This self-diagnosis has one or two trip detection logic. DTC No. P0605 0605 Trouble diagnosis name Engine control module DTC detecting condition A) ECM calculation function is malfunctioning. B) ECM EEP-ROM system is malfunctioning. C) ECM self shut-off function is malfunctioning. Possible cause ● ECM FAIL-SAFE MODE ECM enters fail-safe mode when malfunction A is detected. Detected items Malfunction A Engine operation condition in fail-safe mode ECM stops the electric throttle control actuator control, throttle valve is maintained at a fixed opening (approx. 5 degrees) by the return spring. DTC Confirmation Procedure BBS004O5 Perform PROCEDURE FOR MALFUNCTION A first. If the 1st trip DTC cannot be confirmed, perform PROCEDURE FOR MALFUNCTION B. If there is no malfunction on PROCEDURE FOR MALFUNCTION B, perform PROCEDURE FOR MALFUNCTION C. NOTE: If DTC Confirmation Procedure has been previously conducted, always turn ignition switch OFF and wait at least 10 seconds before conducting the next test. PROCEDURE FOR MALFUNCTION A With CONSULT-II 1. 2. 3. Turn ignition switch ON. Select “DATA MONITOR” mode with CONSULT-II. If 1st trip DTC is detected, go to EC-1422, "Diagnostic Procedure" . SEF058Y Without CONSULT-II 1. 2. 3. Turn ignition switch ON. Turn ignition switch OFF, wait at least 10 seconds and then turn ON. Perform Diagnostic Test Mode II (Self-diagnostic results) with ECM. EC-1420 DTC P0605 ECM [HR (WITHOUT EURO-OBD)] 4. If 1st trip DTC is detected, go to EC-1422, "Diagnostic Procedure" . A PROCEDURE FOR MALFUNCTION B With CONSULT-II 1. 2. 3. 4. Turn ignition switch ON and wait at least 1 second. Select “DATA MONITOR” mode with CONSULT-II. Turn ignition switch OFF, wait at least 10 seconds and then turn ON. If 1st trip DTC is detected, go to EC-1422, "Diagnostic Procedure" . EC C D E SEF058Y Without CONSULT-II 1. 2. 3. 4. F Turn ignition switch ON and wait at least 1 second. Turn ignition switch OFF, wait at least 10 seconds and then turn ON. Perform Diagnostic Test Mode II (Self-diagnostic results) with ECM. If 1st trip DTC is detected, go to EC-1422, "Diagnostic Procedure" G PROCEDURE FOR MALFUNCTION C With CONSULT-II H 1. 2. 3. I 4. 5. Turn ignition switch ON and wait at least 1 second. Select “DATA MONITOR” mode with CONSULT-II. Turn ignition switch OFF, wait at least 10 seconds and then turn ON. Repeat step 3 for 32 times. If 1st trip DTC is detected, go to EC-1422, "Diagnostic Procedure" . J K SEF058Y L Without CONSULT-II 1. 2. 3. 4. 5. 6. Turn ignition switch ON and wait at least 1 second. Turn ignition switch OFF and wait at least 10 seconds. Repeat step 1 to 2 for 32 times. Turn ignition switch OFF, wait at least 10 seconds and then turn ON. Perform Diagnostic Test Mode II (Self-diagnostic results) with ECM. If 1st trip DTC is detected, go to EC-1422, "Diagnostic Procedure" . EC-1421 M DTC P0605 ECM [HR (WITHOUT EURO-OBD)] Diagnostic Procedure BBS004O6 1. INSPECTION START 1. 2. 3. 4. 5. With CONSULT-II Turn ignition switch ON. Select “SELF DIAG RESULTS” mode with CONSULT-II. Touch “ERASE”. Perform DTC Confirmation Procedure. See EC-1420, "DTC Confirmation Procedure" . Is the 1st trip DTC P0605 displayed again? Without CONSULT-II 1. Turn ignition switch ON. 2. Erase the Diagnostic Test Mode II (Self-diagnostic results) memory. Refer to EC-1269, "How to Erase Diagnostic Test Mode II (Self-diagnostic Results)" . 3. Perform DTC Confirmation Procedure. See EC-1420, "DTC Confirmation Procedure" . 4. Is the 1st trip DTC 0605 displayed again? Yes or No Yes >> GO TO 2. No >> INSPECTION END 2. REPLACE ECM 1. 2. 3. 4. 5. Replace ECM. Perform initialization of NATS system and registration of all NATS ignition key IDs. Refer to BL-218, "ECM Re-communicating Function" . Perform EC-1278, "Accelerator Pedal Released Position Learning" . Perform EC-1279, "Throttle Valve Closed Position Learning" . Perform EC-1279, "Idle Air Volume Learning" . >> INSPECTION END EC-1422 DTC P1065 ECM [HR (WITHOUT EURO-OBD)] DTC P1065 ECM Component Description PFP:23710 A BBS004O7 ECM has the memory function of the DTC memory, the air-fuel ratio feedback compensation value memory, the Idle Air Volume Learning value memory, etc. even when the ignition switch is turned OFF. EC C D PBIA9222J E On Board Diagnosis Logic DTC No. P1065* 1065 Trouble diagnosis name Engine control module BBS004O8 DTC detecting condition ECM back-up RAM system does not function properly. Possible cause F ● ECM *: This self-diagnosis is not for ECM power supply circuit, even though “ECM BACK UP/CIRCUIT” is displayed on CONSULT-II screen. DTC Confirmation Procedure NOTE: If DTC Confirmation Procedure has been previously conducted, always turn ignition switch OFF and wait at least 10 seconds before conducting the next test. WITH CONSULT-II 1. 2. 3. 4. 5. 6. G BBS004O9 H I Turn ignition switch ON and wait at least 1 second. Select “DATA MONITOR” mode with CONSULT-II. Start engine and let it idle for 1 second. Turn ignition switch OFF, wait at least 10 seconds and then turn ON. Repeat steps 3 and 4 for 4 times. If 1st trip DTC is detected, go to EC-1424, "Diagnostic Procedure" . J K L SEF058Y WITHOUT CONSULT-II 1. 2. 3. 4. 5. 6. M Start engine and let it idle for 1 second. Turn ignition switch OFF, wait at least 10 seconds and then turn ON. Repeat steps 1 to 2 for 4 times. Turn ignition switch OFF, wait at least 10 seconds and then turn ON. Perform Diagnostic Test Mode II (Self-diagnostic results) with ECM. If 1st trip DTC is detected, go to EC-1424, "Diagnostic Procedure" . EC-1423 DTC P1065 ECM [HR (WITHOUT EURO-OBD)] Diagnostic Procedure BBS004OA 1. INSPECTION START 1. 2. 3. 4. 5. With CONSULT-II Turn ignition switch ON. Select “SELF-DIAG RESULTS” mode with CONSULT-II. Touch “ERASE”. Perform DTC Confirmation Procedure. See EC-1423, "DTC Confirmation Procedure" . Is the 1st trip DTC P1065 displayed again? Without CONSULT-II 1. Turn ignition switch ON. 2. Erase the Diagnostic Test Mode II (Self-diagnostic results) memory. Refer to EC-1269, "How to Erase Diagnostic Test Mode II (Self-diagnostic Results)" 3. Perform DTC Confirmation Procedure. See EC-1423, "DTC Confirmation Procedure" . 4. Is the 1st trip DTC 1065 displayed again? Yes or No Yes >> GO TO 2. No >> INSPECTION END 2. REPLACE ECM 1. 2. 3. 4. 5. Replace ECM. Perform initialization of NATS system and registration of all NATS ignition key IDs. Refer to BL-218, "ECM Re-communicating Function" . Perform EC-1278, "Accelerator Pedal Released Position Learning" . Perform EC-1279, "Throttle Valve Closed Position Learning" . Perform EC-1279, "Idle Air Volume Learning" . >> INSPECTION END EC-1424 DTC P1111 IVT CONTROL SOLENOID VALVE [HR (WITHOUT EURO-OBD)] DTC P1111 IVT CONTROL SOLENOID VALVE Component Description PFP:23796 A BBS004OB Intake valve timing control solenoid valve is activated by ON/OFF pulse duty (ratio) signals from the ECM. The intake valve timing control solenoid valve changes the oil amount and direction of flow through intake valve timing control unit or stops oil flow. The longer pulse width advances valve angle. The shorter pulse width retards valve angle. When ON and OFF pulse widths become equal, the solenoid valve stops oil pressure flow to fix the intake valve angle at the control position. EC C D PBIB1842E E CONSULT-II Reference Value in Data Monitor Mode BBS004OC Specification data are reference values. MONITOR ITEM INT/V SOL (B1) CONDITION ● Engine: After warming up ● Air conditioner switch: OFF ● Shift lever: P or N (A/T), Neutral (M/T) ● No load 0% - 2% 2,500 rpm Approx. 0% - 90% G H On Board Diagnosis Logic DTC No. P1111 1111 Trouble diagnosis name Intake valve timing control solenoid valve circuit F SPECIFICATION Idle BBS004OD DTC detecting condition An improper voltage is sent to the ECM through intake valve timing control solenoid valve. Possible cause I ● Harness or connectors (Solenoid valve circuit is open or shorted.) ● Intake valve timing control solenoid valve DTC Confirmation Procedure BBS004OE NOTE: If DTC Confirmation Procedure has been previously conducted, always turn ignition switch OFF and wait at least 10 seconds before conducting the next test. WITH CONSULT-II 1. 2. 3. 4. WITHOUT CONSULT-II Start engine and wait at least 5 seconds. Turn ignition switch OFF, wait at least 10 seconds and then turn ON. Perform Diagnostic Test Mode II (Self-diagnostic results) with ECM. If 1st trip DTC is detected, go to EC-1428, "Diagnostic Procedure" . EC-1425 K L Turn ignition switch ON. Select “DATA MONITOR” mode with CONSULT-II. Start engine and let it idle for 5 seconds. If 1st trip DTC is detected, go to EC-1428, "Diagnostic Procedure" . M SEF058Y 1. 2. 3. 4. J DTC P1111 IVT CONTROL SOLENOID VALVE [HR (WITHOUT EURO-OBD)] Wiring Diagram BBS004OF MBWA1471E EC-1426 DTC P1111 IVT CONTROL SOLENOID VALVE [HR (WITHOUT EURO-OBD)] Specification data are reference values and are measured between each terminal and ground. Pulse signal is measured by CONSULT-II. A CAUTION: Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM's transistor. Use a ground other than ECM terminals, such as the ground. EC TERMINAL NO. WIRE COLOR ITEM CONDITION C [Engine is running] [Ignition switch: OFF] ● 32 DATA (DC Voltage) P ECM relay (Self shut-off) For a few seconds after turning ignition switch OFF [Ignition switch: OFF] ● More than a few seconds after turning ignition switch OFF 0 - 1.0V D BATTERY VOLTAGE (11 - 14V) E BATTERY VOLTAGE (11 - 14V) F [Engine is running] ● Warm-up condition ● Idle speed 7 - 10V 73 LG Intake valve timing control solenoid valve G [Engine is running] ● Warm-up condition ● Engine speed: 2,000 rpm H PBIA4937J 105 G Power supply for ECM [Ignition switch: ON] : Average voltage for pulse signal (Actual pulse signal can be confirmed by oscilloscope.) BATTERY VOLTAGE (11 - 14V) I J K L M EC-1427 DTC P1111 IVT CONTROL SOLENOID VALVE [HR (WITHOUT EURO-OBD)] Diagnostic Procedure BBS004OG 1. CHECK INTAKE VALVE TIMING CONTROL SOLENOID VALVE POWER SUPPLY CIRCUIT 1. 2. 3. Turn ignition switch OFF. Disconnect intake valve timing control solenoid valve (1) harness connector. Turn ignition switch ON. MBIB1546E 4. Check voltage between intake valve timing control solenoid valve terminal 2 and ground with CONSULT-II or tester. Voltage: Battery voltage OK or NG OK >> GO TO 3. NG >> GO TO 2. PBIB0192E 2. DETECT MALFUNCTION PART Check the following. ● Harness connectors E59, F1 ● Harness for open or short between intake valve timing control solenoid valve and IPDM E/R >> Repair or replace harness or connectors. 3. CHECK INTAKE VALVE TIMING CONTROL SOLENOID VALVE OUTPUT SIGNAL CIRCUIT FOR OPEN AND SHORT 1. 2. 3. Turn ignition switch OFF. Disconnect ECM harness connector. Check harness continuity between ECM terminal 73 and intake valve timing control solenoid valve terminal 1. Refer to Wiring Diagram. Continuity should exist. 4. Also check harness for short to ground and short to power. OK or NG OK >> GO TO 4. NG >> Repair open circuit or short to ground or short to power in harness or connectors. 4. CHECK INTAKE VALVE TIMING CONTROL SOLENOID VALVE Refer to EC-1429, "Component Inspection" . OK or NG OK >> GO TO 5. NG >> Replace intake valve timing control solenoid valve. EC-1428 DTC P1111 IVT CONTROL SOLENOID VALVE [HR (WITHOUT EURO-OBD)] 5. CHECK INTERMITTENT INCIDENT A Refer to EC-1336, "TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT" . EC >> INSPECTION END Component Inspection BBS004OH INTAKE VALVE TIMING CONTROL SOLENOID VALVE 1. 2. 3. 4. C Disconnect intake valve timing control solenoid valve harness connector. Check resistance between intake valve timing control solenoid valve as follows. Terminal Resistance 1 and 2 6.7 - 7.7Ω [at 20°C (68°F)] 1 or 2 and ground ∞Ω (Continuity should not exist.) If NG, replace intake valve timing control solenoid valve. If OK, go to next step. Remove intake valve timing control solenoid valve. Provide 12V DC between intake valve timing control solenoid valve terminals and then interrupt it. Make sure that the plunger moves as shown in the figure. CAUTION: Do not apply 12V DC continuously for 5 seconds or more. Doing so may result in damage to the coil in intake valve timing control solenoid valve. If NG, replace intake valve timing control solenoid valve. NOTE: Always replace O-ring when intake valve timing control solenoid valve is removed. Removal and Installation D E F PBIB0193E G H I J PBIB2275E BBS004OI INTAKE VALVE TIMING CONTROL SOLENOID VALVE K Refer to EM-142, "TIMING CHAIN" . L M EC-1429 DTC P1121 ELECTRIC THROTTLE CONTROL ACTUATOR [HR (WITHOUT EURO-OBD)] DTC P1121 ELECTRIC THROTTLE CONTROL ACTUATOR Component Description PFP:16119 BBS004OJ Electric throttle control actuator consists of throttle control motor, throttle position sensor, etc. The throttle control motor is operated by the ECM and it opens and closes the throttle valve. The throttle position sensor detects the throttle valve position, and the opening and closing speed of the throttle valve and feeds the voltage signals to the ECM. The ECM judges the current opening angle of the throttle valve from these signals and the ECM controls the throttle control motor to make the throttle valve opening angle properly in response to driving condition. On Board Diagnosis Logic BBS004OK This self-diagnosis has the one trip detection logic. DTC No. P1121 1121 Trouble diagnosis name Electric throttle control actuator DTC detecting condition A) Electric throttle control actuator does not function properly due to the return spring malfunction. B) Throttle valve opening angle in fail-safe mode is not in specified range. C) ECM detect the throttle valve is stuck open. Possible cause ● Electric throttle control actuator FAIL-SAFE MODE When the malfunction is detected, the ECM enters fail-safe mode and the MI lights up. Detected items Engine operating condition in fail-safe mode Malfunction A The ECM controls the electric throttle actuator by regulating the throttle opening around the idle position. The engine speed will not rise more than 2,000 rpm. Malfunction B ECM controls the electric throttle control actuator by regulating the throttle opening to 20 degrees or less. Malfunction C While the vehicle is driving, it slows down gradually by fuel cut. After the vehicle stops, the engine stalls. The engine can restart in N or P position (A/T), Neutral position (M/T) and engine speed will not exceed 1,000 rpm or more. DTC Confirmation Procedure BBS004OL NOTE: ● Perform PROCEDURE FOR MALFUNCTION A AND B first. If the DTC cannot be confirmed, perform PROCEDURE FOR MALFUNCTION C. ● If DTC Confirmation Procedure has been previously conducted, always turn ignition switch OFF and wait at least 10 seconds before conducting the next test. PROCEDURE FOR MALFUNCTION A AND B With CONSULT-II 1. 2. 3. Turn ignition witch ON and wait at least 1 second. Select “DATA MONITOR” mode with CONSULT-II. Set shift lever to D position (A/T), 1st position (M/T) and wait at least 3 seconds. 4. Set shift lever to P position (A/T), Neutral position (M/T). 5. Turn ignition switch OFF and wait at least 10 seconds. 6. Turn ignition switch ON and wait at least 1 second. 7. Set shift lever to D position (A/T), 1st position (M/T) and wait at least 3 seconds. 8. Set shift lever to P position (A/T), Neutral position (M/T). 9. Turn ignition switch OFF, wait at least 10 seconds and then turn ON. 10. If DTC is detected, go to EC-1431, "Diagnostic Procedure" . EC-1430 SEF058Y DTC P1121 ELECTRIC THROTTLE CONTROL ACTUATOR [HR (WITHOUT EURO-OBD)] Without CONSULT-II 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. A Turn ignition witch ON and wait at least 1 second. Set shift lever to D position (A/T), 1st position (M/T) and wait at least 3 seconds. Set shift lever to P position (A/T), Neutral position (M/T). Turn ignition switch OFF and wait at least 10 seconds. Turn ignition switch ON and wait at least 1 second. Set shift lever to D position (A/T), 1st position (M/T) and wait at least 3 seconds. Set shift lever to P position (A/T), Neutral position (M/T). Turn ignition switch OFF, wait at least 10 seconds and then turn ON. Perform Diagnostic Test Mode II (Self-diagnostic results) with ECM. If DTC is detected, go to EC-1431, "Diagnostic Procedure" . EC C D PROCEDURE FOR MALFUNCTION C With CONSULT-II 1. 2. 3. 4. 5. 6. E Turn ignition switch ON and wait at least 1 second. Select “DATA MONITOR” mode with CONSULT-II. Set shift lever to D position (A/T), 1st position (M/T) and wait at least 3 seconds. Set shift lever to P position (A/T), Neutral position (M/T). Start engine and let it idle for 3 seconds. If DTC is detected, go to EC-1431, "Diagnostic Procedure" . F G H SEF058Y I Without CONSULT-II 1. 2. 3. 4. 5. 6. 7. Turn ignition witch ON and wait at least 1 second. Set shift lever to D position (A/T), 1st position (M/T) and wait at least 3 seconds. Set shift lever to P position (A/T), Neutral position (M/T). Start engine and let it idle for 3 seconds. Turn ignition switch OFF, wait at least 10 seconds and then turn ON. Perform Diagnostic Test Mode II (Self-diagnostic results) with ECM. If DTC is detected, go to EC-1431, "Diagnostic Procedure" . Diagnostic Procedure J K L BBS004OM 1. CHECK ELECTRIC THROTTLE CONTROL ACTUATOR VISUALLY 1. 2. M Remove the intake air duct. Check if a foreign matter is caught between the throttle valve (1) and the housing. – : Vehicle front OK or NG OK >> GO TO 2. NG >> Remove the foreign matter and clean the electric throttle control actuator inside. PBIB2974E EC-1431 DTC P1121 ELECTRIC THROTTLE CONTROL ACTUATOR [HR (WITHOUT EURO-OBD)] 2. REPLACE ELECTRIC THROTTLE CONTROL ACTUATOR 1. 2. 3. Replace the electric throttle control actuator. Perform EC-1279, "Throttle Valve Closed Position Learning" . Perform EC-1279, "Idle Air Volume Learning" . >> INSPECTION END Removal and Installation BBS004ON Refer to EM-120, "INTAKE MANIFOLD" . EC-1432 DTC P1122 ELECTRIC THROTTLE CONTROL FUNCTION [HR (WITHOUT EURO-OBD)] DTC P1122 ELECTRIC THROTTLE CONTROL FUNCTION Description PFP:16119 A BBS004OO NOTE: If DTC P1122 is displayed with DTC P1121 or P1126, first perform the trouble diagnosis for DTC P1121 EC or P1126. Refer to EC-1430, "DTC P1121 ELECTRIC THROTTLE CONTROL ACTUATOR" or EC-1439, "DTC P1124, P1126 THROTTLE CONTROL MOTOR RELAY" . Electric throttle control actuator consists of throttle control motor, throttle position sensor, etc. C The throttle control motor is operated by the ECM and it opens and closes the throttle valve. The current opening angle of the throttle valve is detected by the throttle position sensor and it provides feedback to the ECM to control the throttle control motor to make the throttle valve opening angle properly in response to driving condition. D On Board Diagnosis Logic BBS004OP This self-diagnosis has the one trip detection logic. DTC No. Trouble diagnosis name E DTC detecting condition Possible cause ● P1122 1122 Electric throttle control performance Electric throttle control function does not operate properly. ● Harness or connectors (Throttle control motor circuit is open or shorted) F Electric throttle control actuator G FAIL-SAFE MODE When the malfunction is detected, ECM enters fail-safe mode and the MI lights up. H Engine operating condition in fail-safe mode ECM stops the electric throttle control actuator control, throttle valve is maintained at a fixed opening (approx. 5 degrees) by the return spring. DTC Confirmation Procedure I BBS004OQ NOTE: If DTC Confirmation Procedure has been previously conducted, always turn ignition switch OFF and wait at least 10 seconds before conducting the next test. TESTING CONDITION: Before performing the following procedure, confirm that battery voltage is more than 11V when engine is running. J K WITH CONSULT-II 1. 2. 3. 4. Turn ignition switch ON and wait at least 2 seconds. Select “DATA MONITOR” mode with CONSULT-II. Start engine and let it idle for 5 seconds. If DTC is detected, go to EC-1435, "Diagnostic Procedure" . L M SEF058Y WITHOUT CONSULT-II 1. 2. 3. 4. 5. Turn ignition switch ON and wait at least 2 seconds. Start engine and let it idle for 5 seconds. Turn ignition switch OFF, wait at least 10 seconds and then turn ON. Perform Diagnostic Test Mode II (Self-diagnostic results) with ECM. If DTC is detected, go to EC-1435, "Diagnostic Procedure" . EC-1433 DTC P1122 ELECTRIC THROTTLE CONTROL FUNCTION [HR (WITHOUT EURO-OBD)] Wiring Diagram BBS004OR MBWA1472E EC-1434 DTC P1122 ELECTRIC THROTTLE CONTROL FUNCTION [HR (WITHOUT EURO-OBD)] Specification data are reference values and are measured between each terminal and ground. Pulse signal is measured by CONSULT-II. A CAUTION: Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM's transistor. Use a ground other than ECM terminals, such as the ground. EC TERMINAL NO. WIRE COLOR ITEM CONDITION DATA (DC Voltage) C 0 - 14V [Ignition switch: ON] 1 P Throttle control motor (Open) ● Engine stopped ● Shift lever: D (A/T), 1st (M/T) ● Accelerator pedal: Fully depressed D E PBIB1105E 2 LG Throttle control motor relay power supply BATTERY VOLTAGE (11 - 14V) [Ignition switch: ON] F 0 - 14V [Ignition switch: ON] 4 L Throttle control motor (Close) ● Engine stopped ● Shift lever: D (A/T), 1st (M/T) ● Accelerator pedal: Released G H PBIB1104E 15 G Throttle control motor relay [Ignition switch: OFF] BATTERY VOLTAGE (11 - 14V) [Ignition switch: ON] 0 - 1.0V I : Average voltage for pulse signal (Actual pulse signal can be confirmed by oscilloscope.) J Diagnostic Procedure BBS004OS 1. CHECK GROUND CONNECTIONS 1. 2. K Turn ignition switch OFF. Loosen and retighten ground screws on the body. Refer to EC-1342, "Ground Inspection" . L M MBIB1550E 1. IPDM E/R 2. Body ground OK or NG OK >> GO TO 2. NG >> Repair or replace ground connections. EC-1435 3. Body ground DTC P1122 ELECTRIC THROTTLE CONTROL FUNCTION [HR (WITHOUT EURO-OBD)] 2. CHECK THROTTLE CONTROL MOTOR RELAY INPUT SIGNAL CIRCUIT-I Check voltage between ECM terminal 2 and ground under the following conditions with CONSULT-II or tester. Ignition switch Voltage OFF Approximately 0V ON Battery voltage (11 - 14V) OK or NG OK >> GO TO 10. NG >> GO TO 3. PBIA9568J 3. CHECK THROTTLE CONTROL MOTOR RELAY POWER SUPPLY CIRCUIT-I 1. 2. Turn ignition switch OFF. Check voltage between ECM terminal 15 and ground with CONSULT-II or tester. Voltage: Battery voltage OK or NG OK >> GO TO 7. NG >> GO TO 4. PBIA9569J 4. CHECK THROTTLE CONTROL MOTOR RELAY POWER SUPPLY CIRCUIT-II 1. 2. 3. Disconnect ECM harness connector. Disconnect IPDM E/R harness connector E5. Check harness continuity between ECM terminal 15 and IPDM E/R terminal 70. Refer to Wiring Diagram. Continuity should exist. 4. Also check harness for short to ground and short to power. OK or NG OK >> GO TO 6. NG >> GO TO 5. 5. DETECT MALFUNCTIONING PART Check the following. Harness connectors E59, F1 ● Harness for open or short between ECM and IPDM E/R ● >> Repair open circuit or short to ground or short to power in harness or connectors. 6. CHECK FUSE 1. Disconnect 20A fuse. 2. Check 20A fuse for blown. OK or NG OK >> GO TO 9. NG >> Replace 20A fuse. EC-1436 DTC P1122 ELECTRIC THROTTLE CONTROL FUNCTION [HR (WITHOUT EURO-OBD)] 7. CHECK THROTTLE CONTROL MOTOR RELAY INPUT SIGNAL CIRCUIT-II 1. 2. 3. A Disconnect ECM harness connector. Disconnect IPDM E/R harness connector E7. Check harness continuity between ECM terminal 2 and IPDM E/R terminal 28. Refer to Wiring Diagram. EC Continuity should exist. C 4. Also check harness for short to ground and short to power. OK or NG OK >> GO TO 9. NG >> GO TO 8. D 8. DETECT MALFUNCTIONING PART E Check the following. ● Harness connectors E59, F1 ● Harness for open or short between ECM and IPDM E/R F >> Repair open circuit or short to ground or short to power in harness or connectors. G 9. CHECK INTERMITTENT INCIDENT Refer to EC-1336, "TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT" . OK or NG OK >> Replace IPDM E/R. Refer to PG-18, "IPDM E/R (INTELLIGENT POWER DISTRIBUTION MODULE ENGINE ROOM)" . NG >> Repair or replace harness or connectors. 10. CHECK THROTTLE CONTROL MOTOR OUTPUT SIGNAL CIRCUIT FOR OPEN OR SHORT 1. 2. Turn ignition switch OFF. Disconnect electric throttle control actuator (1) harness connector. – : Vehicle front Disconnect ECM harness connector. Check harness continuity between the following terminals. Refer to Wiring Diagram. 3. 4. Electric throttle control actuator terminal 5 6 ECM terminal Should not exist 4 Should exist 1 Should exist 4 Should not exist K L M PBIB2965E 5. Also check harness for short to ground and short to power. OK or NG OK >> GO TO 11. NG >> Repair or replace. EC-1437 I J Continuity 1 H DTC P1122 ELECTRIC THROTTLE CONTROL FUNCTION [HR (WITHOUT EURO-OBD)] 11. CHECK ELECTRIC THROTTLE CONTROL ACTUATOR VISUALLY 1. 2. Remove the intake air duct. Check if foreign matter is caught between the throttle valve (1) and the housing. : Vehicle front – Illustration shows the view with intake air duct removed. OK or NG OK >> GO TO 12. NG >> Remove the foreign matter and clean the electric throttle control actuator inside. – PBIB2974E 12. CHECK THROTTLE CONTROL MOTOR Refer to EC-1438, "Component Inspection" . OK or NG OK >> GO TO 13. NG >> GO TO 14. 13. CHECK INTERMITTENT INCIDENT Refer to EC-1336, "TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT" . OK or NG OK >> GO TO 14. NG >> Repair or replace harness or connectors. 14. REPLACE ELECTRIC THROTTLE CONTROL ACTUATOR 1. 2. 3. Replace the electric throttle control actuator. Perform EC-1279, "Throttle Valve Closed Position Learning" . Perform EC-1279, "Idle Air Volume Learning" . >> INSPECTION END Component Inspection BBS004OT THROTTLE CONTROL MOTOR 1. 2. Disconnect electric throttle control actuator harness connector. Check resistance between terminals 5 and 6. Resistance: Approximately 1 - 15 Ω [at 25 °C (77°F)] 3. 4. 5. If NG, replace electric throttle control actuator and go to next step. Perform EC-1279, "Throttle Valve Closed Position Learning" . Perform EC-1279, "Idle Air Volume Learning" . PBIB2909E Removal and Installation BBS004OU ELECTRIC THROTTLE CONTROL ACTUATOR Refer to EM-120, "INTAKE MANIFOLD" . EC-1438 DTC P1124, P1126 THROTTLE CONTROL MOTOR RELAY [HR (WITHOUT EURO-OBD)] DTC P1124, P1126 THROTTLE CONTROL MOTOR RELAY Component Description PFP:16119 A BBS004OV Power supply for the throttle control motor is provided to the ECM via throttle control motor relay. The throttle control motor relay is ON/OFF controlled by the ECM. When the ignition switch is turned ON, the ECM sends EC an ON signal to throttle control motor relay and battery voltage is provided to the ECM. When the ignition switch is turned OFF, the ECM sends an OFF signal to throttle control motor relay and battery voltage is not provided to the ECM. C CONSULT-II Reference Value in Data Monitor Mode BBS004OW Specification data are reference values. MONITOR ITEM THRTL RELAY CONDITION ● SPECIFICATION Ignition switch: ON D ON On Board Diagnosis Logic BBS004OX E These self-diagnoses have the one trip detection logic. DTC No. P1124 1124 P1126 1126 Trouble diagnosis name Throttle control motor relay circuit short Throttle control motor relay circuit open DTC detecting condition F Possible cause ● Harness or connectors (Throttle control motor relay circuit is shorted) ● Throttle control motor relay ● Harness or connectors (Throttle control motor relay circuit is open) ECM detect the throttle control motor relay is stuck ON. ECM detects a voltage of power source for throttle control motor is excessively low. ● G H Throttle control motor relay I FAIL-SAFE MODE When the malfunction is detected, ECM enters fail-safe mode and the MI lights up. J Engine operating condition in fail-safe mode ECM stops the electric throttle control actuator control, throttle valve is maintained at a fixed opening (approx. 5 degrees) by the return spring. DTC Confirmation Procedure K BBS004OY NOTE: If DTC Confirmation Procedure has been previously conducted, always turn ignition switch OFF and wait at least 10 seconds before conducting the next test. L PROCEDURE FOR DTC P1124 With CONSULT-II M 1. 2. 3. Turn ignition switch ON and wait at least 1 seconds. Select “DATA MONITOR” mode with CONSULT-II. If DTC is detected, go to EC-1442, "Diagnostic Procedure" . SEF058Y Without CONSULT-II 1. 2. Turn ignition switch ON and wait at least 1 second. Turn ignition switch OFF, wait at least 10 seconds and then turn ON. EC-1439 DTC P1124, P1126 THROTTLE CONTROL MOTOR RELAY [HR (WITHOUT EURO-OBD)] 3. 4. Perform Diagnostic Test Mode II (Self-diagnostic results) with ECM. If DTC is detected, go to EC-1442, "Diagnostic Procedure" . PROCEDURE FOR DTC P1126 TESTING CONDITION: Before performing the following procedure, confirm that battery voltage is more than 8V. With CONSULT-II 1. 2. 3. 4. Turn ignition switch ON and wait at least 2 second. Select “DATA MONITOR” mode with CONSULT-II. Start engine and let it idle for 5 seconds. If DTC is detected, go to EC-1442, "Diagnostic Procedure" . SEF058Y Without CONSULT-II 1. 2. 3. 4. 5. Turn ignition switch ON and wait at least 2 seconds. Start engine and let it idle for 5 seconds. Turn ignition switch OFF, wait at least 10 seconds and then turn ON. Perform Diagnostic Test Mode II (Self-diagnostic results) with ECM. If DTC is detected, go to EC-1442, "Diagnostic Procedure" . EC-1440 DTC P1124, P1126 THROTTLE CONTROL MOTOR RELAY [HR (WITHOUT EURO-OBD)] Wiring Diagram BBS004OZ A EC C D E F G H I J K L M MBWA1473E EC-1441 DTC P1124, P1126 THROTTLE CONTROL MOTOR RELAY [HR (WITHOUT EURO-OBD)] Specification data are reference values and are measured between each terminal and ground. Pulse signal is measured by CONSULT-II. CAUTION: Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM's transistor. Use a ground other than ECM terminals, such as the ground. TERMINAL NO. WIRE COLOR ITEM CONDITION DATA (DC Voltage) 0 - 14V [Ignition switch: ON] 1 P Throttle control motor (Open) ● Engine stopped ● Shift lever: D (A/T), 1st (M/T) ● Accelerator pedal: Fully depressed PBIB1105E 2 LG Throttle control motor relay power supply [Ignition switch: ON] BATTERY VOLTAGE (11 - 14V) 0 - 14V [Ignition switch: ON] 4 L Throttle control motor (Close) ● Engine stopped ● Shift lever: D D (A/T), 1st (M/T) ● Accelerator pedal: Released PBIB1104E 15 G Throttle control motor relay [Ignition switch: OFF] BATTERY VOLTAGE (11 - 14V) [Ignition switch: ON] 0 - 1.0V : Average voltage for pulse signal (Actual pulse signal can be confirmed by oscilloscope.) Diagnostic Procedure BBS004P0 1. CHECK THROTTLE CONTROL MOTOR RELAY POWER SUPPLY CIRCUIT-I 1. 2. Turn ignition switch OFF. Check voltage between ECM terminal 15 and ground with CONSULT-II or tester. Voltage: Battery voltage OK or NG OK >> GO TO 5. NG >> GO TO 2. PBIA9569J EC-1442 DTC P1124, P1126 THROTTLE CONTROL MOTOR RELAY [HR (WITHOUT EURO-OBD)] 2. CHECK THROTTLE CONTROL MOTOR RELAY POWER SUPPLY CIRCUIT-II 1. 2. 3. A Disconnect ECM harness connector. Disconnect IPDM E/R harness connector E5. Check continuity between ECM terminal 15 and IPDM E/R terminal 70. Refer to Wiring Diagram. EC Continuity should exist. C 4. Also check harness for short to ground and short to power. OK or NG OK >> GO TO 4. NG >> GO TO 3. D 3. DETECT MALFUNCTIONING PART E Check the following. ● Harness connectors E59, F1 ● Harness for open or short between ECM and IPDM E/R F >> Repair open circuit or short to ground or short to power in harness or connectors. G 4. CHECK FUSE H 1. Disconnect 20A fuse. 2. Check 20A fuse for blown. OK or NG OK >> GO TO 8. NG >> Replace 20A fuse. I 5. CHECK THROTTLE CONTROL MOTOR RELAY INPUT SIGNAL CIRCUIT-I 1. Check voltage between ECM terminal 2 and ground under the following conditions with CONSULT-II or tester. Ignition switch Voltage OFF Approximately 0V ON Battery voltage (11 - 14V) OK or NG OK >> GO TO 8. NG >> GO TO 6. K L M PBIA9568J 6. CHECK THROTTLE CONTROL MOTOR RELAY INPUT SIGNAL CIRCUIT-II 1. 2. 3. 4. J Turn ignition switch OFF. Disconnect ECM harness connector. Disconnect IPDM E/R harness connector E7. Check continuity between ECM terminal 2 and IPDM E/R terminal 28. Refer to Wiring Diagram. Continuity should exist. 5. Also check harness for short to ground and short to power. OK or NG OK >> GO TO 8. NG >> GO TO 7. EC-1443 DTC P1124, P1126 THROTTLE CONTROL MOTOR RELAY [HR (WITHOUT EURO-OBD)] 7. DETECT MALFUNCTIONING PART Check the following. ● Harness connectors E59, F1 ● Harness for open or short between ECM and IPDM E/R >> Repair open circuit or short to ground or short to power in harness or connectors. 8. CHECK INTERMITTENT INCIDENT Refer to EC-1336, "TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT" . OK or NG OK >> Replace IPDM E/R. Refer to PG-18, "IPDM E/R (INTELLIGENT POWER DISTRIBUTION MODULE ENGINE ROOM)" . NG >> Repair or replace harness or connectors. EC-1444 DTC P1128 THROTTLE CONTROL MOTOR [HR (WITHOUT EURO-OBD)] DTC P1128 THROTTLE CONTROL MOTOR Component Description PFP:16119 A BBS004P1 The throttle control motor is operated by the ECM and it opens and closes the throttle valve. The current opening angle of the throttle valve is detected by the throttle position sensor and it provides feed- EC back to the ECM to control the throttle control motor to make the throttle valve opening angle properly in response to driving condition. On Board Diagnosis Logic BBS004P2 C This self-diagnosis has the one trip detection logic. DTC No. P1128 1128 Trouble diagnosis name Throttle control motor circuit short DTC detecting condition ECM detects short in both circuits between ECM and throttle control motor. Possible cause D ● Harness or connectors (Throttle control motor circuit is shorted.) ● Electric throttle control actuator (Throttle control motor) E FAIL-SAFE MODE F When the malfunction is detected, ECM enters fail-safe mode and the MI lights up. Engine operating condition in fail-safe mode ECM stops the electric throttle control actuator control, throttle valve is maintained at a fixed opening (approx. 5 degrees) by the return spring. DTC Confirmation Procedure BBS004P3 NOTE: If DTC Confirmation Procedure has been previously conducted, always turn ignition switch OFF and wait at least 10 seconds before conducting the next test. G H I WITH CONSULT-II 1. 2. 3. 4. Turn ignition switch ON and wait at least 2 seconds. Select “DATA MONITOR” mode with CONSULT-II. Start engine and let it idle for 5 seconds. If DTC is detected, go to EC-1447, "Diagnostic Procedure" . J K L SEF058Y WITHOUT CONSULT-II 1. 2. 3. 4. 5. Turn ignition switch ON and wait at least 2 seconds. Start engine and let it idle for 5 seconds. Turn ignition switch OFF, wait at least 10 seconds and then turn ON. Perform Diagnostic Test Mode II (Self-diagnostic results) with ECM. If DTC is detected, go to EC-1447, "Diagnostic Procedure" . EC-1445 M DTC P1128 THROTTLE CONTROL MOTOR [HR (WITHOUT EURO-OBD)] Wiring Diagram BBS004P4 MBWA1474E EC-1446 DTC P1128 THROTTLE CONTROL MOTOR [HR (WITHOUT EURO-OBD)] Specification data are reference values and are measured between each terminal and ground. Pulse signal is measured by CONSULT-II. A CAUTION: Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM's transistor. Use a ground other than ECM terminals, such as the ground. EC TERMINAL NO. WIRE COLOR ITEM CONDITION DATA (DC Voltage) C 0 - 14V [Ignition switch: ON] 1 P Throttle control motor (Open) ● Engine stopped ● Shift lever: D (A/T), 1st (M/T) ● Accelerator pedal: Fully depressed D E PBIB1105E 2 LG Throttle control motor relay power supply BATTERY VOLTAGE (11 - 14V) [Ignition switch: ON] F 0 - 14V [Ignition switch: ON] 4 L Throttle control motor (Close) ● Engine stopped ● Shift lever: D D (A/T), 1st (M/T) ● Accelerator pedal: Released G H PBIB1104E 15 G Throttle control motor relay [Ignition switch: OFF] BATTERY VOLTAGE (11 - 14V) [Ignition switch: ON] 0 - 1.0V I : Average voltage for pulse signal (Actual pulse signal can be confirmed by oscilloscope.) J Diagnostic Procedure BBS004P5 1. CHECK GROUND CONNECTIONS 1. 2. K Turn ignition switch OFF. Loosen and retighten ground screws on the body. Refer to EC-1342, "Ground Inspection" . L M MBIB1550E 1. IPDM E/R 2. Body ground OK or NG OK >> GO TO 2. NG >> Repair or replace ground connections. EC-1447 3. Body ground DTC P1128 THROTTLE CONTROL MOTOR [HR (WITHOUT EURO-OBD)] 2. CHECK THROTTLE CONTROL MOTOR OUTPUT SIGNAL CIRCUIT FOR OPEN AND SHORT 1. Disconnect electric throttle control actuator (1) harness connector. – : Vehicle front Disconnect ECM harness connector. Check harness continuity between the following terminals. Refer to Wiring Diagram. 2. 3. Electric throttle control actuator terminal 5 6 ECM terminal Continuity 1 Should not exist 4 Should exist 1 Should exist 4 Should not exist PBIB2965E 4. Also check harness for short to ground and short to power. OK or NG OK >> GO TO 3. NG >> Repair or replace. 3. CHECK THROTTLE CONTROL MOTOR Refer to EC-1449, "Component Inspection" . OK or NG OK >> GO TO 4. NG >> GO TO 5. 4. CHECK INTERMITTENT INCIDENT Refer to EC-1336, "TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT" . OK or NG OK >> GO TO 5. NG >> Repair or replace harness or connectors. 5. REPLACE ELECTRIC THROTTLE CONTROL ACTUATOR 1. 2. 3. Replace the electric throttle control actuator. Perform EC-1279, "Throttle Valve Closed Position Learning" . Perform EC-1279, "Idle Air Volume Learning" . >> INSPECTION END EC-1448 DTC P1128 THROTTLE CONTROL MOTOR [HR (WITHOUT EURO-OBD)] Component Inspection BBS004P6 A THROTTLE CONTROL MOTOR 1. 2. Disconnect electric throttle control actuator harness connector. Check resistance between terminals 5 and 6. EC Resistance: Approximately 1 - 15 Ω [at 25 °C (77°F)] 3. 4. 5. If NG, replace electric throttle control actuator and go to next step. Perform EC-1279, "Throttle Valve Closed Position Learning" . Perform EC-1279, "Idle Air Volume Learning" . C D PBIB2909E E Removal and Installation BBS004P7 ELECTRIC THROTTLE CONTROL ACTUATOR Refer to EM-120, "INTAKE MANIFOLD" . F G H I J K L M EC-1449 DTC P1212 TCS COMMUNICATION LINE [HR (WITHOUT EURO-OBD)] DTC P1212 TCS COMMUNICATION LINE Description PFP:47850 BBS004PC NOTE: ● If DTC P1212 is displayed with DTC U1000 or U1001, first perform the trouble diagnosis for DTC U1000, U1001. Refer to EC-1344, "DTC U1000, U1001 CAN COMMUNICATION LINE" . ● If DTC P1212 is displayed with DTC U1010, first perform the trouble diagnosis for DTC U1010. Refer to EC-1347, "DTC U1010 CAN COMMUNICATION" . This CAN communication line is used to control the smooth engine operation during the TCS operation. Pulse signals are exchanged between ECM and “ABS actuator and electric unit (control unit)”. Be sure to erase the malfunction information such as DTC not only for “ABS actuator and electric unit (control unit)” but also for ECM after TCS related repair. On Board Diagnosis Logic BBS004PD The MI will not light up for this self-diagnosis. Freeze frame data is not stored in the ECM for this self-diagnosis. DTC No. P1212 1212 Trouble diagnosis name TCS communication line DTC detecting condition ECM can not receive the information from “ABS actuator and electric unit (control unit)” continuously. Possible cause ● Harness or connectors (The CAN communication line is open or shorted.) ● ABS actuator and electric unit (control unit) ● Dead (Weak) battery DTC Confirmation Procedure BBS004PE TESTING CONDITION: Before performing the following procedure, confirm that battery voltage is more than 10.5V at idle. WITH CONSULT-II 1. 2. 3. 4. Turn ignition switch ON. Select “DATA MONITOR” mode with CONSULT-II. Start engine and let it idle for at least 10 seconds. If 1st trip DTC is detected, go to EC-1450, "Diagnostic Procedure" . SEF058Y WITHOUT CONSULT-II 1. 2. 3. 4. Start engine and let it idle for at least 10 seconds. Turn ignition switch OFF and wait at least 10 seconds and then turn ON. Perform Diagnostic Test Mode II (Self-diagnostic results) with ECM. If 1st trip DTC is detected, go to EC-1450, "Diagnostic Procedure" . Diagnostic Procedure BBS004PF Refer to BRC-49, "TROUBLE DIAGNOSIS" . EC-1450 DTC P1217 ENGINE OVER TEMPERATURE [HR (WITHOUT EURO-OBD)] DTC P1217 ENGINE OVER TEMPERATURE System Description PFP:00000 A BBS004UV SYSTEM DESCRIPTION NOTE: EC ● If DTC P1217 is displayed with DTC U1000 or U1001, first perform the trouble diagnosis for DTC U1000, U1001. Refer to EC-1344, "DTC U1000, U1001 CAN COMMUNICATION LINE" . ● If DTC P1217 is displayed with DTC U1010, first perform the trouble diagnosis for DTC U1010. C Refer to EC-1347, "DTC U1010 CAN COMMUNICATION" . Cooling Fan Control Sensor Input Signal to ECM Crankshaft position sensor (POS) Camshaft position sensor (PHASE) Engine speed*1 Battery Battery voltage*1 Wheel sensor Vehicle speed*2 Engine coolant temperature sensor Air conditioner switch* 3 Refrigerant pressure sensor*3 ECM function Actuator D E Cooling fan control IPDM E/R (Cooling fan relays) Engine coolant temperature F Air conditioner ON signal*2 Refrigerant pressure G *1: The ECM determines the start signal status by the signals of engine speed and battery voltage. *2: This signal is sent to ECM through CAN communication line. *3: Models with air conditioner H The ECM controls the cooling fan corresponding to the vehicle speed, engine coolant temperature, refrigerant pressure, and air conditioner ON signal. The control system has 3-step control [HIGH/LOW/OFF] (Models with A/C) or 2-step control [ON/OFF] (Models without A/C). I Cooling Fan Operation Models with A/C J K L M MBIB1451E EC-1451 DTC P1217 ENGINE OVER TEMPERATURE [HR (WITHOUT EURO-OBD)] Models without A/C MBIB1393E Cooling Fan Relay Operation The ECM controls cooling fan relays in the IPDM E/R through CAN communication line. Cooling fan relay Cooling fan speed LO HI Stop (OFF) OFF OFF Low (LOW) ON OFF High (HI) OFF ON CONSULT-II Reference Value in Data Monitor Mode BBS004UW Specification data are reference values. MONITOR ITEM AIR COND SIG CONDITION ● Engine: After warming up, idle the engine ● Engine: After warming up, idle the engine ● Air conditioner switch: OFF COOLING FAN SPECIFICATION Air conditioner switch: OFF OFF Air conditioner switch: ON (Compressor operates.) ON Engine coolant temperature is 97°C (207°F) or less OFF Engine coolant temperature is between 98°C (208°F) and 99°C (210°F) or more LOW* Engine coolant temperature is 100°C (212°F) or more HIGH* *: Models without air conditioner, cooling fan operates only ON and OFF operation, but CONSULT-II display will change OFF, LOW and HI depends on engine coolant temperature. On Board Diagnosis Logic BBS004UX If the cooling fan or another component in the cooling system malfunctions, engine coolant temperature will rise. When the engine coolant temperature reaches an abnormally high temperature condition, a malfunction is indicated. This self-diagnosis has the one trip detection logic. EC-1452 DTC P1217 ENGINE OVER TEMPERATURE [HR (WITHOUT EURO-OBD)] DTC No. Trouble diagnosis name DTC detecting condition ● P1217 1217 Engine over temperature (Overheat) Cooling fan does not operate properly (Overheat). Possible cause A ● Harness or connectors (The cooling fan circuit is open or shorted.) ● Cooling fan ● IPDM E/R (Cooling fan relays) ● Radiator hose Radiator C ● Cooling fan system does not operate properly (Overheat). ● ● Reservoir tank (M/T models with A/C) ● Engine coolant was not added to the system using the proper filling method. ● Reservoir tank cap (M/T models with A/C) ● Engine coolant is not within the specified range. ● Radiator cap (M/T models without A/C and A/T models) ● Water pump ● Thermostat For more information, refer to EC-1465, "Main 12 Causes of Overheating" . CAUTION: When a malfunction is indicated, be sure to replace the coolant. Refer to MA-39, "Changing Engine Coolant" . Also, replace the engine oil. Refer to MA-45, "Changing Engine Oil" . 1. Fill radiator with coolant up to specified level with a filling speed of 2 liters per minute. Be sure to use coolant with the proper mixture ratio. Refer to MA-26, "Engine Coolant Mixture Ratio" . 2. After refilling coolant, run engine to ensure that no water-flow noise is emitted. Overall Function Check BBS004UY Use this procedure to check the overall function of the cooling fan. During this check, a DTC might not be confirmed. WARNING: Never remove the reservoir tank cap (M/T models with A/C) or the radiator cap (M/T models without A/ C and A/T models) when the engine is hot. Serious burns could be caused by high pressure fluid escaping from the reservoir tank or the radiator. Wrap a thick cloth around cap. Carefully remove the cap by turning it a quarter turn to allow built-up pressure to escape. Then turn the cap all the way off. WITH CONSULT-II 1. 2. 3. Check the coolant level in the reservoir tank and radiator. Allow engine to cool before checking coolant level. If the coolant level in the reservoir tank and/or radiator is below the proper range, skip the following steps and go to EC-1458, "PROCEDURE FOR MODELS WITH AIR CONDITIONER" or EC-1462, "PROCEDURE FOR MODELS WITHOUT AIR CONDITIONER" . Confirm whether customer filled the coolant or not. If customer filled the coolant, skip the following steps and go to EC-1458, "PROCEDURE FOR MODELS WITH AIR CONDITIONER" or EC-1462, "PROCEDURE FOR MODELS WITHOUT AIR CONDITIONER" . Turn ignition switch ON. EC-1453 EC D E F G H I J K L M SEF621W DTC P1217 ENGINE OVER TEMPERATURE [HR (WITHOUT EURO-OBD)] 4. 5. Perform “COOLING FAN” in “ACTIVE TEST” mode with CONSULT-II. If the results are NG, go to EC-1458, "PROCEDURE FOR MODELS WITH AIR CONDITIONER" or EC-1462, "PROCEDURE FOR MODELS WITHOUT AIR CONDITIONER" . SEF646X WITH GST Models with Air Conditioner 1. Check the coolant level in the reservoir tank and radiator. Allow engine to cool before checking coolant level. If the coolant level in the reservoir tank and/or radiator is below the proper range, skip the following steps and go to EC-1458, "PROCEDURE FOR MODELS WITH AIR CONDITIONER" . 2. Confirm whether customer filled the coolant or not. If customer filled the coolant, skip the following steps and go to EC-1458, "PROCEDURE FOR MODELS WITH AIR CONDITIONER" . 3. Start engine. CAUTION: Be careful not to overheat engine. 4. Set temperature control switch to full cold position. 5. Turn air conditioner switch ON. 6. Turn blower fan switch ON. 7. Run engine at idle for a few minutes with air conditioner operating. CAUTION: Be careful not to overheat engine. 8. Make sure that cooling fans operates at low speed. If NG, go to EC-1458, "PROCEDURE FOR MODELS WITH AIR CONDITIONER" . If OK, go to the following step. 9. Turn ignition switch OFF. 10. Turn air conditioner switch and blower fan switch OFF. 11. Disconnect engine coolant temperature sensor harness connector. 12. Connect 150Ω resistor to engine coolant temperature sensor harness connector. SEF621W MBIB0651E 13. Restart engine and make sure that cooling fan operates at higher speed than low speed. CAUTION: Be careful not to overheat engine. 14. If NG, go to EC-1458, "PROCEDURE FOR MODELS WITH AIR CONDITIONER" . SEF023R EC-1454 DTC P1217 ENGINE OVER TEMPERATURE [HR (WITHOUT EURO-OBD)] Models without Air Conditioner 1. 2. 3. 4. 5. 6. Check the coolant level in the reservoir tank and radiator. Allow engine to cool before checking coolant level. If the coolant level in the reservoir tank and/or radiator is below the proper range, skip the following steps and go to EC-1462, "PROCEDURE FOR MODELS WITHOUT AIR CONDITIONER" . Confirm whether customer filled the coolant or not. If customer filled the coolant, skip the following steps and go to EC-1462, "PROCEDURE FOR MODELS WITHOUT AIR CONDITIONER" . Disconnect engine coolant temperature sensor harness connector. Connect 150Ω resistor to engine coolant temperature sensor harness connector. Start engine and make that cooling fan operates. Be careful not to overheat engine. If NG, go to EC-1462, "PROCEDURE FOR MODELS WITHOUT AIR CONDITIONER" . A EC C SEF621W D E F G H SEF023R I J K L M EC-1455 DTC P1217 ENGINE OVER TEMPERATURE [HR (WITHOUT EURO-OBD)] Wiring Diagram BBS004UZ MODELS WITH AIR CONDITIONER MBWA1475E EC-1456 DTC P1217 ENGINE OVER TEMPERATURE [HR (WITHOUT EURO-OBD)] MODELS WITHOUT AIR CONDITIONER A EC C D E F G H I J K L M MBWA1476E EC-1457 DTC P1217 ENGINE OVER TEMPERATURE [HR (WITHOUT EURO-OBD)] Diagnostic Procedure BBS004V0 PROCEDURE FOR MODELS WITH AIR CONDITIONER 1. INSPECTION START Do you have CONSULT-II? Yes or No Yes >> GO TO 2. No >> GO TO 4. 2. CHECK COOLING FAN LOW SPEED OPERATION With CONSULT-II Turn ignition switch ON. Perform “COOLING FAN” in “ACTIVE TEST” mode with CONSULT-II and touch “LOW” on the CONSULT-II screen. 3. Make sure that cooling fan operates at low speed. OK or NG OK >> GO TO 3. NG >> Check cooling fan control circuit. (Go to EC-1460, "PROCEDURE A" .) 1. 2. SEF784Z 3. CHECK COOLING FAN HIGH SPEED OPERATION With CONSULT-II 1. Touch “HIGH” on the CONSULT-II screen. 2. Make sure that cooling fan operates at higher speed than low speed. OK or NG OK >> GO TO 6. NG >> Check cooling fan control circuit. (Go to EC-1460, "PROCEDURE A" .) SEF785Z EC-1458 DTC P1217 ENGINE OVER TEMPERATURE [HR (WITHOUT EURO-OBD)] 4. CHECK COOLING FAN LOW SPEED OPERATION A Without CONSULT-II 1. Start engine and let it idle. 2. Turn air conditioner switch ON. 3. Turn blower fan switch ON. 4. Make sure that cooling fan operates at low speed. OK or NG OK >> GO TO 5. NG >> Check cooling fan low speed control circuit. (Go to EC1460, "PROCEDURE A" .) EC C D E MBIB0651E F 5. CHECK COOLING FAN HIGH SPEED OPERATION G Without CONSULT-II 1. Turn ignition switch OFF. 2. Turn air conditioner switch and blower fan switch OFF. 3. Disconnect engine coolant temperature sensor harness connector. 4. Connect 150Ω resistor to engine coolant temperature sensor harness connector. 5. Restart engine and make sure that cooling fan operates at higher speed than low speed. OK or NG OK >> GO TO 6. NG >> Check cooling fan high speed control circuit. (Go to EC1460, "PROCEDURE A" .) H I J K SEF023R L 6. CHECK COOLING SYSTEM FOR LEAK Refer to CO-27, "ENGINE COOLANT" . OK or NG OK >> GO TO 8. NG >> GO TO 7. M 7. DETECT MALFUNCTIONING PART Check the following for leak. ● Hose ● Radiator ● Water pump (Refer to CO-36, "WATER PUMP" .) ● Reservoir tank >> Repair or replace. EC-1459 DTC P1217 ENGINE OVER TEMPERATURE [HR (WITHOUT EURO-OBD)] 8. CHECK RESERVOIR TANK CAP (M/T MODELS) OR RADIATOR CAP (A/T MODELS) Refer to CO-35, "Checking Reservoir Tank Cap (M/T with A/C Models)" or CO-34, "Checking Radiator Cap (All Models Except M/T with A/C)" . OK or NG OK >> GO TO 9. NG >> Replace reservoir tank cap (M/T models) or radiator cap (A/T models). 9. CHECK THERMOSTAT Refer to CO-38, "THERMOSTAT" . OK or NG OK >> GO TO 10. NG >> Replace thermostat. 10. CHECK ENGINE COOLANT TEMPERATURE SENSOR Refer to EC-1365, "Component Inspection" . OK or NG OK >> GO TO 11. NG >> Replace engine coolant temperature sensor. 11. CHECK MAIN 12 CAUSES If the cause cannot be isolated, go to EC-1465, "Main 12 Causes of Overheating" . >> INSPECTION END PROCEDURE A 1. CHECK POWER SUPPLY CIRCUIT 1. 2. 3. Turn ignition switch OFF. Disconnect IPDM E/R harness connector E6. Check voltage between IPDM E/R terminal 14 and ground with CONSULT-II or tester. Voltage: Battery voltage OK or NG OK >> GO TO 3. NG >> GO TO 2. MBIB1307E 2. DETECT MALFUNCTIONING PART Check the following. ● 40A fusible link ● Harness for open or short between IPDM E/R and battery >> Repair open circuit or short to ground or short to power in harness or connectors. EC-1460 DTC P1217 ENGINE OVER TEMPERATURE [HR (WITHOUT EURO-OBD)] 3. CHECK COOLING FAN MOTOR CIRCUIT A 1. Disconnect cooling fan motor harness connector (1). – : Vehicle front Disconnect IPDM E/R harness connectors E11 and E12. Check harness continuity between cooling fan motor terminal 1 and IPDM E/R terminal 10, cooling fan motor terminal 2 and ground. Refer to wiring diagram. 2. 3. EC C Continuity should exist. 4. 5. D Also check harness for short to ground and short to power. Check harness continuity between IPDM E/R terminal 12 and cooling fan motor terminal 1. Refer to wiring diagram. MBIB1549E E Continuity should exist. 6. 7. Also check harness for short to ground and short to power. Check harness continuity between IPDM E/R terminals 3, 53 and ground. Refer to Wiring Diagram. F G Continuity should exist. 8. Also check harness for short to ground and short to power. OK or NG OK >> GO TO 5. NG >> GO TO 4. 4. DETECT MALFUNCTIONING PART Check the following. ● Harness for open or short between cooling fan motor and IPDM E/R ● Harness for open or short between cooling fan motor and ground ● Harness for open or short between resistor and IPDM E/R ● Harness for open or short between resistor and cooling fan motor ● Resistor E62 H I J K L >> Repair open circuit or short to ground or short to power in harness or connectors. 5. CHECK COOLING FAN MOTOR M Refer to EC-1466, "Component Inspection" . OK or NG OK >> GO TO 6. NG >> Replace cooling fan motor. 6. CHECK INTERMITTENT INCIDENT Perform EC-1336, "TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT" . OK or NG OK >> Replace IPDM E/R. Refer to PG-18, "IPDM E/R (INTELLIGENT POWER DISTRIBUTION MODULE ENGINE ROOM)" . NG >> Repair or replace harness or connector. EC-1461 DTC P1217 ENGINE OVER TEMPERATURE [HR (WITHOUT EURO-OBD)] PROCEDURE FOR MODELS WITHOUT AIR CONDITIONER 1. INSPECTION START Do you have CONSULT-II? Yes or No Yes >> GO TO 2. No >> GO TO 3. 2. CHECK COOLING FAN OPERATION With CONSULT-II 1. Turn ignition switch ON. 2. Perform “COOLING FAN” in “ACTIVE TEST” mode with CONSULT-II and touch “LOW” on the CONSULT-II screen. 3. Make sure that cooling fan operates. OK or NG OK >> GO TO4. NG >> Check cooling fan control circuit. (Go to EC-1463, "PROCEDURE B" .) SEF784Z 3. CHECK COOLING FAN OPERATION Without CONSULT-II 1. Turn ignition switch OFF. 2. Disconnect engine coolant temperature sensor harness connector. 3. Connect 150Ω resistor to engine coolant temperature sensor harness connector. 4. Restart engine and make sure that cooling fan operates. OK or NG OK >> GO TO 4. NG >> Check cooling fan speed control circuit. (Go to EC-1463, "PROCEDURE B" .) SEF023R 4. CHECK COOLING SYSTEM FOR LEAK Refer to CO-27, "ENGINE COOLANT" . OK or NG OK >> GO TO 6. NG >> GO TO 5. EC-1462 DTC P1217 ENGINE OVER TEMPERATURE [HR (WITHOUT EURO-OBD)] 5. DETECT MALFUNCTIONING PART A Check the following for leak. ● Hose ● Radiator ● Water pump (Refer to CO-36, "WATER PUMP" .) EC C >> Repair or replace. 6. CHECK RADIATOR CAP D Refer to CO-34, "Checking Radiator Cap (All Models Except M/T with A/C)" . OK or NG OK >> GO TO 7. NG >> Replace radiator cap. E 7. CHECK THERMOSTAT F Refer to CO-38, "THERMOSTAT" . OK or NG OK >> GO TO 8. NG >> Replace thermostat. G 8. CHECK ENGINE COOLANT TEMPERATURE SENSOR H Refer to EC-1365, "Component Inspection" . OK or NG OK >> GO TO 9. NG >> Replace engine coolant temperature sensor. I 9. CHECK MAIN 12 CAUSES J If the cause cannot be isolated, go to EC-1465, "Main 12 Causes of Overheating" . K >> INSPECTION END PROCEDURE B L 1. CHECK POWER SUPPLY CIRCUIT 1. 2. 3. Turn ignition switch OFF. Disconnect IPDM E/R harness connector E6. Check voltage between IPDM E/R terminal 14 and ground with CONSULT-II or tester. M Voltage: Battery voltage OK or NG OK >> GO TO 3. NG >> GO TO 2. MBIB1307E EC-1463 DTC P1217 ENGINE OVER TEMPERATURE [HR (WITHOUT EURO-OBD)] 2. DETECT MALFUNCTIONING PART Check the following. ● 40A fusible link ● Harness for open or short between IPDM E/R and battery >> Repair open circuit or short to ground or short to power in harness or connectors. 3. CHECK COOLING FAN MOTORS CIRCUIT 1. Disconnect cooling fan motor harness connector (1). – : Vehicle front Disconnect IPDM E/R harness connectors E11 and E12. Check harness continuity between cooling fan motor terminal 1 and IPDM E/R terminal 10, cooling fan motor terminal 2 and ground. Refer to wiring diagram. 2. 3. Continuity should exist. 4. 5. Also check harness for short to ground and short to power. Check harness continuity between IPDM E/R terminals 3, 53 and ground. Refer to Wiring Diagram. MBIB1549E Continuity should exist. 6. Also check harness for short to ground and short to power. OK or NG OK >> GO TO 5. NG >> GO TO 4. 4. DETECT MALFUNCTIONING PART Check the following. ● Harness for open or short between cooling fan motor and IPDM E/R ● Harness for open or short between cooling fan motor and ground >> Repair open circuit or short to ground or short to power in harness or connectors. 5. CHECK COOLING FAN MOTOR Refer to EC-1466, "Component Inspection" . OK or NG OK >> GO TO 6. NG >> Replace cooling fan motor. 6. CHECK INTERMITTENT INCIDENT Perform EC-1336, "TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT" . OK or NG OK >> Replace IPDM E/R. Refer to PG-18, "IPDM E/R (INTELLIGENT POWER DISTRIBUTION MODULE ENGINE ROOM)" . NG >> Repair or replace harness or connector. EC-1464 DTC P1217 ENGINE OVER TEMPERATURE [HR (WITHOUT EURO-OBD)] Main 12 Causes of Overheating BBS004V1 A Engine Step OFF 1 Inspection item Equipment Blocked radiator ● Blocked condenser ● Blocked radiator grille ● Blocked bumper 2 ● Coolant mixture ● Coolant tester 50 - 50% coolant mixture See MA-26, "Engine Coolant Mixture Ratio" . 3 ● Coolant level ● Visual Coolant up to MAX level in reservoir tank and radiator filler neck See CO-27, "LEVEL CHECK" . 59 - 98 kPa (0.59 - 0.98 bar, 0.6 - 1.0 See CO-34, "Checking Radiator Cap (All Models Except M/T with A/C)" . 4*5 ● Radiator cap No blocking Reference page ● ● Visual Standard — EC ● Pressure tester kg/cm2 , 9 - 14 psi) (Limit) 88 kPa (0.88 bar, 0.90 kg/ See CO-35, "Checking Reservoir Tank Cap (M/T with A/C Models)" . 4*6 ● Reservoir tank cap ● Pressure tester ON*2 5 ● Coolant leaks ● Visual No leaks See CO-27, "LEAK CHECK" . ON*2 6 ● Thermostat ● Touch the upper and lower radiator hoses Both hoses should be hot See CO-38, "THERMOSTAT" , and CO-31, "RADIATOR" . ON*1 7 ● Cooling fan ● CONSULT-II Operating See trouble diagnosis for DTC P1217 (EC-1458, "Diagnostic Procedure" ). OFF 8 ● Combustion gas leak ● Color checker chemical tester 4 Gas analyzer Negative — ON*3 9 ● Coolant temperature gauge ● Visual Gauge less than 3/4 when driving — ● Coolant overflow to reservoir tank ● Visual No overflow during driving and idling See MA-39, "Changing Engine Coolant" . cm2 , 12.8psi) C D E F G H I J OFF*4 10 ● Coolant return from reservoir tank to radiator ● Visual Should be initial level in reservoir tank See CO-27, "LEVEL CHECK" . K OFF 11 ● Cylinder head ● Straight gauge feeler gauge 0.1 mm (0.004 in) Maximum distortion (warping) See EM-173, "CYLINDER HEAD" . L 12 ● Cylinder block and pistons ● Visual No scuffing on cylinder walls or piston See EM-189, "CYLINDER BLOCK" . *1: Turn the ignition switch ON. *2: Engine running at 3,000 rpm for 10 minutes. *3: Drive at 90 km/h (55 MPH) for 30 minutes and then let idle for 10 minutes. *4: After 60 minutes of cool down time. *5: M/T models without A/C and A/T models. *6: M/T models with A/C. For more information, refer to CO-24, "OVERHEATING CAUSE ANALYSIS" . EC-1465 M DTC P1217 ENGINE OVER TEMPERATURE [HR (WITHOUT EURO-OBD)] Component Inspection BBS004V2 COOLING FAN MOTOR 1. 2. Disconnect cooling fan motor harness connectors. Supply cooling fan motor terminals with battery voltage and check operation. Terminals Cooling fan motor (+) (-) 1 2 MBIB0607E EC-1466 DTC P1225 TP SENSOR [HR (WITHOUT EURO-OBD)] DTC P1225 TP SENSOR Component Description PFP:16119 A BBS004PO Electric throttle control actuator consists of throttle control motor, throttle position sensor, etc. The throttle position sensor responds to the throttle valve movement. The throttle position sensor has the two sensors. These sensors are a kind of potentiometers which transform the throttle valve position into output voltage, and emit the voltage signal to the ECM. In addition, these sensors detect the opening and closing speed of the throttle valve and feed the voltage signals to the ECM. The ECM judges the current opening angle of the throttle valve from these signals and the ECM controls the throttle control motor to make the throttle valve opening angle properly in response to driving condition. EC C D PBIB0145E E On Board Diagnosis Logic BBS004PP The MI will not light up for this diagnosis. F DTC No. P1225 1225 Trouble diagnosis name DTC detecting condition Closed throttle position learning performance Closed throttle position learning value is excessively low. DTC Confirmation Procedure Possible cause ● Electric throttle control actuator (TP sensor 1 and 2) G BBS004PQ NOTE: If DTC Confirmation Procedure has been previously conducted, always turn ignition switch OFF and wait at least 10 seconds before conducting the next test. TESTING CONDITION: Before performing the following procedure, confirm that battery voltage is more than 10V at idle. H I WITH CONSULT-II 1. 2. 3. 4. 5. Turn ignition switch ON. Select “DATA MONITOR” mode with CONSULT-II. Turn ignition switch OFF and wait at least 10 seconds. Turn ignition switch ON. If 1st trip DTC is detected, go to EC-1468, "Diagnostic Procedure" . J K L M SEF058Y WITHOUT CONSULT-II 1. 2. 3. 4. Turn ignition switch ON. Turn ignition switch OFF, wait at least 10 seconds and then turn ON. Perform Diagnostic Test Mode II (Self-diagnostic results) with ECM. If 1st trip DTC is detected, go to EC-1468, "Diagnostic Procedure" . EC-1467 DTC P1225 TP SENSOR [HR (WITHOUT EURO-OBD)] Diagnostic Procedure BBS004PR 1. CHECK ELECTRIC THROTTLE CONTROL ACTUATOR VISUALLY 1. 2. 3. Turn ignition switch OFF. Remove the intake air duct. Check if foreign matter is caught between the throttle valve (1) and the housing. : Vehicle front Illustration shows the view with intake air duct removed. OK or NG OK >> GO TO 2. NG >> Remove the foreign matter and clean the electric throttle control actuator inside. – – PBIB2974E 2. REPLACE ELECTRIC THROTTLE CONTROL ACTUATOR 1. 2. 3. Replace the electric throttle control actuator. Perform EC-1279, "Throttle Valve Closed Position Learning" . Perform EC-1279, "Idle Air Volume Learning" . >> INSPECTION END Removal and Installation BBS004PS ELECTRIC THROTTLE CONTROL ACTUATOR Refer to EM-120, "INTAKE MANIFOLD" . EC-1468 DTC P1226 TP SENSOR [HR (WITHOUT EURO-OBD)] DTC P1226 TP SENSOR Component Description PFP:16119 A BBS004PT Electric throttle control actuator consists of throttle control motor, throttle position sensor, etc. The throttle position sensor responds to the throttle valve movement. The throttle position sensor has the two sensors. These sensors are a kind of potentiometers which transform the throttle valve position into output voltage, and emit the voltage signal to the ECM. In addition, these sensors detect the opening and closing speed of the throttle valve and feed the voltage signals to the ECM. The ECM judges the current opening angle of the throttle valve from these signals and the ECM controls the throttle control motor to make the throttle valve opening angle properly in response to driving condition. EC C D PBIB0145E E On Board Diagnosis Logic BBS004PU The MI will not light up for this diagnosis. F DTC No. P1226 1226 Trouble diagnosis name Closed throttle position learning performance DTC detecting condition Closed throttle position learning is not performed successfully, repeatedly. DTC Confirmation Procedure Possible cause ● Electric throttle control actuator (TP sensor 1 and 2) G BBS004PV NOTE: If DTC Confirmation Procedure has been previously conducted, always turn ignition switch OFF and wait at least 10 seconds before conducting the next test. TESTING CONDITION: Before performing the following procedure, confirm that battery voltage is more than 10V at idle. H I WITH CONSULT-II 1. 2. 3. 4. 5. 6. Turn ignition switch ON. Select “DATA MONITOR” mode with CONSULT-II. Turn ignition switch OFF and wait at least 10 seconds. Turn ignition switch ON. Repeat step 3 and 4 for 32 times. If 1st trip DTC is detected, go to EC-1470, "Diagnostic Procedure" . J K L M SEF058Y WITHOUT CONSULT-II 1. 2. 3. 4. 5. Turn ignition switch ON. Turn ignition switch OFF, wait at least 10 seconds and then turn ON. Repeat step 2 for 32 times. Perform Diagnostic Test Mode II (Self-diagnostic results) with ECM. If 1st trip DTC is detected, go to EC-1470, "Diagnostic Procedure" . EC-1469 DTC P1226 TP SENSOR [HR (WITHOUT EURO-OBD)] Diagnostic Procedure BBS004PW 1. CHECK ELECTRIC THROTTLE CONTROL ACTUATOR VISUALLY 1. 2. 3. Turn ignition switch OFF. Remove the intake air duct. Check if foreign matter is caught between the throttle valve (1) and the housing. : Vehicle front Illustration shows the view with intake air duct removed. OK or NG OK >> GO TO 2. NG >> Remove the foreign matter and clean the electric throttle control actuator inside. – – PBIB2974E 2. REPLACE ELECTRIC THROTTLE CONTROL ACTUATOR 1. 2. 3. Replace the electric throttle control actuator. Perform EC-1279, "Throttle Valve Closed Position Learning" . Perform EC-1279, "Idle Air Volume Learning" . >> INSPECTION END Removal and Installation BBS004PX ELECTRIC THROTTLE CONTROL ACTUATOR Refer to EM-120, "INTAKE MANIFOLD" . EC-1470 DTC P1229 SENSOR POWER SUPPLY [HR (WITHOUT EURO-OBD)] DTC P1229 SENSOR POWER SUPPLY On Board Diagnosis Logic PFP:16119 A BBS004PY This self-diagnosis has the one trip detection logic. DTC No. P1229 1229 EC Trouble diagnosis name Sensor power supply circuit short DTC detecting condition Possible cause ● Harness or connectors (APP sensor 1 circuit is shorted.) (Throttle position sensor circuit is shorted.) [Camshaft position sensor (PHASE) circuit is shorted.] ● Accelerator pedal position sensor ● Throttle position sensor ● Camshaft position sensor (PHASE) ECM detects a voltage of power source for sensor is excessively low or high. C D E FAIL-SAFE MODE When the malfunction is detected, ECM enters fail-safe mode and the MI lights up. F Engine operation condition in fail-safe mode ECM stops the electric throttle control actuator control, throttle valve is maintained at a fixed opening (approx. 5 degrees) by the return spring. DTC Confirmation Procedure G BBS004PZ NOTE: If DTC Confirmation Procedure has been previously conducted, always turn ignition switch OFF and wait at least 10 seconds before conducting the next test. TESTING CONDITION: Before performing the following procedure, confirm that battery voltage is more than 10V at idle. H I WITH CONSULT-II 1. 2. 3. 4. J Turn ignition switch ON. Select “DATA MONITOR” mode with CONSULT-II. Start engine and let it idle for 1 second. If DTC is detected, go to EC-1476, "Diagnostic Procedure" . K L M SEF058Y WITHOUT CONSULT-II 1. 2. 3. 4. Start engine and let it idle for 1 second. Turn ignition switch OFF, wait at least 10 seconds and then turn ON. Perform Diagnostic Test Mode II (Self-diagnostic results) with ECM. If DTC is detected, go to EC-1476, "Diagnostic Procedure" . EC-1471 DTC P1229 SENSOR POWER SUPPLY [HR (WITHOUT EURO-OBD)] Wiring Diagram BBS004Q0 LHD MODELS MBWA1477E EC-1472 DTC P1229 SENSOR POWER SUPPLY [HR (WITHOUT EURO-OBD)] Specification data are reference values and are measured between each terminal and ground. CAUTION: Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM's transistor. Use a ground other than ECM terminals, such as the ground. TERMINAL NO. WIRE COLOR EC ITEM CONDITION DATA (DC Voltage) 72 L Sensor power supply (Throttle position sensor) [Ignition switch: ON] Approximately 5V 78 O Sensor power supply [Camshaft position sensor (PHASE)] [Ignition switch: ON] Approximately 5V 102 BR Sensor power supply (APP sensor 2) [Ignition switch: ON] Approximately 5V G Accelerator pedal position sensor 2 ● Engine stopped ● Accelerator pedal: Fully released C D E [Ignition switch: ON] 103 A 0.3 - 0.6V F [Ignition switch: ON] ● Engine stopped ● Accelerator pedal: Fully depressed 1.95 - 2.4V G [Engine is running] 104 106 B O Sensor ground (APP sensor 2) Sensor power supply (APP sensor 1) ● Warm-up condition ● Idle speed [Ignition switch: ON] Approximately 0V H Approximately 5V I [Ignition switch: ON] 110 W Accelerator pedal position sensor 1 ● Engine stopped ● Accelerator pedal: Fully released 0.6 - 0.9V J [Ignition switch: ON] ● Engine stopped ● Accelerator pedal: Fully depressed 3.9 - 4.7V K [Engine is running] 111 B Sensor ground (APP sensor 1) ● Warm-up condition ● Idle speed Approximately 0V L M EC-1473 DTC P1229 SENSOR POWER SUPPLY [HR (WITHOUT EURO-OBD)] RHD MODELS MBWA1478E EC-1474 DTC P1229 SENSOR POWER SUPPLY [HR (WITHOUT EURO-OBD)] Specification data are reference values and are measured between each terminal and ground. CAUTION: Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM's transistor. Use a ground other than ECM terminals, such as the ground. TERMINAL NO. WIRE COLOR EC ITEM CONDITION DATA (DC Voltage) 72 L Sensor power supply (Throttle position sensor) [Ignition switch: ON] Approximately 5V 78 O Sensor power supply [Camshaft position sensor (PHASE)] [Ignition switch: ON] Approximately 5V 102 BR Sensor power supply (APP sensor 2) [Ignition switch: ON] Approximately 5V G Accelerator pedal position sensor 2 ● Engine stopped ● Accelerator pedal: Fully released C D E [Ignition switch: ON] 103 A 0.3 - 0.6V F [Ignition switch: ON] ● Engine stopped ● Accelerator pedal: Fully depressed 1.95 - 2.4V G [Engine is running] 104 106 B O Sensor ground (APP sensor 2) Sensor power supply (APP sensor 1) ● Warm-up condition ● Idle speed [Ignition switch: ON] Approximately 0V H Approximately 5V I [Ignition switch: ON] 110 W Accelerator pedal position sensor 1 ● Engine stopped ● Accelerator pedal: Fully released 0.6 - 0.9V J [Ignition switch: ON] ● Engine stopped ● Accelerator pedal: Fully depressed 3.9 - 4.7V K [Engine is running] 111 B Sensor ground (APP sensor 1) ● Warm-up condition ● Idle speed Approximately 0V L M EC-1475 DTC P1229 SENSOR POWER SUPPLY [HR (WITHOUT EURO-OBD)] Diagnostic Procedure BBS004Q1 1. CHECK GROUND CONNECTIONS 1. 2. Turn ignition switch OFF. Loosen and retighten ground screws on the body. Refer to EC-1342, "Ground Inspection" . MBIB1550E 1. IPDM E/R 2. Body ground 3. Body ground OK or NG OK >> GO TO 2. NG >> Repair or replace ground connections. 2. CHECK ACCELERATOR PEDAL POSITION SENSOR 1 POWER SUPPLY CIRCUIT 1. – – 2. Disconnect accelerator pedal position (APP) sensor harness connector (1). Accelerator pedal position sensor (2) Accelerator pedal (3) Turn ignition switch ON. PBIB2975E 3. Check voltage between APP sensor terminal 4 and ground with CONSULT-II or tester. Voltage: Approximately 5V OK or NG OK >> GO TO 7. NG >> GO TO 3. PBIA9606J EC-1476 DTC P1229 SENSOR POWER SUPPLY [HR (WITHOUT EURO-OBD)] 3. CHECK ACCELERATOR PEDAL POSITION SENSOR 1 POWER SUPPLY CIRCUIT-II 1. 2. 3. Turn ignition switch OFF. Disconnect ECM harness connector. Check harness continuity between APP sensor terminal 4 and ECM terminal 106. Refer to Wiring Diagram. Continuity should exist. A EC C OK or NG OK >> GO TO 5. NG >> GO TO 4. D 4. DETECT MALFUNCTIONING PART E Check the following. ● Harness connectors M201, M8 (RHD models) ● Harness connectors M1, E101 (RHD models) ● Harness for open or short between APP sensor and ECM F >> Repair open circuit. G 5. CHECK SENSOR POWER SUPPLY CIRCUITS Check harness for short to power and short to ground, between the following terminals. ECM terminal Sensor terminal Reference Wiring Diagram 72 Throttle position sensor terminal 1 EC-1397, "Wiring Diagram" 78 Camshaft position sensor (PHASE) terminal 1 EC-1415, "Wiring Diagram" 106 APP sensor terminal 4 EC-1494, "Wiring Diagram" OK or NG OK >> GO TO 6. NG >> Repair short to ground or short to power in harness or connectors. 6. CHECK COMPONENTS Check the following. ● Throttle position sensor (Refer to EC-1400, "Component Inspection" .) ● Camshaft position sensor (PHASE) (Refer to EC-1418, "Component Inspection" .) OK or NG OK >> GO TO 7. NG >> Replace malfunctioning component. 7. CHECK APP SENSOR Refer to EC-1206, "Component Inspection" . OK or NG OK >> GO TO 9. NG >> GO TO 8. EC-1477 H I J K L M DTC P1229 SENSOR POWER SUPPLY [HR (WITHOUT EURO-OBD)] 8. REPLACE ACCELERATOR PEDAL ASSEMBLY 1. 2. 3. 4. Replace accelerator pedal assembly. Perform EC-1278, "Accelerator Pedal Released Position Learning" . Perform EC-1279, "Throttle Valve Closed Position Learning" . Perform EC-1279, "Idle Air Volume Learning" . >> INSPECTION END 9. CHECK INTERMITTENT INCIDENT Refer to EC-1336, "TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT" . >> INSPECTION END EC-1478 DTC P1706 PNP SWITCH [HR (WITHOUT EURO-OBD)] DTC P1706 PNP SWITCH Component Description PFP:32006 A BBS004Q2 When the shift lever position is P or N (A/T), Neutral (M/T), park/neutral position (PNP) switch is ON. ECM detects the position because the continuity of the line (the ON signal) exists. EC CONSULT-II Reference Value in Data Monitor Mode BBS004Q3 Specification data are reference values. MONITOR ITEM P/N POSI SW C CONDITION ● Ignition switch: ON SPECIFICATION Shift lever: P or N (A/T), Neutral (M/T) ON Shift lever: Except above OFF D On Board Diagnosis Logic DTC No. P1706 1706 BBS004Q4 Trouble diagnosis name DTC detecting condition Park/neutral position switch The signal of the park/neutral position (PNP) switch is not changed in the process of engine starting and driving. Overall Function Check E Possible cause ● Harness or connectors (PNP switch circuit is open or shorted.) ● Park/neutral position (PNP) switch BBS004Q6 Use this procedure to check the overall function of the park/neutral position (PNP) switch circuit. During this check, a 1st trip DTC might not be confirmed. WITH CONSULT-II 1. 2. G H Turn ignition switch ON. Select “P/N POSI SW” in “DATA MONITOR” mode with CONSULT-II. Then check the “P/N POSI SW” signal under the following conditions. Position (Shift lever) F I Known-good signal J N or P position (A/T) Neutral position (M/T) ON Except above position OFF K If NG, go to EC-1483, "Diagnostic Procedure" . SEF212Y L WITHOUT CONSULT-II 1. 2. Turn ignition switch ON. Check voltage between ECM terminal 70 (PNP switch signal) and ground under the following conditions. Condition (Gear position) Voltage (Known-good data) P or N position (A/T) Neutral position (M/T) Approx. 0 Except above position BATTERY VOLTAGE (11 - 14V) 3. M If NG, go to EC-1483, "Diagnostic Procedure" . MBIB1397E EC-1479 DTC P1706 PNP SWITCH [HR (WITHOUT EURO-OBD)] Wiring Diagram BBS004Q7 A/T MODELS MBWA1479E EC-1480 DTC P1706 PNP SWITCH [HR (WITHOUT EURO-OBD)] Specification data are reference values and are measured between each terminal and ground. CAUTION: Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM's transistor. Use a ground other than ECM terminals, such as the ground. TERMINAL NO. WIRE COLOR EC ITEM CONDITION DATA (DC Voltage) [Ignition switch: ON] 70 GR A Park/Neutral position (PNP) switch ● Shift lever: P or N (A/T models) ● Shift lever: Neutral (M/T models) [Ignition switch: ON] ● Except above position C Approximately 0V BATTERY VOLTAGE (11 - 14V) D E F G H I J K L M EC-1481 DTC P1706 PNP SWITCH [HR (WITHOUT EURO-OBD)] M/T MODELS MBWA1480E EC-1482 DTC P1706 PNP SWITCH [HR (WITHOUT EURO-OBD)] Specification data are reference values and are measured between each terminal and ground. CAUTION: Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM's transistor. Use a ground other than ECM terminals, such as the ground. TERMINAL NO. EC WIRE COLOR ITEM CONDITION DATA (DC Voltage) [Ignition switch: ON] 70 GR Park/Neutral position (PNP) switch ● Shift lever: P or N (A/T models) ● Shift lever: Neutral (M/T models) [Ignition switch: ON] ● Except above position Diagnostic Procedure C Approximately 0V D BATTERY VOLTAGE (11 - 14V) BBS004Q8 1. CHECK PNP SWITCH CIRCUIT 1. 2. A Turn ignition switch ON. Check voltage between IPDM E/R terminal 31 and ground under following condition. Shift lever position F G Voltage P or N (A/T models) Neutral (M/T models) Battery voltage (11- 14V) Except above position Approximately 0V OK or NG OK >> GO TO 8. NG >> GO TO 2. E H I MBIB0652E J K L M EC-1483 DTC P1706 PNP SWITCH [HR (WITHOUT EURO-OBD)] 2. CHECK PNP SWITCH POWER SUPPLY CIRCUIT 1. 2. 3. 4. Turn ignition switch OFF. Disconnect PNP switch harness connector. Turn ignition switch ON. Check voltage between PNP switch terminal 1 (A/T models), 2 (M/T models) and ground with CONSULT-II or tester. MBIB0654E MBIB0653E Voltage: Battery voltage OK or NG OK >> GO TO 4. NG >> GO TO 3. 3. DETECT MALFUNCTIONING PARTS Check the following. ● 10A fuse ● Harness connectors E59, F1 ● IPDM E/R connector E7 ● Harness for short or open between PNP switch and fuse >> Repair or replace harness or connectors. EC-1484 DTC P1706 PNP SWITCH [HR (WITHOUT EURO-OBD)] 4. CHECK HARNESS CONTINUTY BETWEEN PNP SWITCH AND IPDM E/R 1. 2. 3. A Turn ignition switch OFF. Disconnect IPDM E/R harness connector E7. Check harness continuity between IPDM E/R terminal 31 and PNP switch terminal 2 (A/T models), 3 (M/T EC models). Refer to Wiring Diagram. Continuity should exist. C 4. Also check harness for short to ground and short to power. OK or NG OK >> GO TO 6. NG >> GO TO 5. 5. DETECT MALFUNCTIONING PART D E Check the following. ● Harness connectors E59, F1 ● Harness for open or short between IPDM E/R and PNP switch >> Repair open circuit or short to ground or short to power in harness or connectors. F G 6. CHECK PNP SWITCH Refer to AT-109, "Component Inspection" (A/T models) or MT-16, "Park/Neutral Position Switch" (M/T models). OK or NG OK >> GO TO 7. NG >> Replace PNP switch. 7. CHECK INTERMITTENT INCIDENT H I J Refer to EC-1336, "TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT" . K >> INSPECTION END 8. CHECK PNP SWITCH GROUND CIRCUIT FOR OPEN AND SHORT 1. 2. 3. Turn ignition switch OFF. Disconnect IPDM E/R harness connectors E11 and E12. Check harness continuity between IPDM E/R terminal 3, 54 and ground. Refer to Wiring Diagram. Continuity should exist. 4. Also check harness for short to power. OK or NG OK >> GO TO 9. NG >> Repair open circuit or short to power in harness or connectors. EC-1485 L M DTC P1706 PNP SWITCH [HR (WITHOUT EURO-OBD)] 9. CHECK PNP SWITCH INPUT SIGNAL CIRCUIT FOR OPEN AND SHORT 1. 2. 3. Disconnect IPDM E/R harness connector E5 Disconnect ECM harness connector. Check harness continuity between ECM terminal 70 and IPDM E/R terminal 64. Refer to Wiring Diagram. Continuity should exist. 4. Also check harness for short to ground and short to power. OK or NG OK >> GO TO 10. NG >> Repair open circuit or short to ground or short to power in harness or connectors. 10. CHECK INTERMITTENT INCIDENT Refer to EC-1336, "TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT" . OK or NG OK >> Replace IPDM E/R. Refer to PG-18, "IPDM E/R (INTELLIGENT POWER DISTRIBUTION MODULE ENGINE ROOM)" . NG >> Repair or replace. EC-1486 DTC P1805 BRAKE SWITCH [HR (WITHOUT EURO-OBD)] DTC P1805 BRAKE SWITCH Description PFP:25320 A BBS004Q9 Brake switch signal is applied to the ECM through the stop lamp switch when the brake pedal is depressed. This signal is used mainly to decrease the engine speed when the vehicle is driving. EC CONSULT-II Reference Value in Data Monitor Mode BBS004QA Specification data are reference values. C MONITOR ITEM BRAKE SW CONDITION ● Ignition switch: ON SPECIFICATION Brake pedal: Fully released OFF Brake pedal: Slightly depressed ON On Board Diagnosis Logic D BBS004QB E This self-diagnosis has the one trip detection logic. DTC No. Trouble diagnosis name P1805 1805 Brake switch DTC detecting condition A brake switch signal is not sent to ECM for extremely long time while the vehicle is driving. Possible cause ● Harness or connectors (Stop lamp switch circuit is open or shorted.) ● Stop lamp switch FAIL-SAFE MODE BBS004QC F G When the malfunction is detected, ECM enters fail-safe mode and MI light up. H Engine operation condition in fail-fail safe mode ECM controls the electric throttle control actuator by regulating the throttle opening to a small range. Therefore, acceleration will be poor. Vehicle condition Driving condition When engine is idling Normal When accelerating Poor acceleration DTC Confirmation Procedure I J BBS004QD WITH CONSULT-II 1. 2. 3. 4. 5. K Turn ignition switch ON. Fully depress the brake pedal for at least 5 seconds. Erase the DTC with CONSULT-II. Select “DATA MONITOR” mode with CONSULT-II. If DTC is detected, go to EC-1489, "Diagnostic Procedure" . L M PBIB1952E WITHOUT CONSULT-II 1. 2. 3. 4. 5. 6. Turn ignition switch ON. Fully depress the brake pedal for at least 5 seconds. Erase the Diagnostic Test Mode II (Self-diagnostic results) memory. Refer to EC-1269, "How to Erase Diagnostic Test Mode II (Self-diagnostic Results)" . Turn ignition switch OFF, wait at least 10 seconds and then turn ON. Perform Diagnostic Test Mode II (Self-diagnostic results) with ECM. If DTC is detected, go to EC-1489, "Diagnostic Procedure" . EC-1487 DTC P1805 BRAKE SWITCH [HR (WITHOUT EURO-OBD)] Wiring Diagram BBS004QE MBWA1481E EC-1488 DTC P1805 BRAKE SWITCH [HR (WITHOUT EURO-OBD)] Specification data are reference values and are measured between each terminal and ground. CAUTION: Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM's transistor. Use a ground other than ECM terminals, such as the ground. TERMINAL NO. EC WIRE COLOR ITEM CONDITION [Ignition switch: OFF] ● 99 R Stop lamp switch Brake pedal: Fully released [Ignition switch: OFF] ● Brake pedal: Slightly depressed DATA (DC Voltage) C Approximately 0V BATTERY VOLTAGE (11 - 14V) Diagnostic Procedure D BBS004QF 1. CHECK STOP LAMP SWITCH CIRCUIT 1. 2. E Turn ignition switch OFF. Check the stop lamp when depressing and releasing the brake pedal. Brake pedal Stop lamp Fully released Not illuminated Slightly depressed Illuminated F G OK or NG OK >> GO TO 4. NG >> GO TO 2. H 2. CHECK STOP LAMP SWITCH POWER SUPPLY CIRCUIT 1. – A I Disconnect stop lamp switch (1) harness connector. Brake pedal (2) J K L PBIB2976E 2. M Check voltage between stop lamp switch terminal 1 and ground with CONSULT-II or tester. PBIB2284E Voltage: Battery voltage OK or NG OK >> GO TO 4. NG >> GO TO 3. EC-1489 DTC P1805 BRAKE SWITCH [HR (WITHOUT EURO-OBD)] 3. DETECT MALFUNCTIONING PART Check the following. ● Harness connectors M1, E101 (LHD models) ● Harness connectors M8, M201 (RHD models) ● 10A fuse ● Harness for open and short between stop lamp switch and battery >> Repair open circuit or short to ground or short to power in harness or connectors. 4. CHECK STOP LAMP SWITCH INPUT SIGNAL CIRCUIT FOR OPEN AND SHORT 1. – 2. 3. Disconnect stop lamp switch (1) harness connector. Brake pedal (2) Disconnect ECM harness connector. Check harness continuity between stop lamp switch terminal 2 and ECM terminal 99. Refer to Wiring Diagram. Continuity should exist. 4. Also check harness for short to ground and short to power. OK or NG OK >> GO TO 6. NG >> GO TO 5. 5. DETECT MALFUNCTIONING PART Check the following. ● Harness connectors M8, M201 (RHD models) ● Harness connectors M1, E101 (RHD models) ● Harness for open and short between stop lamp switch and ECM >> Repair open circuit or short to ground or short to power in harness connectors. 6. CHECK STOP LAMP SWITCH Refer to EC-1491, "Component Inspection" . OK or NG OK >> GO TO 7. NG >> Replace stop lamp switch. 7. CHECK INTERMITTENT INCIDENT Refer to EC-1336, "TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT" . >> INSPECTION END EC-1490 PBIB2976E DTC P1805 BRAKE SWITCH [HR (WITHOUT EURO-OBD)] Component Inspection BBS004QG A STOP LAMP SWITCH 1. 2. 3. Turn ignition switch OFF. Disconnect stop lamp switch harness connector. Check continuity between stop lamp switch terminals 1 and 2 under the following conditions. EC C D E PBIB2285E Condition Brake pedal: Fully released. Brake pedal: Slightly depressed. Continuity F Should not exist. Should exist. G If NG, adjust stop lamp switch installation, refer to BR-6, "BRAKE PEDAL" , and perform step 3 again. H I J K L M EC-1491 DTC P2122, P2123 APP SENSOR [HR (WITHOUT EURO-OBD)] DTC P2122, P2123 APP SENSOR Component Description PFP:18002 BBS004QH The accelerator pedal position sensor is installed on the upper end of the accelerator pedal assembly. The sensor detects the accelerator position and sends a signal to the ECM. Accelerator pedal position sensor has two sensors. These sensors are a kind of potentiometers which transform the accelerator pedal position into output voltage, and emit the voltage signal to the ECM. In addition, these sensors detect the opening and closing speed of the accelerator pedal and feed the voltage signals to the ECM. The ECM judges the current opening angle of the accelerator pedal from these signals and controls the throttle control motor based on these signals. PBIB1741E Idle position of the accelerator pedal is determined by the ECM receiving the signal from the accelerator pedal position sensor. The ECM uses this signal for the engine operation such as fuel cut. CONSULT-II Reference Value in Data Monitor Mode BBS004QI Specification data are reference values. MONITOR ITEM ACCEL SEN 1 ACCEL SEN 2* CLSD THL POS CONDITION ● ● ● SPECIFICATION Ignition switch: ON (Engine stopped) Accelerator pedal: Fully released 0.6 - 0.9V Accelerator pedal: Fully depressed 4.0 - 4.8V Ignition switch: ON (Engine stopped) Accelerator pedal: Fully released 0.6 - 0.9V Accelerator pedal: Fully depressed 3.9 - 4.8V Ignition switch: ON (Engine stopped) Accelerator pedal: Fully released ON Accelerator pedal: Slightly depressed OFF *: Accelerator pedal position sensor 2 signal is converted by ECM internally. Thus, it differs from ECM terminal voltage. On Board Diagnosis Logic BBS004QJ These self-diagnoses have the one trip detection logic. NOTE: If DTC P2122 or P2123 is displayed with DTC P1229, first perform the trouble diagnosis for DTC P1229. Refer to EC-1471, "DTC P1229 SENSOR POWER SUPPLY" . DTC No. Trouble diagnosis name DTC detecting condition P2122 2122 Accelerator pedal position sensor 1 circuit low input An excessively low voltage from the APP sensor 1 is sent to ECM. P2123 2123 Accelerator pedal position sensor 1 circuit high input An excessively high voltage from the APP sensor 1 is sent to ECM. Possible cause ● Harness or connectors (APP sensor 1 circuit is open or shorted.) ● Accelerator pedal position sensor (APP sensor 1) FAIL-SAFE MODE When the malfunction is detected, ECM enters fail-safe mode and the MI lights up. Engine operating condition in fail-safe mode The ECM controls the electric throttle control actuator in regulating the throttle opening in order for the idle position to be within +10 degrees. The ECM regulates the opening speed of the throttle valve to be slower than the normal condition. So, the acceleration will be poor. EC-1492 DTC P2122, P2123 APP SENSOR [HR (WITHOUT EURO-OBD)] DTC Confirmation Procedure BBS004QK A NOTE: If DTC Confirmation Procedure has been previously conducted, always turn ignition switch OFF and wait at least 10 seconds before conducting the next test. EC TESTING CONDITION: Before performing the following procedure, confirm that battery voltage is more than 10V at idle. WITH CONSULT-II 1. 2. 3. 4. C Turn ignition switch ON. Select “DATA MONITOR” mode with CONSULT-II. Start engine and let it idle for 1 second. If DTC is detected, go to EC-1497, "Diagnostic Procedure" . D E F SEF058Y WITHOUT CONSULT-II 1. 2. 3. 4. G Start engine and let it idle for 1 second. Turn ignition switch OFF, wait at least 10 seconds and then turn ON. Perform Diagnostic Test Mode II (Self-diagnostic results) with ECM. If DTC is detected, go to EC-1497, "Diagnostic Procedure" . H I J K L M EC-1493 DTC P2122, P2123 APP SENSOR [HR (WITHOUT EURO-OBD)] Wiring Diagram BBS004QL LHD MODELS MBWA1482E EC-1494 DTC P2122, P2123 APP SENSOR [HR (WITHOUT EURO-OBD)] Specification data are reference values and are measured between each terminal and ground. CAUTION: Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM's transistor. Use a ground other than ECM terminals, such as the ground. TERMINAL NO. 102 WIRE COLOR BR A EC ITEM Sensor power supply (APP sensor 2) CONDITION [Ignition switch: ON] DATA (DC Voltage) Approximately 5V C 0.3 - 0.6V D 1.95 - 2.4V E Approximately 0V F Approximately 5V G [Ignition switch: ON] 103 G Accelerator pedal position sensor 2 ● Engine stopped ● Accelerator pedal: Fully released [Ignition switch: ON] ● Engine stopped ● Accelerator pedal: Fully depressed [Engine is running] 104 106 B O Sensor ground (APP sensor 2) Sensor power supply (APP sensor 1) ● Warm-up condition ● Idle speed [Ignition switch: ON] [Ignition switch: ON] 110 W Accelerator pedal position sensor 1 ● Engine stopped ● Accelerator pedal: Fully released 0.6 - 0.9V H [Ignition switch: ON] ● Engine stopped ● Accelerator pedal: Fully depressed 3.9 - 4.7V I Approximately 0V J [Engine is running] 111 B Sensor ground (APP sensor 1) ● Warm-up condition ● Idle speed K L M EC-1495 DTC P2122, P2123 APP SENSOR [HR (WITHOUT EURO-OBD)] RHD MODELS MBWA1483E EC-1496 DTC P2122, P2123 APP SENSOR [HR (WITHOUT EURO-OBD)] Specification data are reference values and are measured between each terminal and ground. CAUTION: Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM's transistor. Use a ground other than ECM terminals, such as the ground. TERMINAL NO. 102 WIRE COLOR BR A EC ITEM CONDITION Sensor power supply (APP sensor 2) DATA (DC Voltage) [Ignition switch: ON] Approximately 5V C 0.3 - 0.6V D 1.95 - 2.4V E Approximately 0V F Approximately 5V G [Ignition switch: ON] 103 G Accelerator pedal position sensor 2 ● Engine stopped ● Accelerator pedal: Fully released [Ignition switch: ON] ● Engine stopped ● Accelerator pedal: Fully depressed [Engine is running] 104 106 B O Sensor ground (APP sensor 2) Sensor power supply (APP sensor 1) ● Warm-up condition ● Idle speed [Ignition switch: ON] [Ignition switch: ON] 110 W Accelerator pedal position sensor 1 ● Engine stopped ● Accelerator pedal: Fully released 0.6 - 0.9V H [Ignition switch: ON] ● Engine stopped ● Accelerator pedal: Fully depressed 3.9 - 4.7V I Approximately 0V J [Engine is running] 111 B Sensor ground (APP sensor 1) ● Warm-up condition ● Idle speed Diagnostic Procedure BBS004QM 1. CHECK GROUND CONNECTIONS 1. 2. Turn ignition switch OFF. Loosen and retighten ground screws on the body. Refer to EC-1342, "Ground Inspection" . K L M MBIB1550E 1. IPDM E/R 2. Body ground OK or NG OK >> GO TO 2. NG >> Repair or replace ground connections. EC-1497 3. Body ground DTC P2122, P2123 APP SENSOR [HR (WITHOUT EURO-OBD)] 2. CHECK APP SENSOR 1 POWER SUPPLY CIRCUIT 1. – – 2. Disconnect accelerator pedal position (APP) sensor harness connector (1). Accelerator pedal position sensor (2) Accelerator pedal (3) Turn ignition switch ON. PBIB2975E 3. Check voltage between APP sensor terminal 4 and ground with CONSULT-II or tester. Voltage: Approximately 5V OK or NG OK >> GO TO 4. NG >> GO TO 3. PBIA9606J 3. DETECT MALFUNCTIONING PART Check the following. ● Harness connectors M201, M8 (RHD models) ● Harness connectors M1, E101 (RHD models) ● Harness for open or short between APP sensor and ECM >> Repair open circuit or short to ground or short to power in harness or connectors. 4. CHECK APP SENSOR 1 GROUND CIRCUIT FOR OPEN AND SHORT 1. 2. 3. Turn ignition switch OFF. Disconnect ECM harness connector. Check harness continuity between ECM terminal 111 and APP sensor terminal 2. Refer to Wiring Diagram. Continuity should exist. 4. Also check harness for short to ground and short to power. OK or NG OK >> GO TO 6. NG >> GO TO 5. 5. DETECT MALFUNCTIONING PART Check the following. Harness connectors M201, M8 (RHD models) ● Harness connectors M1, E101 (RHD models) ● Harness for open or short between APP sensor and ECM ● >> Repair open circuit or short to ground or short to power in harness or connectors. EC-1498 DTC P2122, P2123 APP SENSOR [HR (WITHOUT EURO-OBD)] 6. CHECK APP SENSOR 1 INPUT SIGNAL CIRCUIT FOR OPEN AND SHORT 1. A Check harness continuity between ECM terminal 110 and APP sensor terminal 3. Refer to Wiring Diagram. EC Continuity should exist. 2. Also check harness for short to ground and short to power. OK or NG OK >> GO TO 8. NG >> GO TO 7. C 7. DETECT MALFUNCTIONING PART D Check the following. ● Harness connectors M201, M8 (RHD models) ● Harness connectors M1, E101 (RHD models) ● Harness for open or short between APP sensor and ECM E F >> Repair open circuit or short to ground or short to power in harness or connectors. 8. CHECK APP SENSOR G Refer to EC-1499, "Component Inspection" . OK or NG OK >> GO TO 10. NG >> GO TO 9. H I 9. REPLACE ACCELERATOR PEDAL ASSEMBLY 1. 2. 3. 4. Replace accelerator pedal assembly. Perform EC-1278, "Accelerator Pedal Released Position Learning" . Perform EC-1279, "Throttle Valve Closed Position Learning" . Perform EC-1279, "Idle Air Volume Learning" . J K >> INSPECTION END L 10. CHECK INTERMITTENT INCIDENT Refer to EC-1336, "TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT" . M >> INSPECTION END Component Inspection BBS004QN ACCELERATOR PEDAL POSITION SENSOR 1. 2. Reconnect all harness connectors disconnected. Turn ignition switch ON. EC-1499 DTC P2122, P2123 APP SENSOR [HR (WITHOUT EURO-OBD)] 3. Check voltage between ECM terminals 110 (APP sensor 1 signal), 103 (APP sensor 2 signal) and ground under the following conditions. Terminal Accelerator pedal Voltage 110 (Accelerator pedal position sensor 1) Fully released 0.6 - 0.9V Fully depressed 3.9 - 4.7V Fully released 0.3 - 0.6V Fully depressed 1.95 - 2.4V 103 (Accelerator pedal position sensor 2) 4. 5. 6. 7. PBIA9572J If NG, replace accelerator pedal assembly and go to next step. Perform EC-1278, "Accelerator Pedal Released Position Learning" . Perform EC-1279, "Throttle Valve Closed Position Learning" . Perform EC-1279, "Idle Air Volume Learning" . Removal and Installation BBS004QO ACCELERATOR PEDAL Refer to ACC-2, "ACCELERATOR CONTROL SYSTEM" . EC-1500 DTC P2127, P2128 APP SENSOR [HR (WITHOUT EURO-OBD)] DTC P2127, P2128 APP SENSOR Component Description PFP:18002 A BBS004QP The accelerator pedal position sensor is installed on the upper end of the accelerator pedal assembly. The sensor detects the acceleraEC tor position and sends a signal to the ECM. Accelerator pedal position sensor has two sensors. These sensors are a kind of potentiometers which transform the accelerator pedal C position into output voltage, and emit the voltage signal to the ECM. In addition, these sensors detect the opening and closing speed of the accelerator pedal and feed the voltage signals to the ECM. The ECM judges the current opening angle of the accelerator pedal from D these signals and controls the throttle control motor based on these signals. PBIB1741E Idle position of the accelerator pedal is determined by the ECM E receiving the signal from the accelerator pedal position sensor. The ECM uses this signal for the engine operation such as fuel cut. CONSULT-II Reference Value in Data Monitor Mode BBS004QQ F Specification data are reference values. MONITOR ITEM ACCEL SEN 1 ACCEL SEN 2* CLSD THL POS CONDITION ● ● ● SPECIFICATION Ignition switch: ON (Engine stopped) Accelerator pedal: Fully released 0.6 - 0.9V Accelerator pedal: Fully depressed 4.0 - 4.8V Ignition switch: ON (Engine stopped) Accelerator pedal: Fully released 0.6 - 0.9V Accelerator pedal: Fully depressed 3.9 - 4.8V Ignition switch: ON (Engine stopped) Accelerator pedal: Fully released ON Accelerator pedal: Slightly depressed OFF G H I *: Accelerator pedal position sensor 2 signal is converted by ECM internally. Thus, it differs from ECM terminal voltage. On Board Diagnosis Logic BBS004QR J These self-diagnoses have the one trip detection logic. DTC No. P2127 2127 P2128 2128 Trouble diagnosis name Accelerator pedal position sensor 2 circuit low input Accelerator pedal position sensor 2 circuit high input DTC detecting condition An excessively low voltage from the APP sensor 2 is sent to ECM. An excessively high voltage from the APP sensor 2 is sent to ECM. Possible cause ● Harness or connectors (APP sensor 2 circuit is open or shorted.) [Crankshaft position sensor (POS) circuit is shorted.] (Refrigerant pressure sensor circuit is shorted.) ● Accelerator pedal position sensor (APP sensor 2) ● Crankshaft position sensor (POS) ● Refrigerant pressure sensor FAIL-SAFE MODE When the malfunction is detected, ECM enters fail-safe mode and the MI lights up. Engine operating condition in fail-safe mode The ECM controls the electric throttle control actuator in regulating the throttle opening in order for the idle position to be within +10 degrees. The ECM regulates the opening speed of the throttle valve to be slower than the normal condition. So, the acceleration will be poor. EC-1501 K L M DTC P2127, P2128 APP SENSOR [HR (WITHOUT EURO-OBD)] DTC Confirmation Procedure BBS004QS NOTE: If DTC Confirmation Procedure has been previously conducted, always turn ignition switch OFF and wait at least 10 seconds before conducting the next test. TESTING CONDITION: Before performing the following procedure, confirm that battery voltage is more than 10V at idle. WITH CONSULT-II 1. 2. 3. 4. Turn ignition switch ON. Select “DATA MONITOR” mode with CONSULT-II. Start engine and let it idle for 1 second. If DTC is detected, go to EC-1507, "Diagnostic Procedure" . SEF058Y WITHOUT CONSULT-II 1. 2. 3. 4. Start engine and let it idle for 1 second. Turn ignition switch OFF, wait at least 10 seconds and then turn ON. Perform Diagnostic Test Mode II (Self-diagnostic results) with ECM. If DTC is detected, go to EC-1507, "Diagnostic Procedure" . EC-1502 DTC P2127, P2128 APP SENSOR [HR (WITHOUT EURO-OBD)] Wiring Diagram BBS004QT A LHD MODELS EC C D E F G H I J K L M MBWA1484E EC-1503 DTC P2127, P2128 APP SENSOR [HR (WITHOUT EURO-OBD)] Specification data are reference values and are measured between each terminal and ground. CAUTION: Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM's transistor. Use a ground other than ECM terminals, such as the ground. TERMINAL NO. WIRE COLOR ITEM CONDITION DATA (DC Voltage) 74 W Sensor power supply (Refrigerant pressure sensor) [Ignition switch: ON] Approximately 5V 75 G Sensor power supply [Crankshaft position sensor (POS)] [Ignition switch: ON] Approximately 5V 102 BR Sensor power supply (APP sensor 2) [Ignition switch: ON] Approximately 5V [Ignition switch: ON] 103 G Accelerator pedal position sensor 2 ● Engine stopped ● Accelerator pedal: Fully released 0.3 - 0.6V [Ignition switch: ON] ● Engine stopped ● Accelerator pedal: Fully depressed 1.95 - 2.4V [Engine is running] 104 106 B O Sensor ground (APP sensor 2) Sensor power supply (APP sensor 1) ● Warm-up condition ● Idle speed [Ignition switch: ON] Approximately 0V Approximately 5V [Ignition switch: ON] 110 W Accelerator pedal position sensor 1 ● Engine stopped ● Accelerator pedal: Fully released 0.6 - 0.9V [Ignition switch: ON] ● Engine stopped ● Accelerator pedal: Fully depressed 3.9 - 4.7V [Engine is running] 111 B Sensor ground (APP sensor 1) ● Warm-up condition ● Idle speed EC-1504 Approximately 0V DTC P2127, P2128 APP SENSOR [HR (WITHOUT EURO-OBD)] RHD MODELS A EC C D E F G H I J K L M MBWA1485E EC-1505 DTC P2127, P2128 APP SENSOR [HR (WITHOUT EURO-OBD)] Specification data are reference values and are measured between each terminal and ground. CAUTION: Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM's transistor. Use a ground other than ECM terminals, such as the ground. TERMINAL NO. WIRE COLOR ITEM CONDITION DATA (DC Voltage) 74 W Sensor power supply (Refrigerant pressure sensor) [Ignition switch: ON] Approximately 5V 75 G Sensor power supply [Crankshaft position sensor (POS)] [Ignition switch: ON] Approximately 5V 102 BR Sensor power supply (APP sensor 2) [Ignition switch: ON] Approximately 5V [Ignition switch: ON] 103 G Accelerator pedal position sensor 2 ● Engine stopped ● Accelerator pedal: Fully released 0.3 - 0.6V [Ignition switch: ON] ● Engine stopped ● Accelerator pedal: Fully depressed 1.95 - 2.4V [Engine is running] 104 106 B O Sensor ground (APP sensor 2) Sensor power supply (APP sensor 1) ● Warm-up condition ● Idle speed [Ignition switch: ON] Approximately 0V Approximately 5V [Ignition switch: ON] 110 W Accelerator pedal position sensor 1 ● Engine stopped ● Accelerator pedal: Fully released 0.6 - 0.9V [Ignition switch: ON] ● Engine stopped ● Accelerator pedal: Fully depressed 3.9 - 4.7V [Engine is running] 111 B Sensor ground (APP sensor 1) ● Warm-up condition ● Idle speed EC-1506 Approximately 0V DTC P2127, P2128 APP SENSOR [HR (WITHOUT EURO-OBD)] Diagnostic Procedure BBS004QU 1. CHECK GROUND CONNECTIONS 1. 2. A Turn ignition switch OFF. Loosen and retighten ground screws on the body. Refer to EC-1342, "Ground Inspection" . EC C D E MBIB1550E 1. IPDM E/R 2. Body ground 3. F Body ground OK or NG OK >> GO TO 2. NG >> Repair or replace ground connections. G 2. CHECK APP SENSOR 2 POWER SUPPLY CIRCUIT-I 1. – – 2. H Disconnect accelerator pedal position (APP) sensor harness connector (1). Accelerator pedal position sensor (2) Accelerator pedal (3) Turn ignition switch ON. I J K PBIB2975E 3. Check voltage between APP sensor terminal 5 and ground with CONSULT-II or tester. L Voltage: Approximately 5V M OK or NG OK >> GO TO 7. NG >> GO TO 3. PBIA9607J EC-1507 DTC P2127, P2128 APP SENSOR [HR (WITHOUT EURO-OBD)] 3. CHECK APP SENSOR 2 POWER SUPPLY CIRCUIT-II 1. 2. 3. Turn ignition switch OFF. Disconnect ECM harness connector. Check harness continuity between APP sensor terminal 5 and ECM terminal 102. Refer to Wiring Diagram. Continuity should exist. OK or NG OK >> GO TO 5. NG >> GO TO 4. 4. DETECT MALFUNCTIONING PART Check the following. ● Harness connectors M201, M8 (RHD models) ● Harness connectors M1, E101 (RHD models) ● Harness for open or short between APP sensor and ECM >> Repair open circuit in harness or connectors. 5. CHECK APP SENSOR 2 POWER SUPPLY CIRCUIT-III Check harness for short to power and short to ground, between the following terminals. ECM terminal Sensor terminal Reference Wiring Diagram 74 Refrigerant pressure sensor terminal 3 EC-1591, "Wiring Diagram" 75 Crankshaft position sensor (POS) terminal 1 EC-1407, "Wiring Diagram" 102 APP sensor terminal 5 EC-1503, "Wiring Diagram" OK or NG OK >> GO TO 6. NG >> Repair short to ground or short to power in harness or connectors. 6. CHECK COMPONENTS Check the following. ● Crankshaft position sensor (POS) (Refer to EC-1412, "Component Inspection" .) ● Refrigerant pressure sensor (Refer to ATC-85, "Refrigerant Pressure Sensor" .) OK or NG OK >> GO TO 13. NG >> Replace malfunctioning component. 7. CHECK APP SENSOR 2 GROUND CIRCUIT FOR OPEN AND SHORT 1. 2. 3. Turn ignition switch OFF. Disconnect ECM harness connector. Check harness continuity between ECM terminal 104 and APP sensor terminal 1. Refer to Wiring Diagram. Continuity should exist. 4. Also check harness for short to ground and short to power. OK or NG OK >> GO TO 9. NG >> GO TO 8. EC-1508 DTC P2127, P2128 APP SENSOR [HR (WITHOUT EURO-OBD)] 8. DETECT MALFUNCTIONING PART A Check the following. ● Harness connectors M201, M8 (RHD models) ● Harness connectors M1, E101 (RHD models) ● Harness for open or short between APP sensor and ECM EC C >> Repair open circuit or short to ground or short to power in harness or connectors. 9. CHECK APP SENSOR 2 INPUT SIGNAL CIRCUIT FOR OPEN AND SHORT 1. D Check harness continuity between ECM terminal 103 and APP sensor terminal 6. Refer to Wiring Diagram. E Continuity should exist. 2. Also check harness for short to ground and short to power. OK or NG OK >> GO TO 11. NG >> GO TO 10. F 10. DETECT MALFUNCTIONING PART G Check the following. ● Harness connectors M201, M8 (RHD models) ● Harness connectors M1, E101 (RHD models) ● Harness for open or short between APP sensor and ECM H I >> Repair open circuit or short to ground or short to power in harness or connectors. 11. CHECK APP SENSOR J Refer to EC-1509, "Component Inspection" . OK or NG OK >> GO TO 13. NG >> GO TO 12. K L 12. REPLACE ACCELERATOR PEDAL ASSEMBLY 1. 2. 3. 4. Replace accelerator pedal assembly. Perform EC-1278, "Accelerator Pedal Released Position Learning" . Perform EC-1279, "Throttle Valve Closed Position Learning" . Perform EC-1279, "Idle Air Volume Learning" . M >> INSPECTION END 13. CHECK INTERMITTENT INCIDENT Refer to EC-1336, "TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT" . >> INSPECTION END Component Inspection BBS004QV ACCELERATOR PEDAL POSITION SENSOR 1. 2. Reconnect all harness connectors disconnected. Turn ignition switch ON. EC-1509 DTC P2127, P2128 APP SENSOR [HR (WITHOUT EURO-OBD)] 3. Check voltage between ECM terminals 110 (APP sensor 1 signal), 103 (APP sensor 2 signal) and ground under the following conditions. Terminal Accelerator pedal Voltage 110 (Accelerator pedal position sensor 1) Fully released 0.6 - 0.9V Fully depressed 3.9 - 4.7V Fully released 0.3 - 0.6V Fully depressed 1.95 - 2.4V 103 (Accelerator pedal position sensor 2) 4. 5. 6. 7. PBIA9572J If NG, replace accelerator pedal assembly and go to next step. Perform EC-1278, "Accelerator Pedal Released Position Learning" . Perform EC-1279, "Throttle Valve Closed Position Learning" . Perform EC-1279, "Idle Air Volume Learning" . Removal and Installation BBS004QW ACCELERATOR PEDAL Refer to ACC-2, "ACCELERATOR CONTROL SYSTEM" . EC-1510 DTC P2135 TP SENSOR [HR (WITHOUT EURO-OBD)] DTC P2135 TP SENSOR Component Description PFP:16119 A BBS004QX Electric throttle control actuator consists of throttle control motor, throttle position sensor, etc. The throttle position sensor responds to the throttle valve movement. The throttle position sensor has the two sensors. These sensors are a kind of potentiometers which transform the throttle valve position into output voltage, and emit the voltage signal to the ECM. In addition, these sensors detect the opening and closing speed of the throttle valve and feed the voltage signals to the ECM. The ECM judges the current opening angle of the throttle valve from these signals and the ECM controls the throttle control motor to make the throttle valve opening angle properly in response to driving condition. EC C D PBIB0145E E CONSULT-II Reference Value in Data Monitor Mode BBS004QY Specification data are reference values. MONITOR ITEM CONDITION ● Ignition switch: ON (Engine stopped) Accelerator pedal: Fully released More than 0.36V ● Shift lever: D (A/T), 1st (M/T) Accelerator pedal: Fully depressed Less than 4.75V THRTL SEN 1 THRTL SEN 2* F SPECIFICATION G *: Throttle position sensor 2 signal is converted by ECM internally. Thus, it differs from ECM terminal voltage signal. On Board Diagnosis Logic BBS004QZ This self-diagnosis has the one trip detection logic. NOTE: If DTC P2135 is displayed with DTC P1229, first perform the trouble diagnosis for DTC P1229. Refer to EC-1471, "DTC P1229 SENSOR POWER SUPPLY" . DTC No. P2135 2135 Trouble diagnosis name DTC detecting condition Throttle position sensor circuit range/performance Rationally incorrect voltage is sent to ECM compared with the signals from TP sensor 1 and TP sensor 2. Possible cause ● Harness or connector (TP sensor 1 and 2 circuit is open or shorted.) ● Electric throttle control actuator (TP sensor 1 and 2) H I J K L FAIL-SAFE MODE When the malfunction is detected, the ECM enters fail-safe mode and the MI lights up. Engine operation condition in fail-safe mode The ECM controls the electric throttle control actuator in regulating the throttle opening in order for the idle position to be within +10 degrees. The ECM regulates the opening speed of the throttle valve to be slower than the normal condition. So, the acceleration will be poor. EC-1511 M DTC P2135 TP SENSOR [HR (WITHOUT EURO-OBD)] DTC Confirmation Procedure BBS004R0 NOTE: If DTC Confirmation Procedure has been previously conducted, always turn ignition switch OFF and wait at least 10 seconds before conducting the next test. TESTING CONDITION: Before performing the following procedure, confirm that battery voltage is more than 10V at idle. WITH CONSULT-II 1. 2. 3. 4. Turn ignition switch ON. Select “DATA MONITOR” mode with CONSULT-II. Start engine and let it idle for 1 second. If DTC is detected, go to EC-1514, "Diagnostic Procedure" . SEF058Y WITHOUT CONSULT-II 1. 2. 3. 4. Start engine and let it idle for 1 second. Turn ignition switch OFF, wait at least 10 seconds and then turn ON. Perform Diagnostic Test Mode II (Self-diagnostic results) with ECM. If DTC is detected, go to EC-1514, "Diagnostic Procedure" . EC-1512 DTC P2135 TP SENSOR [HR (WITHOUT EURO-OBD)] Wiring Diagram BBS004R1 A EC C D E F G H I J K L M MBWA1486E EC-1513 DTC P2135 TP SENSOR [HR (WITHOUT EURO-OBD)] Specification data are reference values and are measured between each terminal and ground. CAUTION: Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM's transistor. Use a ground other than ECM terminals, such as the ground. TERMINAL NO. WIRE COLOR ITEM CONDITION DATA (DC Voltage) [Ignition switch: ON] 33 Y ● Engine stopped ● Shift lever: D (A/T), 1st (M/T) ● Accelerator pedal: Fully released Throttle position sensor 1 More than 0.36V [Ignition switch: ON] ● Engine stopped ● Shift lever: D (A/T), 1st (M/T) ● Accelerator pedal: Fully depressed Less than 4.75V [Ignition switch: ON] 34 R Throttle position sensor 2 ● Engine stopped ● Shift lever: D (A/T), 1st (M/T) ● Accelerator pedal: Fully released Less than 4.75V [Ignition switch: ON] ● Engine stopped ● Shift lever: D (A/T), 1st (M/T) ● Accelerator pedal: Fully depressed More than 0.36V [Engine is running] 36 72 BR L Sensor ground (Throttle position sensor) Sensor power supply (Throttle position sensor) ● Warm-up condition ● Idle speed Approximately 0V [Ignition switch: ON] Approximately 5V Diagnostic Procedure BBS004R2 1. CHECK GROUND CONNECTIONS 1. 2. Turn ignition switch OFF. Loosen and retighten ground screws on the body. Refer to EC-1342, "Ground Inspection" . MBIB1550E 1. IPDM E/R 2. Body ground OK or NG OK >> GO TO 2. NG >> Repair or replace ground connections. EC-1514 3. Body ground DTC P2135 TP SENSOR [HR (WITHOUT EURO-OBD)] 2. CHECK THROTTLE POSITION SENSOR POWER SUPPLY CIRCUIT 1. 2. A Disconnect electric throttle control actuator (1) harness connector. : Vehicle front Turn ignition switch ON. EC C D PBIB2965E 3. Check voltage between electric throttle control actuator terminal 1 and ground with CONSULT-II or tester. E Voltage: Approximately 5V F OK or NG OK >> GO TO 3. NG >> Repair open circuit or short to ground or short to power in harness or connectors. G PBIA9580J H 3. CHECK THROTTLE POSITION SENSOR GROUND CIRCUIT FOR OPEN AND SHORT 1. 2. 3. Turn ignition switch OFF. Disconnect ECM harness connector. Check harness continuity between electric throttle control actuator terminal 4 and ECM terminal 36. Refer to Wiring Diagram. I J Continuity should exist. 4. Also check harness for short to ground and short to power. OK or NG OK >> GO TO 4. NG >> Repair open circuit or short to ground or short to power in harness or connectors. K L 4. CHECK THROTTLE POSITION SENSOR INPUT SIGNAL CIRCUIT FOR OPEN AND SHORT 1. Check harness continuity between electric throttle control actuator terminal 2 and ECM terminal 33, electric throttle control actuator terminal 3 and ECM terminal 34. Refer to Wiring Diagram. Continuity should exist. 2. Also check harness for short to ground and short to power. OK or NG OK >> GO TO 5. NG >> Repair open circuit or short to ground or short to power in harness or connectors. 5. CHECK THROTTLE POSITION SENSOR Refer to EC-1516, "Component Inspection" . OK or NG OK >> GO TO 7. NG >> GO TO 6. EC-1515 M DTC P2135 TP SENSOR [HR (WITHOUT EURO-OBD)] 6. REPLACE ELECTRIC THROTTLE CONTROL ACTUATOR 1. 2. 3. Replace the electric throttle control actuator. Perform EC-1279, "Throttle Valve Closed Position Learning" . Perform EC-1279, "Idle Air Volume Learning" . >> INSPECTION END 7. CHECK INTERMITTENT INCIDENT Refer to EC-1336, "TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT" . >> INSPECTION END Component Inspection BBS004R3 THROTTLE POSITION SENSOR 1. 2. 3. 4. 5. Reconnect all harness connectors disconnected. Perform EC-1279, "Throttle Valve Closed Position Learning" . Turn ignition switch ON. Set shift lever to D position (A/T) or 1st position (M/T). Check voltage between ECM terminals 33 (TP sensor 1 signal), 34 (TP sensor 2 signal) and ground under the following conditions. Terminal Accelerator pedal Voltage 33 (Throttle position sensor 1) Fully released More than 0.36V Fully depressed Less than 4.75V Fully released Less than 4.75V Fully depressed More than 0.36V 34 (Throttle position sensor 2) 6. 7. 8. If NG, replace electric throttle control actuator and go to the next step. Perform EC-1279, "Throttle Valve Closed Position Learning" . Perform EC-1279, "Idle Air Volume Learning" . Removal and Installation PBIB3038E BBS004R4 ELECTRIC THROTTLE CONTROL ACTUATOR Refer to EM-120, "INTAKE MANIFOLD" . EC-1516 DTC P2138 APP SENSOR [HR (WITHOUT EURO-OBD)] DTC P2138 APP SENSOR Component Description PFP:18002 A BBS004R5 The accelerator pedal position sensor is installed on the upper end of the accelerator pedal assembly. The sensor detects the acceleraEC tor position and sends a signal to the ECM. Accelerator pedal position sensor has two sensors. These sensors are a kind of potentiometers which transform the accelerator pedal C position into output voltage, and emit the voltage signal to the ECM. In addition, these sensors detect the opening and closing speed of the accelerator pedal and feed the voltage signals to the ECM. The ECM judges the current opening angle of the accelerator pedal from D these signals and controls the throttle control motor based on these signals. PBIB1741E Idle position of the accelerator pedal is determined by the ECM E receiving the signal from the accelerator pedal position sensor. The ECM uses this signal for the engine operation such as fuel cut. CONSULT-II Reference Value in Data Monitor Mode BBS004R6 F Specification data are reference values. MONITOR ITEM ACCEL SEN 1 ACCEL SEN 2* CLSD THL POS CONDITION ● ● ● SPECIFICATION Ignition switch: ON (Engine stopped) Accelerator pedal: Fully released 0.6 - 0.9V Accelerator pedal: Fully depressed 4.0 - 4.8V Ignition switch: ON (Engine stopped) Accelerator pedal: Fully released 0.6 - 0.9V Accelerator pedal: Fully depressed 3.9 - 4.8V Ignition switch: ON (Engine stopped) Accelerator pedal: Fully released ON Accelerator pedal: Slightly depressed OFF G H I *: Accelerator pedal position sensor 2 signal is converted by ECM internally. Thus, it differs from ECM terminal voltage. On Board Diagnosis Logic BBS004R7 This self-diagnosis has the one trip detection logic. NOTE: If DTC P2138 is displayed with DTC P1229, first perform the trouble diagnosis for DTC P1229. Refer to EC-1471, "DTC P1229 SENSOR POWER SUPPLY" . DTC No. Trouble diagnosis name DTC detecting condition Possible cause ● P2138 2138 Accelerator pedal position sensor circuit range/performance Rationally incorrect voltage is sent to ECM compared with the signals from APP sensor 1 and APP sensor 2. EC-1517 Harness or connector (APP sensor 1 and 2 circuit is open or shorted.) [Crankshaft position sensor (POS) circuit is shorted.] (Refrigerant pressure sensor circuit is shorted.) ● Accelerator pedal position sensor (APP sensor 1 and 2) ● Crankshaft position sensor (POS) ● Refrigerant pressure sensor J K L M DTC P2138 APP SENSOR [HR (WITHOUT EURO-OBD)] FAIL-SAFE MODE When the malfunction is detected, ECM enters fail-safe mode and the MI lights up. Engine operating condition in fail-safe mode The ECM controls the electric throttle control actuator in regulating the throttle opening in order for the idle position to be within +10 degrees. The ECM regulates the opening speed of the throttle valve to be slower than the normal condition. So, the acceleration will be poor. DTC Confirmation Procedure BBS004R8 NOTE: If DTC Confirmation Procedure has been previously conducted, always turn ignition switch OFF and wait at least 10 seconds before conducting the next test. TESTING CONDITION: Before performing the following procedure, confirm that battery voltage is more than 10V at idle. WITH CONSULT-II 1. 2. 3. 4. Turn ignition switch ON. Select “DATA MONITOR” mode with CONSULT-II. Start engine and let it idle for 1 second. If DTC is detected, go to EC-1523, "Diagnostic Procedure" . SEF058Y WITHOUT CONSULT-II 1. 2. 3. 4. Start engine and let it idle for 1 second. Turn ignition switch OFF, wait at least 10 seconds and then turn ON. Perform Diagnostic Test Mode II (Self-diagnostic results) with ECM. If DTC is detected, go to EC-1523, "Diagnostic Procedure" . EC-1518 DTC P2138 APP SENSOR [HR (WITHOUT EURO-OBD)] Wiring Diagram BBS004R9 A LHD MODELS EC C D E F G H I J K L M MBWA1487E EC-1519 DTC P2138 APP SENSOR [HR (WITHOUT EURO-OBD)] Specification data are reference values and are measured between each terminal and ground. CAUTION: Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM's transistor. Use a ground other than ECM terminals, such as the ground. TERMINAL NO. WIRE COLOR ITEM CONDITION DATA (DC Voltage) 74 W Sensor power supply (Refrigerant pressure sensor) [Ignition switch: ON] Approximately 5V 75 G Sensor power supply [Crankshaft position sensor (POS)] [Ignition switch: ON] Approximately 5V 102 BR Sensor power supply (APP sensor 2) [Ignition switch: ON] Approximately 5V [Ignition switch: ON] 103 G Accelerator pedal position sensor 2 ● Engine stopped ● Accelerator pedal: Fully released 0.3 - 0.6V [Ignition switch: ON] ● Engine stopped ● Accelerator pedal: Fully depressed 1.95 - 2.4V [Engine is running] 104 106 B O Sensor ground (APP sensor 2) Sensor power supply (APP sensor 1) ● Warm-up condition ● Idle speed [Ignition switch: ON] Approximately 0V Approximately 5V [Ignition switch: ON] 110 W Accelerator pedal position sensor 1 ● Engine stopped ● Accelerator pedal: Fully released 0.6 - 0.9V [Ignition switch: ON] ● Engine stopped ● Accelerator pedal: Fully depressed 3.9 - 4.7V [Engine is running] 111 B Sensor ground (APP sensor 1) ● Warm-up condition ● Idle speed EC-1520 Approximately 0V DTC P2138 APP SENSOR [HR (WITHOUT EURO-OBD)] RHD MODELS A EC C D E F G H I J K L M MBWA1488E EC-1521 DTC P2138 APP SENSOR [HR (WITHOUT EURO-OBD)] Specification data are reference values and are measured between each terminal and ground. CAUTION: Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM's transistor. Use a ground other than ECM terminals, such as the ground. TERMINAL NO. WIRE COLOR ITEM CONDITION DATA (DC Voltage) 74 W Sensor power supply (Refrigerant pressure sensor) [Ignition switch: ON] Approximately 5V 75 G Sensor power supply [Crankshaft position sensor (POS)] [Ignition switch: ON] Approximately 5V 102 BR Sensor power supply (APP sensor 2) [Ignition switch: ON] Approximately 5V [Ignition switch: ON] 103 G Accelerator pedal position sensor 2 ● Engine stopped ● Accelerator pedal: Fully released 0.3 - 0.6V [Ignition switch: ON] ● Engine stopped ● Accelerator pedal: Fully depressed 1.95 - 2.4V [Engine is running] 104 106 B O Sensor ground (APP sensor 2) Sensor power supply (APP sensor 1) ● Warm-up condition ● Idle speed [Ignition switch: ON] Approximately 0V Approximately 5V [Ignition switch: ON] 110 W Accelerator pedal position sensor 1 ● Engine stopped ● Accelerator pedal: Fully released 0.6 - 0.9V [Ignition switch: ON] ● Engine stopped ● Accelerator pedal: Fully depressed 3.9 - 4.7V [Engine is running] 111 B Sensor ground (APP sensor 1) ● Warm-up condition ● Idle speed EC-1522 Approximately 0V DTC P2138 APP SENSOR [HR (WITHOUT EURO-OBD)] Diagnostic Procedure BBS004RA 1. CHECK GROUND CONNECTIONS 1. 2. A Turn ignition switch OFF. Loosen and retighten ground screws on the body. Refer to EC-1342, "Ground Inspection" . EC C D E MBIB1550E 1. IPDM E/R 2. Body ground 3. F Body ground OK or NG OK >> GO TO 2. NG >> Repair or replace ground connections. G 2. CHECK APP SENSOR 1 POWER SUPPLY CIRCUIT 1. – – 2. H Disconnect accelerator pedal position (APP) sensor harness connector (1). Accelerator pedal position sensor (2) Accelerator pedal (3) Turn ignition switch ON. I J K PBIB2975E 3. Check voltage between APP sensor terminal 4 and ground with CONSULT-II or tester. L Voltage: Approximately 5V M OK or NG OK >> GO TO 4. NG >> GO TO 3. PBIA9606J 3. DETECT MALFUNCTIONING PART Check the following. ● Harness connectors M201, M8 (RHD models) ● Harness connectors M1, E101 (RHD models) ● Harness for open or short between APP sensor and ECM >> Repair open circuit or short to ground or short to power in harness or connectors. EC-1523 DTC P2138 APP SENSOR [HR (WITHOUT EURO-OBD)] 4. CHECK APP SENSOR 2 POWER SUPPLY CIRCUIT-I 1. 2. Turn ignition switch ON. Check voltage between APP sensor terminal 5 and ground with CONSULT-II or tester. Voltage: Approximately 5V OK or NG OK >> GO TO 9. NG >> GO TO 5. PBIA9607J 5. CHECK APP SENSOR 2 POWER SUPPLY CIRCUIT-II 1. 2. 3. Turn ignition switch OFF. Disconnect ECM harness connector. Check harness continuity between APP sensor terminal 5 and ECM terminal 102. Refer to Wiring Diagram. Continuity should exist. OK or NG OK >> GO TO 7. NG >> GO TO 6. 6. DETECT MALFUNCTIONING PART Check the following. ● Harness connectors M201, M8 (RHD models) ● Harness connectors M1, E101 (RHD models) ● Harness for open between APP sensor and ECM >> Repair open circuit in harness or connectors. 7. CHECK APP SENSOR 2 POWER SUPPLY CIRCUIT-III Check harness for short to power and short to ground, between the following terminals. ECM terminal Sensor terminal Reference Wiring Diagram 74 Refrigerant pressure sensor terminal 3 EC-1591, "Wiring Diagram" 75 Crankshaft position sensor (POS) terminal 1 EC-1407, "Wiring Diagram" 102 APP sensor terminal 5 EC-1519, "Wiring Diagram" OK or NG OK >> GO TO 8. NG >> Repair short to ground or short to power in harness or connectors. 8. CHECK COMPONENTS Check the following. Crankshaft position sensor (POS) (Refer to EC-1412, "Component Inspection" .) ● Refrigerant pressure sensor (Refer to ATC-85, "Refrigerant Pressure Sensor" .) OK or NG OK >> GO TO 15. NG >> Replace malfunctioning component. ● EC-1524 DTC P2138 APP SENSOR [HR (WITHOUT EURO-OBD)] 9. CHECK APP SENSOR GROUND CIRCUIT FOR OPEN AND SHORT 1. 2. 3. A Turn ignition switch OFF. Disconnect ECM harness connector. Check harness continuity between ECM terminal 111 and APP sensor terminal 2, ECM terminal 104 and EC APP sensor terminal 1. Refer to Wiring Diagram. C Continuity should exist. 4. Also check harness for short to ground and short to power. OK or NG OK >> GO TO 11. NG >> GO TO 10. D E 10. DETECT MALFUNCTIONING PART Check the following. Harness connectors M201, M8 (RHD models) ● Harness connectors M1, E101 (RHD models) ● Harness for open between APP sensor and ECM ● F G >> Repair open circuit in harness or connectors. 11. CHECK APP SENSOR INPUT SIGNAL CIRCUIT FOR OPEN AND SHORT 1. Check harness continuity between ECM terminal 110 and APP sensor terminal 3, ECM terminal 103 and APP sensor terminal 6. Refer to Wiring Diagram. H I Continuity should exist. 2. Also check harness for short to ground and short to power. OK or NG OK >> GO TO 13. NG >> GO TO 12. 12. DETECT MALFUNCTIONING PART J K L Check the following. ● Harness connectors M201, M8 (RHD models) ● Harness connectors M1, E101 (RHD models) ● Harness for open between APP sensor and ECM >> Repair open circuit in harness or connectors. 13. CHECK APP SENSOR Refer to EC-1527, "Component Inspection" . OK or NG OK >> GO TO 15. NG >> GO TO 14. EC-1525 M DTC P2138 APP SENSOR [HR (WITHOUT EURO-OBD)] 14. REPLACE ACCELERATOR PEDAL ASSEMBLY 1. 2. 3. 4. Replace accelerator pedal assembly. Perform EC-1278, "Accelerator Pedal Released Position Learning" . Perform EC-1279, "Throttle Valve Closed Position Learning" . Perform EC-1277, "Idle Speed and Ignition Timing Check" . >> INSPECTION END 15. CHECK INTERMITTENT INCIDENT Refer to EC-1336, "TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT" . >> INSPECTION END EC-1526 DTC P2138 APP SENSOR [HR (WITHOUT EURO-OBD)] Component Inspection BBS004RB A ACCELERATOR PEDAL POSITION SENSOR 1. 2. 3. Reconnect all harness connectors disconnected. Turn ignition switch ON. Check voltage between ECM terminals 110 (APP sensor 1 signal), 103 (APP sensor 2 signal) and ground under the following conditions. Terminal Accelerator pedal Voltage 110 (Accelerator pedal position sensor 1) Fully released 0.6 - 0.9V Fully depressed 3.9 - 4.7V Fully released 0.3 - 0.6V Fully depressed 1.95 - 2.4V 103 (Accelerator pedal position sensor 2) 4. 5. 6. 7. EC C D E PBIA9572J If NG, replace accelerator pedal assembly and go to next step. Perform EC-1278, "Accelerator Pedal Released Position Learning" . Perform EC-1279, "Throttle Valve Closed Position Learning" . Perform EC-1279, "Idle Air Volume Learning" . Removal and Installation F BBS004RC G ACCELERATOR PEDAL Refer to ACC-2, "ACCELERATOR CONTROL SYSTEM" . H I J K L M EC-1527 ELECTRICAL LOAD SIGNAL [HR (WITHOUT EURO-OBD)] ELECTRICAL LOAD SIGNAL CONSULT-II Reference Value in Data Monitor Mode PFP:25350 BBS004RG Specification data are reference values. MONITOR ITEM LOAD SIGNAL CONDITION ● HEATER FAN SW ● Ignition switch: ON Ignition switch: ON SPECIFICATION Rear window defogger switch is ON and/or lighting switch is in 2nd position. ON Rear window defogger switch is OFF and lighting switch is OFF. OFF Heater fan is operating. ON Heater fan is not operating. OFF Diagnostic Procedure BBS004RH 1. CHECK LOAD SIGNAL CIRCUIT OVERALL FUNCITION-I 1. 2. Turn ignition switch ON. Check “LOAD SIGNAL” in “DATA MONITOR” mode with CONSULT-II under the following conditions. Condition LOAD SIGNAL Lighting switch: ON at 2nd position ON Lighting switch: OFF OFF OK or NG OK >> GO TO 2. NG >> GO TO 4. PBIB0103E 2. CHECK LOAD SIGNAL CIRCUIT OVERALL FUNCTION-II Check “LOAD SIGNAL” in “DATA MONITOR” mode with CONSULTII under the following conditions. Condition LOAD SIGNAL Rear window defogger switch: ON ON Rear window defogger switch: OFF OFF OK or NG OK >> GO TO 3. NG >> GO TO 5. PBIB0103E 3. CHECK HEATER FAN SIGNAL CIRCUIT OVERALL FUNCTION Check “HEATER FAN SW” in “DATA MONITOR” mode with CONSULT-II under the following conditions. Condition HEATER FAN SW Heater fan control switch: ON ON Heater fan control switch: OFF OFF OK or NG OK >> INSPECTION END. NG >> GO TO 6. PBIB1995E EC-1528 ELECTRICAL LOAD SIGNAL [HR (WITHOUT EURO-OBD)] 4. CHECK HEADLAMP SYSTEM A Refer to LT-7, "HEADLAMP -CONVENTIONAL TYPE-" or LT-35, "HEADLAMP - DAYTIME LIGHT SYSTEM ". EC >> INSPECTION END 5. CHECK REAR WINDOW DEFOGGER SYSTEM C Refer to GW-12, "REAR WINDOW DEFOGGER" . D >> INSPECTION END 6. CHECK HEATER FAN CONTROL SYSTEM E Refer to ATC-26, "TROUBLE DIAGNOSIS" (models with automatic air conditioner) or MTC-23, "TROUBLE DIAGNOSIS" (models with manual air conditioner). F >> INSPECTION END G H I J K L M EC-1529 EVAP CANISTER PURGE VOLUME CONTROL SOLENOID VALVE [HR (WITHOUT EURO-OBD)] EVAP CANISTER PURGE VOLUME CONTROL SOLENOID VALVE Description PFP:14920 BBS004RI SYSTEM DESCRIPTION Sensor Input Signal to ECM Crankshaft position sensor (POS) Camshaft position sensor (PHASE) Engine speed*1 Mass air flow sensor Amount of intake air Engine coolant temperature sensor Engine coolant temperature Battery Battery voltage*1 Throttle position sensor Throttle position Accelerator pedal position sensor Accelerator pedal position Heated oxygen sensor 1 Density of oxygen in exhaust gas (Mixture ratio feedback signal) Wheel sensor Vehicle speed*2 ECM function Actuator EVAP canister purge flow control EVAP canister purge volume control solenoid valve *1: ECM determines the start signal status by the signals of engine speed and battery voltage. *2: This signal is sent to the ECM through CAN communication line. This system controls flow rate of fuel vapor from the EVAP canister. The opening of the vapor by-pass passage in the EVAP canister purge volume control solenoid valve changes to control the flow rate. The EVAP canister purge volume control solenoid valve repeats ON/OFF operation according to the signal sent from the ECM. The opening of the valve varies for optimum engine control. The optimum value stored in the ECM is determined by considering various engine conditions. When the engine is operating, the flow rate of fuel vapor from the EVAP canister is regulated as the air flow changes. COMPONENT DESCRIPTION The EVAP canister purge volume control solenoid valve uses a ON/ OFF duty to control the flow rate of fuel vapor from the EVAP canister. The EVAP canister purge volume control solenoid valve is moved by ON/OFF pulses from the ECM. The longer the ON pulse, the greater the amount of fuel vapor that will flow through the valve. PBIA9215J CONSULT-II Reference Value in Data Monitor Mode BBS004RJ Specification data are reference values. MONITOR ITEM CONDITION ● Engine: After warming up ● Shift lever: P or N (A/T), Neutral (M/T) ● Air conditioner switch: OFF ● No load PURG VOL C/V SPECIFICATION Idle 0% 2,000 rpm 0 - 50% EC-1530 EVAP CANISTER PURGE VOLUME CONTROL SOLENOID VALVE [HR (WITHOUT EURO-OBD)] Wiring Diagram BBS004RK A EC C D E F G H I J K L M MBWA1496E EC-1531 EVAP CANISTER PURGE VOLUME CONTROL SOLENOID VALVE [HR (WITHOUT EURO-OBD)] Specification data are reference values and are measured between each terminal and ground. Pulse signal is measured by CONSULT-II. CAUTION: Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM's transistor. Use a ground other than ECM terminals, such as the ground. TERMINAL NO. WIRE COLOR ITEM CONDITION DATA (DC Voltage) BATTERY VOLTAGE (11 - 14V) [Engine is running] ● 9 LG Idle speed EVAP canister purge volume control solenoid valve PBIB0050E Approximately 10V [Engine is running] ● Engine speed: About 2,000 rpm (More than 100 seconds after starting engine) NOTE: Voltage and Duty percent may vary. PBIB0520E [Engine is running] [Ignition switch: OFF] ● 32 P ECM relay (Self shut-off) [Ignition switch: OFF] ● 105 G Power supply for ECM For a few seconds after turning ignition switch OFF More than a few seconds after turning ignition switch OFF [Ignition switch: ON] : Average voltage for pulse signal (Actual pulse signal can be confirmed by oscilloscope.) EC-1532 0 - 1.0V BATTERY VOLTAGE (11 - 14V) BATTERY VOLTAGE (11 - 14V) EVAP CANISTER PURGE VOLUME CONTROL SOLENOID VALVE [HR (WITHOUT EURO-OBD)] Diagnostic Procedure BBS004RL 1. CHECK OVERALL FUNCTION A With CONSULT-II 1. Turn ignition switch OFF. 2. Disconnect the EVAP purge hose (2) connected to the EVAP canister (1). – – 3. EC C : Vehicle front Illustration shows the view from under the vehicle. Turn ignition switch ON. D E MBIB1497E 4. 5. 6. F Select “PURG VOL CONT/V” in “ACTIVE TEST” mode with CONSULT-II. Start engine and let it idle. Change the valve opening percentage with touching “Qu” or “Qd” on CONSULT-II screen, and check for vacuum existence at the EVAP purge hose under the following conditions. Conditions (PURG VOL CONT/V) Vacuum 0% Should not exist. 100% Should exist. G H I PBIB0569E J Without CONSULT-II 1. Turn ignition switch OFF. 2. Disconnect the EVAP purge hose (2) connected to the EVAP canister (1). – – 3. 4. K : Vehicle front Illustration shows the view from under the vehicle. Start engine and let it idle for at least 100 seconds. Check for vacuum existence at the EVAP purge hose under the following conditions. Conditions At idle Engine speed: About 2,000 rpm L M Vacuum Should not exist. Should exist. OK or NG OK >> GO TO 2. NG >> GO TO 3. 2. CHECK EVAP CANISTER Refer to EC-1260, "EVAP CANISTER" . OK or NG OK >> INSPECTION END NG >> Replace EVAP canister. EC-1533 MBIB1497E EVAP CANISTER PURGE VOLUME CONTROL SOLENOID VALVE [HR (WITHOUT EURO-OBD)] 3. CHECK EVAP PURGE LINE Check EVAP purge line (pipe, rubber tube, fuel tank and EVAP canister) for cracks or improper connection. Refer to EC-1258, "EVAPORATIVE EMISSION LINE DRAWING" . OK or NG OK >> GO TO 4. NG >> Repair or reconnect the hose. 4. CHECK EVAP CANISTER PURGE VOLUME CONTROL SOLENOID VALVE POWER SUPPLY CIRCUIT 1. 2. Turn ignition switch OFF. Disconnect EVAP canister purge volume control solenoid valve (1) harness connector. – : Vehicle front Turn ignition switch ON. 3. PBIB2972E 4. Check voltage between EVAP canister purge volume control solenoid valve terminal 1 and ground with CONSULT-II or tester. Voltage: Battery voltage OK or NG OK >> GO TO 6. NG >> GO TO 5. PBIB0148E 5. DETECT MALFUNCTIONING PART Check the following. ● Harness connectors E59, F1 ● Harness for open or short between EVAP canister purge volume control solenoid valve and IPDM E/R ● Harness for open or short between EVAP canister purge volume control solenoid valve and ECM >> Repair open circuit or short to ground or short to power in harness or connectors. EC-1534 EVAP CANISTER PURGE VOLUME CONTROL SOLENOID VALVE [HR (WITHOUT EURO-OBD)] 6. CHECK EVAP CANISTER PURGE VOLUME CONTROL SOLENOID VALVE OUTPUT SIGNAL CIRCUIT FOR OPEN AND SHORT 1. 2. 3. A Turn ignition switch OFF. EC Disconnect ECM harness connector. Check harness continuity between EVAP canister purge volume control solenoid valve terminal 2 and ECM terminal 9. Refer to Wiring Diagram. C Continuity should exist. 4. Also check harness for short to ground and short to power. OK or NG OK (With CONSULT-II)>>GO TO 7. OK (Without CONSULT-II)>>GO TO 8. NG >> Repair open circuit or short to ground or short to power in harness or connectors. D E 7. CHECK EVAP CANISTER PURGE VOLUME CONTROL SOLENOID VALVE OPERATION F With CONSULT-II 1. Reconnect all harness connectors disconnected. 2. Start engine. 3. Perform “PURG VOL CONT/V” in “ACTIVE TEST” mode with CONSULT-II. Check that engine speed varies according to the valve opening. OK or NG OK >> GO TO 9. NG >> GO TO 8. G H I J PBIB0569E 8. CHECK EVAP CANISTER PURGE VOLUME CONTROL SOLENOID VALVE K Refer to EC-1536, "Component Inspection" . OK or NG OK >> GO TO 9. NG >> Replace EVAP canister purge volume control solenoid valve. L M 9. CHECK INTERMITTENT INCIDENT Refer to EC-1336, "TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT" . >> INSPECTION END EC-1535 EVAP CANISTER PURGE VOLUME CONTROL SOLENOID VALVE [HR (WITHOUT EURO-OBD)] Component Inspection BBS004RM EVAP CANISTER PURGE VOLUME CONTROL SOLENOID VALVE With CONSULT-II Check air passage continuity of EVAP canister purge volume control solenoid valve under the following conditions. Condition (PURG VOL CONT/V value) Air passage continuity between A and B 100% Yes 0% No PBIA9668J Without CONSULT-II Check air passage continuity of EVAP canister purge volume control solenoid valve under the following conditions. Condition Air passage continuity between A and B 12V direct current supply between terminals 1 and 2 Yes No supply No PBIA9560J Removal and Installation BBS004RN EVAP CANISTER PURGE VOLUME CONTROL SOLENOID VALVE Refer to EM-120, "INTAKE MANIFOLD" . EC-1536 FUEL INJECTOR [HR (WITHOUT EURO-OBD)] FUEL INJECTOR Component Description PFP:16600 A BBS004RO The fuel injector is a small, precise solenoid valve. When the ECM supplies a ground to the fuel injector circuit, the coil in the fuel injector is energized. The energized coil pulls the ball valve back and allows fuel to flow through the fuel injector into the intake manifold. The amount of fuel injected depends upon the injection pulse duration. Pulse duration is the length of time the fuel injector remains open. The ECM controls the injection pulse duration based on engine fuel needs. EC C D SEF375Z E CONSULT-II Reference Value in Data Monitor Mode BBS004RP Specification data are reference values. MONITOR ITEM B/FUEL SCHDL INJ PULSE-B1 CONDITION SPECIFICATION F See EC-1326, "TROUBLE DIAGNOSIS - SPECIFICATION VALUE" . ● Engine: After warming up ● Air conditioner switch: OFF ● Shift lever: P or N (A/T), Neutral (M/T) ● No load Idle 2.0 - 3.0 msec 2,000 rpm 1.9 - 2.9 msec G H I J K L M EC-1537 FUEL INJECTOR [HR (WITHOUT EURO-OBD)] Wiring Diagram BBS004RQ MBWA1489E EC-1538 FUEL INJECTOR [HR (WITHOUT EURO-OBD)] Specification data are reference values and are measured between each terminal and ground. Pulse signal is measured by CONSULT-II. A CAUTION: Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM's transistor. Use a ground other than ECM terminals, such as the ground. EC TERMINAL NO. WIRE COLOR ITEM CONDITION DATA (DC Voltage) C BATTERY VOLTAGE [Engine is running] 25 29 30 31 R O GR L ● Warm-up condition ● Idle speed (11 - 14V) D NOTE: The pulse cycle changes depending on rpm at idle Fuel injector No. 4 Fuel injector No. 3 Fuel injector No. 2 Fuel injector No. 1 E PBIB0529E BATTERY VOLTAGE F (11 - 14V) [Engine is running] ● Warm-up condition ● Engine speed: 2,000 rpm G H PBIA4943J : Average voltage for pulse signal (Actual pulse signal can be confirmed by oscilloscope.) I Diagnostic Procedure BBS004RR 1. INSPECTION START J Turn ignition switch to START. Is any cylinder ignited? Yes or No Yes >> GO TO 2. No >> GO TO 3. K L M EC-1539 FUEL INJECTOR [HR (WITHOUT EURO-OBD)] 2. CHECK OVERALL FUNCTION With CONSULT-II Start engine. Perform “POWER BALANCE” in “ACTIVE TEST” mode with CONSULT-II. 3. Make sure that each circuit produces a momentary engine speed drop. 1. 2. PBIB0133E Without CONSULT-II 1. Start engine. 2. Listen to each fuel injector operating sound. Clicking noise should be heard. PBIB1986E OK or NG OK >> INSPECTION END NG >> GO TO 3. EC-1540 FUEL INJECTOR [HR (WITHOUT EURO-OBD)] 3. CHECK FUEL INJECTOR POWER SUPPLY CIRCUIT 1. 2. – 3. A Turn ignition switch OFF. Disconnect fuel injector (2) harness connector. Ignition coil (1) Turn ignition switch ON. EC C D PBIB2968E E 4. Check voltage between fuel injector terminal 1 and ground with CONSULT-II or tester. F Voltage: Battery voltage OK or NG OK >> GO TO 5. NG >> GO TO 4. G H PBIB0582E 4. DETECT MALFUNCTIONING PART I Check the following. ● Harness connectors E59, F1 ● IPDM E/R harness connector E10 ● 10A fuse ● Harness for open or short between fuel injector and fuse J K >> Repair open circuit or short to ground or short to power in harness or connectors. 5. CHECK FUEL INJECTOR OUTPUT SIGNAL CIRCUIT FOR OPEN AND SHORT 1. 2. 3. Turn ignition switch OFF. Disconnect ECM harness connector. Check harness continuity between fuel injector terminal 2 and ECM terminals 25, 29, 30, 31. Refer to Wiring Diagram. Continuity should exist. 4. Also check harness for short to ground and short to power. OK or NG OK >> GO TO 6. NG >> Repair open circuit or short to ground or short to power in harness or connectors. 6. CHECK FUEL INJECTOR Refer to EC-1542, "Component Inspection" . OK or NG OK >> GO TO 7. NG >> Replace fuel injector. EC-1541 L M FUEL INJECTOR [HR (WITHOUT EURO-OBD)] 7. CHECK INTERMITTENT INCIDENT Refer to EC-1336, "TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT" . >> INSPECTION END Component Inspection BBS004RS FUEL INJECTOR 1. 2. Disconnect fuel injector harness connector. Check resistance between terminals as shown in the figure. Resistance: 11.1 - 14.5Ω [at 10 - 60°C (50 - 140°F)] PBIB1727E Removal and Installation BBS004RT FUEL INJECTOR Refer to EM-135, "FUEL INJECTOR AND FUEL TUBE" . EC-1542 FUEL PUMP [HR (WITHOUT EURO-OBD)] FUEL PUMP Description PFP:17042 A BBS004RU SYSTEM DESCRIPTION Sensor Input Signal to ECM Crankshaft position sensor (POS) Camshaft position sensor (PHASE) Engine speed* Battery Battery voltage* ECM Function Actuator Fuel pump control EC Fuel pump relay C *: ECM determines the start signal status by the signals of engine speed and battery voltage. The ECM activates the fuel pump for several seconds after the ignition switch is turned ON to improve engine startability. If the ECM receives a engine speed signal from the crankshaft position sensor (POS) and camshaft position sensor (PHASE), it knows that the engine is rotating, and causes the pump to operate. If the engine speed signal is not received when the ignition switch is ON, the engine stalls. The ECM stops pump operation and prevents battery discharging, thereby improving safety. The ECM does not directly drive the fuel pump. It controls the ON/OFF fuel pump relay, which in turn controls the fuel pump. Condition D E Fuel pump operation Ignition switch is turned to ON Operates for 1 second Engine running and cranking Operates When engine is stopped Stops in 1.5 seconds Except as shown above Stops F G COMPONENT DESCRIPTION H A turbine type design fuel pump is used in the fuel tank. I J K MBIB0291E CONSULT-II Reference Value in Data Monitor Mode BBS004RV L Specification data are reference values. MONITOR ITEM FUEL PUMP RLY CONDITION ● For 1 second after turning ignition switch ON ● Engine running or cranking ● Except above conditions SPECIFICATION ON OFF EC-1543 M FUEL PUMP [HR (WITHOUT EURO-OBD)] Wiring Diagram BBS004RW MBWA1490E EC-1544 FUEL PUMP [HR (WITHOUT EURO-OBD)] Specification data are reference values and are measured between each terminal and ground. CAUTION: Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM's transistor. Use a ground other than ECM terminals, such as the ground. TERMINAL NO. EC WIRE COLOR ITEM CONDITION DATA (DC Voltage) [Ignition switch: ON] ● 23 R A Fuel pump relay For 1 second after turning ignition switch ON C 0 - 1.0V [Engine is running] [Ignition switch: ON] ● More than 1 second after turning ignition switch ON D BATTERY VOLTAGE (11 - 14V) E Diagnostic Procedure BBS004RX 1. CHECK OVERALL FUNCTION 1. 2. – F Turn ignition switch ON. Pinch fuel feed hose (1) with two fingers. Illustration shows the view with intake air duct removed. G Fuel pressure pulsation should be felt on the fuel feed hose for 1 second after ignition switch is turned ON. H OK or NG OK >> INSPECTION END NG >> GO TO 2. I PBIB2978E 2. CHECK FUEL PUMP POWER SUPPLY CIRCUIT-I 1. 2. 3. 4. J Turn ignition switch OFF. Disconnect ECM harness connector. Turn ignition switch ON. Check voltage between ECM terminal 23 and ground with CONSULT-II or tester. K L Voltage: Battery voltage OK or NG OK >> GO TO 5. NG >> GO TO 3. M PBIA9573J EC-1545 FUEL PUMP [HR (WITHOUT EURO-OBD)] 3. CHECK FUEL PUMP POWER SUPPLY CIRCUIT-II 1. 2. 3. Turn ignition switch OFF. Disconnect IPDM E/R harness connector E5. Check harness continuity between ECM terminal 23 and IPDM E/R terminal 69. Refer to Wiring Diagram. Continuity should exist. 4. Also check harness for short to ground and short to power. OK or NG OK >> GO TO 11. NG >> GO TO 4. 4. DETECT MALFUNCTIONING PART Check the following. ● Harness or connectors E59, F1 ● Harness for open or short between IPDM E/R and ECM >> Repair harness or connectors. 5. CHECK FUEL PUMP POWER SUPPLY CIRCUIT-III 1. 2. 3. 4. Turn ignition switch OFF. Reconnect all harness connectors disconnected. Disconnect “fuel level sensor unit and fuel pump” harness connector. Turn ignition switch ON. MBIB0288E 5. Check voltage between “fuel level sensor unit and fuel pump” terminal 1 and ground with CONSULT-II or tester. Voltage: Battery voltage should exist for 1 second after ignition switch is turned ON. OK or NG OK >> GO TO 9. NG >> GO TO 6. PBIB3004E EC-1546 FUEL PUMP [HR (WITHOUT EURO-OBD)] 6. CHECK 15A FUSE A 1. Turn ignition switch OFF. 2. Disconnect 15A fuse. 3. Check 15A fuse. OK or NG OK >> GO TO 7. NG >> Replace fuse. EC C 7. CHECK FUEL PUMP POWER SUPPLY CIRCUIT-IV 1. 2. Disconnect IPDM E/R harness connector E10. Check harness continuity between IPDM E/R terminal 20 and “fuel level sensor unit and fuel pump” terminal 1. Refer to Wiring Diagram. D E Continuity should exist. 3. Also check harness for short to ground and short to power. OK or NG OK >> GO TO 11. NG >> GO TO 8. F G 8. DETECT MALFUNCTIONING PART H Check the following. ● Harness or connectors M1, E101 ● Harness or connectors M72, B21 ● Harness for open or short between IPDM E/R and “fuel level sensor unit and fuel pump” I J >> Repair harness or connectors. 9. CHECK FUEL PUMP GROUND CIRCUIT 1. Check harness continuity between “fuel level sensor unit and fuel pump” terminal 3 and ground. Refer to Wiring Diagram. Continuity should exist. K L 2. Also check harness for short to power. OK or NG OK >> GO TO 10. NG >> Repair or replace harness or connectors. 10. CHECK FUEL PUMP Refer to EC-1548, "Component Inspection" . OK or NG OK >> GO TO 11. NG >> Replace “fuel level sensor unit and fuel pump”. 11. CHECK INTERMITTENT INCIDENT Refer to EC-1336, "TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT" . OK or NG OK >> Replace IPDM E/R. Refer to PG-18, "IPDM E/R (INTELLIGENT POWER DISTRIBUTION MODULE ENGINE ROOM)" . NG >> Repair or replace harness or connectors. EC-1547 M FUEL PUMP [HR (WITHOUT EURO-OBD)] Component Inspection BBS004RY FUEL PUMP 1. 2. Disconnect “fuel level sensor unit and fuel pump” harness connector. Check resistance between “fuel level sensor unit and fuel pump” terminals 1 and 3. Resistance: Approximately 0.2 - 5.0Ω [at 25°C (77°F)] MBIB0311E Removal and Installation BBS004RZ FUEL PUMP Refer to FL-15, "FUEL LEVEL SENSOR UNIT, FUEL FILTER AND FUEL PUMP ASSEMBLY" . EC-1548 HO2S1 [HR (WITHOUT EURO-OBD)] HO2S1 Component Description PFP:22690 A BBS004S0 The heated oxygen sensor 1 is placed into the exhaust manifold. It detects the amount of oxygen in the exhaust gas compared to the outside air. The heated oxygen sensor 1 has a closed-end tube made of ceramic zirconia. The zirconia generates voltage from approximately 1V in richer conditions to 0V in leaner conditions. The heated oxygen sensor 1 signal is sent to the ECM. The ECM adjusts the injection pulse duration to achieve the ideal air-fuel ratio. The ideal air-fuel ratio occurs near the radical change from 1V to 0V. EC C D SEF463R E F G H SEF288D CONSULT-II Reference Value in Data Monitor Mode BBS004S1 I Specification data are reference values. MONITOR ITEM CONDITION J 0 - 0.3V ←→ Approx. 0.6 - 1.0V HO2S1 (B1) ● HO2S1 MNTR (B1) SPECIFICATION Engine: After warming up Maintaining engine speed at 2,000 rpm LEAN ←→ RICH Changes more than 5 times during 10 seconds. K L M EC-1549 HO2S1 [HR (WITHOUT EURO-OBD)] Wiring Diagram BBS004S2 MBWA1497E EC-1550 HO2S1 [HR (WITHOUT EURO-OBD)] Specification data are reference values and are measured between each terminal and ground. Pulse signal is measured by CONSULT-II. A CAUTION: Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM's transistor. Use a ground other than ECM terminals, such as the ground. EC TERMINAL NO. WIRE COLOR ITEM CONDITION DATA (DC Voltage) C Approximately 10V [Engine is running] 3 Y ● Warm-up condition ● Engine speed: Below 3,600 rpm D Heated oxygen sensor 1 heater E PBIA8148J [Ignition switch: ON] ● Engine stopped [Engine is running] ● BATTERY VOLTAGE (11 - 14V) Engine speed: Above 3,600 rpm G [Engine is running] 49 56 BR R Heated oxygen sensor 1 Sensor ground (Heated oxygen sensor 1) ● Warm-up condition ● Engine speed: 2,000 rpm [Engine is running] ● F Idle speed : Average voltage for pulse signal (Actual pulse signal can be confirmed by oscilloscope.) 0 - Approximately 1.0V (Periodically change) H Approximately 0V I J K L M EC-1551 HO2S1 [HR (WITHOUT EURO-OBD)] Diagnostic Procedure BBS004S3 1. CHECK OVERALL FUNCTION With CONSULT-II 1. Start engine and warm it up to normal operating temperature. 2. Select “HO2S1 MNTR (B1)” in “DATA MONITOR” mode with CONSULT-II. 3. Keep the engine speed at 2,000 rpm under no load, and make sure that the monitors fluctuates between LEAN and RICH more than five times in 10 seconds. 1 time: RICH → LEAN → RICH 2 times: RICH → LEAN → RICH → LEAN →RICH SEF820Y Without CONSULT-II Start engine and warm it up to normal operating temperature. Stop engine and wait at least 10 seconds. Set ECM in Diagnostic test mode - II (Heated oxygen sensor 1 monitor). Refer to EC-1269, "HOW TO SWITCH DIAGNOSTIC TEST MODE" . 4. Keep the engine speed at 2,000 rpm under no load, and make sure that the MI comes ON more than five times in 10 seconds. OK or NG OK >> INSPECTION END NG >> GO TO 2. 1. 2. 3. SAT652J 2. CHECK GROUND CONNECTIONS 1. 2. Turn ignition switch OFF. Loosen and retighten ground screws on the body. Refer to EC-1342, "Ground Inspection" . MBIB1550E 1. IPDM E/R 2. Body ground OK or NG OK >> GO TO 3. NG >> Repair or replace ground connections. EC-1552 3. Body ground HO2S1 [HR (WITHOUT EURO-OBD)] 3. RETIGHTEN HEATED OXYGEN SENSOR 1 A Loosen and retighten heated oxygen sensor 1. ● ● : Vehicle front Exhaust manifold (2) EC Tightening torque: 50 N·m (5.1 kg-m, 37 ft-lb) C >> GO TO 4. D PBIB2966E 4. CHECK FOR EXHAUST GAS LEAK 1. 2. E Start engine and run it at idle. Listen for an exhaust gas leak before three way catalyst (Manifold). F G H I SEC502D OK or NG OK >> GO TO 5. NG >> Repair or replace. J 5. CHECK FOR INTAKE AIR LEAK K Listen for an intake air leak after the mass air flow sensor. OK or NG OK >> GO TO 6. NG >> Repair or replace. L 6. CHECK HO2S1 GROUND CIRCUIT FOR OPEN AND SHORT M 1. 2. Turn ignition switch OFF. Disconnect heated oxygen sensor 1 harness connector (1). – : Vehicle front Disconnect ECM harness connector. Check harness continuity between ECM terminal 56 and HO2S1 terminal 1. Refer to Wiring Diagram. 3. 4. Continuity should exist. 5. Also check harness for short to ground and short to power. OK or NG OK >> GO TO 7. NG >> Repair open circuit or short to ground or short to power in harness or connectors. EC-1553 PBIB2967E HO2S1 [HR (WITHOUT EURO-OBD)] 7. CHECK HO2S1 INPUT SIGNAL CIRCUIT FOR OPEN AND SHORT 1. Check harness continuity between ECM terminal 49 and HO2S1 terminal 4. Refer to Wiring Diagram. Continuity should exist. 2. Check harness continuity between ECM terminal 49 or HO2S1 terminal 4 and ground. Refer to Wiring Diagram. Continuity should not exist. 3. Also check harness for short to power. OK or NG OK >> GO TO 8. NG >> Repair open circuit or short to ground or short to power in harness or connectors. 8. CHECK MASS AIR FLOW SENSOR Refer to EC-1359, "Component Inspection" . OK or NG OK >> GO TO 9. NG >> Replace mass air flow sensor. 9. CHECK PCV VALVE Refer to EC-1262, "Component Inspection" . OK or NG OK >> GO TO 10. NG >> Replace PCV valve. 10. CHECK HEATED OXYGEN SENSOR 1 Refer to EC-1555, "Component Inspection" . OK or NG OK >> GO TO 11. NG >> Replace heated oxygen sensor 1. 11. CHECK INTERMITTENT INCIDENT Refer to EC-1336, "TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT" . >> INSPECTION END EC-1554 HO2S1 [HR (WITHOUT EURO-OBD)] Component Inspection BBS004S4 A HEATED OXYGEN SENSOR 1 With CONSULT-II 1. 2. 3. 4. 5. Start engine and warm it up to normal operating temperature. Select “MANU TRIG” and adjust “TRIGGER POINT” to 100% in “DATA MONITOR” mode with CONSULT- EC II. Select “HO2S1 (B1)” and “HO2S1 MNTR (B1)”. C Hold engine speed at 2,000 rpm under no load during the following steps. Touch “RECORD” on CONSULT-II screen. D E SEF646Y F 6. Check the following. ● “HO2S1 MNTR (B1)” in “DATA MONITOR” mode changes from “RICH” to “LEAN” to “RICH” more than 5 times in 10 seconds. 5 times (cycles) are counted as shown at right. ● “HO2S1 (B1)” voltage goes above 0.6V at least once. ● “HO2S1 (B1)” voltage goes below 0.3V at least once. ● “HO2S1 (B1)” voltage never exceeds 1.0V. G H I SEF217YA J K L SEF648Y CAUTION: Discard any heated oxygen sensor which has been dropped from a height of more than 0.5 m (19.7 in) onto a hard surface such as a concrete floor; use a new one. ● Before installing new oxygen sensor, clean exhaust system threads using Oxygen Sensor Thread Cleaner tool and approved anti-seize lubricant. ● Without CONSULT-II 1. 2. Start engine and warm it up to normal operating temperature. Set voltmeter probes between ECM terminal 49 (HO2S1 signal) and ground. EC-1555 M HO2S1 [HR (WITHOUT EURO-OBD)] 3. Check the following with engine speed held at 2,000 rpm constant under no load. ● The voltage fluctuates between 0 to 0.3V and 0.6 to 1.0V more than 5 times within 10 seconds. ● The maximum voltage is over 0.6V at least 1 time. ● The minimum voltage is below 0.3V at least 1 time. ● The voltage never exceeds 1.0V. 1 time: 0 - 0.3V → 0.6 - 1.0V → 0 - 0.3V 2 times: 0 - 0.3V → 0.6 - 1.0V → 0 - 0.3V → 0.6 - 1.0V → 0 0.3V PBIA9566J CAUTION: ● Discard any heated oxygen sensor which has been dropped from a height of more than 0.5 m (19.7 in) onto a hard surface such as a concrete floor; use a new one. ● Before installing new oxygen sensor, clean exhaust system threads using Oxygen Sensor Thread Cleaner tool and approved anti-seize lubricant. Removal and Installation BBS004S5 HEATED OXYGEN SENSOR 1 Refer to EM-124, "EXHAUST MANIFOLD" . EC-1556 HO2S1 HEATER [HR (WITHOUT EURO-OBD)] HO2S1 HEATER Description PFP:22690 A BBS004S6 SYSTEM DESCRIPTION Sensor Input Signal to ECM Camshaft position sensor (PHASE) Crankshaft position sensor (POS) Engine speed Engine coolant temperature sensor Engine coolant temperature ECM function Heated oxygen sensor 1 heater control Actuator EC Heated oxygen sensor 1 heater The ECM performs ON/OFF duty control of the heated oxygen sensor 1 heater corresponding to the engine speed and engine coolant temperature. The duty percent varies with engine coolant temperature when engine is started. OPERATION D E Engine speed Heated oxygen sensor 1 heater Above 3,600 rpm OFF Below 3,600 rpm after warming up ON F CONSULT-II Reference Value in Data Monitor Mode BBS004S7 Specification data are reference values. MONITOR ITEM HO2S1 HTR (B1) C G CONDITION ● Engine: After warming up ● Engine speed: Below 3,600 rpm ● Engine speed: Above 3,600 rpm ● Engine coolant temperature when engine started: More than 80°C (176°F) ● Engine speed: Below 3,600 rpm O2SEN HTR DTY SPECIFICATION ON H OFF Approx. 30% I J K L M EC-1557 HO2S1 HEATER [HR (WITHOUT EURO-OBD)] Wiring Diagram BBS004S8 MBWA1497E EC-1558 HO2S1 HEATER [HR (WITHOUT EURO-OBD)] Specification data are reference values and are measured between each terminal and ground. Pulse signal is measured by CONSULT-II. A CAUTION: Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM's transistor. Use a ground other than ECM terminals, such as the ground. EC TERMINAL NO. WIRE COLOR ITEM CONDITION DATA (DC Voltage) C Approximately 10V [Engine is running] 3 Y ● Warm-up condition ● Engine speed: Below 3,600 rpm. D Heated oxygen sensor 1 heater E PBIA8148J [Ignition switch: ON] ● Engine stopped [Engine is running] ● BATTERY VOLTAGE (11 - 14V) Engine speed: Above 3,600 rpm. G [Engine is running] 49 56 BR R Heated oxygen sensor 1 Sensor ground (Heated oxygen sensor 1) ● Warm-up condition ● Engine speed: 2,000 rpm [Engine is running] ● F Idle speed : Average voltage for pulse signal (Actual pulse signal can be confirmed by oscilloscope.) 0 - Approximately 1.0V (Periodically change) H Approximately 0V I J K L M EC-1559 HO2S1 HEATER [HR (WITHOUT EURO-OBD)] Diagnostic Procedure BBS004S9 1. CHECK OVERALL FUNCTION 1. 2. 3. 4. 5. 6. Start engine and warm it up to normal operating temperature. Turn ignition switch OFF and wait at least 10 seconds. Turn ignition switch ON. Set tester prove between ECM terminal 3 (HO2S1 heater signal) and ground. Start engine and let it idle. Check the voltage under the following conditions. Verify that the oscilloscope screen shows the signal waves as shown below. Conditions Voltage Approximately 7.0V At idle MBIB1394E PBIB0519E Engine speed is above 3,600 rpm BATTERY VOLTAGE (11 - 14V) : Average voltage for pulse signal (Actual pulse signal can be confirmed by oscilloscope.) OK or NG OK >> INSPECTION END NG >> GO TO 2. 2. CHECK GROUND CONNECTIONS 1. 2. Turn ignition switch OFF. Loosen and retighten ground screws on the body. Refer to EC-1342, "Ground Inspection" . MBIB1550E 1. IPDM E/R 2. Body ground OK or NG OK >> GO TO 3. NG >> Repair or replace ground connections. EC-1560 3. Body ground HO2S1 HEATER [HR (WITHOUT EURO-OBD)] 3. CHECK HO2S1 POWER SUPPLY CIRCUIT A 1. Disconnect heated oxygen sensor 1 harness connector (1). – : Vehicle front Turn ignition switch ON. 2. EC C D MBIB1340E 3. E Check voltage between HO2S1 terminal 2 and ground with CONSULT-II or tester. Voltage: Battery voltage F OK or NG OK >> GO TO 5. NG >> GO TO 4. G PBIA9576J H 4. DETECT MALFUNCTIONING PART Check the following. ● Harness connectors E59, F1 ● IPDM E/R connector E10 ● 10A fuse ● Harness for open or short between heated oxygen sensor 1 and fuse I J K >> Repair open circuit or short to ground or short to power in harness or connectors. 5. CHECK HO2S1 OUTPUT SIGNAL CIRCUIT FOR OPEN AND SHORT L 1. 2. 3. M Turn ignition switch OFF. Disconnect ECM harness connector. Check harness continuity between HO2S1 terminal 3 and ECM terminal 3. Refer to Wiring Diagram. Continuity should exist. 4. Also check harness for short to ground and short to power. OK or NG OK >> GO TO 6. NG >> Repair open circuit or short to ground or short to power in harness or connectors. 6. CHECK HEATED OXYGEN SENSOR 1 HEATER Refer to EC-1562, "Component Inspection" . OK or NG OK >> GO TO 7. NG >> Replace heated oxygen sensor 1. EC-1561 HO2S1 HEATER [HR (WITHOUT EURO-OBD)] 7. CHECK INTERMITTENT INCIDENT Refer to EC-1336, "TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT" . >> INSPECTION END Component Inspection BBS004SA HEATED OXYGEN SENSOR 1 HEATER 1. Check resistance between HO2S1 terminals as follows. Terminal No. Resistance 2 and 3 3.4 - 4.4 Ω [at 25°C (77°F)] 1 and 2, 3, 4 ∞Ω (Continuity should not exist) 4 and 1, 2, 3 2. If NG, replace heated oxygen sensor 1. CAUTION: ● Discard any heated oxygen sensor which has been dropped from a height of more than 0.5 m (19.7 in) onto a hard surface such as a concrete floor; use a new one. ● Before installing new oxygen sensor, clean exhaust system threads using Oxygen Sensor Thread Cleaner tool and approved anti-seize lubricant. PBIA9577J Removal and Installation BBS004SB HEATED OXYGEN SENSOR 1 Refer to EM-124, "EXHAUST MANIFOLD" . EC-1562 HO2S2 [HR (WITHOUT EURO-OBD)] HO2S2 Component Description PFP:226A0 A BBS004SC The heated oxygen sensor 2, after three way catalyst (manifold), monitors the oxygen level in the exhaust gas on each bank. Even if switching characteristics of the heated oxygen sensor 1 are shifted, the air-fuel ratio is controlled to stoichiometric, by the signal from the heated oxygen sensor 2. This sensor is made of ceramic zirconia. The zirconia generates voltage from approximately 1V in richer conditions to 0V in leaner conditions. Under normal conditions the heated oxygen sensor 2 is not used for engine control operation. EC C D SEF327R E CONSULT-II Reference Value in Data Monitor Mode BBS004SD Specification data are reference values. MONITOR ITEM HO2S2 (B1) HO2S2 MNTR (B1) CONDITION ● Revving engine from idle to 3,000 rpm quickly after the following conditions are met. – Engine: After warming up. – Keep the engine speed between 3,500 rpm and 4,000 rpm for 1 minute and idle for 1 minute under no load. SPECIFICATION F 0 - 0.3V ←→ Approx. 0.6 1.0V G LEAN ←→ RICH H I J K L M EC-1563 HO2S2 [HR (WITHOUT EURO-OBD)] Wiring Diagram BBS004SE MBWA1498E EC-1564 HO2S2 [HR (WITHOUT EURO-OBD)] Specification data are reference values and are measured between each terminal and ground. Pulse signal is measured by CONSULT-II. A CAUTION: Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM's transistor. Use a ground other than ECM terminals, such as the ground. EC TERMINAL NO. WIRE COLOR ITEM CONDITION C [Engine is running] 5 DATA (DC Voltage) GR ● Below 3,600 rpm after the following conditions are met. – Engine: After warming up – Keeping the engine speed between 3,500 and 4,000 rpm for 1 minute and at idle for 1 minute under no load Heated oxygen sensor 2 heater Approximately 10V D E PBIA8148J [Ignition switch: ON] ● Engine stopped [Engine is running] ● F BATTERY VOLTAGE (11 - 14V) Engine speed: Above 3,600 rpm G [Engine is running] 50 B Heated oxygen sensor 2 ● Revving engine from idle to 3,000 rpm quickly after the following conditions are met. – Engine: After warming up. – Keep the engine speed between 3,500 rpm and 4,000 rpm for 1 minute and at idle for 1 minute under no load. H 0 - Approximately 1.0V I [Engine is running] 59 LG Sensor ground (Heated oxygen sensor 2) ● Warm-up condition ● Idle speed Approximately 0V J : Average voltage for pulse signal (Actual pulse signal can be confirmed by oscilloscope.) Diagnostic Procedure BBS004SF K 1. CHECK OVERALL FUNCTION - I 1. 2. 3. 4. 5. 6. Start engine and warm it up to the normal operating temperature. Turn ignition switch OFF and wait at least 10 seconds. Start engine and keep the engine speed between 3,500 and 4,000 rpm for at least 1 minute under no load. Let engine idle for 1 minute. Set voltmeter probes between ECM terminal 50 (HO2S2 signal) and ground. Check the voltage while revving engine up to 4,000 rpm under no load at least 10 times. (Depress and release the accelerator pedal as quickly as possible.) The voltage does not remain in the range of 0.2 - 0.4V OK or NG OK >> INSPECTION END NG >> GO TO 2. PBIB3000E EC-1565 L M HO2S2 [HR (WITHOUT EURO-OBD)] 2. CHECK OVERALL FUNCTION - II Keep engine at idle for 10 minutes, then check the voltage between ECM terminal 50 (HO2S2 signal) and ground, or check the voltage when coasting at 80 km/h (50 MPH) in D position with OD “OFF” (A/T), 3rd gear position (M/T). The voltage does not remain in the range of 0.2 - 0.4V OK or NG OK >> INSPECTION END NG >> GO TO 3. 3. CHECK GROUND CONNECTIONS 1. 2. Turn ignition switch OFF. Loosen and retighten ground screws on the body. Refer to EC-1342, "Ground Inspection" . MBIB1550E 1. IPDM E/R 2. Body ground 3. Body ground OK or NG OK >> GO TO 4. NG >> Repair or replace ground connections. 4. CHECK HO2S2 GROUND CIRCUIT FOR OPEN AND SHORT 1. – 2. 3. Disconnect heated oxygen sensor 2 harness connector (2). Heated oxygen sensor 2 (1) Disconnect ECM harness connector. Check harness continuity between HO2S2 terminal 1 and ECM terminal 59. Refer to Wiring Diagram. Continuity should exist. 4. Also check harness for short to ground and short to power. OK or NG OK >> GO TO 5. NG >> Repair open circuit or short to ground or short to power in harness or connectors. EC-1566 PBIB2949E HO2S2 [HR (WITHOUT EURO-OBD)] 5. CHECK HO2S2 INPUT SIGNAL CIRCUIT FOR OPEN AND SHORT 1. A Check harness continuity between HO2S2 terminal 4 ECM terminal 50. Refer to Wiring Diagram. EC Continuity should exist. 2. Check harness continuity between ECM terminal 50 or HO2S2 terminal 4 and ground. Refer to Wiring Diagram. C Continuity should not exist. 3. Also check harness for short to power. OK or NG OK >> GO TO 6. NG >> Repair open circuit or short to ground or short to power in harness or connectors. D E 6. CHECK HEATED OXYGEN SENSOR 2 Refer to EC-1567, "Component Inspection" . OK or NG OK >> GO TO 7. NG >> Replace heated oxygen sensor 2. F G 7. CHECK INTERMITTENT INCIDENT H Refer to EC-1336, "TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT" . >> INSPECTION END I Component Inspection BBS004SG HEATED OXYGEN SENSOR 2 With CONSULT-II 1. 2. 3. 4. 5. J Start engine and warm it up to the normal operating temperature. Turn ignition switch OFF and wait at least 10 seconds. Start engine and keep the engine speed between 3,500 and 4,000 rpm for at least 1 minute under no load. Let engine idle for 1 minute. Select “FUEL INJECTION” in “ACTIVE TEST” mode, and select “HO2S2 (B1)” as the monitor item with CONSULT-II. K L M SEF662Y EC-1567 HO2S2 [HR (WITHOUT EURO-OBD)] 6. Check “HO2S2 (B1)” at idle speed when adjusting “FUEL INJECTION” to ±25%. PBIB0551E “HO2S2 (B1)” should be above 0.68V at least once when the “FUEL INJECTION” is +25%. “HO2S2 (B1)” should be below 0.50V at least once when the “FUEL INJECTION” is −25%. CAUTION: ● Discard any heated oxygen sensor which has been dropped from a height of more than 0.5 m (19.7 in) onto a hard surface such as a concrete floor; use a new one. ● Before installing new oxygen sensor, clean exhaust system threads using Oxygen Sensor Thread Cleaner tool and approved anti-seize lubricant. Without CONSULT-II 1. 2. 3. 4. 5. 6. Start engine and warm it up to the normal operating temperature. Turn ignition switch OFF and wait at least 10 seconds. Start engine and keep the engine speed between 3,500 and 4,000 rpm for at least 1 minute under no load. Let engine idle for 1 minute. Set voltmeter probes between ECM terminal 50 (HO2S2 signal) and ground. Check the voltage when revving up to 4,000 rpm under no load at least 10 times. (Depress and release accelerator pedal as soon as possible.) The voltage should be above 0.68V at least once during this procedure. If the voltage is above 0.68V at step 6, step 7 is not necessary. 7. Keep vehicle idling for 10 minutes, then check voltage. Or check the voltage when coasting from 80 km/h (50 MPH) in D position with “OD” OFF (A/T), 3rd gear position (M/T). The voltage should be below 0.50V at least once during this PBIB2996E procedure. 8. If NG, replace heated oxygen sensor 2. CAUTION: ● Discard any heated oxygen sensor which has been dropped from a height of more than 0.5 m (19.7 in) onto a hard surface such as a concrete floor; use a new one. ● Before installing new oxygen sensor, clean exhaust system threads using Oxygen Sensor Thread Cleaner tool and approved anti-seize lubricant. Removal and Installation BBS004SH HEATED OXYGEN SENSOR 2 Refer to EX-3, "EXHAUST SYSTEM" . EC-1568 HO2S2 HEATER [HR (WITHOUT EURO-OBD)] HO2S2 HEATER Description PFP:226A0 A BBS004SI SYSTEM DESCRIPTION Sensor Camshaft position sensor (PHASE) Input Signal to ECM ECM Function Actuator EC Heated oxygen sensor 2 heater control Heated oxygen sensor 2 heater C Engine speed Crankshaft position sensor (POS) Engine coolant temperature sensor Engine coolant temperature Mass air flow sensor Amount of intake air D The ECM performs ON/OFF control of the heated oxygen sensor 2 heater corresponding to the engine speed, amount of intake air and engine coolant temperature. OPERATION E Engine speed Heated oxygen sensor 2 heater Above 3,600 rpm OFF ● Below 3,600 rpm after the following conditions are met. – Engine: After warming up – Keeping the engine speed between 3,500 and 4,000 rpm for 1 minute and at idle for 1 minute under no load F ON G CONSULT-II Reference Value in Data Monitor Mode BBS004SJ H Specification data are reference values. MONITOR ITEM HO2S2 HTR (B1) CONDITION ● Engine speed: Above 3,600 rpm ● Below 3,600 rpm after the following conditions are met. – Engine: After warming up – Keeping the engine speed between 3,500 and 4,000 rpm for 1 minute and at idle for 1 minute under no load SPECIFICATION OFF ON I J K L M EC-1569 HO2S2 HEATER [HR (WITHOUT EURO-OBD)] Wiring Diagram BBS004SK MBWA1498E EC-1570 HO2S2 HEATER [HR (WITHOUT EURO-OBD)] Specification data are reference values and are measured between each terminal and ground. Pulse signal is measured by CONSULT-II. A CAUTION: Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM's transistor. Use a ground other than ECM terminals, such as the ground. EC TERMINAL NO. WIRE COLOR ITEM CONDITION C [Engine is running] 5 DATA (DC Voltage) GR ● Engine speed: Below 3,600 rpm after the following conditions are met. – Engine: After warming up – Keeping the engine speed between 3,500 and 4,000 rpm for 1 minute and at idle for 1 minute under no load Heated oxygen sensor 2 heater Approximately 10V D E PBIA8148J [Ignition switch: ON] ● Engine stopped [Engine is running] ● BATTERY VOLTAGE (11 - 14V) Engine speed: Above 3,600 rpm. G [Engine is running] 50 B Heated oxygen sensor 2 F ● Revving engine from idle to 3,000 rpm quickly after the following conditions are met. – Engine: After warming up – Keeping the engine speed between 3,500 and 4,000 rpm for 1 minute and at idle for 1 minute under no load 0 - Approximately 1.0V H I [Engine is running] 59 LG Sensor ground (Heated oxygen sensor 2) ● Warm-up condition ● Idle speed Approximately 0V J : Average voltage for pulse signal (Actual pulse signal can be confirmed by oscilloscope.) K L M EC-1571 HO2S2 HEATER [HR (WITHOUT EURO-OBD)] Diagnostic Procedure BBS004SL 1. CHECK OVERALL FUNCTION 1. 2. 3. 4. 5. 6. Start engine and warm it up to the normal operating temperature. Turn ignition switch OFF and wait at least 10 seconds. Start engine and keep the engine speed between 3,500 and 4,000 rpm for at least 1 minute under no load. Let engine idle for 1 minute. Set tester proves between ECM terminal 5 (HO2S2 heater signal) and ground. Check the voltage under the following conditions. Verify that the oscilloscope screen shows the signal waves as shown below. Conditions Voltage Approximately 10V At idle MBIB1395E PBIA8148J Engine speed is above 3,600 rpm BATTERY VOLTAGE (11 - 14V) : Average voltage for pulse signal (Actual pulse signal can be confirmed by oscilloscope.) OK or NG OK >> INSPECTION END NG >> GO TO 2. 2. CHECK GROUND CONNECTIONS 1. 2. Turn ignition switch OFF. Loosen and retighten ground screws on the body. Refer to EC-1342, "Ground Inspection" . MBIB1550E 1. IPDM E/R 2. Body ground OK or NG OK >> GO TO 3. NG >> Repair or replace ground connections. EC-1572 3. Body ground HO2S2 HEATER [HR (WITHOUT EURO-OBD)] 3. CHECK HO2S2 POWER SUPPLY CIRCUIT 1. – 2. A Disconnect heated oxygen sensor 2 harness connector (2). Heated oxygen sensor 2 (1). Turn ignition switch ON. EC C D PBIB2949E 3. E Check voltage between HO2S2 terminal 2 and ground with CONSULT-II or tester. Voltage: Battery voltage F OK or NG OK >> GO TO 5. NG >> GO TO 4. G PBIA9576J H 4. DETECT MALFUNCTIONING PART Check the following. ● Harness connectors E59, F1 ● IPDM E/R connector E10 ● 10A fuse ● Harness for open or short between heated oxygen sensor 2 and fuse I J K >> Repair open circuit or short to ground or short to power in harness or connectors. 5. CHECK HO2S2 OUTPUT SIGNAL CIRCUIT FOR OPEN AND SHORT L 1. 2. 3. M Turn ignition switch OFF. Disconnect ECM harness connector. Check harness continuity between HO2S2 terminal 3 and ECM terminal 5. Refer to Wiring Diagram. Continuity should exist. 4. Also check harness for short to ground and short to power. OK or NG OK >> GO TO 6. NG >> Repair open circuit or short to ground or short to power in harness or connectors. 6. CHECK HEATED OXYGEN SENSOR 2 HEATER Refer to EC-1574, "Component Inspection" . OK or NG OK >> GO TO 7. NG >> Replace heated oxygen sensor 2. EC-1573 HO2S2 HEATER [HR (WITHOUT EURO-OBD)] 7. CHECK INTERMITTENT INCIDENT Refer to EC-1336, "TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT" . >> INSPECTION END Component Inspection BBS004SM HEATED OXYGEN SENSOR 2 HEATER 1. Check resistance between HO2S2 terminals as follows. Terminal No. Resistance 2 and 3 3.4 - 4.4 Ω [at 25°C (77°F)] 1 and 2, 3, 4 ∞Ω (Continuity should not exist) 4 and 1, 2, 3 2. If NG, replace heated oxygen sensor 2. CAUTION: ● Discard any heated oxygen sensor which has been dropped from a height of more than 0.5 m (19.7 in) onto a hard surface such as a concrete floor; use a new one. ● Before installing new oxygen sensor, clean exhaust system threads using Oxygen Sensor Thread Cleaner tool and approved anti-seize lubricant. PBIA9577J Removal and Installation BBS004SN HEATED OXYGEN SENSOR 2 Refer to EX-3, "EXHAUST SYSTEM" . EC-1574 IAT SENSOR [HR (WITHOUT EURO-OBD)] IAT SENSOR Component Description PFP:22630 A BBS004SO The intake air temperature sensor is built-into mass air flow sensor (1). The sensor detects intake air temperature and transmits a signal to the ECM. The temperature sensing unit uses a thermistor which is sensitive to the change in temperature. Electrical resistance of the thermistor decreases in response to the temperature rise. EC C D PBIA9559J E Intake air temperature °C (°F) Voltage* V Resistance F kΩ 25 (77) 3.3 1.800 - 2.200 80 (176) 1.2 0.283 - 0.359 G *: This data is reference value and is measured between ECM terminal 46 (Intake air temperature sensor) and ground. CAUTION: Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM's transistor. Use a ground other than ECM terminals, such as the ground. H SEF012P I J K L M EC-1575 IAT SENSOR [HR (WITHOUT EURO-OBD)] Wiring Diagram BBS004SP MBWA1499E EC-1576 IAT SENSOR [HR (WITHOUT EURO-OBD)] Diagnostic Procedure BBS004SQ 1. CHECK OVERALL FUNCTION 1. 2. A Turn ignition switch ON. Check voltage between ECM terminal 46 and ground with CONSULT-II or tester. EC Voltage: Approximately 0 - 4.8V C OK or NG OK >> INSPECTION END NG >> GO TO 2. D MBIB1396E E 2. CHECK GROUND CONNECTIONS 1. 2. F Turn ignition switch OFF. Loosen and retighten ground screws on the body. Refer to EC-1342, "Ground Inspection" . G H I J MBIB1550E 1. IPDM E/R 2. Body ground OK or NG OK >> GO TO 3. NG >> Repair or replace ground connections. 3. Body ground K L M EC-1577 IAT SENSOR [HR (WITHOUT EURO-OBD)] 3. CHECK INTAKE AIR TEMPERATURE SENSOR POWER SUPPLY CIRCUIT 1. 2. Turn ignition switch OFF. Disconnect mass air flow sensor (intake air temperature sensor is built-into) (1) harness connector. – : Vehicle front Turn ignition switch ON. 3. PBIB2948E 4. Check voltage between mass air flow sensor terminal 5 and ground with CONSULT-II or tester. Voltage: Approximately 5V OK or NG OK >> GO TO 4. NG >> Repair open circuit or short to ground or short to power in harness or connectors. PBIB1169E 4. CHECK INTAKE AIR TEMPERATURE SENSOR GROUND CIRCUIT FOR OPEN AND SHORT 1. 2. 3. Turn ignition switch OFF. Disconnect ECM harness connector. Check harness continuity between mass air flow sensor terminal 6 and ECM terminal 55. Refer to Wiring Diagram. Continuity should exist. 4. Also check harness for short to ground and short to power. OK or NG OK >> GO TO 5. NG >> Repair open circuit or short to ground or short to power in harness or connectors. 5. CHECK INTAKE AIR TEMPERATURE SENSOR Refer to EC-1579, "Component Inspection" . OK or NG OK >> GO TO 6. NG >> Replace mass air flow sensor (with intake air temperature sensor). 6. CHECK INTERMITTENT INCIDENT Refer to EC-1336, "TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT" . >> INSPECTION END EC-1578 IAT SENSOR [HR (WITHOUT EURO-OBD)] Component Inspection BBS004SR A INTAKE AIR TEMPERATURE SENSOR 1. 2. Check resistance between mass air flow sensor (1) terminals 5 and 6 under the following conditions. Intake air temperature °C (°F) Resistance kΩ 25 (77) 1.800 - 2.200 EC If NG, replace mass air flow sensor (with intake air temperature sensor). C D PBIA9559J E F G SEF012P Removal and Installation H BBS004SS MASS AIR FLOW SENSOR Refer to EM-118, "AIR CLEANER AND AIR DUCT" . I J K L M EC-1579 IGNITION SIGNAL [HR (WITHOUT EURO-OBD)] IGNITION SIGNAL Component Description PFP:22448 BBS004ST IGNITION COIL & POWER TRANSISTOR The ignition signal from the ECM is sent to and amplified by the power transistor. The power transistor turns ON and OFF the ignition coil (1) primary circuit. This ON/OFF operation induces the proper high voltage in the coil secondary circuit. ● Fuel injector (2) PBIB2968E EC-1580 IGNITION SIGNAL [HR (WITHOUT EURO-OBD)] Wiring Diagram BBS004SU A EC C D E F G H I J K L M MBWA1491E EC-1581 IGNITION SIGNAL [HR (WITHOUT EURO-OBD)] Specification data are reference values and are measured between each terminal and ground. CAUTION: Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM's transistor. Use a ground other than ECM terminals, such as the ground. TERMINAL NO. WIRE COLOR ITEM CONDITION [Engine is running] [Ignition switch: OFF] ● 32 P ECM relay (Self shut-off) [Ignition switch: OFF] ● 105 G Power supply for ECM For a few seconds after turning ignition switch OFF More than a few seconds after turning ignition switch OFF [Ignition switch: ON] EC-1582 DATA (DC Voltage) 0 - 1.0V BATTERY VOLTAGE (11 - 14V) BATTERY VOLTAGE (11 - 14V) IGNITION SIGNAL [HR (WITHOUT EURO-OBD)] A EC C D E F G H I J K L M MBWA1492E EC-1583 IGNITION SIGNAL [HR (WITHOUT EURO-OBD)] Specification data are reference values and are measured between each terminal and ground. Pulse signal is measured by CONSULT-II. CAUTION: Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM's transistor. Use a ground other than ECM terminals, such as the ground. TERMINAL NO. WIRE COLOR ITEM CONDITION [Engine is running] 17 18 21 22 V BR G Y ● Warm-up condition ● Idle speed DATA (DC Voltage) 0 - 0.3V NOTE: The pulse cycle changes depending on rpm at idle Ignition signal No. 1 Ignition signal No. 2 Ignition signal No. 4 Ignition signal No. 3 PBIA9265J 0.2 - 0.5V [Engine is running] ● Warm-up condition ● Engine speed: 2,000 rpm PBIA9266J : Average voltage for pulse signal (Actual pulse signal can be confirmed by oscilloscope.) Diagnostic Procedure BBS004SV 1. CHECK ENGINE START Turn ignition switch OFF, and restart engine. Is engine running? Yes or No Yes (With CONSULT-II)>>GO TO 2. Yes (Without CONSULT-II)>>GO TO 3. No >> GO TO 4. 2. CHECK OVERALL FUNCTION With CONSULT-II Perform “POWER BALANCE” in “ACTIVE TEST” mode with CONSULT-II. 2. Make sure that each circuit produces a momentary engine speed drop. OK or NG OK >> INSPECTION END NG >> GO TO 10. 1. PBIB0133E EC-1584 IGNITION SIGNAL [HR (WITHOUT EURO-OBD)] 3. CHECK OVERALL FUNCTION A Without CONSULT-II Let engine idle. Read the voltage signal between ECM terminals 17, 18, 21, 22 and ground with an oscilloscope. 3. Verify that the oscilloscope screen shows the signal wave as shown below. NOTE: The pulse cycle changes depending on rpm at idle. 1. 2. EC C D E PBIA9567J PBIA9265J F OK or NG OK >> INSPECTION END NG >> GO TO 10. G 4. CHECK IGNITION COIL POWER SUPPLY CIRCUIT-I 1. 2. Turn ignition switch OFF, wait at least 10 seconds and then turn ON. Check voltage between ECM terminal 105 and ground with CONSULT-II or tester. H Voltage: Battery voltage I OK or NG OK >> GO TO 5. NG >> Go to EC-1337, "POWER SUPPLY AND GROUND CIRCUIT" . J K PBIA9575J L M EC-1585 IGNITION SIGNAL [HR (WITHOUT EURO-OBD)] 5. CHECK IGNITION COIL POWER SUPPLY CIRCUIT-II 1. 2. Turn ignition switch OFF. Disconnect condenser (1) harness connector. – : Vehicle front Turn ignition switch ON. 3. MBIB1548E 4. Check voltage between condenser terminal 1 and ground with CONSULT-II or tester. Voltage: Battery voltage OK or NG OK >> GO TO 8. NG >> GO TO 6. PBIB0624E 6. CHECK IGNITION COIL POWER SUPPLY CIRCUIT-III 1. 2. 3. Turn ignition switch OFF. Disconnect IPDM E/R harness connector E7. Check harness continuity between IPDM E/R terminal 33 and condenser terminal 1. Refer to Wiring Diagram. Continuity should exist. 4. Also check harness for short to ground and short to power. OK or NG OK >> Go to EC-1337, "POWER SUPPLY AND GROUND CIRCUIT" . NG >> GO TO 7. 7. DETECT MALFUNCTIONING PART Check the following. ● Harness connectors E59, F1 ● Harness for open or short between IPDM E/R and condenser >> Repair open circuit or short to ground or short to power in harness or connectors. EC-1586 IGNITION SIGNAL [HR (WITHOUT EURO-OBD)] 8. CHECK CONDENSER GROUND CIRCUIT FOR OPEN AND SHORT 1. 2. A Turn ignition switch OFF. Check harness continuity between condenser terminal 2 and ground. Refer to Wiring Diagram. EC Continuity should exist. 3. Also check harness for short to power. OK or NG OK >> GO TO 9. NG >> Repair open circuit or short to power in harness or connectors. C D 9. CHECK CONDENSER E Refer to EC-1588, "Component Inspection" OK or NG OK >> GO TO 10. NG >> Replace condenser. F 10. CHECK IGNITION COIL POWER SUPPLY CIRCUIT-IV 1. 2. 3. – 4. G Turn ignition switch OFF. Reconnect all harness connectors disconnected. Disconnect ignition coil (1) harness connector. Fuel injector (2) Turn ignition switch ON. H I J PBIB2968E 5. Check voltage between ignition coil terminal 1 and ground with CONSULT-II or tester. K L Voltage: Battery voltage OK or NG OK >> GO TO 12. NG >> GO TO 11. M SEF107S 11. DETECT MALFUNCTIONING PART Check the following. ● Harness connector F1 ● Harness for open or short between ignition coil and harness connector F1 >> Repair or replace harness or connectors. EC-1587 IGNITION SIGNAL [HR (WITHOUT EURO-OBD)] 12. CHECK IGNITION COIL GROUND CIRCUIT FOR OPEN AND SHORT 1. 2. Turn ignition switch OFF. Check harness continuity between ignition coil terminal 2 and ground. Refer to Wiring Diagram. Continuity should exist. 3. Also check harness for short to power. OK or NG OK >> GO TO 13. NG >> Repair open circuit or short to power in harness or connectors. 13. CHECK IGNITION COIL OUTPUT SIGNAL CIRCUIT FOR OPEN AND SHORT 1. 2. Disconnect ECM harness connector. Check harness continuity between ECM terminals 17, 18, 21, 22 and ignition coil terminal 3. Refer to Wiring Diagram. Continuity should exist. 3. Also check harness for short to ground and short to power. OK or NG OK >> GO TO 14. NG >> Repair open circuit or short to ground or short to power in harness or connectors. 14. CHECK IGNITION COIL WITH POWER TRANSISTOR Refer to EC-1588, "Component Inspection" . OK or NG OK >> GO TO 15. NG >> Replace ignition coil with power transistor. 15. CHECK INTERMITTENT INCIDENT Refer to EC-1336, "TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT" . >> INSPECTION END Component Inspection BBS004SW IGNITION COIL WITH POWER TRANSISTOR CAUTION: Do the following procedure in the place where ventilation is good without the combustible. 1. Turn ignition switch OFF. 2. Disconnect ignition coil harness connector. 3. Check resistance between ignition coil terminals as follows. Terminal No. (Polarity) Resistance Ω [at 25°C (77°F)] 1 and 2 Except 0 or ∞ 1 and 3 2 and 3 4. 5. 6. Except 0 If NG, replace ignition coil with power transistor. If OK, go to next step. Turn ignition switch OFF. Reconnect all harness connectors disconnected. EC-1588 MBIB0032E IGNITION SIGNAL [HR (WITHOUT EURO-OBD)] 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. Remove fuel pump fuse in IPDM E/R to release fuel pressure. NOTE: Do not use CONSULT-II to release fuel pressure, or fuel pressure applies again during the following procedure. Start engine. After engine stalls, crank it two or three times to release all fuel pressure. Turn ignition switch OFF. Remove all ignition coil harness connectors to avoid the electrical discharge from the ignition coils. Remove ignition coil and spark plug of the cylinder to be checked. Crank engine for 5 seconds or more to remove combustion gas in the cylinder. Connect spark plug and harness connector to ignition coil. Fix ignition coil using a rope etc. with gap of 13 - 17 mm between the edge of the spark plug and grounded metal portion as shown in the figure. Crank engine for about three seconds, and check whether spark is generated between the spark plug and the grounded metal portion. A EC C MBIB0277E D E F G Spark should be generated. CAUTION: ● Do not approach to the spark plug and the ignition coil within 50cm. Be careful not to get an electrical shock PBIB2325E while checking, because the electrical discharge voltage becomes 20kV or more. ● It might cause to damage the ignition coil if the gap of more than 17 mm is taken. NOTE: When the gap is less than 13 mm, the spark might be generated even if the coil is malfunctioning. 17. If NG, replace ignition coil with power transistor. CONDENSER 1. 2. 3. I J K Turn ignition switch OFF. Disconnect condenser harness connector. Check resistance between condenser terminals 1 and 2. Resistance: H L Above 1 MΩ at 25°C (77°F) M PBIB0794E Removal and Installation BBS004SX IGNITION COIL WITH POWER TRANSISTOR Refer to EM-132, "IGNITION COIL" . EC-1589 REFRIGERANT PRESSURE SENSOR [HR (WITHOUT EURO-OBD)] REFRIGERANT PRESSURE SENSOR Component Description PFP:92136 BBS004SY The refrigerant pressure sensor (1) is installed at the condenser of the air conditioner system. The sensor uses an electrostatic volume pressure transducer to convert refrigerant pressure to voltage. The voltage signal is sent to ECM, and ECM controls cooling fan system. ● : Vehicle front PBIB2980E PBIB2657E EC-1590 REFRIGERANT PRESSURE SENSOR [HR (WITHOUT EURO-OBD)] Wiring Diagram BBS004SZ A EC C D E F G H I J K L M MBWA1493E EC-1591 REFRIGERANT PRESSURE SENSOR [HR (WITHOUT EURO-OBD)] Specification data are reference values and are measured between each terminal and ground. CAUTION: Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM's transistor. Use a ground other than ECM terminals, such as the ground. TERMINAL NO. WIRE COLOR ITEM CONDITION DATA (DC Voltage) [Engine is running] 41 BR ● Warm-up condition ● Both A/C switch and blower fan switch: ON Refrigerant pressure sensor 1.0 - 4.0V (Compressor operates) [Engine is running] 48 74 Y W Sensor ground (Refrigerant pressure sensor) Sensor power supply (Refrigerant pressure sensor) ● Warm-up condition ● Idle speed Approximately 0V [Ignition switch: ON] Approximately 5V Diagnostic Procedure BBS004T0 1. CHECK REFRIGERANT PRESSURE SENSOR OVERALL FUNCTION 1. 2. 3. Start engine and warm it up to normal operating temperature. Turn A/C switch and blower fan switch ON. Check voltage between ECM terminal 41 and ground with CONSULT-II or tester. Voltage: 1.0 - 4.0V OK or NG OK >> INSPECTION END NG >> GO TO 2. PBIA9574J 2. CHECK GROUND CONNECTIONS 1. 2. 3. Turn A/C switch and blower fan switch OFF. Stop engine. Loosen and retighten ground screws on the body. Refer to EC-1342, "Ground Inspection" . MBIB1550E 1. IPDM E/R 2. Body ground OK or NG OK >> GO TO 3. NG >> Repair or replace ground connections. EC-1592 3. Body ground REFRIGERANT PRESSURE SENSOR [HR (WITHOUT EURO-OBD)] 3. CHECK REFRIGERANT PRESSURE SENSOR POWER SUPPLY CIRCUIT 1. Disconnect refrigerant pressure sensor (1) harness connector. – : Vehicle front Turn ignition switch ON. 2. A EC C D PBIB2980E 3. E Check voltage between refrigerant pressure sensor terminal 3 and ground with CONSULT-II or tester. Voltage: Approximately 5V F OK or NG OK >> GO TO 5. NG >> GO TO 4. G SEF479Y H 4. DETECT MALFUNCTIONING PART Check the following. ● Harness connectors E59, F1 ● Harness for open or short between refrigerant pressure sensor and ECM I J >> Repair open circuit or short to ground or short to power in harness or connectors. 5. CHECK REFRIGERANT PRESSURE SENSOR GROUND CIRCUIT FOR OPEN AND SHORT 1. 2. 3. Turn ignition switch OFF. Disconnect ECM harness connector. Check harness continuity between refrigerant pressure sensor terminal 1 and ECM terminal 48. Refer to Wiring Diagram. Continuity should exist. 4. Also check harness for short to ground and short to power. OK or NG OK >> GO TO 7. NG >> GO TO 6. 6. DETECT MALFUNCTIONING PART Check the following. ● Harness connectors E59, F1 ● Harness for open or short between refrigerant pressure sensor and ECM >> Repair open circuit or short to ground or short to power in harness or connectors. EC-1593 K L M REFRIGERANT PRESSURE SENSOR [HR (WITHOUT EURO-OBD)] 7. CHECK REFRIGERANT PRESSURE SENSOR INPUT SIGNAL CIRCUIT FOR OPEN AND SHORT 1. Check harness continuity between refrigerant pressure sensor terminal 2 and ECM terminal 41. Refer to Wiring Diagram. Continuity should exist. 2. Also check harness for short to ground and short to power. OK or NG OK >> GO TO 9. NG >> GO TO 8. 8. DETECT MALFUNCTIONING PART Check the following. Harness connectors E59, F1 ● Harness for open or short between refrigerant pressure sensor and ECM ● >> Repair open circuit or short to ground or short to power in harness or connectors. 9. CHECK INTERMITTENT INCIDENT Refer to EC-1336, "TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT" . OK or NG OK >> Replace refrigerant pressure sensor. NG >> Repair or replace. Removal and Installation BBS004T1 REFRIGERANT PRESSURE SENSOR Refer to ATC-135, "REFRIGERANT LINES" or MTC-81, "REFRIGERANT LINES" . EC-1594 VSS [HR (WITHOUT EURO-OBD)] VSS Description PFP:32702 A BBS004T2 The vehicle speed signal is sent to the combination meter from the “ABS actuator and electric unit (control unit)” by CAN communication line. The combination meter then sends a signal to the ECM by CAN communi- EC cation line. Diagnostic Procedure BBS004T3 1. INSPECTION START C Do you have CONSULT-II? Yes or No Yes >> GO TO 2. No >> GO TO 3. D E 2. CHECK OVERALL FUNCTION 1. 2. 3. 4. 5. Turn ignition switch OFF. Lift up the vehicle. Start engine and let it idle. Select “VHCL SPEED SE” in “DATA MONITOR” mode with CONSULT-II. Select “VHCL SPEED SE” indication when rotating wheels with suitable gear position. F G H “VHCL SPEED SE” indication should exceed 10 km/h (6 MPH). I OK or NG OK >> INSPECTION END NG >> GO TO 3. PBIB0164E J 3. CHECK DTC WITH “ABS ACTUATOR AND ELECTRIC UNIT (CONTROL UNIT)” Refer to BRC-8, "TROUBLE DIAGNOSIS" or BRC-49, "TROUBLE DIAGNOSIS" . OK or NG OK >> GO TO 4. NG >> Repair or replace. K L 4. CHECK COMBINATION METER FUNCTION M Refer to DI-4, "COMBINATION METERS" . >> INSPECTION END EC-1595 MI & DATA LINK CONNECTORS [HR (WITHOUT EURO-OBD)] MI & DATA LINK CONNECTORS Wiring Diagram PFP:24814 BBS004T4 MBWA1494E EC-1596 SERVICE DATA AND SPECIFICATIONS (SDS) [HR (WITHOUT EURO-OBD)] SERVICE DATA AND SPECIFICATIONS (SDS) Fuel Pressure PFP:00030 A BBS004T5 Approximately 350 kPa (3.5 bar, 3.57 kg/cm2 , 51 psi) Fuel pressure at idle EC Idle Speed and Ignition Timing Target idle speed Air conditioner: ON Ignition timing BBS004T6 A/T No load* (in P or N position) 700 ± 50 rpm M/T No load* (in Neutral position) 650 ± 50 rpm A/T In P or N position 700 rpm or more M/T In Neutral position 750 rpm or more A/T In P or N position M/T In Neutral position C D 6 ± 5° BTDC E *: Under the following conditions: ● Air conditioner switch: OFF ● Electric load: OFF (Lights, heater fan & rear window defogger) ● Steering wheel: Kept in straight-ahead position F Mass Air Flow Sensor BBS004T7 Supply voltage G Battery voltage (11 - 14V) Output voltage at idle 1.0 - 1.3*V *: Engine is warmed up to normal operating temperature and running under no load. H Intake Air Temperature Sensor BBS004T8 Temperature °C (°F) Resistance kΩ 25 (77) 1.800 - 2.200 80 (176) 0.283 - 0.359 J Engine Coolant Temperature Sensor Temperature °C (°F) I BBS004T9 Resistance kΩ 20 (68) 2.1 - 2.9 50 (122) 0.68 - 1.00 90 (194) 0.236 - 0.260 Knock Sensor K L BBS00587 Resistance [at 20°C (68°F)] Approximately 530 – 590kΩ Heated Oxygen Sensor 1 Heater M BBS004TA Resistance [at 25°C (77°F)] 3.4 - 4.4Ω Heated Oxygen sensor 2 Heater BBS004TB Resistance [at 25°C (77°F)] 3.4 - 4.4Ω Crankshaft Position Sensor (POS) BBS004TC Refer to EC-1412, "Component Inspection" . Camshaft Position Sensor (PHASE) BBS004TD Refer to EC-1418, "Component Inspection" . Intake Valve Timing Control Solenoid Valve Resistance [at 20°C (68°F)] BBS00588 6.7 – 7.7Ω EC-1597 SERVICE DATA AND SPECIFICATIONS (SDS) [HR (WITHOUT EURO-OBD)] Throttle Control Motor BBS004TE Resistance [at 25°C (77°F)] Approximately 1 - 15Ω Fuel Injector BBS004TF Resistance [at 10 - 60°C (50 - 140°F)] 11.1 - 14.5Ω Fuel Pump BBS004TG Resistance [at 25°C (77°F)] Approximately 0.2 - 5.0Ω EC-1598 INDEX FOR DTC [K9K] INDEX FOR DTC DTC No. Index [K9K] PFP:00024 A BBS003ZX X: Applicable —: Not applicable DTC*1 *2 Items (CONSULT-II screen item) MI lighting up Trip Red PC001 MULTIPLXD NETWORK 3 P0016 COHERENCE CMSFT/SN 3 P0045 TURBO ACT CIRC 3 Reference page × EC-1705 EC-1708 × C EC-1710 P0070 AIR TEMP SEN CIRC 3 P0087 FLOW CAPACITY 3 × EC-1719 P0089 RAIL PRESS REGULTN 3 × EC-1721 P0100 AIR FLOW SEN CIRC 3 EC-1722 P0115 WATER TMP SEN CIRC 3 EC-1727 P0170 INJECTOR CODE PROG 3 EC-1731 P0180 FUEL TEMP SEN CIRC 3 EC-1732 P0190 RAIL/PRESS SEN CIR 3 × EC-1736 P0200 INJECTOR CTRL CIRC 3 × EC-1740 P0201 CYL 1 INJ CTRL CIR 3 × × EC-1745 P0202 CYL 2 INJ CTRL CIR 3 × × EC-1745 P0203 CYL 3 INJ CTRL CIR 3 × × EC-1745 P0204 CYL 4 INJ CTRL CIR 3 × × EC-1745 P0225 PDL POTEN CIRC TK1 3 × EC-1751 P0231 L/PR ACTR CTRL CIR 3 × EC-1759 P0235 IN-MANI PRES CIRC 3 × EC-1763 P0263 MISFIRE ON CYL 1 3 × EC-1768 P0266 MISFIRE ON CYL 2 3 × EC-1768 P0269 MISFIRE ON CYL 3 3 × EC-1768 P0272 MISFIRE ON CYL 4 3 × EC-1768 P0325 ACCELEROMETER CIRC 3 P0335 ENGNE SPD SEN CIRC 3 P0340 CAMSHAFT SEN CIRC 3 EC-1778 P0380 PRHT DGNSTC CNECT 3 EC-1784 P0382 PRHT UNIT CTRL CIR 3 EC-1788 P0400 EGR SOL/VLV CIRC 3 × × EC-1791 P0403 EGR COMMAND CIRC 3 × × EC-1795 P0409 EGR POIFTN SEN CIR 3 P0487 EGR POSITN OFFSET 3 P0500 VEHL/SPD INF CIRC 3 EC-1810 P0513 ENGINE IMMOBILIZER 3 BL-215 P0530 REFRIGERNT SEN CIR 3 P0560 CPU SUPPLY VOLTAGE 3 P0571 BRAKE SWITCH CIRC 3 P0604 ECU MEMORY 3 × EC-1825 P0606 COMPUTER(C/U) 3 × EC-1826 P062F MEMORY SAVED 3 × EC-1599 EC Yellow EC-1715 D E F G H I J K EC-1770 × EC-1774 EC-1800 × EC-1805 EC-1811 × EC-1816 EC-1820 × EC-1828 L M INDEX FOR DTC [K9K] DTC*1 *2 MI lighting up Items (CONSULT-II screen item) Trip Red Yellow Reference page P0641 SEN SUPPLY N-1 VOL 3 × EC-1830 P0651 SEN SUPPLY N-2 VOL 3 × EC-1837 P0685 MAIN RLY CTRL CIRC 3 EC-1845 P0703 BRAKE INFORMATION 3 EC-1850 P2120 PDL POTEN CIRC TK2 3 P2226 ATMOS PRES ASE CIR 3 *1: 1st trip DTC No. and 2nd trip DTC No. are the same as DTC No. *2: This number is prescribed by ISO 15031-6. EC-1600 × EC-1855 EC-1863 INDEX FOR DTC [K9K] Alphabetical Index BBS003ZW X: Applicable —: Not applicable Items (CONSULT-II screen item) MI lighting up Reference page DTC*1 *2 Trip ACCELEROMETER CIRC P0325 3 EC-1770 AIR FLOW SEN CIRC P0100 3 EC-1722 AIR TEMP SEN CIRC P0070 3 EC-1715 ATMOS PRES ASE CIR P2226 3 EC-1863 BRAKE INFORMATION P0703 3 EC-1850 BRAKE SWITCH CIRC P0571 3 EC-1820 CAMSHAFT SEN CIRC P0340 3 EC-1778 COHERENCE CMSFT/SN P0016 3 EC-1708 COMPUTER(C/U) P0606 3 × EC-1826 CPU SUPPLY VOLTAGE P0560 3 × EC-1816 CYL 1 INJ CTRL CIR P0201 3 × × EC-1745 CYL 2 INJ CTRL CIR P0202 3 × × EC-1745 CYL 3 INJ CTRL CIR P0203 3 × × EC-1745 × EC-1745 Red Yellow EC CYL 4 INJ CTRL CIR P0204 3 × ECU MEMORY P0604 3 × EGR COMMAND CIRC P0403 3 × EGR POIFTN SEN CIR P0409 3 EGR POSITN OFFSET P0487 3 EGR SOL/VLV CIRC P0400 3 ENGINE IMMOBILIZER P0513 3 ENGNE SPD SEN CIRC P0335 3 × EC-1774 FLOW CAPACITY P0087 3 × EC-1719 FUEL TEMP SEN CIRC P0180 3 EC-1732 INJECTOR CODE PROG P0170 3 EC-1731 INJECTOR CTRL CIRC P0200 3 × EC-1740 IN-MANI PRES CIRC P0235 3 × EC-1763 L/PR ACTR CTRL CIR P0231 3 × EC-1759 MAIN RLY CTRL CIRC P0685 3 MEMORY SAVED P062F 3 × MISFIRE ON CYL 1 P0263 3 × EC-1768 MISFIRE ON CYL 2 P0266 3 × EC-1768 MISFIRE ON CYL 3 P0269 3 × EC-1768 MISFIRE ON CYL 4 P0272 3 × EC-1768 MULTIPLXD NETWORK PC001 3 × EC-1705 PDL POTEN CIRC TK1 P0225 3 × EC-1751 PDL POTEN CIRC TK2 P2120 3 × EC-1855 C D E F G EC-1825 × EC-1795 H EC-1800 × × EC-1805 × EC-1791 I BL-215 EC-1845 × EC-1828 PRHT DGNSTC CNECT P0380 3 EC-1784 PRHT UNIT CTRL CIR P0382 3 EC-1788 RAIL PRESS REGULTN P0089 3 × EC-1721 RAIL/PRESS SEN CIR P0190 3 × EC-1736 REFRIGERNT SEN CIR P0530 3 × EC-1811 EC-1601 A J K L M INDEX FOR DTC [K9K] Items (CONSULT-II screen item) MI lighting up Reference page DTC*1 *2 Trip SEN SUPPLY N-1 VOL P0641 3 × EC-1830 SEN SUPPLY N-2 VOL P0651 3 × EC-1837 TURBO ACT CIRC P0045 3 × EC-1710 VEHL/SPD INF CIRC P0500 3 × EC-1810 WATER TMP SEN CIRC P0115 3 × EC-1727 *1: 1st trip DTC No. and 2nd trip DTC No. are the same as DTC No. *2: This number is prescribed by ISO 15031-6. EC-1602 Red Yellow PRECAUTIONS [K9K] PRECAUTIONS PFP:00001 Precautions for Supplemental Restraint System (SRS) “AIR BAG” and “SEAT BELT PRE-TENSIONER” A BBS003ZY The Supplemental Restraint System such as “AIR BAG” and “SEAT BELT PRE-TENSIONER”, used along EC with a front seat belt, helps to reduce the risk or severity of injury to the driver and front passenger for certain types of collision. Information necessary to service the system safely is included in the SRS and SB section of this Service Manual. C WARNING: ● To avoid rendering the SRS inoperative, which could increase the risk of personal injury or death in the event of a collision which would result in air bag inflation, all maintenance must be perD formed by an authorized NISSAN/INFINITI dealer. ● Improper maintenance, including incorrect removal and installation of the SRS, can lead to personal injury caused by unintentional activation of the system. For removal of Spiral Cable and Air E Bag Module, see the SRS section. ● Do not use electrical test equipment on any circuit related to the SRS unless instructed to in this Service Manual. SRS wiring harnesses can be identified by yellow and/or orange harnesses or harness connectors. F Maintenance Information BBS005AU If any of following part is replaced, always replace with new* one. If it's not (or fail to do so), the electrical system may not be operated properly. *: New one means a virgin control unit that has never been energized on-board. G RHD MODELS H ● ● ● ● ● ● BCM (Models without Intelligent Key system) Intelligent Key unit (Models with Intelligent Key system) ECM IPDM E/R Combination meter EPS control unit I J LHD MODELS ● ● ● BCM (Models without Intelligent Key system) Intelligent Key unit (Models with Intelligent Key system) ECM Precautions for Procedures without Cowl Top Cover K L BBS00589 When performing the procedure after removing cowl top cover, cover the lower end of windshield with urethane, etc. M PIIB3706J On Board Diagnostic (OBD) System of Engine BBS003ZZ The ECM has an on board diagnostic system. It will light up the malfunction indicator (MI) to warn the driver of a malfunction causing emission deterioration. CAUTION: ● Be sure to turn the ignition switch OFF and disconnect the battery negative cable before any repair or inspection work. The open/short circuit of related switches, sensors, solenoid valves, etc. will cause the MI to light up. EC-1603 PRECAUTIONS [K9K] ● ● ● ● ● Be sure to connect and lock the connectors securely after work. A loose (unlocked) connector will cause the MI to light up due to the open circuit. (Be sure the connector is free from water, grease, dirt, bent terminals, etc.) Certain systems and components, especially those related to OBD, may use a new style slidelocking type harness connector. For description and how to disconnect, refer to PG-88, "HARNESS CONNECTOR" . Be sure to route and secure the harnesses properly after work. The interference of the harness with a bracket, etc. may cause the MI to light up due to the short circuit. Be sure to connect rubber tubes properly after work. A misconnected or disconnected rubber tube may cause the MI to light up due to the malfunction of the fuel system, etc. Be sure to erase the unnecessary malfunction information (repairs completed) from the ECM before returning the vehicle to the customer. Precautions ● ● ● ● BBS00400 Always use a 12 volt battery as power source. Do not attempt to disconnect battery cables while engine is running. Before connecting or disconnecting the ECM harness connector, turn ignition switch OFF and disconnect battery negative cable. Failure to do so may damage the ECM because battery voltage is applied to ECM even if ignition switch is turned OFF. Before removing parts, turn ignition switch OFF and then disconnect battery negative cable. SEF289H ● Do not disassemble ECM. MBIB1517E ● – – When connecting ECM harness connector, fasten (A) it securely with levers (1) as far as they will go as shown in the figure. ECM (2) Loosen (B) MBIB1518E EC-1604 PRECAUTIONS [K9K] ● ● ● ● ● ● ● ● ● ● ● ● ● When connecting or disconnecting pin connectors into or from ECM, take care not to damage pin terminals (bend or break). Make sure that there are not any bends or breaks on ECM pin terminal, when connecting pin connectors. Securely connect ECM harness connectors. A poor connection can cause an extremely high (surge) voltage to develop in coil and condenser, thus resulting in damage to IC's. Keep engine control system harness at least 10cm (4 in) away from adjacent harness, to prevent engine control system malfunctions due to receiving external noise, degraded operation of IC's, etc. Keep engine control system parts and harness dry. Handle mass air flow sensor carefully to avoid damage. Do not disassemble mass air flow sensor. Do not clean mass air flow sensor with any type of detergent. Even a slight leak in the air intake system can cause serious incidents. Do not shock or jar the camshaft position sensor, crankshaft position sensor. When measuring ECM signals with a circuit tester, never allow the two tester probes to contact. Accidental contact of probes will cause a short circuit and damage the ECM power transistor. Do not use ECM ground terminals when measuring input/ output voltage. Doing so may result in damage to the ECM's transistor. Use a ground other than ECM terminals, such as the ground. Do not disassemble fuel pump. If NG, take proper action. Do not disassemble fuel injector. If NG, replace fuel injector. A EC C SEF291H D E F G H I J K L M SEF348N ● ● ● Do not depress accelerator pedal when staring. Immediately after staring, do not rev up engine unnecessarily. Do not rev up engine just prior to shutdown. SEF709Y EC-1605 PRECAUTIONS [K9K] ● – – – – When installing C.B. ham radio or a mobile phone, be sure to observe the following as it may adversely affect electronic control systems depending on installation location. Keep the antenna as far as possible from the electronic control units. Keep the antenna feeder line more than 20 cm (8 in) away from the harness of electronic controls. Do not let them run parallel for a long distance. Adjust the antenna and feeder line so that the standingwave radio can be kept smaller. Be sure to ground the radio to vehicle body. SEF708Y Cleanliness BBS004TI CLEANLINESS INSTRUCTIONS WHICH MUST BE FOLLOWED WHEN WORKING ON THE HIGH PRESSURE DIRECT INJECTION SYSTEM Risks Relating to Contamination The system is very sensitive to contamination. The risks caused by the introduction of contamination are: ● Damage or destruction of the high pressure injection system and the engine ● Seizing or leaking of a component All After-Sales operations must be performed under very clean conditions. This means that no impurities (particles a few microns in size) get into the system during dismantling or into the circuits via the fuel unions. The cleanliness principle must be applied from the filter to the fuel injectors. WHAT ARE THE SOURCES OF CONTAMINATION? Contamination is caused by: ● Metal or plastic chips ● Paint ● fibres: – Boxes – Brushes – Paper – Clothing – Cloths ● Foreign bodies such as hair ● Ambient air ● etc IMPORTANT: It is not possible to clean the engine using a high pressure washer because of the risk of damaging connections. In addition, moisture may collect in the connectors and create electrical connection malfunctions. INSTRUCTIONS TO BE FOLLOWED BEFORE ANY WORK IS CARRIED OUT ON THE INJECTION SYSTEM ● ● ● Ensure that you have the plugs for the unions to be opened (bag of plugs sold at the Parts Store - Nissan part No.: 16830 BN700, Renault part No.: 77 01 206 804). Plugs are to be used once only. After use, they must be thrown away (once used they are soiled and cleaning is not sufficient to make them reusable). Unused plugs must be thrown away. Ensure that you have hermetically resealable plastic bags for storing removed parts. Stored parts will therefore be less subject to the risk of impurities. The bags must be used only once, and after use they must be thrown away. Lint-free towelettes to be used for injection pump related service purpose. The use of a normal cloth or paper for cleaning purposes is forbidden. These are not lint-free and may contaminate the fuel circuit of the system. Each lint-free cloth should only be used once. INSTRUCTIONS TO BE FOLLOWED BEFORE OPENING THE FUEL CIRCUIT ● ● For each operation, use new thinner (used thinner contains impurities). Pour it into a clean receptacle. For each operation, use a clean brush which is in good condition (the brush must not shed its bristles). EC-1606 PRECAUTIONS [K9K] ● ● ● ● Use a brush and thinners to clean the connections to be opened. Blow compressed air over the cleaned parts (tools, cleaned the same way as the parts, connections and A injection system zone). Check that no bristles remain adhered. Wash your hands before and during the operation if necessary. EC When wearing leather protective gloves, cover these with latex gloves. INSTRUCTIONS TO BE FOLLOWED DURING THE OPERATION ● ● ● ● ● As soon as the circuit is open, all openings must be plugged to prevent impurities from entering the system. The plugs to be used are available from the Parts Stores - Nissan part No.: 16830 BN700, Renault part No.: 77 01 206 804. They must not, under any circumstances, be reused. Close the hermetically sealed bag, even if it has to be reopened shortly afterwards. Ambient air carries contamination. All components of the injection system that are removed must be stored in a hermetically sealed plastic bag once the plugs have been inserted. The use of a brush, thinner, bellows, sponge or normal cloth is strictly forbidden once the circuit has been opened. These items are likely to allow impurities to enter the system. A new component replacing an old one must not be removed from its packaging until it is to be fitted to the vehicle. C D E F G H I J K L M EC-1607 PRECAUTIONS [K9K] Instructions for Fitting The Plugs Nissan part number: 16830 BN700 (Renault part number: 77 01 206 804) MBIB0321E CAUTION: ● The engine must not run with: – Diesel containing more than 10% diester – Gasoline, even in very small amounts. ● The system can inject the fuel into the engine at a pressure of up to 140,000 kPa (1,400 bar, 1,428 kg/cm2 , 20,300 psi). Before carrying out any work, check that the fuel rail is no longer pressurized and that the fuel temperature is not too high. ● You must respect the cleaning and safety advice specified in this document for any work on the high pressure injection system. EC-1608 ENGINE CONTROL SYSTEM [K9K] ENGINE CONTROL SYSTEM System Diagram PFP:23710 A BBS00403 EC C D E F G H I J K L M MBIB1473E EC-1609 ENGINE CONTROL SYSTEM [K9K] 1. ECM 2. EGR volume control valve 3. Fuel rail pressure sensor 4. Fuel rail 5. Fuel pump temperature sensor 6. Fuel flow actuator (Fuel pressure regulator) 7. Turbocharger boost sensor (63 kW engine models only) 8. Charge air cooler 9. Fuel pump 10. Engine coolant temperature sensor 11. Crankshaft position sensor 12. Mass air flow sensor and intake air temperature sensor 13. Air cleaner 14. Stop lamp switch 15. Accelerator pedal position sensor 16. Turbocharger 17. Turbocharger boost control actuator 18. Turbocharger boost control solenoid valve (63 kW engine models only) 19. Vacuum side 20. Ambient side 21. Glow control unit 22. Exhaust gas 23. Catalyst 24. Camshaft position sensor 25. Battery 26. Ignition switch 27. Mlfunction indicator 28. Glow lamp 29. Glow plug 30. Fuel injector 31. Fuel return 32. EGR cooler 33. CAN communication 34. Intake mamifold EC-1610 ENGINE CONTROL SYSTEM [K9K] Vacuum Hose Drawing BBS00404 A EC C D E F G H I J K L M MBIB1474E 1. Cylinder head 2. Turbocharger boost control solenoid valve 4. Turbocharger 5. Turbocharger boost control actuator 3. NOTE: Do not use soapy water or any type of solvent while installing vacuum hose. Refer to EC-1609, "System Diagram" for Vacuum Control System. EC-1611 Vacuum pump ENGINE CONTROL SYSTEM [K9K] System Overview BBS004TJ The DCM1.2 injection system used on the K9K engine is an electronically-controlled high-pressure injection system. The fuel is compressed by a high-pressure pump and then stored in a fuel rail that feeds the fuel injectors. Injection takes place when a current pulse applied to the fuel injector holder. The injection delivery is proportional to the fuel rail pressure and the length of pulse applied, and the start of injection is synchronised with the start of the pulse. The circuit comprises two sub-systems that can be distinguished from one another by the pressure level of the fuel: ● The low-pressure circuit comprises the reservoir, the fuel filter, the transfer pump and the fuel injector holder return pipes ● The high-pressure circuit consists of the high-pressure pump, the fuel rail, the fuel injector holders and the high-pressure tubes Finally, there are a certain number of regulation sensors and actuators that allow command and control of the system as a whole. Fuel Injection Control BBS004TL The high pressure injection system is intended to deliver a specific quantity of fuel to the engine at a specific time. ● DELPHI DCM1.2 Common Rail injection system Refer to EC-1609, "System Diagram" for details. ● The system consists of: – Priming pump on the low pressure circuit – Fuel filter – High pressure pump incorporating a low pressure pump (transfer pump) – Flow actuator (fuel pressure regulator) attached to the fuel pump – Fuel rail – Fuel rail pressure sensor located in the fuel rail – Four fuel injectors – Fuel pump temperature sensor – Engine coolant temperature sensor – Intake air temperature sensor – Camshaft position sensor (cylinder reference sensor) – Turbocharger boost sensor – Knock sensor – EGR volume control valve – Accelerator pedal position sensor – ECM ● The “common rail” direct high pressure injection system works sequentially. ● This new injection system reduces operating noise, reduces the volume of pollutant gases and particles and produces high engine torque at low engine speeds thanks to a pre-injection procedure. ● The high pressure pump generates the high pressure sent to the fuel rail. The flow actuator on the pump controls the quantity of fuel supplied according to the demand determined by the ECM. The fuel rail supplies each fuel injector through a steel pipe. ● The ECM: – Determines the value of injection pressure necessary for the engine to operate well and then controls the pressure regulator. It checks that the pressure value is correct by analyzing the value transmitted by the fuel rail pressure sensor located on the fuel rail. – Determines the injection time necessary to deliver the right quantity of fuel and the moment when injection should be started. – Controls each fuel injector electrically and individually after determining these two values. ● The injected flow to the engine is determined by: – The duration of fuel injector control EC-1612 ENGINE CONTROL SYSTEM [K9K] – – – – ● – – – – – ● – – ● The fuel injector opening and closing speed A The needle travel (determined by a constant for the type of fuel injector) The nominal hydraulic flow of the fuel injector (unique to each fuel injector) The fuel rail pressure controlled by the ECM EC The ECM controls: The idle speed adjustment The exhaust gas flow reinjected into the intake manifold C The fuel supply control (advance, flow and fuel rail pressure) The cooling fan control The glow plug (pre/post heating) control D The high pressure pump is supplied at low pressure by an integrated low pressure pump (transfer pump). It supplies the fuel rail whose pressure is controlled for charge by the flow actuator and for discharging by the fuel injector valves. Falls in pressure can be compensated for in this way. The flow actuator allows the E high pressure pump to provide just the amount of fuel necessary to maintain the pressure in the fuel rail. Thanks to this element, heat generation is minimized and engine output improved. In order to discharge the fuel rail using the fuel injector valves, the valves are controlled by short electrical F impulses: Short enough not to open the fuel injector, (through the return circuit from the fuel injectors) Long enough to open the valves and discharge the fuel rail G The ECM controls the cooling fans and the engine coolant temperature warning light on the instrument panel. IMPORTANT ● – – ● ● ● ● ● ● ● ● ● ● ● ● H The engine must not operate with: Fuel containing more than 10% diester Gasoline, even in tiny quantities The system can inject the fuel into the engine at a pressure up to 1400 bars. Before carrying out any work, check that the fuel rail is not under pressure and that the fuel temperature is not too high. You must respect the cleaning and safety advice specified in this document for any work on the high pressure injection system. Removal of the interior of the pump and fuel injectors is prohibited. Only the flow actuator, the fuel pump temperature sensor and the venturi can be replaced. For safety reasons, it is strictly forbidden to slacken a high pressure pipe union when the engine is running. It is not possible to remove the fuel rail pressure sensor from the fuel rail because this may cause circuit contamination malfunctions. If the fuel rail pressure sensor fails, the fuel rail pressure sensor, the fuel rail and the five high pressure pipes must be replaced. It is strictly forbidden to remove any injection pump pulley marked number 070 575. If the pump is being replaced, the pulley must be replaced. It is forbidden to repair the wiring connecting the knock sensor and the crankshaft positon sensor. If the wiring should malfunction, it has to be replaced with new wiring. Applying 12V directly to any component in the system is prohibited. Ultrasonic carbon removal and cleaning are prohibited. Never start the engine without the battery being connected correctly. Disconnect the injection system ECM when carrying out any welding work on the vehicle. It is essential to replace all the disconnected air intake plastic pipes. Functions Performed BBS004TK Function: Fuel supply management (advance, delivery and pressure). Quantity of fuel injected and regulation of injection advance. The injection control parameters are the quantities to be injected and their respective advances. These are calculated by the ECM on the basis of information from the following signals: ● Engine speed (crankshaft + cam for synchronisation) ● Accelerator pedal position EC-1613 I J K L M ENGINE CONTROL SYSTEM [K9K] Charge air pressure Intake air temperature ● Charge air pressure ● Engine coolant temperature ● Fuel rail pressure ● Ambient barometric pressure The quantities to be injected and their respective advances are converted into: ● Reference tooth ● Time between this tooth and the start of the pulse ● Time for which the fuel injector holder is fed An electrical current (pulse) is sent to each fuel injector holder as a function of the previously calculated data. The system performs between one and four injections (a pilot injection, a pre-injection, a main injection and a post-injection). The general principle is to calculate a total delivery injected which will then be distributed across the deliveries of the various injections to promote efficient combustion and a reduction in pollutant emissions. ● ● A knock sensor is used to control some of the deviations when the fuel is injected. This plays a number of roles: ● Protection of the engine by detecting injection losses (disabled on the basic version) ● Checking of the pilot quantity by measurement of the deviations and dispersions By modifying the duration on the one hand and the injection advance on the other, it is possible to readjust the quantity of fuel injected and the instant of ignition of the mixture. FUEL RAIL PRESSURE CONTROL The quality of combustion is influenced by the size of the droplets atomised in the cylinder. In the combustion chamber, smaller drops of fuel will have time to burn completely and not produce smoke or nonburned particles. To meet anti-pollution requirements it is necessary to reduce the size of the droplets and thus the injection holes. The smaller these holes are, the less fuel can be introduced at a given pressure which limits the power. To overcome this malfunction it is necessary to increase the quantity of fuel injected which in practice means increasing the pressure (and the number of openings of the fuel injector nozzles). In the case of the Delphi Common Rail, the pressure can reach 1600 bar in the fuel rail and must be permanently controlled. The measurement circuit is comprised an active fuel rail pressure sensor on the fuel rail linked to an analogue port of the ECM. The high-pressure pump is fed at low pressure (5 bar) by an integral transfer pump. This feeds the fuel rail, the pressure of which is controlled for the charging by the fuel flow actuator (fuel pressure regulator) and for discharge by the fuel injector. This allows drops in pressure to be compensated. The fuel flow actuator (fuel pressure regulator) allows the high-pressure pump to only supply the quantity of fuel necessary to maintain the pressure in the fuel rail. Thanks to this device, the generation of heat is minimised and the efficiency of the engine is improved. In order to discharge the fuel rail using the fuel injectors, the fuel injectors are operated by means of small electrical pulses: ● Sufficiently small not to open the fuel injector (the fuel passes through the return circuit from the fuel injectors) ● Sufficiently long to open the valves and discharge the fuel rail Surplus fuel is fed back to the fuel filter or to the reservoir according to its delivery. In the event of non-actuation of the fuel flow actuator (fuel pressure regulator), the pressure in the fuel rail is limited by a pressure relief valve fitted on the pump. IDLING CONTROL The ECM is responsible for idling control. In practice it has to take into account the instantaneous power level to be delivered as a function of the following elements: ● Engine coolant temperature EC-1614 ENGINE CONTROL SYSTEM [K9K] ● ● ● ● Gear ratio selected A Battery charge Whether electrical loads (additional heating, climate control, engine ventilator set, rear window defogger, etc.) are on or off EC System malfunctions detected INDIVIDUAL FUEL INJECTOR CORRECTION The fuel injectors of the DCM1.2 system must be calibrated with fuel injector adjusting values in order to accurately set their delivery. Calibration of each fuel injector is performed for various pressures on a test bed and the characteristics are shown on a label attached to the fuel injector holder body. These fuel injector adjusting values are then entered in the ECM memory thereby allowing it to operate the fuel injectors taking into account their manufacturing variance. C D MEASUREMENT OF THE ANGULAR POSITION Crankshaft position sensor (CKPS): Measurement of the angular position is performed by means of a magneto-inductive sensor that is excited by machined into the flywheel of the crankshaft. This flywheel comprises sixty teeth with a spacing of six degrees, less two missing teeth to form a notch. Camshaft position sensor (CMPS): A second sensor (Hall effect) excited by a tooth machined in the drive pulley of the high-pressure pump (in synch with the camshaft), rotates at half the speed of the engine and provides information on the operation of the injection cycle. By comparing the signals from these two sensors, the angular position subsystem (APS) of the ECM is capable of providing the system as a whole with the following synchronisation information: the angular position of the flywheel, the speed, the number of the active fuel injector and the advance in the injection cycle. This module also provides the system with information on the speed of rotation. E F G H NEW PUMP HOUSING FUEL FLOW STRATEGY (PUMP FUEL FLOW) Lubrication of the pump is by means of a fuel flow cycle during which the pump is filled and comes up to pressure before transferring the fuel to the fuel rail. This lubrication is performed using a strategy known as “new pump housing fuel flow” which prevents starting for around 10 seconds, which is the time needed for filling of the pump and starting. For vehicles equipped with keys, if the key is released before this “first start-up” phase it is not necessary to perform a power latch before proceeding to restart the vehicle. This strategy applies following an initial start-up in the factory and then whenever there is a change of ECM if the fuel rail pressure parameters are not copied over to the new ECM, or also following reprogramming of the ECM. I J K VARIABLE LOW CAPACITY (VLC) FUNCTION Due to the combination of a number of parameters such as the temperature of the fuel, wear of parts, clogging of the fuel filter, and so on, the system′s limit may be reached during its lifetime. In this case, the pressure in the fuel rail cannot be maintained because of a lack of capacity of the pump. In the event of a lack of pump capacity, therefore, this strategy will reduce the delivery required to a value that allows the pressure controller to re-check the pressure. EGR VOLUME CONTROL VALVE OPERATION The EGR system (exhaust gas recirculation) is comprised a direct current proportional EGR volume control valve with integral potentiometer to read the position of the valve. The EGR volume control position is controlled in a closed circuit via the potentiometer and/or the change in the estimated air deliver AIR DELIVERY CALCULATION The delivery of fresh air that enters the engine is indicated by a mass air flow sensor. This mass air flow sensor allows management of the quantity of exhaust gas to be recirculated in order to guarantee the best recirculation rates. An intake air temperature sensor is incorporated in the mass air flow sensor. Measurement of the air delivery allows closed-circuit control via the EGR volume control valve. TURBO CONTROL K9K 63kw Engine: The turbo system is comprised a solenoid valve that allows control of the waste gate in order to create a boost pressure or a depression in the admission circuit. EC-1615 L M ENGINE CONTROL SYSTEM [K9K] K9K 50kw Engine: The turbo system is self-regulating and does not need to be controlled by the ECM. FUNCTION: STORED FUNCTIONS Climate Control Management Assistance With climate controlled models, the DCM1.2 system offers the possibility of deactivating the air conditioning under certain usage conditions: ● Intentional interruption by the driver ● During the start-up phases ● In the event of overheating (in order to reduce the power to be supplied by the engine) ● When the speed is maintained at a very high level (protection of the compressor) ● For temporary periods (such as strong acceleration demands during overtaking, anti-stalling and moving off). These conditions are only taken into account where they occur repeatedly, in order to avoid instability of the system (untimely deactivations) ● When certain malfunctions arise Cold Loop Climate Control The climate control is the cold loop type and its management shared between a number of control units. The ECM is responsible for: ● Managing the demand for cold as a function of the controls in the passenger compartment and the pressure value ● Determining the power absorbed by the compressor from the pressure ● Determining the engine ventilator set commands as a function of the speed of the vehicle and the pressure The driver turns on the climate control from the instrument panel. The information is sent to the ECM via the CAN system. This demand for cold is authorised or declined as a function of the measured pressure. If this pressure is outside the operational limits, the cold loop strategy is not activated. NOTE: These demands for operation of the air cooling set can be made from the ECM but they pass via the CAN. These demands are a function of the climate control, but also the engine coolant temperature and the speed of the vehicle. Passenger Compartment Climate Control A direct injection engine is characterised by injection of the fuel directly into the combustion chamber. The result is a reduction in heat losses from the upper part of the engine and consequently a smaller cylinder head cooling circuit is needed. The effect of this reduction is that the temperature of the water passing through is increased more slowly. This water is then used by the passenger compartment heating system. During severe cold spells, therefore, it becomes difficult to quickly reach a comfortable temperature in the passenger compartment. In order to limit the heating delay, air heating resistors are incorporated in the passenger compartment heating circuit. The passenger compartment heating unit determines the need to operate the heating resistors, the IPDM E/R physically controls the heating resistors and the ECM determines on the one hand as a function of the alternator the operational power limits of the heating resistors and on the other when to disable the heating resistors as a function of the engine speed, the load and the speed of the vehicle. Idle Speed Control BBS004TM The ECM takes over calculation of the idle speed to maintain the idle speed at the recommended level and to compensate for any variation in the mechanical or electrical couple as regards: ● Engine coolant temperature ● Battery voltage ● Gear selected on the transmission ● Electrical loads (climate control system, cooling fan assembly etc.) ● Any malfunctions found At the normal operating temperature, without high electrical load, the idle speed is 800 ± 50 rpm. EC-1616 ENGINE CONTROL SYSTEM [K9K] IDLE SPEED CORRECTION ACCORDING TO ENGINE COOLANT TEMPERATURE A EC C D E F MBIB1475E X. Engine speed in rpm Y. Engine coolant temperature in °C SPEED ADJUSTMENT WHEN THERE IS AN ACCELERATOR PEDAL POSITION SENSOR MALFUNCTION ● ● ● ● If one or both terminals of the accelerator pedal position sensor are suspected, the ECM overrides the idle speed to maintain it at 1100 rpm. This fail-safe mode limits performance. The orange malfunction indicator lights up and flashes. If the accelerator pedal position sensor is blocked, is no longer being supplied, or is not transmitting an output signal, the ECM overrides the idle speed to maintain it at 1300 rpm. This mode limits performance. The orange malfunction indicator lights up and flashes. In both cases, when the brake pedal is depressed, the idle speed is stabilised at the recommended speed. If the information from the accelerator pedal position sensor and the brake switch information does not correspond, the speed is changed to 1100 rpm. IDLE SPEED ADJUSTMENT WHEN THERE IS AN FUEL INJECTOR CODE MALFUNCTION When there is an fuel injector code malfunction, the ECM overrides the idle speed to maintain it at 1300 rpm. This mode limits performance. The orange malfunction indicator lights up and flashes. G H I J K L CORRECTION OF THE IDLING SPEED ACCORDING TO THE GEAR RATIOS The idling speed is modified according to the gear selected in the transmission: ● in neutral, 1st and 2nd gear, the speed is (at the normal operating temperature) 850 rpm (graph A), ● for the other gears, the speed is (at the normal operating temperature) 900 rpm (graph B). EC-1617 M ENGINE CONTROL SYSTEM [K9K] MBIB1476E X. Engine speed in rpm Y. Engine coolant temperature in °C Air Conditioning Control BBS004TN AIR CONDITIONING CONTROL The compressor is a variable displacement type. The air conditioning relay is controlled by IPDM E/R. COMPRESSOR OPERATION PROGRAMMING During certain stages of operation, the ECM stops the compressor from functioning. Engine Starting Program The compressor is prevented from operating for 4 seconds after the engine has started. Thermal Protection Program The compressor is not engaged when the engine coolant temperature is higher than 115 °C (239 °F) or from 110 °C (230 °F) at high speed, 4500 rpm for more than 3 seconds. Fan Motor Control Programming At idling speed and also when driving, with the air conditioning activated, the speed of the fan motor is determined according to the refrigerant pressure and the vehicle speed. Recovery of Performance When pressure is applied to the accelerator pedal above 70%, the compressor is disengaged for 5 seconds. Recovery of Output When The Vehicle Starts Moving In order to help the vehicle move off, the air conditioning compressor is disengaged if the position of the accelerator pedal is above 35% and the idling speed less than 1250 rpm. Anti-Stall Protection The compressor is disengaged if the engine speed is lower than 750 rpm. Engine Overspeed Timed Protection Program The compressor is disengaged when the engine speed reaches 4500 rpm for more than 3 seconds. NOTE: The time between the compressor being disengaged twice is always greater than 10 seconds. EC-1618 ENGINE CONTROL SYSTEM [K9K] Pre/Postheating (Glow Plug) Control BBS004TO A The pre/postheating function is controlled by the glow control unit. PRE/POSTHEATING (GLOW PLUG) OPERATING PRINCIPLE “Preheating” at Ignition Switch ON 1. EC Variable preheating The time period for the glow lamp to light up and the feed to heater plugs depends on the engine coolant temperature and the battery voltage. C D E F G H MBIB1477E X. 2. Time in seconds Y. Temperature in °C Whatever the situation, the preheating glow lamp cannot be lit for more than 10 seconds (except in the event of an engine coolant temperature sensor malfunction). Fixed preheating After the glow lamp goes out the plugs remain supplied for a fixed period of 5 seconds. I J K “Post Heating” With The Engine Running During this phase the plugs are supplied continuously according to engine coolant temperature. For idle speed without depressing the accelerator pedal. L M MBIB1478E X. Time in seconds Y. Engine coolant temperature in °C EC-1619 ENGINE CONTROL SYSTEM [K9K] Glow Plugs BBS004TP The resistance of a glow plug is 0.6Ω. TIGHTENING TORQUE Glow plug: 1.5 N·m, 15 kg/cm, 13 in/lb Plugs may be removed without having to open the high pressure circuit. REMOVAL 1. 2. 3. 4. Disconnect the battery. Unclip the plug connector. Clean the outside of the plug to avoid any dirt entering the cylinder. Loosen and remove the plugs. MBIB1479E To undo the plug on cylinder 4 use a 10 mm long radio socket attached to a universal joint. Once the plug is loosened use a hose to unscrew it completely. REFITTING Proceed in the reverse order of removal. Cooling Fan Control BBS004TQ The cooling fan motor is controlled by the ECM. COOLING FAN OPERATION WITH THE ENGINE RUNNING The cooling fan motor is controlled: ● At slow speed if the engine coolant temperature exceeds 96 °C (205 °F) or if there is an engine coolant temperature sensor malfunction, and is switched off when the temperature falls below 93 °C (199 °F). ● at high speed if the engine coolant temperature exceeds 99 °C (210 °F) or if there is a low speed malfunction, and is switched off when the temperature falls below 96 °C (205 °F). The cooling fan motor low and high speeds are controlled when the air conditioning function is selected on the instrument panel. If the low speed setting is suspected, the high speed setting operates under the low speed conditions. EC-1620 ENGINE CONTROL SYSTEM [K9K] A EC C D E F G H I J K L M MBIB1472E OPERATION OF THE ENGINE COOLANT TEMPERATURE WARNING LIGHT The engine coolant temperature warning light remains lit if the engine coolant temperature exceeds 114 °C (237 °F). It goes out when the temperature falls below 111 °C (232 °F). EC-1621 ENGINE CONTROL SYSTEM [K9K] Oil Vapour Rebreathing BBS004TR CIRCUIT DIAGRAM MBIB1480E ● ● 1. Cylinder head cover 2. Oil vapour rebreathing duct 4. Air inlet duct 5. Turbocharger 3. Oil vapour recirculation valve A: When there is a low charge, the vacuum in the intake air duct is below the spring set point. The oil vapours are extensively rebreathed by the vacuum in the intake air duct. B: When there is a medium or high charge, the pressure in the intake air duct exhausts the valve diaphragm, the oil vapours are breathed in small quantities via a calibrated hole. CHECKING To ensure the correct operation of the anti-pollution system, the oil vapour rebreathing circuit must be kept clean and in good condition. Exhaust Gas Recirculation (EGR) BBS004TS CIRCUIT DIAGRAM MBIB1481E 1. Engine 2. Air filter unit 3. Air distributor 4. Exhaust manifold 5. EGR volume control valve 6. Turbocharger 7. ECM A. Air inlet B. Exhaust gas outlet EC-1622 ENGINE CONTROL SYSTEM [K9K] PURPOSE OF THE EGR SYSTEM A Exhaust gas recirculation is used to reduce the nitrogen oxide (NOx) content of the exhaust gases. The ECM authorises gas to pass by controlling an EGR volume control valve. OPERATING PRINCIPLE The valve is controlled by an RCO (Opening Cyclic Ratio) signal sent by the ECM. The RCO signal modulates the opening of the valve and consequently the quantity of exhaust gas directed back to the intake manifold. The ECM continuously carries out a test to detect the position of the EGR volume control valve. NOTE: The position of the EGR volume control valve is determined by the calculation of the amount of air taken in by the engine. EC C D OPERATING CONDITIONS The parameters which determine the activation of the EGR volume control valve are as follows: ● Engine coolant temperature ● Intake air temperature ● Ambient barometric pressure ● Accelerator pedal position ● Injected fuel flow ● Engine speed Operating point for the EGR volume control valve test: The EGR volume control valve is activated when: ● Intake air temperature is > 15 °C (59 °F) and engine coolant temperature is > 70 °C (158 °F) ● Intake air temperature is > 50 °C (122 °F) and engine coolant temperature is > 40 °C (104 °F) ● Engine speed is between 850 and 1,000 rpm ● Injected fuel flow is between 2 and 5 mg/stroke ● Ambient barometric pressure is between 980 and 1,000 mbar In this case, the CONSULT-II can read an RCO value of the EGR volume control valve equals to 16%. EGR function is disabled if: ● Battery voltage is less than 9 V ● Engine speed is below 500 rpm ● Mapping (engine speed/load) exceeds a given threshold ● Air conditioning compressor is activated The EGR volume control valve is not supplied for 2 seconds after the engine starts. If there is a malfunction in: ● EGR volume control valve ● Turbocharger boost sensor the operation of the EGR volume control valve is cut. MBIB1482E 1. Position sensor signal (sensor signal) 2. Position sensor earth (sensor ground) 3. Position sensor feed (sensor power) 4. Valve earth control (ground control) 5. Not used 6. Valve feed (power supply) EC-1623 E F G H I J K L M ENGINE CONTROL SYSTEM [K9K] CAN Communication BBS0040B SYSTEM DESCRIPTION CAN (Controller Area Network) is a serial communication line for real time application. It is an on-vehicle multiplex communication line with high data communication speed and excellent error detection ability. Many electronic control units are equipped onto a vehicle, and each control unit shares information and links with other control units during operation (not independent). In CAN communication, control units are connected with 2 communication lines (CAN H line, CAN L line) allowing a high rate of information transmission with less wiring. Each control unit transmits/receives data but selectively reads required data only. Refer to LAN-27, "CAN Communication Unit" , about CAN communication for detail. EC-1624 BASIC SERVICE PROCEDURE [K9K] BASIC SERVICE PROCEDURE Fuel Filter PFP:00018 A BBS0040C DESCRIPTION A water draining cock is on the lower side and a priming pump for bleeding air is on the upper side. EC AIR BLEEDING After fuel filter is replaced and after fuel system components are removed/installed, bleed air from fuel line as follows: 1. Prime the circuit using the priming pump. 2. Perform engine cranking with repeating several times until engine starting. CAUTION: ● Crank engine until it starts. Do not crank engine for more than 30 seconds. ● Prepare a tray to collect fuel. Prevent fuel from adhering to rubber parts, especially the engine mounting insulator. C D E WATER DRAINING 1. 2. 3. 4. 5. Prepare a tray at the drain plug open end. Loosen drain plug, and operate priming pump to drain water from fuel filter. CAUTION: ● Water in filter is drained with fuel. Prepare larger capacity pan than fuel filter volume. ● Drained water is mixed with fuel. Prevent fuel from adhering to rubber parts such as engine mounting insulator. After draining, close drain plug by hand. CAUTION: If drain plug is tightened excessively, it may be damaged and fuel will leak. Do not use tools to tighten drain cock. Bleed air in fuel piping. Refer to EC-1625, "AIR BLEEDING" . Start engine and make sure there is no fuel leakage. Injector Adjustment Value Registration BBS0040E There is a 16 digit code on the fuel injectors called injector adjustment value. This code is specific to each fuel injector, and takes into account differences in manufacture and specifies the flow injected by each of them. When a fuel injector is replaced, it is necessary to program the injector adjustment value of the new fuel injector into the ECM. When an ECM is replaced, it is necessary to program the injector adjustment values of the four fuel injectors. There are two possibilities: ● If it is possible to communicate with the ECM: – Read out the data from the ECM using the “SAVE DATA FOR REPLACE” in “WORK SUPPORT” mode with CONSULT-II. – Turn ignition switch OFF. – Remove battery negative cable. – Change the ECM. – Reprogram the data from the “WRITE DATA AFTER REPLACE” in “WORK SUPPORT” mode with CONSULT-II to the replaced ECM. – After replacement, ensure that the ECM has not detected malfunctions relating to the injector adjustment value and check that the MI is turned OFF. ● If it is not possible to communicate with the ECM: – Turn ignition switch OFF. – Remove battery negative cable. – Change the ECM. – Read the data on the fuel injectors. – Enter the data in the ECM using the “ENTER INJCTR CALIB DATA” in “WORK SUPPORT” mode with CONSULT-II manually. EC-1625 F G H I J K L M BASIC SERVICE PROCEDURE [K9K] – – Reconfigure the different elements such as the power-assisted steering pump assembly and the thermoplungers etc. Using CONSULT-II, ensure that the ECM has not detected malfunctions relating to the injector adjustment value and check that the MI is turned OFF. Tightening The High Pressure Pipes BBS004TX All the high pressure pipe removed must be systematically replaced along with the clips. NOTE: Fit the pump/rail pipe before the rail/injector pipes. RAIL-PUMP PIPE ● ● ● ● ● ● ● Undo the rail, Grease the threads of the high pressure pipe nuts, Insert the high pressure pipe olive into the taper of the high pressure pump outlet, Insert the high pressure pipe olive into the taper of the high pressure rail inlet. Move the nut into position by hand, on the rail side then the pump side, Tighten the rail, Tighten the high pressure pipe nuts on the rail side then on the pump side. MBIB1483E RAIL/INJECTOR PIPES Undo the rail, Grease the threads of the high pressure pipe nuts, ● Insert the high pressure pipe olive into the taper of the high pressure injector inlet, ● Insert the high pressure pipe olive into the taper of the high pressure rail outlet, ● Move the nuts into position by hand, on the injector side then the rail side, ● Tighten the rail, ● Ensure that the new clip, supplied with the new high pressure pipe, is fitted, ● Tighten the nuts of the high pressure pipes on the injector side first and then on the fuel rail side. NOTE: Before fitting a new high pressure pipe, move back the nuts on the pipe then lightly lubricate the nut threads with the oil from the sachet (1) provided in the parts kit. ● ● Checking Sealing After Repair BBS004TY After any operation, check that there are no fuel leaks. Reprime the circuit using the priming pump. Start the engine and allow to warm up at idle speed, visually inspecting for any fuel leaks. Apply tracing fluid around the high pressure connections of the pipe that has been replaced. Once the engine coolant temperature is above 50 °C and provided there are no malfunctions present, carry out a road test, taking the engine speed up to 4,000 rpm at least once to check that there are no leaks. Perform a visual inspection after the road test to make sure that there are no high pressure leaks. Clean off the tracing fluid. Replacing ECM BBS004TZ The system can be reprogrammed using CONSULT-II. Before an ECM is replaced in after-sales, the following must be done. EC-1626 BASIC SERVICE PROCEDURE [K9K] ● ● ● Check the injector adjustment value using “WORK SUPPORT” mode with CONSULT-II. After replacing ECM, enter each injector adjustment value using “WORK SUPPORT” mode with CONSULT-II. Also set the system configuration using “CONFIGURATION” mode with CONSULT-II. A EC Replacing Fuel Injectors BBS004U0 NOTE: Injector adjustment value is a factory calibration carried out on each fuel injector to adjust the flow of each one precisely, taking into account differences in manufacture. The injector adjustment values are written on a label affixed to each fuel injector then entered in the ECM which can then control each fuel injector by taking account of their differences in manufacture. The system can be programmed “WORK SUPPORT” mode with CONSULT-II. The injector adjustment values (16 digit code) must be replaced after replacing a fuel injector. ● Entering each injector adjustment value, when replacing the ECM. C D E F G H I J K L M EC-1627 ON BOARD DIAGNOSTIC (OBD) SYSTEM [K9K] ON BOARD DIAGNOSTIC (OBD) SYSTEM Introduction PFP:00028 BBS0040I The ECM controls the display on the instrument panel of certain information relating to the operation of the engine. Four functions are involved here: The OBD malfunction indicator [MI(Yellow)] for the EOBD (European On Board Diagnostics), the pre/post heating, the engine coolant temperature and engine malfunction [MI(Red)]. These four functions are represented by four lights given out by the ECM PRE/POST HEATING LAMP This lamp indicates that the pre-heating has been activated. ENGINE COOLANT TEMPERATURE LIGHT This light is used as an indicator of engine overheating. ● In the event of overheating, it is up to the driver whether to stop the vehicle or not. OBD LIGHT The OBD malfunction indicator [MI(Yellow)] is used to alert the driver to the existence of engine control system malfunctions involving excessive pollution or if the EOBD system is deactivated. The ECM makes a request for lighting of the MI(Yellow) only where there is a malfunction present at the end of three consecutive cycles. The 3-second visual check upon powering up (automatic test procedure controlled by the IPDM E/R) is performed by the ECM. In the event of a confirmed OBD malfunction by lighting of the OBD light, no flashing of the light must be observed following the lighting test. DTCs Causing MI to Light DTC Description Characterization Reference page P0201 Cylinder 1 injector control circuit (Open circuit) (Short circuit) CC CO EC-1745, "DTC P0201 - P0204 FUEL INJECTOR" P0202 Cylinder 2 injector control circuit (Open circuit) (Short circuit) CC CO EC-1745, "DTC P0201 - P0204 FUEL INJECTOR" P0203 Cylinder 3 injector control circuit (Open circuit) (Short circuit) CC CO EC-1745, "DTC P0201 - P0204 FUEL INJECTOR" P0204 Cylinder 4 injector control circuit (Open circuit) (Short circuit) CC CO EC-1745, "DTC P0201 - P0204 FUEL INJECTOR" P0400 EGR volume control valve (EGR volume control valve blocked open) 4.DEF EC-1791, "DTC P0400 EGR FUNCTION" P0403 EGR volume control valve (Open circuit or short circuit to ground) CO.0 EC-1795, "DTC P0403 EGR VOLUME CONTROL VALVE" P0487 EGR volume control valve control position sensor circuit (Open circuit or short circuit to ground) (Short circuit to +12V) CO.0 CC.1 EC-1805, "DTC P0487 EGR VOLUME CONTROL VALVE CONTROL POSITION SENSOR" P062F ECM (Reading to EEPROM memory) 2.DEF EC-1828, "DTC P062F ECM" ENGINE WARNING LIGHT In the event of an engine malfunction, the ECM may request the display of an engine warning light [MI(Red)]. How to Erase DTC BBS004UN With CONSULT-II The DTC in the ECM can be erased by selecting “ERASE” in the “SELF-DIAG RESULTS” mode with CONSULT-II. EC-1628 ON BOARD DIAGNOSTIC (OBD) SYSTEM [K9K] 1. 2. 3. 4. If the ignition switch stays ON after repair work, be sure to turn ignition switch OFF once. Wait at least 5 seconds and then turn it ON (engine stopped) again. A Touch “ENGINE”. Touch “SELF-DIAG RESULTS”. EC Touch “ERASE”. (The DTC in the ECM will be erased.) C D E F G PBIB2452E NATS (Nissan Anti-Theft System) ● ● ● H BBS0040L If the security indicator lights up with the ignition switch in the ON position or “NATS MALFUNCTION””is displayed on “SELF-DIAG RESULTS” screen, perform self-diagnostic results mode with CONSULT-II using NATS program card. Refer to BL-215, "NATS (Nissan Anti-Theft System)" . Confirm no self-diagnostic results of NATS is displayed before touching “ERASE” in “SELF-DAIG RESULTS” mode with CONSULT-II. When replacing ECM, initialization of NATS system and registration of all NATS ignition key IDs must be carried out SEF543X with CONSULT-II using NATS program card. Therefore, be sure to receive all keys from vehicle owner. Regarding the procedure of NATS initialization and all NATS ignition key ID registration, refer to CONSULT-II operation manual, NATS. REPLACING THE ECM This vehicle is fitted with an engine immobilizer system which is controlled by a key recognition system. The ECM is supplied without a code but they must all be programmed with one. If an ECM is replaced, it must be programmed with the code of the vehicle and the correct operation of the engine immobilizer function must be checked. WARNING: These vehicles have a special ECM which does not function unless it is coded. Consequently, it is strongly recommended that you do not carry out tests using ECMs borrowed from the warehouse or on another vehicle to prevent coding and uncoding malfunctions which may leave the ECM useless. UNCODING PROCEDURE If the ECM has learnt a code and must be returned to the workshop, it is imperative that you uncode it before removing it. EC-1629 I J K L M TROUBLE DIAGNOSIS [K9K] TROUBLE DIAGNOSIS Trouble Diagnosis Introduction PFP:00004 BBS0040O SCOPE OF THIS DOCUMENT This document presents the trouble diagnosis method applicable to all ECMs with the following specifications: Vehicle(s): E11 with K9K Function concerned: DELPHI, DIRECT DIESEL INJECTION, COMMON RAIL MULTI INJECTION Name of ECM: INJECTION DCM1.2 Program No.: 4D VDIAG No.: 48 PREREQUISITES FOR TROUBLE DIAGNOSIS To begin trouble diagnosis, it is essential to have the following items available: Documentation Type Diagnostic procedures: ● Assisted with CONSULT-II, Service Manual. ● Wiring diagrams. Special tool required PLUGGED RAIL tools REMINDERS Trouble Diagnosis: There are present DTCs and stored DTCs (which appeared in a certain context and have since disappeared or which are still present but have not had trouble diagnosis performed on them in the current context). The “present” or “stored” status of DTCs must be considered when activating the diagnostic tool after power is supplied to the ECM (without activating the system components). Deal with present DTCs according to the procedure specified in the corresponding DTC trouble diagnosis. For stored DTCs, note the DTCs displayed and follow the instructions in the Notes section. If the DTC is confirmed when the instructions in the Notes section are applied, the malfunction is present. Deal with the DTC. If the DTC is not confirmed, check: ● Electrical lines which correspond to the malfunction ● Connectors for these lines (for oxidation, bent pins, etc.) ● Resistance of the malfunction component ● Condition of the wires (melted or cut insulation, wear) Conformity Check The conformity check is designed to check the states and data monitor items which do not display any DTCs on the diagnostic tool when inconsistent. This phase therefore allows: ● Diagnoses malfunctions that do not have a DTC display, and which may correspond to a customer complaint. ● Checks that the system is operating correctly and that there is no risk of a DTC reappearing after repairs. This section gives the trouble diagnosis procedures for states and parameters and the conditions for checking them. If a state is not operating normally or a data monitor value is outside permitted tolerance values, you should consult the corresponding trouble diagnosis page. Customer Complaints - Trouble Diagnosis If the test with the CONSULT-II is OK, but the customer complaint still present, the malfunction should be treated by customer complaints. A synopsis of the general procedure to follow is provided on the next page in the form of a flow chart. EC-1630 TROUBLE DIAGNOSIS [K9K] DIAGNOSTIC PROCEDURE A EC C D E F G H I J K L M MBIB1484E EC-1631 TROUBLE DIAGNOSIS [K9K] Wiring Control Diagnostics malfunctions Removing the connectors and/or handling the wirings may temporarily remove the origin of a DTC. The measurements of the electrical voltages, resistance and insulation are generally correct, especially when the DTC is not present at the time of the analysis (stored DTC). Visual Check Look for impacts under the bonnet and in the passenger compartment. Perform a careful check of the protections, insulation and correct running of wirings. Look for traces of oxidation. Tactile Check While manipulating the wirings, use the diagnostic tool to detect a change in DTC states from “stored” to “present”. Ensure that the connectors are correctly engaged. Apply light stresses to the connectors. Gently manipulate the wiring harness. If a change of state occurs, try to isolate the origin of the incident. Examination of Each Element Disconnect the connectors and check the appearance of the clips and blades and their crimping (no crimping on the insulating part). Check that the clips and blades are properly engaged in the receptacles. Ensure that there is no rebounding of clips or blades at the time of connection. Check the contact pressure of the clips using a suitable model blade. Resistance Control Test the continuity of the lines in their entirety, then section by section. Try to create a short-circuit to earth, on the + 12 V or with another wire. If a DTC is detected, repair or replace the wiring. SAFETY INSTRUCTIONS All work on components requires that the safety rules be obeyed to prevent damage or injury: ● Make sure the battery is properly charged to avoid damaging the ECM with a low charge. ● Use the proper tools. Cleanliness instructions which must be followed when working on the high-pressure direct injection system: Risks Relating to Contamination: The system is very sensitive to contamination. The risks caused by the introduction of contamination are damage to or destruction of the high-pressure injection system and the engine, seizing or incorrect sealing of a component. All After-Sales operations must be performed under very clean conditions. This means that no impurities (particles a few microns in size) get into the system during dismantling or into the circuits via the fuel unions. The cleanliness guidelines must be applied from the filter through to the injectors. ● What are the sources of contamination? Contamination is caused by: – Metal or plastic chips – Paint – Fibres from cardboard, brushes, paper, clothing, cloths – Foreign bodies such as hair – Ambient atmosphere, etc. WARNING: Before working on the injection system, ensure that the system pressure is nearing 0 bar. CAUTION: it is not possible to clean the engine using a high-pressure washer because of the risk of damaging the connections. In addition, moisture may collect in the connectors and cause electrical connection malfunctions. Instructions to Be Followed before Any Work is Carried Out on The Injection System: ● Ensure that you have the plugs for the unions to be opened (bag of plugs available from the Parts Stores, NISSAN part No:16830 BN700, Renault part No: 77 01 206 804). Plugs are to be used once only. After EC-1632 TROUBLE DIAGNOSIS [K9K] ● ● use, they must be thrown away (once used they are soiled and cleaning is not sufficient to make them reusable). Unused plugs must be thrown away. A Ensure that you have hermetically resealable plastic bags for storing removed parts. There is less risk of parts stored in this way being exposed to contamination. The bags must be used only once, and after use they must be thrown away. EC Ensure that lint-free towelettes are used for injection pump related service purposes. The use of a normal cloth or paper for cleaning purposes is prohibited. They are not lint-free and may contaminate the fuel circuit of the system. A lint-free cloth should only be used once. C Instructions to Be Followed before Opening The Fuel Circuit: Use new thinner for each operation (used thinner contains impurities). Pour it into a clean receptacle. For each operation, use a clean brush in good condition (the brush must not shed its bristles). Use a brush and thinners to clean the connections to be opened. Blow compressed air over the cleaned parts (tools, cleaned the same way as the parts, connections and injection system zone). Check that no bristles remain adhering. Wash your hands before and during the operation if necessary. When wearing leather protective gloves, cover them with latex gloves. Instructions to Be Followed During The Operation: As soon as the circuit is open, all openings must be plugged to prevent impurities from entering the system. The plugs to be used are available from the Parts Stores. They must not, under any circumstances, be reused. Close the resealable bag, even if it has to be reopened shortly afterwards. The ambient atmosphere carries impurities. All components removed from the injection system must be stored in a hermetically sealed plastic bag once the plugs have been inserted. The use of a brush, thinner, bellows, sponge or normal cloth is strictly forbidden once the circuit has been opened. These items are likely to allow contaminants to enter the system. A new component replacing an old one must not be removed from its packaging until it is to be fitted to the vehicle. D E F G H I ECM REPLACEMENT, PROGRAMMING OR REPROGRAMMING OPERATION Following items can be (re)programmed via the DLC using the CONSULT-II. ● System configuration ● Injector adjustment value Before replacing the ECM in after-sales operations, the following data must be readout using CONSULT-II: ● The injector adjustment values to be noted to appropriate paper or CONSULT-II copying function. NOTE: The injector adjustment value for each fuel injector must be entered manually after the ECM has been replaced or (re)programmed by reading the injector adjustment value on each fuel injector. IMPORTANT: It is not possible to test an ECM from the parts stores because it cannot be fitted to any other vehicle. REPLACING THE INJECTORS NOTE: The injector adjustment value is a calibration made on each fuel injector in the factory in order to adjust its flow precisely. These injector adjustment values are written on a label affixed to each fuel injector then entered into the ECM which then controls each fuel injector taking into account its individual manufacturing variations. When replacing one or more fuel injectors, the parameters of the fuel injector output concerned must be modified. The system can be configured using the CONSULT-II. EC-1633 J K L M TROUBLE DIAGNOSIS [K9K] Trouble Diagnosis - Symptom BBS004U2 NOTE: Only consult this customer complaint after a complete check using the CONSULT-II. Symptom Trouble diagnosis Reference page CHART 1 EC-1635 The engine does not start CHART 2 EC-1636 The engine starts with difficulty or starts then stalls CHART 3 EC-1638 Starting difficult with warm engine CHART 4 EC-1640 Rough idle speed (pumping) CHART 5 EC-1641 Idle speed too high or too low CHART 6 EC-1642 Unexpected acceleration/deceleration and engine stalling CHART 7 EC-1642 Response malfunction CHART 8 EC-1643 Engine stop (timing) CHART 9 EC-1644 Engine jerking CHART 10 EC-1646 Lack of power CHART 11 EC-1647 Too much power CHART 12 EC-1648 Excessive consumption CHART 13 EC-1649 Overspeed when lifting off accelerator or changing gear CHART 14 EC-1650 Engine dies when pulling away CHART 15 EC-1651 The engine does not stop CHART 16 EC-1652 Clanking engine, noisy engine CHART 17 EC-1653 Squalling noise CHART 18 EC-1654 General mechanical noises CHART 19 EC-1654 Blue, white or black smoke CHART 20 EC-1656 Exhaust odors CHART 21 EC-1657 Diesel odors CHART 22 EC-1657 Smoke (blue, white or black) on acceleration CHART 23 EC-1658 No communication with the ECM Starting malfunction Idle speed malfunction Behavior while driving Road holding (continued) Noise, odors or smoke EC-1634 TROUBLE DIAGNOSIS [K9K] CHART 1: NO COMMUNICATION WITH THE ECM A 1. INSPECTION START Ensure that CONSULT-II is not causing the malfunction by trying to establish dialogue with an ECM on another vehicle. If the CONSULT-II is not at malfunction, and dialogue cannot be established with any other ECM on EC the same vehicle, the cause could be a suspected ECM interfering on the CAN communication line. Check the voltage of the battery and carry out the operations necessary to obtain a voltage which is to specification (9.5 V < U battery < 17.5 V). C >> GO TO 2. D 2. CHECK CAN COMMUNICATION Perform trouble diagnosis on the CAN communication line using CONSULT-II. E >> GO TO 3. 3. CHECK ECM GROUND F Check the ECM earth (ground) point on the side strut tower. G >> GO TO 4. 4. CHECK DLC CONNECTOR CIRCUIT H Check the followings: ● Connection between the CONSULT-II and the DLC (wiring in good condition) ● Engine and passenger compartment fuses >> GO TO 5. I J 5. CHECK DLC CONNECTOR CIRCUIT Check for the presence of 12 V on terminal 16 with ignition switch OFF, 12 V on terminal 8 with ignition switch ON and an earth (ground) on terminals 4 and 5 of the data link connector. Repair if necessary. K L >> GO TO 6. M EC-1635 TROUBLE DIAGNOSIS [K9K] 6. CHECK ECM POWER SUPPLY AND GROUND CIRCUIT Connect the CONSULT-II and check the insulation, continuity and absence of interference resistance of the connections: ● ECM terminal 104 and IPDM E/R harness connector terminal 29 ● ECM terminal 109 and IPDM E/R harness connector terminal 32 ● ECM terminal 110 and IPDM E/R harness connector terminal 32 ● ECM terminal 22 and fuse block M7 ● ECM terminal 25 and ground ● ECM terminal 26 and ground ● ECM terminal 27 and ground ● ECM terminal 32 and ground ● ECM terminal 2 and DLC terminal 7 (Refer to EC-1698, "Wiring Diagram" .) Repair if necessary. >> INSPECTION END CHART 2: THE ENGINE DOES NOT START 1. CHECK FUEL Check that the fuel reservoir is correctly filled and with the right fuel. >> GO TO 2. 2. CHECK ENGINE OIL AND ENGINE COOLANT LEVEL Check the engine oil and coolant levels. >> GO TO 3. 3. CHECK INLET AIR CIRCUIT Check the inlet air circuit using TEST 5. Refer to EC-1663, "TEST 5: AIR INLET CIRCUIT CHECK" . >> GO TO 4. 4. CHECK CATALYTIC CONVERTER Is the catalytic converter clogged or deteriorated? Yes or No Yes >> Replace the catalytic converter. No >> GO TO 5. 5. CHECK ELECTRICAL CIRCUIT Check the electrical circuit using TEST 2. Refer to EC-1661, "TEST 2: ELECTRICAL CIRCUIT CHECK" . >> GO TO 6. EC-1636 TROUBLE DIAGNOSIS [K9K] 6. CHECK DISTRIBUTION A Is the distribution properly adjusted? Yes or No Yes >> GO TO 7. No >> Perform the required repairs. EC 7. CHECK WIRING HARNESS C Visually check the condition of the engine wiring harness. D >> GO TO 8. 8. CHECK STARTER E Is the starter working properly (minimum engine speed of 200 rpm)? Yes or No Yes >> GO TO 9. No >> Perform the required repairs. 9. CHECK COMPRESSION PRESSURE F G Are the compressions correct? Yes or No Yes >> GO TO 10. No >> Perform the required repairs. H 10. CHECK GLOW PLUG I Check the condition of the glow plugs. J >> GO TO 11. 11. CHECK ENGINE PARAMETERS K Check the engine parameters using TEST 4. Refer to EC-1663, "TEST 4: PARAMETER CHECK" . L >> GO TO 12. 12. CHECK FUEL RAIL PRESSURE M Does “RAIL PRESSURE” indicate less than 50 bar under + following contact? Yes or No Yes >> GO TO 13. No >> Perform the trouble diagnosis for FRP sensor. Refer to EC-1736, "DTC P0190 FRP SENSOR" . 13. CHECK LOW PRESSURE CIRCUIT Check the low pressure circuit using TEST 1. Refer to EC-1660, "TEST 1: LOW PRESSURE CIRCUIT CHECK" . >> GO TO 14. EC-1637 TROUBLE DIAGNOSIS [K9K] 14. CHECK HIGH PRESSURE CIRCUIT Visually check the high pressure circuit for leaks using TEST 8. Refer to EC-1665, "TEST 8: HIGH-PRESSURE CIRCUIT LEAK CHECK" . >> GO TO 15. 15. CHECK HIGH PRESSURE SYSTEM Check the high pressure system using TEST 7. Refer to EC-1664, "TEST 7: HIGH PRESSURE SYSTEM CHECK" . >> GO TO 16. 16. CEHCK ECM Check the ECM using TEST 6. Refer to EC-1664, "TEST 6: ECM CHECK" . >> INSPECTION END CHART 3: THE ENGINE STARTS WITH DIFFICULTY OR STARTS THEN STALLS 1. CHECK FUEL Check that the fuel reservoir is correctly filled and with the right fuel. >> GO TO 2. 2. CHECK ENGINE OIL AND ENGINE COOLANT LEVEL Check the engine oil and coolant levels. >> GO TO 3. 3. CHECK INLET AIR CIRCUIT Check the inlet air circuit using TEST 5. Refer to EC-1663, "TEST 5: AIR INLET CIRCUIT CHECK" . >> GO TO 4. 4. CHECK CATALYTIC CONVERTER Is the catalytic converter clogged or deteriorated? Yes or No Yes >> Replace the catalytic converter. No >> GO TO 5. 5. CHECK DISTRIBUTION Is the distribution properly adjusted? Yes or No Yes >> GO TO 6. No >> Perform the required repairs. EC-1638 TROUBLE DIAGNOSIS [K9K] 6. CHECK COMPRESSION PRESSURE A Are the compressions correct? Yes or No Yes >> GO TO 7. No >> Perform the required repairs. EC 7. CHECK GLOW PLUG C Check the condition of the glow plugs. D >> GO TO 8. 8. CHECK WIRING HARNESS E Visually check the condition of the engine wiring harness. F >> GO TO 9. 9. CHECK ELECTRICAL CIRCUIT Check the electrical circuit using TEST 2. Refer to EC-1661, "TEST 2: ELECTRICAL CIRCUIT CHECK" . >> GO TO 10. G H 10. CHECK ENGINE PARAMETERS Check the engine parameters using TEST 4. Refer to EC-1663, "TEST 4: PARAMETER CHECK" . >> GO TO 11. I J 11. CHECK LOW PRESSURE CIRCUIT Check the low pressure circuit using TEST 1. Refer to EC-1660, "TEST 1: LOW PRESSURE CIRCUIT CHECK" . >> GO TO 12. K L 12. CHECK HIGH PRESSURE CIRCUIT Visually check the high pressure circuit for leaks using TEST 8. Refer to EC-1665, "TEST 8: HIGH-PRESSURE CIRCUIT LEAK CHECK" . >> GO TO 13. 13. CHECK HIGH PRESSURE SYSTEM Check the high pressure system using TEST 7. Refer to EC-1664, "TEST 7: HIGH PRESSURE SYSTEM CHECK" . >> GO TO 14. 14. CHECK ECM Check the ECM using TEST 6. Refer to EC-1664, "TEST 6: ECM CHECK" . >> INSPECTION END EC-1639 M TROUBLE DIAGNOSIS [K9K] CHART 4: STARTING DIFFICULT WITH WARM ENGINE 1. CHECK FUEL Check that the fuel reservoir is correctly filled and with the right fuel. >> GO TO 2. 2. CHECK INLET AIR CIRCUIT Check the inlet air circuit using TEST 5. Refer to EC-1663, "TEST 5: AIR INLET CIRCUIT CHECK" . >> GO TO 3. 3. CHECK COMPRESSION PRESSURE Are the compressions correct? Yes or No Yes >> GO TO 4. No >> Perform the required repairs. 4. CHECK CATALYTIC CONVERTER Is the catalytic converter clogged or deteriorated? Yes or No Yes >> Replace the catalytic converter. No >> GO TO 5. 5. CHECK ENGINE PARAMETERS Check the engine parameters using TEST 4. Refer to EC-1663, "TEST 4: PARAMETER CHECK" . >> GO TO 6. 6. CHECK WIRING HARNESS Visually check the condition of the engine wiring harness. >> GO TO 7. 7. CHECK LOW PRESSURE CIRCUIT Check the low pressure circuit using TEST 1. Refer to EC-1660, "TEST 1: LOW PRESSURE CIRCUIT CHECK" . >> GO TO 8. 8. CHECK FUEL INJECTORS Operate the fuel injectors via ACTIVE TEST with CONSULT-II. >> GO TO 9. EC-1640 TROUBLE DIAGNOSIS [K9K] 9. CHECK FUEL INECTORS A Is movement of the valve audible 1 m away from the vehicle? Yes or No EC Yes >> GO TO 10. No >> Perform TEST 11. Refer to EC-1666, "TEST 11: FUEL FILTER CHECK" . If TEST 11 is in order, replace the malfunctioning fuel injector(s). C CHECK ECM 10. Check the ECM using TEST 6. Refer to EC-1664, "TEST 6: ECM CHECK" . D >> INSPECTION END CHART 5: ROUGH IDLE SPEED (PUMPING) E 1. CHECK LOW PRESSURE CIRCUIT Check the low pressure circuit using TEST 1. Refer to EC-1660, "TEST 1: LOW PRESSURE CIRCUIT CHECK" . F G >> GO TO 2. 2. CHECK ENGINE PARAMETERS Check the engine parameters using TEST 4. Refer to EC-1663, "TEST 4: PARAMETER CHECK" . >> GO TO 3. H I 3. CHECK WIRING HARNESS Is the engine wiring harness cut off or jammed? Yes or No Yes >> Carry out the required repairs. No >> GO TO 4. J K 4. CHECK FUEL PUMP L Is the high pressure actuator blocked? Yes or No Yes >> Carry out the required repairs. No >> GO TO 5. M 5. CHECK HIGH PRESSURE CIRCUIT Check for leaks in the high pressure circuit using TEST 8. Refer to EC-1665, "TEST 8: HIGH-PRESSURE CIRCUIT LEAK CHECK" . >> GO TO 6. 6. CHECK GLOW PLUG Check that the glow plugs are working properly. Is the glow plug resistance above 1Ω? Yes or No Yes >> Replace the glow plugs. No >> GO TO 7. EC-1641 TROUBLE DIAGNOSIS [K9K] 7. CHECK COMPRESSION PRESSURE Are the compressions correct? Yes or No Yes >> GO TO 8. No >> Carry out the required repairs. 8. CHECEK FUEL INJECTORS Check the fuel injectors using TEST 3. Refer to EC-1662, "TEST 3: FUEL INJECTOR CHECK" . >> GO TO 9. 9. CHECK FUEL PUMP Check the high pressure pump using TEST 7. Refer to EC-1664, "TEST 7: HIGH PRESSURE SYSTEM CHECK" . >> INSPECTION END CHART 6: IDLE SPEED TOO HIGH/TOO LOW 1. CHECK ENGINE PARAMETERS Check the engine parameters using TEST 4. Refer to EC-1663, "TEST 4: PARAMETER CHECK" . >> GO TO 2. 2. CHECK ELECTRICAL CIRCUIT Check the electrical circuit using TEST 2. Refer to EC-1661, "TEST 2: ELECTRICAL CIRCUIT CHECK" . >> GO TO 3. 3. CHECK CLUTCH LINKAGE Is the clutch linkage correct? Yes or No Yes >> GO TO 4. No >> Carry out the required repairs 4. CHECK ECM Check the ECM using TEST 6. Refer to EC-1664, "TEST 6: ECM CHECK" . >> INSPECTION END CHART 7: UNEXPECTED ACCELERATION/DECELERATION AND ENGINE OVERCHARGING 1. CHECK ENGINE PARAMETERS Check the engine parameters using TEST 4. Refer to EC-1663, "TEST 4: PARAMETER CHECK" . >> GO TO 2. EC-1642 TROUBLE DIAGNOSIS [K9K] 2. CHECK INLET AIR CIRCUIT A Check the air inlet circuit using TEST 5. Refer to EC-1663, "TEST 5: AIR INLET CIRCUIT CHECK" . EC >> GO TO 3. 3. CHECK WIRING HARNESS C Is the engine wiring harness cut off or pinched? Yes or No Yes >> Carry out the required repairs. No >> GO TO 4. D 4. CHECK FUEL INJECTORS E Check the fuel injectors using TEST 3. Refer to EC-1662, "TEST 3: FUEL INJECTOR CHECK" . F >> GO TO 5. 5. CHECK ENGINE ASPIRATION Check that the engine has not aspirated its oil (engine stalls). Yes or No Yes >> Carry out the required repairs. No >> GO TO 6. 6. CHECK ECM G H I Check the ECM using TEST 6. Refer to EC-1664, "TEST 6: ECM CHECK" . J >> INSPECTION END CHART 8: RESPONSE MALFUNCTION 1. CHECK INLET AIR CIRCUIT K Check the inlet air circuit using TEST 5. Refer to EC-1663, "TEST 5: AIR INLET CIRCUIT CHECK" . L >> GO TO 2. 2. CHECK COMPRESSION PRESSURE M Are the compressions correct? Yes or No Yes >> GO TO 3. No >> Carry out the required repairs. 3. CHECK ENGINE PARAMETERS Check the engine parameters using TEST 4. Refer to EC-1663, "TEST 4: PARAMETER CHECK" . >> GO TO 4. EC-1643 TROUBLE DIAGNOSIS [K9K] 4. CHECK TURBOCHARGER Check that the turbocharger is working properly. Is the turbocharger correct? Yes or No Yes >> GO TO 5. No >> Carry out the required repairs. 5. CHECK LOW PRESSURE CIRCUIT Check the low pressure circuit using TEST 1. Refer to EC-1660, "TEST 1: LOW PRESSURE CIRCUIT CHECK" . >> GO TO 6. 6. CHECK HIGH PRESSURE CIRCUIT Check for leaks in the high pressure circuit using TEST 8. Refer to EC-1665, "TEST 8: HIGH-PRESSURE CIRCUIT LEAK CHECK" . >> GO TO 7. 7. CHECK FUEL PUMP Is the high pressure actuator blocked? Yes or No Yes >> Carry out the required repairs. No >> GO TO 8. 8. CHECK FUEL INJECTORS Check the fuel injectors using TEST 3. Refer to EC-1662, "TEST 3: FUEL INJECTOR CHECK" . >> GO TO 9. 9. CHECK ECM Check the ECM using TEST 6. Refer to EC-1664, "TEST 6: ECM CHECK" . >> INSPECTION END CHART 9: ENGINE STOP/STALLING 1. CHECK FUEL Check that the fuel reservoir is correctly filled and with the right fuel. >> GO TO 2. 2. CHECK ENGINE OIL AND ENGINE COOLANT Check the engine oil and coolant levels. >> GO TO 3. EC-1644 TROUBLE DIAGNOSIS [K9K] 3. CEHCK ENGINE ASPIRATION A Check that the engine has not aspirated its oil (engine racing). EC >> GO TO 4. 4. CHECK INLET AIR CIRCUIT Check the inlet air circuit using TEST 5. Refer to EC-1663, "TEST 5: AIR INLET CIRCUIT CHECK" . >> GO TO 5. C D 5. CHECK CATALYTIC CONVERTER Is the catalytic converter clogged or deteriorated? Yes or No Yes >> Replace the catalytic converter. No >> GO TO 6. E F 6. CHECK WIRING HARNESS Visually check the condition of the engine wiring harness. >> GO TO 7. G H 7. CHECK ELECTRICAL CIRCUIT Check the electrical circuit using TEST 2. Refer to EC-1661, "TEST 2: ELECTRICAL CIRCUIT CHECK" . >> GO TO 8. I J 8. CHECK ENGINE PARAMETERS Check the engine parameters using TEST 4. Refer to EC-1663, "TEST 4: PARAMETER CHECK" . K >> GO TO 9. L 9. CHECK LOW PRESSURE CIRCUIT Check the low pressure circuit using TEST 1. Refer to EC-1660, "TEST 1: LOW PRESSURE CIRCUIT CHECK" . >> GO TO 10. 10. CHECK HIGH PRESSURE CURCUIT Visually check the high pressure circuit for leaks using TEST 8. Refer to EC-1665, "TEST 8: HIGH-PRESSURE CIRCUIT LEAK CHECK" . >> GO TO 11. 11. CHECK HIGH PRESSURE SYSTEM Check the high pressure system using TEST 7. Refer to EC-1660, "Trouble Diagnosis - Basic Test Procedure" . >> GO TO 12. EC-1645 M TROUBLE DIAGNOSIS [K9K] 12. CHECK ECM Check the ECM using TEST 6. Refer to EC-1664, "TEST 6: ECM CHECK" . >> INSPECTION END CHART 10: ENGINE JERKING 1. CHECK FUEL Check that the fuel tank is correctly filled and that the fuel type is suitable. Is the fuel type suitable and the tank correctly filled? Yes or No Yes >> GO TO 2. No >> Refill the fuel tank correctly. 2. CHECK LOW PRESSURE CIRCUIT Check the low pressure circuit using TEST 1. Refer to EC-1660, "TEST 1: LOW PRESSURE CIRCUIT CHECK" . >> GO TO 3. 3. CHECK ENGINE PARAMETERS Check the engine parameters using TEST 4. Refer to EC-1663, "TEST 4: PARAMETER CHECK" . >> GO TO 4. 4. CHECK WIRING HARNESS Is the engine wiring harness cut off or pinched? Yes or No Yes >> Carry out the required repairs. No >> GO TO 5. 5. CEHCK GLOW PLUG Check that the glow plugs are working properly. Is the glow plug resistance above 1Ω? Yes or No Yes >> Replace the glow plugs. No >> GO TO 6. 6. CHECK COMPRESSION PRESSURE Are the compressions correct? Yes or No Yes >> GO TO 7. No >> Carry out the required repairs. 7. CHECK VALVE CLEARANCE Is the valve clearance properly adjusted? Yes or No Yes >> GO TO 8. No >> Make the necessary adjustments. EC-1646 TROUBLE DIAGNOSIS [K9K] 8. CHECK FUEL PUMP A Check the high pressure pump using TEST 7. Refer to EC-1664, "TEST 7: HIGH PRESSURE SYSTEM CHECK" . EC >> GO TO 9. 9. CHECK ECM C Check the ECM using TEST 6. Refer to EC-1664, "TEST 6: ECM CHECK" . D >> INSPECTION END CHART 11: LACK OF POWER E 1. CHECK ENGINE PARAMETERS Check the engine parameters using TEST 4. Refer to EC-1663, "TEST 4: PARAMETER CHECK" . F >> GO TO 2. 2. CHECK INLET AIR CIRCUIT G Check the inlet air circuit using TEST 5. Refer to EC-1663, "TEST 5: AIR INLET CIRCUIT CHECK" . H >> GO TO 3. 3. CHECK ENGINE OIL LEVEL I Is the engine oil level correct? Yes or No Yes >> GO TO 4. No >> Top up the oil. J 4. CEHCK CATALYTIC CONVERTER K Is the catalytic converter sealed off or damaged? Yes or No Yes >> Replace the catalytic converter. No >> GO TO 5. L 5. CHECK TURBOCHARGER M Check that the turbocharger is working properly. Is the turbocharger correct? Yes or No Yes >> GO TO 6. No >> Carry out the required repairs. 6. CHECK LOW PRESSURE CURCUIT Check the low pressure circuit using TEST 1. Refer to EC-1660, "TEST 1: LOW PRESSURE CIRCUIT CHECK" . >> GO TO 7. EC-1647 TROUBLE DIAGNOSIS [K9K] 7. CHECK FUEL INJECTORS Check the fuel injectors using TEST 3. Refer to EC-1662, "TEST 3: FUEL INJECTOR CHECK" . >> GO TO 8. 8. CEHCK COMPRESSION PRESSURE Are the compressions correct? Yes or No Yes >> GO TO 9. No >> Carry out the required repairs. 9. CEHCK VALVE CLEARANCE Is the valve clearance properly adjusted? Yes or No Yes >> INSPECTION END No >> Make the necessary adjustments. CHART 12: TOO MUCH POWER 1. CHECK ENGINE PARAMETERS Check the engine parameters using TEST 4. Refer to EC-1663, "TEST 4: PARAMETER CHECK" . >> GO TO 2. 2. CEHCK INLET AIR CIRCUIT Check the inlet air circuit using TEST 5. Refer to EC-1663, "TEST 5: AIR INLET CIRCUIT CHECK" . >> GO TO 3. 3. CHECK ENGINE ASPIRATION Check that the engine has not aspirated its oil (engine stalls). Yes or No Yes >> Carry out the required repairs. No >> GO TO 4. 4. CHECK FUEL INJECTORS Check the fuel injectors using TEST 3. Refer to EC-1662, "TEST 3: FUEL INJECTOR CHECK" . >> GO TO 5. 5. CHECK ECM Check the ECM using TEST 6. Refer to EC-1664, "TEST 6: ECM CHECK" . >> INSPECTION END EC-1648 TROUBLE DIAGNOSIS [K9K] CHART 13: EXCESSIVE CONSUMPTION A 1. CHECK LOW PRESSURE CIRCUIT Check the low pressure circuit using TEST 1. Refer to EC-1660, "TEST 1: LOW PRESSURE CIRCUIT EC CHECK" . >> GO TO 2. C 2. CHECK FUEL PUMP Is the high pressure actuator leaking? Yes or No Yes >> Carry out the required repairs. No >> GO TO 3. D E 3. CHECK FUEL PUMP TEMPERATURE SENSOR Is the fuel pump temperature sensor leaking? Yes or No Yes >> Replace the fuel pump temperature sensor. No >> GO TO 4. F G 4. CHECK LOW PRESSURE CIRCUIT Check the low pressure circuit using TEST 1. Refer to EC-1660, "TEST 1: LOW PRESSURE CIRCUIT CHECK" . H I >> GO TO 5. 5. CHECK FUEL INJECTORS J Check the fuel injectors using TEST 3. Refer to EC-1662, "TEST 3: FUEL INJECTOR CHECK" . K >> GO TO 6. 6. CHECK HIGH PRESSURE CIRCUIT Check for leaks in the high pressure circuit using TEST 8. Refer to EC-1665, "TEST 8: HIGH-PRESSURE CIRCUIT LEAK CHECK" . L M >> GO TO 7. 7. CHECK INLET AIR CIRCUIT Check the inlet air circuit using TEST 5. Refer to EC-1663, "TEST 5: AIR INLET CIRCUIT CHECK" . >> GO TO 8. 8. CHECK ENGINE PARAMETERS Check the engine parameters using TEST 4. Refer to EC-1663, "TEST 4: PARAMETER CHECK" . >> GO TO 9. EC-1649 TROUBLE DIAGNOSIS [K9K] 9. CHECK ENGINE OIL LEVEL Is the engine oil level correct? Yes or No Yes >> GO TO 10. No >> Top up the oil. 10. CHECK CATALYTIC CONVERTER Is the catalytic converter clogged or damaged? Yes or No Yes >> Replace the catalytic converter. No >> GO TO 11. 11. CHECK TURBOCHARGER Check that the turbocharger is working properly. Is the turbocharger correct? Yes or No Yes >> GO TO 12. No >> Carry out the required repairs. 12. CHECK COMPRESSION PRESSURE Are the compressions correct? Yes or No Yes >> GO TO 13. No >> Carry out the required repairs. 13. CHECK ECM Check the ECM using TEST 6. Refer to EC-1664, "TEST 6: ECM CHECK" . >> INSPECTION END CHART 14: OVERSPEED WHEN LIFTING OFF ACCELERATOR OR CHANGING GEAR 1. CHECK ACCELERATOR PEDAL Check that there is no obstacle obstructing the accelerator pedal travel (carpet, hard spot, etc.). >> GO TO 2. 2. CHECK ENGINE PARAMETERS Check the engine parameters using TEST 4. Refer to EC-1663, "TEST 4: PARAMETER CHECK" . >> GO TO 3. 3. CHECK WIRING HARNESS Is the engine wiring harness cut or pinched? Yes or No Yes >> Carry out the required repairs. No >> GO TO 4. EC-1650 TROUBLE DIAGNOSIS [K9K] 4. CHECK CLUTCH LINKAGE A Is the clutch linkage properly adjusted? Yes or No Yes >> GO TO 5. No >> Carry out the required repairs. EC 5. CHECK ENGINE ASPIRATION C Check that the engine has not aspirated its oil (engine stalls). Yes or No Yes >> Carry out the required repairs. No >> GO TO 6. D 6. CHECK TURBOCHARGER E Check that the turbocharger is working properly. Is the turbocharger correct? Yes or No Yes >> GO TO 7. No >> Carry out the required repairs. F G 7. CHECK INJECTORS Check the injectors using TEST 3. Refer to EC-1662, "TEST 3: FUEL INJECTOR CHECK" . >> GO TO 8. H I 8. CHECK ECM Check the ECM using TEST 6. Refer to EC-1664, "TEST 6: ECM CHECK" . J >> INSPECTION END CHART 15: ENGINE DIES ON PULLING AWAY K 1. CHECK CLUTCH PEDAL L Is the clutch pedal free travel correctly adjusted? Yes or No Yes >> GO TO 2. No >> Carry out the required repairs. M 2. CHECK ENGINE PARAMETERS Check the engine parameters using TEST 4. Refer to EC-1663, "TEST 4: PARAMETER CHECK" . >> GO TO 3. 3. CHECK INLET AIR CIRCUIT Check the inlet air circuit using TEST 5. Refer to EC-1663, "TEST 5: AIR INLET CIRCUIT CHECK" . >> GO TO 4. EC-1651 TROUBLE DIAGNOSIS [K9K] 4. CHECK CTALYTIC CONVETER Is the catalytic converter clogged or damaged? Yes or No Yes >> Replace the catalytic converter. No >> GO TO 5. 5. CHECK LOW PRESSURE CIRCUIT Check the low pressure circuit using TEST 1. Refer to EC-1660, "TEST 1: LOW PRESSURE CIRCUIT CHECK" . >> GO TO 6. 6. CHECK CLUTCH LINKAGE Is the clutch linkage properly adjusted? Yes or No Yes >> GO TO 7. No >> Carry out the required repairs. 7. CHECK WIRING HARNESS Is the engine wiring harness cut or pinched? Yes or No Yes >> Carry out the required repairs. No >> GO TO 8. 8. CHECK ECM Check the ECM using TEST 6. Refer to EC-1664, "TEST 6: ECM CHECK" . >> INSPECTION END CHART 16: ENGINE BACKFIRES, ENGINE NOISE 1. CHECK FUEL Check that the fuel reservoir is correctly filled and with the right fuel. >> GO TO 2. 2. CHECK ENGINE OIL AND ENGINE COOLANT LEVEL Check the engine oil and coolant levels. >> GO TO 3. 3. CHECK COMPRESSION PRESSURE Are the compressions correct? Yes or No Yes >> GO TO 4. No >> Perform the required repairs. EC-1652 TROUBLE DIAGNOSIS [K9K] 4. CHECK GLOW PLUG A Check the condition of the glow plugs. EC >> GO TO 5. 5. CHECK ENGINE PARAMETERS Check the engine parameters using TEST 4. Refer to EC-1663, "TEST 4: PARAMETER CHECK" . >> GO TO 6. C D 6. CHECK INLET AIR CIRCUIT Check the inlet air circuit using TEST 5. Refer to EC-1663, "TEST 5: AIR INLET CIRCUIT CHECK" . >> GO TO 7. E F 7. CHECK LOW PRESSURE CURCUIT Check the low pressure circuit using TEST 1. Refer to EC-1660, "TEST 1: LOW PRESSURE CIRCUIT CHECK" . >> GO TO 8. G H 8. CHECK INJECTORS Check the injectors using TEST 3. Refer to EC-1662, "TEST 3: FUEL INJECTOR CHECK" . >> INSPECTION END CHART 17: CLANKING ENGINE, NOISY ENGINE I J 1. CHECK ENGINE PARAMETERS K Check the engine parameters using TEST 4. Refer to EC-1663, "TEST 4: PARAMETER CHECK" . >> GO TO 2. L 2. CHECK INLET AIR CIRCUIT Check the inlet air circuit using TEST 5. Refer to EC-1663, "TEST 5: AIR INLET CIRCUIT CHECK" . >> GO TO 3. 3. CHECK GLOW PLUG Check that the glow plugs are working properly. Is the glow plug resistance above 1Ω? Yes or No Yes >> Replace the glow plugs. No >> GO TO 4. EC-1653 M TROUBLE DIAGNOSIS [K9K] 4. CHECK COMPRESSION PRESSURE Are the compressions correct? Yes or No Yes >> GO TO 5. No >> Carry out the required repairs. 5. CHECK LOW PRESSURE CIRCUIT Check the low pressure circuit using TEST 1. Refer to EC-1660, "TEST 1: LOW PRESSURE CIRCUIT CHECK" . >> GO TO 6. 6. CHECK FUEL INECTORS Check the fuel injectors using TEST 3. Refer to EC-1662, "TEST 3: FUEL INJECTOR CHECK" . >> INSPECTION END CHART 18: SQUALLING NOISE 1. CHECK ENGINE PARAMETERS Check the engine parameters using TEST 4. Refer to EC-1663, "TEST 4: PARAMETER CHECK" . >> GO TO 2. 2. CHECK WIRING HARNESS Is the engine wiring harness cut or pinched? Yes or No Yes >> Carry out the required repairs. No >> GO TO 3. 3. CHECK FUEL PUMP Is the high pressure actuator blocked? Yes or No Yes >> Carry out the required repairs. No >> GO TO 4. 4. CHECK ECM Check the ECM using TEST 6. Refer to EC-1664, "TEST 6: ECM CHECK" . >> INSPECTION END CHART 19: VARIOUS MECHANICAL NOISES 1. CHECK FUEL INJECOTR OPERATION Check that the fuel injectors are not making a buzzing noise (injector discharge). Yes or No Yes >> Carry out the required repairs. No >> GO TO 2. EC-1654 TROUBLE DIAGNOSIS [K9K] 2. CHECK FUEL INJECTOR INSTALLATION A Are the mounting clips on the fuel injector pipes broken or missing? Yes or No Yes >> Carry out the required repairs. No >> GO TO 3. 3. CHECK ENGINE PARAMETERS EC C Check the engine parameters using TEST 4. Refer to EC-1663, "TEST 4: PARAMETER CHECK" . D >> GO TO 4. 4. CHECK CATALYTIC CONVERTER E Is the catalytic converter clogged or damaged? Yes or No Yes >> Replace the catalytic converter. No >> GO TO 5. F 5. CHECK INLET AIR CIRCUIT G Check the inlet air circuit using TEST 5. Refer to EC-1663, "TEST 5: AIR INLET CIRCUIT CHECK" . H >> GO TO 6. 6. CHECK FUEL INJECTORS I Check the fuel injectors using TEST 3. Refer to EC-1662, "TEST 3: FUEL INJECTOR CHECK" . J >> GO TO 7. 7. CHECK CLUTCH LINKAGE K Is the clutch linkage properly adjusted? Yes or No Yes >> GO TO 8. No >> Carry out the required repairs. L 8. CHECK TURBOCHARGER M Check that the turbocharger is working properly. Is the turbocharger correct? Yes or No Yes >> GO TO 9. No >> Carry out the required repairs. 9. CHECK VALVE CLEARANCE Is the valve clearance properly adjusted? Yes or No Yes >> INSPECTION END No >> Make the necessary adjustments. EC-1655 TROUBLE DIAGNOSIS [K9K] CHART 20: EXHAUST ODOURS 1. CHECK ENGINE PARAMETERS Check the engine parameters using TEST 4. Refer to EC-1663, "TEST 4: PARAMETER CHECK" . >> GO TO 2. 2. CHECK INLET AIR CIRCUIT Check the inlet air circuit using TEST 5. Refer to EC-1663, "TEST 5: AIR INLET CIRCUIT CHECK" . >> GO TO 3. 3. CHECK ENGINE ASPIRATION Check that the engine has not aspirated its oil (engine stalls). Yes or No Yes >> Carry out the required repairs. No >> GO TO 4. 4. CHECK TURBOCHARGER Check that the turbocharger is working properly. Is the turbocharger correct? Yes or No Yes >> GO TO 5. No >> Carry out the required repairs. 5. CHECK ENGINE OIL Is the engine oil level correct? Yes or No Yes >> GO TO 6. No >> Top up the oil. 6. CHECK CATALYTIC CONVETER Is the catalytic converter clogged or damaged? Yes or No Yes >> Replace the catalytic converter. No >> GO TO 7. 7. CHECK FUEL INJECTORS Check the fuel injectors using TEST 3. Refer to EC-1662, "TEST 3: FUEL INJECTOR CHECK" . >> GO TO 8. 8. CHECK ECM Check the ECM using TEST 6. Refer to EC-1664, "TEST 6: ECM CHECK" . >> INSPECTION END EC-1656 TROUBLE DIAGNOSIS [K9K] CHART 21: DIESEL ODOURS A 1. CHECK LOW PRESSURE CIRCUIT Check the low pressure circuit using TEST 1. Refer to EC-1660, "TEST 1: LOW PRESSURE CIRCUIT EC CHECK" . >> GO TO 2. C 2. CHECK FUEL PUMP Is the high pressure actuator leaking? Yes or No Yes >> Carry out the required repairs. No >> GO TO 3. D E 3. CHECK FUEL PUMP TEMPERATURE SENSOR Is the fuel pump temperature sensor leaking? Yes or No Yes >> Replace the fuel temperature sensor. No >> GO TO 4. F G 4. CHECK FUEL INJECTORS Check the fuel injectors using TEST 3. Refer to EC-1662, "TEST 3: FUEL INJECTOR CHECK" . >> GO TO 5. H I 5. CHECK HIGH PRESSURE CIRCUIT Check for leaks in the high pressure circuit using TEST 8. Refer to EC-1665, "TEST 8: HIGH-PRESSURE CIRCUIT LEAK CHECK" . J K >> INSPECTION END CHART 22: BLUE, WHITE OR BLACK SMOKE 1. CHECK FUEL L Check that the fuel reservoir is correctly filled and with the right fuel. M >> GO TO 2. 2. CHECK ENGINE OIL AND ENGINE COOLANT LEVEL Check the engine oil and coolant levels. >> GO TO 3. 3. CHECK ENGINE ASPIRATION Check that the engine has not aspirated its oil (engine racing). >> GO TO 4. EC-1657 TROUBLE DIAGNOSIS [K9K] 4. CHECK COMPRESSION PRESSURE Are the compressions correct? Yes or No Yes >> GO TO 5. No >> Perform the required repairs. 5. CHECK GLOW PLUG Check the condition of the glow plugs. >> GO TO 6. 6. CHECK CATALYTIC CONVERTER Is the catalytic converter clogged or deteriorated? Yes or No Yes >> Replace the catalytic converter. No >> GO TO 7. 7. CHECK INLET AIR CIRCUIT Check the inlet air circuit using TEST 5. Refer to EC-1663, "TEST 5: AIR INLET CIRCUIT CHECK" . >> GO TO 8. 8. CHECK ENGINE PARAMETERS Check the engine parameters using TEST 4. Refer to EC-1663, "TEST 4: PARAMETER CHECK" . >> GO TO 9. 9. CHECK LOW PRESSURE CIRCUIT Check the low pressure circuit using TEST 1. Refer to EC-1660, "TEST 1: LOW PRESSURE CIRCUIT CHECK" . >> GO TO 10. 10. CHECK FUEL INJECTORS Check the fuel injectors using TEST 3. Refer to EC-1662, "TEST 3: FUEL INJECTOR CHECK" . >> INSPECTION END CHART 23: SMOKE (BLUE, BLACK OR WHITE) ON ACCELERATING 1. CHECK FUEL Check that the fuel reservoir is correctly filled and with the right fuel. >> GO TO 2. 2. CHECK ENGINE OIL AND ENGINE COOLANT LEVEL Check the engine oil and coolant levels. >> GO TO 3. EC-1658 TROUBLE DIAGNOSIS [K9K] 3. CHECK ENGINE ASPIRATION A Check that the engine has not aspirated its oil (engine racing). EC >> GO TO 4. 4. CHECK COMPRESSION PRESSURE C Are the compressions correct? Yes or No Yes >> GO TO 5. No >> Perform the required repairs. D 5. CHECK GLOW PLUG E Check the condition of the glow plugs. F >> GO TO 6. 6. CHECK CATALYTIC CONVERTER Is the catalytic converter clogged or deteriorated? Yes or No Yes >> Replace the catalytic converter. No >> GO TO 7. 7. CHECK INLET AIR CIRCUIT G H I Check the inlet air circuit using TEST 5. Refer to EC-1663, "TEST 5: AIR INLET CIRCUIT CHECK" . J >> GO TO 8. 8. CHECK TURBOCHARGER Ensure that the turbo compressor is working correctly. Is the turbo compressor in order? Yes or No Yes >> GO TO 9. No >> Perform the required repairs. 9. CHECK WIRING HARNESS K L M Visually check the condition of the engine wiring harness. >> GO TO 9. 10. CHECK ENGINE PARAMETERS Check the engine parameters using TEST 4. Refer to EC-1663, "TEST 4: PARAMETER CHECK" . >> GO TO 11. EC-1659 TROUBLE DIAGNOSIS [K9K] 11. CHECK LOW PRESSURE CIRCUIT Check the low pressure circuit using TEST 1. Refer to EC-1660, "TEST 1: LOW PRESSURE CIRCUIT CHECK" . >> GO TO 12. 12. CHECK FUEL INJECTORS Check the fuel injectors using TEST 3. Refer to EC-1662, "TEST 3: FUEL INJECTOR CHECK" . >> GO TO 13. 13. CHECK ECM Check the ECM using TEST 6. Refer to EC-1664, "TEST 6: ECM CHECK" . >> INSPECTION END Trouble Diagnosis - Basic Test Procedure BBS004U3 DESCRIPTION NOTE: Only consult the tests after following the diagnostic procedure chart. Some specific checks are grouped under the “tests” heading and are used as required in different diagnostic charts. Basic test Trouble diagnosis Reference page Low pressure circuit check TEST 1 EC-1660 Electrical circuit check TEST 2 EC-1661 Fuel injector check TEST 3 EC-1662 Parameter check TEST 4 EC-1663 Air inlet circuit check TEST 5 EC-1663 ECM check TEST 6 EC-1664 High pressure pump check TEST 7 EC-1664 High pressure circuit leak check TEST 8 EC-1665 Fuel injector leak check TEST 9 EC-1665 Fuel injector return flow in starting phase TEST 10 EC-1666 Fuel filter check TEST 11 EC-1666 TEST 1: LOW PRESSURE CIRCUIT CHECK 1. CHECK CONFORMITY Check the conformity of the low pressure connections. Is the low pressure circuit connection correct? Yes or No Yes >> GO TO 2. No >> Carry out the required repairs. 2. CHECK FOR LEAK Look for leaks on the unions. Are there leaks in the hoses and unions? Yes or No Yes >> Carry out the required repairs. No >> GO TO 3. EC-1660 TROUBLE DIAGNOSIS [K9K] 3. CHECK FUEL FILTER A Check the correctness of the fuel filter. Is the fuel filter correct? Yes or No Yes >> GO TO 4. No >> Replace the fuel filter with an original part. EC C 4. CHECK FOR WATER Check for water in the fuel filter. Is there water in the fuel filter? Yes or No Yes >> Drain the fuel filter. No >> GO TO 5. D E 5. CHECK FOR AIR BUBBLES Check for air bubbles in the fuel filter. Are there any air bubbles in the low pressure circuit? Yes or No Yes >> GO TO 6. No >> GO TO 7. 6. BLEED AIR F G H Bleed the low pressure circuit. Place a container under the fuel filter: ● Disconnect the return hose at the fuel filter and block the fuel filter. ● Pump using the vacuum pump until there is no air left. ● Reconnect the return hose immediately. I J >> INSPECTION END K 7. INSPECTION END Low pressure circuit OK. L >> INSPECTION END M TEST 2: ELECTRICAL CIRCUIT CHECK 1. CHECK BATTERY AND ALTERNATOR Check the battery charge and ensure that the alternator is working properly. Is the charge circuit correct? Yes or No Yes >> GO TO 2. No >> Carry out the required repairs. 2. CHECK FUSE Check the fuses. Are the fuses correct? Yes or No Yes >> GO TO 3. No >> Carry out the required repairs. EC-1661 TROUBLE DIAGNOSIS [K9K] 3. CHECK ECM RELAY Check that the ECM relay is in working order. Is the ECM relay working properly? Yes or No Yes >> GO TO 4. No >> Replace the relay. 4. CHECK ENGINE GROUND Test the engine ground. Is the engine ground correct? Yes or No Yes >> GO TO 5. No >> Carry out the required repairs. 5. INSPECTION END The electrical circuit is OK. >> INSPECTION END TEST 3: FUEL INJECTOR CHECK 1. VISUALLY CHECK Visually inspect the fuel injector wells. Is there fuel in the fuel injector wells? Yes or No Yes >> Fuel injector ice leak, replace the fuel injector. No >> GO TO 2. 2. PERFORM ACTIVE TEST Perform “ACTIVE TEST”. Can you hear the fuel injector valve moving? Yes or No Yes >> GO TO 3. No >> Carry out test 11. If test 11 is OK, replace the fuel injector. 3. CHECK RETURN FLOW Compare the return flow of the four fuel injectors when hot using a measuring cylinder. See TEST 9. Does one of the four fuel injectors have a greater return flow than the others? Yes or No Yes >> Replace the fuel injector with an unusually high return flow (leak at the valve). No >> GO TO 4. 4. CHECK NO.1 CYLINDER Disconnect cylinder No. 1 fuel injector. Is there a noticeable change in engine noise? Yes or No Yes >> GO TO 5. No >> Replace fuel injector No.1 with a new part. EC-1662 TROUBLE DIAGNOSIS [K9K] 5. CHECK ANOTHER CYLINDER A Reconnect cylinder No. 1 fuel injector. Carry out the same test on the other cylinders to identify a possible suspected fuel injector. The injector is sound. EC >> INSPECTION END C TEST 4: PARAMETER CHECK 1. CHECK INJECTOR ADJUSTMENT VALUE Use the CONSULT-II to check that injector adjustment value corresponds to the fuel injectors. Is injector adjustment value correctly filled in? Yes or No Yes >> GO TO 3. No >> GO TO 2. 2. ENTER INJECTOR ADJUSTMENT VALUE D E F Use the CONSULT-II to program injector adjustment value into the memory, paying attention to the cylinder numbers. G >> INSPECTION END H 3. INSPECTION END Check that the “DATA MONITOR” value (parameter) are consistent. I >> INSPECTION END J TEST 5: AIR INLET CIRCUIT CHECK 1. CHECK AIR LEAK K Check for the presence of a leak/intake of air. Presence of a leak/intake of air. Yes or No Yes >> Carry out the required repairs. No >> GO TO 2. L 2. CHECK AIR FILTER M Check the condition of the air filter. Air filter OK. Yes or No Yes >> GO TO 3. No >> Replace the air filter with a new part. 3. CHECK INTAKE MANIFOLD Check that the intake manifold is not obstructed (dirty). Is the intake manifold blocked? Yes or No Yes >> Clean the intake manifold. No >> Air circuit OK. EC-1663 TROUBLE DIAGNOSIS [K9K] TEST 6: ECM CHECK 1. CHECK ECM CONNECTOR Check that the ECM connectors are locked correctly. Are the connectors poorly locked? Yes or No Yes >> Lock the connectors correctly. No >> Replace the ECM. TEST 7: HIGH PRESSURE SYSTEM CHECK NOTE: Certain malfunctions make it impossible to carry out this test, deal with them first. It is useless and dangerous to engage the starter motor for more than 5 seconds. 1. CHECK FUEL PUMP It is possible to check the high pressure supply pump capacity by carrying out the following procedure: Turn the ignition switch OFF, disconnect the low pressure actuator from the fuel pump (IMV brown connector) and connect a test adaptor (test IMV). ● Disconnect the 4 fuel injectors. ● Turn the ignition switch ON, connect CONSULT-II and select “RAIL PRESSURE” in DATA MONITOR mode. ● Apply brake and start engine. The starter will cut out automatically after 5 seconds. ● Read “RAIL PRESSURE” indication and confirm that maximum value during the test. Is the rail pressure greater than 1050 bar? Yes or No Yes >> GO TO 4. No >> GO TO 2. ● 2. CHECK FUEL RAIL PRESSURE Is the rail pressure greater than 900 bar? Yes or No Yes >> GO TO 3. No >> GO TO 5. 3. CHECK FUEL RAIL PRESSURE Repeat the test when cold. Engine coolant temperature = Intake air temperature. Is the rail pressure greater than 1050 bar? Yes or No Yes >> GO TO 4. No >> GO TO 5. 4. CHECK FUEL INJECTOR SEALING The pump can supply the operating pressure. Turn the ignition switch OFF and reconnect the 4 fuel injectors and low pressure actuator electrically. Turn the ignition switch ON, and erase DTCs using the CONSULT-II. Carry out the trouble diagnosis on the fuel injectors by checking the return volume of the 4 fuel injectors (See TEST 9 fuel injector sealing check). >> Repair or replace. EC-1664 TROUBLE DIAGNOSIS [K9K] 5. CHECK STARTING CIRCUIT A Make sure that the starting circuit is working correctly (minimum engine speed 200 rpm). Turn the ignition switch OFF and reconnect the 4 fuel injectors and low pressure actuator electrically. Turn the ignition switch ON, and erase the DTCs using CONSULT-II. EC >> GO TO 6. C 6. CHECK FUEL FILTER Carry out TEST 11. D >> GO TO 7. 7. CHECK FUEL INJECTOR RETURN VOLUME Carry out the trouble diagnosis on the fuel injectors by checking the return volume of the 4 fuel injectors. See TEST 9 or TEST 10 if the engine does not start. Is TEST 9 or TEST 10 correct? Yes or No Yes >> Replace the high pressure pump. No >> Replace the suspected fuel injector(s). E F G TEST 8: HIGH-PRESSURE CIRCUIT LEAK CHECK NOTE: Certain malfunctions make it impossible to carry out this test, deal with them first. There is a command that performs a leak test on the high-pressure circuit when the engine is running. This command can detect a leak on the high-pressure circuit if a union is improperly fitted or bolted, but cannot detect a small leak if a union is not torque tightened. This command can only be used if the engine temperature is above 60°C. Perform “HIGH PRESS CIRC LEAK T” in ACTIVE TEST mode, the engine will automatically carry out one cycle of 4 accelerations to raise the pressure in the fuel rail and check whether there are leaks in the high pressure circuit. Watch out for any objects (tools, etc.) on the sides of the engine housing during the four accelerations (vibrations possible). H I J K TEST 9: FUEL INJECTOR LEAK CHECK NOTE: Certain malfunctions make it impossible to carry out this test, deal with them first. “HIGH PRESS CIRC LEAK T” in ACTIVE TEST mode also allows you to check the return volume of each fuel injector to detect a leak inside the fuel injectors. Tooling required: ● It is essential to use 4 transparent pipes with an internal diameter of 4 mm and a length of approximately 50 cm. ● 4 graduated measuring cylinders. PROCEDURE ● Check that the engine coolant temperature is above 60°C. ● Turn ignition switch OFF. ● Disconnect the return pipes from the 4 fuel injectors. ● Fit a plug in the pump venturi tube to prevent the low-pressure circuit from depriming. ● Connect the 4 transparent pipes with an internal diameter of 4 mm and a length of 50 cm in place of the return pipes. ● Immerse these 4 pipes into 4 graduated measuring cylinders. Having carried out these preparations, start the engine, then let it run for 2 minutes at idle speed. ● Perform “HIGH PRESS CIRC LEAK T” in ACTIVE TEST mode: the engine will automatically perform one cycle of 4 accelerations to raise the pressure in the fuel rail and measure the leaks inside the fuel injectors in these conditions. EC-1665 L M TROUBLE DIAGNOSIS [K9K] Once the cycle is complete, perform “HIGH PRESS CIRC LEAK T” in ACTIVE TEST mode again for the correct reading of the return volume of each fuel injector. At the end of both cycles, the return volume of each fuel injector should be 35 ml at maximum. If the return volume of one of the fuel injectors is above 35 ml, replace the suspected fuel injector. ● Disconnect the 4 transparent pipes and reconnect the fuel injector return circuit. Watch out for any objects (tools, etc.) at the sides of the engine housing during the four cycles (vibrations possible). ● TEST 10: FUEL INJECTOR RETURN FLOW IN STARTING PHASE NOTE: Certain malfunctions make it impossible to carry out this test, deal with them first. It is useless and dangerous to engage the starter motor for more that 5 seconds. In the event the engine does not start, only the static leak can be measured, that is the leak with the fuel injector closed, inactive and not subject to any high pressure. Make sure that the starting circuit is working correctly (minimum speed 200 rpm). Tooling required: ● It is essential to use four transparent pipes with an internal diameter of 4 mm and approximately 50 cm long. ● A test adapter (TEST IMV) PROCEDURE: 1. Turn ignition switch OFF. 2. Disconnect the four fuel injector return pipes. 3. Fit a plug in the pump venturi tube to prevent the low-pressure circuit from depriming. 4. Connect the four transparent pipes with an internal diameter of 4 mm and a length of approximately 50 cm. 5. Disconnect the low pressure actuator from the pressure (brown IMV connector) and connect the test adapter (test IMV). 6. Electrically disconnect the 4 fuel injectors. 7. Turn ignition switch ON, apply brake and start engine. The starter cuts in automatically after 5 seconds. 8. Measure the amount of fuel in each pipe. Replace the fuel injector(s) whose leak return is greater than 10 cm. Disconnect the four transparent fuel pipes and reconnect the fuel injector return circuit. Disconnect the test IMV and reconnect the low pressure actuator to the pump. TEST 11: FUEL FILTER CHECK 1. CEHCK FUEL FILTER Check the conformity of the fuel filter. Is the fuel filter correct? Yes or No Yes >> GO TO 2. No >> Replace the fuel filter with an original part. 2. CHECK FUEL FILTER Turn ignition switch OFF, analyses the fuel in the fuel filter. ● Disconnect the fuel supply and return hoses from the fuel filter. ● Block the fuel filter inlets and outlets straight away with appropriate plugs. ● Remove the fuel filter from its holder and shake it well, keeping the caps in place and empty the contents of the fuel filter into a glass container by lifting up a protective cap and undoing the bleed screw. Can you see at the bottom of the container a deposit of black particles? Yes or No Yes >> GO TO 3. No >> Fuel filter correct. EC-1666 TROUBLE DIAGNOSIS [K9K] 3. CHECK METAL PARTICLES A Pass a magnet beneath the container to collect only all the metal particles. Take the magnet away from the container. EC Do the particles collected using the magnet cover a surface area greater than 1 cm2 ? Yes or No Yes >> Replace the entire injection system. C No >> Fuel filter correct. D E F G H I J K L M EC-1667 TROUBLE DIAGNOSIS [K9K] Engine Control Component Parts Location BBS0040T MBIB1516E 1. Fuel filter (LHD models) 2. Camshaft position sensor 3. Fuel pump 4. Knock sensor (Accelerometer) 5. Turbocharger boost control solenoid valve 6. Turbocharger boost sensor (63kw engine models only) 7. Crankshaft position sensor 8. Engine coolant temperature sensor 9. Glow control unit 10. ECM 11. Mass air flow sensor 12. EGR volume control valve 13. Fuel injector 14. Fuel rail 15. Primimg pump EC-1668 TROUBLE DIAGNOSIS [K9K] A EC C D E F G H I J K L M MBIB1537E : Vehicle front 1. Turbocharger boost sensor (63kw engine models only) 2. Mass air flow sensor 3. EGR volume control valve 4. Engine coolant temperature sensor 5. Fuel injector 6. Crankshaft position sensor 7. Camshaft position sensor 8. Battery 9. ECM EC-1669 TROUBLE DIAGNOSIS [K9K] MBIB1538E : Vehicle front 1. Turbocharger boost control solenoid valve (63kw engine models only) 2. Turbocharger boost sensor (63kw engine models only) 3. EGR volume control valve 4. Engine oil filler cap 5. Accelerator pedal 6. Accelerator pedal position sensor 7. Refrigerant pressure sensor 8. Knock sensor (Accelerometer) 9. Fuel rail EC-1670 TROUBLE DIAGNOSIS [K9K] Wiring Diagram — ECM — BBS0040U A EC C D E F G H I J K L M MBWA1546E EC-1671 TROUBLE DIAGNOSIS [K9K] MBWA1570E Refer to EC-21, "How to Check Vehicle Type" to confirm the engine type. EC-1672 TROUBLE DIAGNOSIS [K9K] ECM Harness Connector Terminal Layout BBS0040V A EC C MBIB1485E ECM Terminals And Reference Value BBS0040W PREPARATION 1. D E ECM (1) is located in the engine room left side near battery (2). F G H MBIB1519E 2. 3. Disconnect ECM harness connectors. ● When disconnecting ECM harness connectors, loosen (B) it with levers (1) as far as they will go as shown in the figure. – ECM (2) – Fasten (A) Connect a break-out box (SST) and Y-cable adapter (SST) between the ECM and ECM harness connector. ● Use extreme care not to touch 2 pins at one time. ● Data is for comparison and may not be exact. I J K MBIB1518E L M EC-1673 TROUBLE DIAGNOSIS [K9K] ECM INSPECTION TABLE Remarks: Specification data are reference values and are measured between each terminal and ground. Pulse signal is measured by CONSULT-II. CAUTION: Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM's transistor. Use a ground other than ECM terminals, such as the ground. TERMINAL NO. WIRE COLOR ITEM 1 L CAN communication line 2 LG Data link connector CONDITION [Ignition switch ON] [Ignition switch ON] ● CONSULT-II is disconnected. [Ignition switch OFF] ● 5 R Stop lamp switch Brake pedal: Fully released [Ignition switch OFF] ● 6 7 L/R Y Brake pedal: Slightly depressed Sensor ground (Accelerator pedal position sensor 2) [Engine is running] CAN communication line [Ignition switch ON] ● Warm-up condition ● Idle speed DATA (DC Voltage and Pulse Signal) Approximately 2.6V Output voltage varies with the communication status. Approximately 2.6V Approximately 0V BATTERY VOLTAGE (11 - 14V) Approximately 0.3V Approximately 2.4V Output voltage varies with the communication status. [Ignition switch ON] 12 L/W Accelerator pedal position sensor 2 ● Engine stopped ● Accelerator pedal: Fully released Approximately 0.4V [Ignition switch ON] ● Engine stopped ● Accelerator pedal: Fully depressed Approximately 2.0V 18 L Sensor power supply (Accelerator pedal position sensor 2) [Ignition switch ON] Approximately 4.6V 22 O Ignition switch [Ignition switch ON] BATTERY VOLTAGE (11 - 14V) 25 26 27 B B B ECM ground 28 29 B R [Engine is running] Sensor ground (Accelerator pedal position sensor 1) Sensor power supply (Accelerator pedal position sensor 1) ● Warm-up condition ● Idle speed Approximately 0V [Engine is running] ● Warm-up condition ● Idle speed [Ignition switch ON] Approximately 0.24V Approximately 5.0V [Ignition switch ON] 30 W Accelerator pedal position sensor 1 ● Engine stopped ● Accelerator pedal: Fully released Approximately 0.76V [Ignition switch ON] ● Engine stopped ● Accelerator pedal: Fully depressed EC-1674 Approximately 4.2V TROUBLE DIAGNOSIS [K9K] TERMINAL NO. WIRE COLOR ITEM CONDITION DATA (DC Voltage and Pulse Signal) A [Engine is running] 32 B ECM ground ● Warm-up condition ● Idle speed EC Approximately 0V 0 - 12.5V C [Ignition switch ON] 35 R ● Warm-up condition ● Idle speed D MBIB1504E Turbocharger boost control solenoid valve E 0 - 12.5V [Ignition switch ON] ● Warm-up condition ● Engine speed: 2,000 rpm F G MBIB1505E [Engine is running] 37 B ● Warm-up condition ● Idle speed EGR volume control valve Approximately 1.1V H Approximately 0.78V I 0 - 12.5V J [Engine is running] ● Warm-up condition ● Engine speed: 2,000 rpm [Engine is running] ● Warm-up condition ● Idle speed K MBIB1506E 39 P Fuel pump L 0 - 12.5V M [Engine is running] ● Warm-up condition ● Engine speed: 2,000 rpm MBIB1507E [Engine is running] 40 W ● Warm-up condition ● Idle speed EGR volume control valve Approximately 0.7 - 1.9 [Engine is running] 41 44 — W Sensor ground (Knock sensor shield circuit) Knock sensor ● Warm-up condition ● Engine speed: 2,000 rpm [Engine is running] ● Idle speed [Engine is running] ● Idle speed EC-1675 Approximately 1.5 - 1.9V Approximately 0.2V Approximately 0.3V TROUBLE DIAGNOSIS [K9K] TERMINAL NO. WIRE COLOR ITEM CONDITION DATA (DC Voltage and Pulse Signal) 45 O Sensor ground (Knock sensor) [Engine is running] Approximately 0.3V 47 L Sensor power supply (Fuel rail pressure sensor) [Ignition switch ON] Approximately 5.0V 48 V Sensor power supply (Turbocharger boost sensor) [Ignition switch ON] Approximately 5.0V 49 SB Sensor power supply (EGR volume control valve control position sensor) [Ignition switch ON] Approximately 5.0V 50 L Sensor power supply (Mass air flow sensor) [Ignition switch ON] Approximately 5.0V 51 R Intake air temperature sensor [Engine is running] Approximately 0.3 - 5.0V Output voltage varies with intake air temperature ● 53 54 P P Warm-up condition Engine coolant temperature sensor [Engine is running] Fuel pump temperature sensor [Engine is running] ● ● Warm-up condition Warm-up condition [Engine is running] ● Warm-up condition ● Idle speed Approximately 0.3 - 5.0V Output voltage varies with engine coolant temperature Approximately 0.3 - 5.0V Output voltage varies with fuel pump temperature 0 - 12.5V NOTE: The pulse cycle changes depending on rpm at idle. MBIB1508E 55 R Crankshaft position sensor 0 - 12.5V [Engine is running] ● Warm-up condition ● Engine speed: 2,000 rpm MBIB1509E [Engine is running] ● Warm-up condition ● Idle speed 0 - 1V NOTE: The pulse cycle changes depending on rpm at idle. MBIB1510E 56 Y Camshaft position sensor 0 - 1V [Engine is running] ● Warm-up condition ● Engine speed: 2,000 rpm MBIB1511E EC-1676 TROUBLE DIAGNOSIS [K9K] TERMINAL NO. WIRE COLOR ITEM CONDITION DATA (DC Voltage and Pulse Signal) A [Engine is running] 57 R ● Warm-up condition ● Idle speed Fuel rail pressure sensor Approximately 1.0V EC Approximately 1.5V C [Engine is running] ● Warm-up condition ● Engine speed: 2,000 rpm [Engine is running] 58 O ● Warm-up condition ● Idle speed Turbocharger boost sensor Approximately 1.6V [Engine is running] ● Warm-up condition ● Engine speed: 2,000 rpm E Approximately 2.0V F [Engine is running] 59 L EGR volume control valve control position sensor ● Warm-up condition ● Idle speed Approximately 4.1V G [Engine is running] ● Warm-up condition ● Engine speed: 2,000 rpm [Ignition switch: ON] D Approximately 3.3V Approximately 0.36V H [Engine is running] 60 Y Mass air flow sensor ● Warm-up condition ● Idle speed Approximately 1.7V I Approximately 2.2V J Approximately 0.25V K [Engine is running] 63 64 B G ● Warm-up condition ● Engine speed: 2,500 rpm Sensor ground (Engine coolant temperature sensor) [Engine is running] Sensor ground (Fuel pump temperature sensor) [Engine is running] ● Warm-up condition ● Idle speed ● Warm-up condition ● Idle speed Approximately 0.3V [Engine is running] 65 B Sensor ground (Crankshaft position sensor) ● Warm-up condition ● Idle speed M Approximately 0.3V [Engine is running] 66 L Sensor ground (Camshaft position sensor) ● Warm-up condition ● Idle speed Approximately 0.3V [Engine is running] 67 B Sensor ground (Fuel rail pressure sensor) ● Warm-up condition ● Idle speed Approximately 0.45V [Engine is running] 68 69 G P Sensor ground (Turbocharger boost sensor) Sensor ground (EGR volume control valve control position sensor) ● Warm-up condition ● Idle speed Approximately 0.3V [Engine is running] ● Warm-up condition ● Idle speed EC-1677 L Approximately 0.5V TROUBLE DIAGNOSIS [K9K] TERMINAL NO. 70 WIRE COLOR G ITEM Sensor ground (Mass air flow sensor/ Intake air temperature sensor) CONDITION [Engine is running] ● Warm-up condition ● Idle speed [Engine is running] 73 75 77 79 B/P P/L G L Fuel injector No. 2 Fuel injector No. 4 Fuel injector No. 3 Fuel injector No. 1 DATA (DC Voltage and Pulse Signal) ● Warm-up condition ● Idle speed Approximately 0.5V 0 - 9V NOTE: The pulse cycle changes depending on rpm at idle. MBIB1512E 0 - 9V [Engine is running] ● Warm-up condition ● Engine speed: 2,000 rpm MBIB1513E [Engine is running] 74 O 76 V 78 R 80 P Fuel injector power supply No. 2 Fuel injector power supply No. 4 Fuel injector power supply No. 3 Fuel injector power supply No. 1 ● Warm-up condition ● Idle speed 5 - 10V NOTE: The pulse cycle changes depending on rpm at idle. MBIB1514E 5 - 10V [Engine is running] ● Warm-up condition ● Engine speed: 2,000 rpm MBIB1515E 83 W Sensor power supply (Refrigerant pressure sensor) [Ignition switch ON] Approximately 5.0V [Engine is running] 89 BR Refrigerant pressure sensor ● Warm-up condition ● Both A/C switch and blower fan switch: ON (Compressor operates) [Ignition switch ON] [Ignition switch OFF] ● 104 P ECM relay (self-shutoff) For a few seconds after turning ignition switch OFF [Ignition switch OFF] ● More than a few seconds after turning ignition switch OFF EC-1678 Approximately 2.3V Approximately 1.4V BATTERY VOLTAGE (11 - 14V) TROUBLE DIAGNOSIS [K9K] TERMINAL NO. WIRE COLOR ITEM CONDITION DATA (DC Voltage and Pulse Signal) A [Engine is running] 107 109 110 Y G G Sensor ground (Refrigerant pressure sensor) Power supply for ECM ● Warm-up condition ● Idle speed [Ignition switch ON] Approximately 0.3V BATTERY VOLTAGE (11 - 14V) EC C : Average voltage for pulse signal (Actual pulse signal can be confirmed by oscilloscope.) D E F G H I J K L M EC-1679 TROUBLE DIAGNOSIS [K9K] Conformity Check BBS004TH ECM STATUS AND PARAMETERS Test Condition: Engine Stopped and Ignition Switch ON Order Function Parameter or status check or action Display and notes Trouble diagnosis 1 Battery voltage PR074: BATTERY VOL 12 V < BATTERY VOL < 14.4 V In the event of a malfunction, perform the trouble diagnosis for CHARGING SYSTEM. 2 Engine speed PR055: ENGINE SPEED Indicates the engine's rotational speed in rpm. In the event of a malfunction, perform the trouble diagnosis for DTC P0335 CKP SENSOR. 3 Accelerator pedal position PR030: ACCEL/PDL POS 0% Indicates the position of the accelerator pedal as a%. ACCEL/PDL POS = 0% In the event of a malfunction, perform the trouble diagnosis for APP SENSOR (DTC P0225, P0651 and P2120) and DTC P0641 SENSOR POWER SUPPLY. 4 Enginr coolant temperature PR064: WATER TEMP Warm: 90°C Indicates the engine coolant temperature in °C. Default value: 80°C In the event of a malfunction, perform the trouble diagnosis for DTC P0115 ETC SENSOR. 5 Fuel tank temperature PR063: FUEL TEMP Cold = WATER TEMP Warm: 50C Indicates the fuel tank temperature in °C. This value is given by the fuel tank temperature sensor. Default value: 30°C. In the event of a malfunction, perform the trouble diagnosis for DTC P0180 FTT SENSOR. PR035: ATOMOS PRESS Indicates the ambient barometric pressure in mbar. The sensor is incorporated in the ECM. PR032: INLET PRESS Indicates the pressure in the turbocharger in mbar. PR038: RAIL PRESSURE Warm or cold - 90 bar < RAIL PRESSURE > 90 bar Indicates the fuel rail pressure in Bar. This pressure is supplied by the fuel rail pressure sensor. Default value: 2000 Bar. 6 7 Intake air pressure Fuel rail pressure If not consistent, check ATOMOS PRESS, INLET PRESS (in DATA MONITOR mode) and local ambient barometric pressure, with the engine stopped and ignition switch ON. In the event of a malfunction, perform the trouble diagnosis for DTC P0190 FRP SENSOR. Indicates the current status of the engine. 8 Engine ET038: MOTOR Engine + after ignition feed ● + after ignition feed ● CRANKING ● RUNNING ● MAINTAINED SUPPLY: Supply maintained during the power latch phase. ● Stalled: When the engine has stalled. ● PROTECTED: When a level 2 malfunction appears or when the engine speed is limited to a certain engine speed. EC-1680 NONE. TROUBLE DIAGNOSIS [K9K] Order Function Parameter or status check or action Display and notes Trouble diagnosis A Indicates the status of the immobilizer system. ● 9 Immobilizer ET003: ENG IMMOBILIZ INACTIVE ● 10 11 Code programmed Vehicle speed ET006: PR089: CODE PROGRAM YES VEHICLE SPEED INACTIVE: The ECM has recognized the immobilizer code transmitted by the Intelligent Key unit or BCM. EC If ACTIVE, perform the trouble diagnosis for NATS. ACTIVE: The ECM does not recognize the immobilizer code transmitted by the Intelligent Key unit or BCM. D States whether the immobilizer code has been programmed by the ECM or not. ● YES: Code programmed ● NO: Code not programmed by the ECM. Indicates the vehicle speed in kph. This parameter is transmitted by the “ABS actuator and electric unit (control unit)” or combination meter via CAN communication line. If NO, replace ECM. 1 2 Function Battery voltage Engine speed BATTERY VOL 12V < BATTERY VOL < 14.4V PR055: ENGINE SPEED Cold: 900 rpm Warm: 805 rpm Indicates the engine's rotational speed in rpm. In the event of a malfunction, perform the trouble diagnosis for DTC P0335 CKP SENSOR. ACCEL/PDL POS 0% Indicates the position of the accelerator pedal as a%. ACCEL/PDL POS = 0% In the event of a malfunction, perform the trouble diagnosis for APP SENSOR (DTC P0225, P0651 and P2120) and DTC P0641 SENSOR POWER SUPPLY. WATER TEMP Warm: 90°C Indicates the engine coolant temperature in °C. Default value: 80°C. In the event of a malfunction, perform the trouble diagnosis for DTC P0115 ETC SENSOR. PR061: EXT AIR TEMP Indicates the ambient air temperature in °C. This information is provided by BCM via CAN communication line. In the event of a malfunction, perform the trouble diagnosis for DTC P0100 MAF SENSOR. PR059: INLET AIR TEMP Cold = EXT AIR TEMP Warm: 30°C Indicates the intake air temperature in °C. This information is provided by the IAT sensor. Default value: 20°C. In the event of a malfunction, perform the trouble diagnosis for DTC P0070 IAT SENSOR. PR063: FUEL TEMP Cold = WATER TEMP Warm: 50°C Indicates the fuel tank temperature in °C. This value is given by the fuel tank temperature sensor. Default value: 30°C. In the event of a malfunction, perform the trouble diagnosis for DTC P0180 FTT SENSOR. Engine coolant temperature PR064: 5 External air temperature 7 Inlet air temperature Fuel tank temperature Trouble diagnosis PR074: 4 6 Display and notes In the event of a malfunction, perform the trouble diagnosis for CHARGING SYSTEM. PR030: G H Parameter or status check or action Accelerator pedal position 3 E F Perform the trouble diagnosis for CAN communication line. Perform the trouble diagnosis for “ABS actuator and electric unit (control unit)” or combination meter. Test Condition: Engine at Idle Order C EC-1681 I J K L M TROUBLE DIAGNOSIS [K9K] Order Parameter or status check or action Function ATOMOS PRESS Indicates the ambient barometric pressure in mbar. The sensor is incorporated in the ECM. 600 mbar < Cold < 1050 mbar 600 mbar < Warm < 1050 mbar PR032: INLET PRESS Indicates the pressure in the turbocharger in mbar. INLET PRESS = local ambient barometric pressure PR038: RAIL PRESSURE Cold: 260 Bar Warm: 230 Bar Indicates the fuel rail pressure in Bar. This pressure is supplied by the fuel rail pressure sensor. Default value: 2000 Bar. PR035: 8 9 Display and notes Intake air pressure Fuel rail pressure Trouble diagnosis If not consistent, check ATOMOS PRESS, INLET PRESS (in DATA MONITOR mode) and local ambient barometric pressure, with the engine stopped and ignition switch ON. In the event of a malfunction, perform the trouble diagnosis for DTC P0190 FRP SENSOR. START SUBFUNCTION Test Condition: Engine Stopped and Ignition Switch ON Order 1 2 Function ECM + after ignition feed Starting Parameter or status check or action ET001: ET076: C/U+AFTR IGN PRESENT STARTING AUTHORISED Display and notes Trouble diagnosis Indicates that the ECM is supplied with a + after ignition feed. In the event of a malfunction, perform the trouble diagnosis for DTC P0560 BATTERY VOLTAGE or P0685 ECM RELAY. ● Present ● Absent Indicates whether or not starting has been authorized by the ECM. AUTHORISED: The ECM has given starting authorisation. PROHIBITED: The ECM has not given starting authorisation. If PROHIBITED perform the trouble diagnosis for preheating system. Indicates the current status of the engine. 3 4 Engine Battery voltage ET038: PR074: MOTOR Engine + after ignition feed BATTERY VOL ● + after ignition feed ● CRANKING ● RUNNING ● MAINTAINEDSUPPLY: Supply maintained during the power latch phase. ● Stalled: When the engine has stalled. ● Protected: When a malfunction appears or when the engine speed is limited to a certain engine speed. 12V < BATTERY VOL < 13.5V EC-1682 NONE. In the event of a malfunction, perform the trouble diagnosis for CHARGING SYSTEM. TROUBLE DIAGNOSIS [K9K] Test Condition: Engine at Idle Order 1 2 Computer + after ignition feed Starting A Parameter or status check or action Function ET001: ET076: Display and notes Indicates that the ECM is supplied with a + after ignition feed. C/U+ AFTR IGN PRESENT ● Present ● Absent Indicates whether or not starting has been authorized by the ECM. AUTHORISED: The ECM has given starting authorisation. PROHIBITED: The ECM has not given starting authorisation. STARTING AUTHORISED Trouble diagnosis In the event of a malfunction, perform the trouble diagnosis for DTC P0560 BATTERY VOLTAGE or P0685 ECM RELAY. C If PROHIBITED perform the trouble diagnosis for preheating system. 3 4 Engine Battery voltage ET038: PR074: + after ignition feed ● CRANKING ● RUNNING ● MAINTAINED SUPPLY: Supply maintained during the power latch phase. MOTOR Engine + after ignition feed BATTERY VOL ● Stalled: When the engine has stalled. ● Protected: When a malfunction appears or when the engine speed is limited to a certain engine speed. 13V < BATTERY VOL < 14V D E Indicates the current status of the engine. ● EC F G NONE. H I J In the event of a malfunction, perform the trouble diagnosis for CHARGING SYSTEM. K PROTECTION SUBFUNCTION Test Condition: Engine Stopped and Ignition Switch ON Order Function L Parameter or status check or action Display and notes Trouble diagnosis Indicates the status of the immobilizer system. ● 1 Immobilizer ET003: ENG IMMOBILIZ INACTIVE ● 2 3 Code programmed Battery voltage ET006: PR074: CODE PROGRAM YES BATTERY VOL INACTIVE: The ECM has recognized the immobilizer code transmitted by the Intelligent Key unit or BCM. M If ACTIVE, perform the trouble diagnosis for NATS. ACTIVE: The ECM does not recognize the immobilizer code transmitted by the Intelligent Key unit or BCM. States whether the immobilizer code has been programmed by the ECM or not. ● YES: Code programmed ● NO: Code not programmed by the ECM. 12V < BATTERY VOL < 13.5V EC-1683 If NO, replace ECM. In the event of a malfunction, perform the trouble diagnosis for CHARGING SYSTEM. TROUBLE DIAGNOSIS [K9K] Test Condition: Engine at Idle Order Parameter or status check or action Function Display and notes Trouble diagnosis Indicates the status of the immobilizer system. ● 1 Immobilizer ET003: ENG IMMOBLIZ INACTIVE ● 2 3 Code programmed Battery voltage ET006: PR074: CODE PROGRAM YES BATTERY VOL INACTIVE: The ECM has recognized the immobilizer code transmitted by the Intelligent Key unit or BCM. If ACTIVE, perform the trouble diagnosis for NATS. ACTIVE: The ECM does not recognize the immobilizer code transmitted by the Intelligent Key unit or BCM. States whether the immobilizer code has been programmed by the computer or not. ● YES: Code programmed ● NO: Code not programmed by the ECM. 13V < BATTERY VOL < 14V If NO, replace ECM. In the event of a malfunction, perform the trouble diagnosis for CHARGING SYSTEM. SUB SYSTEM COLD LOOP Test Condition: Engine Stopped and Ignition Switch ON Order Function Parameter or status check or action Display and notes States whether the vehicle is fitted with air conditioning or not. 1 Air conditioning present ET079: PRSNC CLMTSTN YES ● YES: Air conditioning is detected by the ECM. ● NO: Air conditioning is not detected by the ECM. Trouble diagnosis If not consistent with the vehicle equipment, perform the trouble diagnosis for CAN communication line. The ECM requests the IPDM E/ R (via CAN communication) to start the compressor ● 2 Compressor engagement request ET088: DMND LNK COMP INACTIVE ● ACTIVE: The CAN communication should not be suspected on the Automatic Transmission, IPDM E/R or Intelligent Key unit or BCM system. The Intelligent Key unit or BCM should request the ECM to be engaged. The refrigerant pressure sensor should not be suspected. Satisfactory engine operating conditions (engine coolant temperature, engine load etc.). INACTIVE: One of the above conditions has not been fulfilled. EC-1684 NONE. TROUBLE DIAGNOSIS [K9K] Order Function Parameter or status check or action Display and notes Trouble diagnosis Non operational information, designed solely for trouble diagnosis purposes. ● 3 Air conditioning authorization ET004: A/C AUTHOR YES ● 4 5 Refrigerant pressure Engine speed PR037: PR055: RFRGERNT PRES ENGINE SPEED YES: Satisfactory engine operating conditions (engine coolant temperature, engine load etc.). The vehicle is not in a specific movement phase (hill start or stop etc.). 6 7 8 9 Fast idle speed request Engine coolant temperature Vehicle speed Power used by the AC compressor ET023: PR064: PR089: PR125: ACCEL IDL RQ ABSENT EC NONE. Indicates the value in Bar for the refrigerant fluid in the system. 2 Bar < RFRGERNT PRES < 27 Bar Default value: 0 Bar In the event of a malfunction, perform the trouble diagnosis for DTC P0530 REFRIGERANT PRESSURE SENSOR. Indicates the engine's rotational speed in rpm. In the event of a malfunction, perform the trouble diagnosis for dtc P0335 CKP SENSOR. ● ABSENT: The Intelligent Key unit or BCM did not make the request ● PRESENT: The Intelligent Key unit or BCM has made a request C D NO: One of the above conditions has not been fulfilled. The Intelligent Key unit or BCM requests fast idle speed to the ECM. A E F G In the event of a malfunction, perform the trouble diagnosis for CAN communication line. Perform the trouble diagnosis for the Intelligent Key unit or BCM. H I WATER TEMP Warm: 90°C Indicates the engine coolant temperature in °C. Default value: 80°C. In the event of a malfunction, perform the trouble diagnosis for DTC P0115 ETC SENSOR. J Perform the trouble diagnosis for CAN communication line. Perform the trouble diagnosis for “ABS actuator and electric unit (control unit)” or combination meter. K VEHICLE SPEED Indicates the vehicle speed in kph. This parameter is transmitted by the “ABS actuator and electric unit (control unit)” or combination meter via CAN communication line. Indicates the power used by the compressor NONE. PWR ABSOB A/C 0 WATT EC-1685 L M TROUBLE DIAGNOSIS [K9K] Order Function Parameter or status check or action Display and notes Trouble diagnosis The ECM requests the IPDM E/ R to start the fan. 10 Fan speed request* ET022: FAN UNIT LOW INACTIVE ● INACTIVE: Engine speed = 0 rpm. ● ACTIVE: Engine speed = idle speed, correct refrigerant pressure and vehicle speed = 0 km/h or high engine coolant temperature. NONE. The ECM requests the IPDM E/ R to start the fans. 11 Fan speed request* ET021: FAN UNIT HIGH INACTIVE ● INACTIVE: Engine speed = 0 rpm. ● ACTIVE: Engine speed = idle speed. Refrigerant pressure > 15 Bar, vehicle speed = 0 km/h or high coolant temperature. NONE. *: When climate control is requested with the engine at idle speed and vehicle speed = 0 km/h, FAN UNIT LOW will always be “ACTIVE” and FAN UNIT HIGH “INACTIVE” (except refrigerant pressure> 15 bar, vehicle speed = 0 km/h and high engine coolant temperature). The fan is prevented from operating under certain engine coolant temperature conditions when driving. Test Condition: Engine at Idle Order Function Parameter or status check or action Display and notes States whether the vehicle is fitted with air conditioning or not. 1 Air conditioning present ET079: PRSNC CLMTSTN YES ● YES: Air conditioning is detected by the ECM. ● NO: Air conditioning is not detected by the ECM. Trouble diagnosis If not consistent with the vehicle equipment, perform the trouble diagnosis for CAN communication line. The ECM requests the IPDM E/ R (via CAN communication line) to start the compressor ● 2 Compressor engagement request ET088: DMND LNK COMP INACTIVE ● ACTIVE: The CAN communication should not be suspected on the Automatic Transmission, IPDM E/R or Intelligent Key unit or BCM system. The Intelligent Key unit or BCM should request the ECM to be engaged. The refrigerant pressure sensor should not be suspected. Satisfactory engine operating conditions (engine coolant temperature, engine load etc.). INACTIVE: One of the above conditions has not been fulfilled or no request has been made by the driver so A/C AUTHOR = NO. EC-1686 NONE. TROUBLE DIAGNOSIS [K9K] Order Function Parameter or status check or action Display and notes Trouble diagnosis Non operational information, designed solely for trouble diagnosis purposes. ● 3 Air conditioning authorization ET004: A/C AUTHOR YES ● YES: Satisfactory engine operating conditions (engine coolant temperature, engine load etc.). The vehicle is not in a specific movement phase (hill start or stop etc.). 4 Refrigerant pressure PR037: RFRGERNT PRES 5 Engine speed PR055: ENGINE SPEED Cold: 900 rpm Warm: 805 rpm Indicates the engine's rotational speed in rpm. The Intelligent Key unit or BCM requests fast idle speed from the ECM. 6 Fast idle speed request ET023: ACCEL IDL RQ ABSENT ● ● 7 Engine coolant temperature PR064: EC C NONE. D INACTIVE: One of the above conditions has not be fulfilled or no request has been made by the driver so DMND LNK COMP = INACTIVE. Indicates the value in Bar for the refrigerant fluid in the system. 2 Bar < RFRGERNT PRES < 27 Bar Default value: 0 Bar. ABSENT: The Intelligent Key unit or BCM did not make the request. PRESENT: The Intelligent Key unit or BCM has made the request. E In the event of a malfunction, perform the trouble diagnosis for DTC P0530 REFRUGERANT PRESSURE SENSOR. In the event of a malfunction, perform the trouble diagnosis for DTC P0335 CKP SENSOR. In the event of a malfunction, perform the trouble diagnosis for CAN communication line. Perform the trouble diagnosis for the Intelligent Key unit or BCM. In the event of a malfunction, perform the trouble diagnosis for DTC P0115 ECT SENSOR. Perform the trouble diagnosis for CAN communication line. Perform the trouble diagnosis for “ABS actuator and electric unit (control unit)” or combination meter. NONE. Vehicle speed PR089: VEHICLE SPEED 9 Power used by the AC compressor PR125: PWR ABSOB A/C 0 WATT Indicates the power used by the compressor EC-1687 G I J Indicates the engine coolant temperature in °C. Default value: 80°C. 8 F H WATER TEMP Warm: 90°C Indicates the vehicle speed in kph. This parameter is transmitted by the “ABS actuator and electric unit (control unit)” or combination meter via CAN communication line. A K L M TROUBLE DIAGNOSIS [K9K] Order Parameter or status check or action Function Display and notes Trouble diagnosis The ECM requests the IPDM E/ R to start the fan. FAN UNIT LOW INACTIVE ET022: 10 ● INACTIVE: The request is not made by theECM because DMND LNK COMP = INACTIVE and A/C AUTHOR = NO. ● ACTIVE: The request is made by the ECM. DMND LNK COMP = ACTIVE and A/C AUTHOR = YES. (correct refrigerant pressure and vehicle speed = 0 km/h or high engine coolant temperature). Fan speed request* NONE. The ECM requests the IPDM E/ R to start the fan. FAN UNIT HIGH INACTIVE ET021: ● INACTIVE: The request is not made by the ECM because DMND LNK COMP = INACTIVE and A/C AUTHOR = NO. ● ACTIVE: The request is made by the ECM. DMND LNK COMP = ACTIVE and A/C AUTHOR = YES. Refrigerant pressure > 15 Bar, vehicle speed = 0 km/h or high engine coolant temperature. *: When climate control is requested with the engine at idle speed and vehicle speed = 0 km/h, FAN UNIT LOW will always be “ACTIVE” and FAN UNIT HIGH “INACTIVE” (except refrigerant pressure > 15 bar, vehicle speed = 0 km/ h and high engine coolant temperature). The fan is prevented from operating under certain engine coolant temperature conditions when driving. HEATING SUBFUNCTION Test Condition: Engine Stopped and Ignition Switch ON Order Function 1 Engine coolant temperature Parameter or status check or action PR064: WATER TEMP Warm: 90°C Display and notes Indicates the engine coolant temperature in °C. Default value: 80°C. Trouble diagnosis In the event of a malfunction, perform the trouble diagnosis for DTC P0115 ECT SENSOR. Test Condition: Engine at Idle Order Function 1 Engine coolant temperature Parameter or status check or action PR064: WATER TEMP Warm: 90°C Display and notes Indicates the engine coolant temperature in °C. Default value: 80°C. EC-1688 Trouble diagnosis In the event of a malfunction, perform the trouble diagnosis for DTC P0115 ECT SENSOR. TROUBLE DIAGNOSIS [K9K] FUEL CIRCUIT SUB FUNCTION Test Condition: Engine Stopped and Ignition Switch ON Order 1 2 3 Function Fuel tank temperature Fuel flow Fuel rail pressure 4 Fuel rail pressure set point 5 Fuel rail pressure sensor voltage 6 Engine speed Parameter or status check or action A Display and notes Trouble diagnosis FUEL TEMP Cold = WATER TEMP Warm: 50°C Indicates the fuel tank temperature in °C. Default value: 30°C. In the event of a malfunction, perform the trouble diagnosis for DTC P0180 FTT SENSOR. PR017: FUEL FLOW 0.0 mg/piston stroke Indicates the fuel flow injected in mg/piston stroke for each injector. FUEL FLOW = 0 mg/piston stroke NONE. PR038: RAIL PRESSURE Cold and warm: - 90 bar < RAIL PRESSURE < 90 bar Indicates the fuel rail pressure in Bar. This pressure is supplied by the fuel rail pressure sensor. Default value: 2000 Bar. In the event of a malfunction, perform the trouble diagnosis for DTC P0190 FRP SENSOR. PR008: RAIL PRES SET 375 bar (Engine starting pressure instruction) Cold: 500 Bar Warm: 300 Bar Indicates a theoretical pressure value for optimum engine operation. 300 bar < RAIL PRES SET < 500 bar. NONE. PR080: RAIL PRES S V Cold: 0.5V Cold: 4.5V Indicates the voltage delivered by the ECM on the fuel rail pressure sensor. 0.5V < RAIL PRES S V < 4.5V Default value: 4.5V NONE. Indicates the engine's rotational speed in rpm. In the event of a malfunction, perform the trouble diagnosis for DTC P0335 CKP SENSOR. J Display and notes Trouble diagnosis K PR063: FUEL TEMP Cold = WATER TEMP Warm: 50°C Indicates the fuel tank temperature in °C. Default value: 30°C. In the event of a malfunction, perform the trouble diagnosis for DTC P0180 FTT SENSOR. PR017: FUEL FLOW 10 < Cold < 2 mg/ piston stroke 4 < Warm < 6 mg/ piston stroke Indicates the fuel flow injected in mg/piston stroke for each injector. NONE. PR038: RAIL PRESSURE Cold: 260 Bar Warm: 230 Bar Indicates the fuel rail pressure in Bar. This pressure is supplied by the fuel rail pressure sensor. Default value: 2000 Bar. In the event of a malfunction, perform the trouble diagnosis for DTC P0190 FRP SENSOR. PR008: RAIL PRES SET 375 bar. (Engine starting pressure specification). Cold: 260 Bar Warm: 230 Bar Indicates a theoretical pressure value for optimum engine operation. NONE. RP063: PR055: ENGINE SPEED EC C D E F G H I Test Condition: Engine at Idle Order 1 2 3 4 Function Fuel tank temperature Fuel flow Fuel rail pressure Fuel rail pressure set point Parameter or status check or action EC-1689 L M TROUBLE DIAGNOSIS [K9K] Order Function Parameter or status check or action Display and notes 5 Fuel rail pressure sensor voltage PR080: RAIL PRES S V Indicates the voltage delivered by the ECM on the fuel rail pressure sensor. 0.5 V (0 bar) < RAIL PRES S V < 4.5 V (1600 bar) 6 Engine speed PR055: ENGINE SPEED Cold: 900 rpm V Warm: 805 rpm Indicates the engine's rotational speed in rpm. Trouble diagnosis NONE. In the event of a malfunction, perform the trouble diagnosis for DTC P0115 ECT SENSOR. PRE-HEATING/IGNITION SUBFUNCTION Test Condition: Engine Stopped and Ignition Switch ON Order Function 1 Engine coolant temperature Parameter or status check or action Display and notes Trouble diagnosis PR064: WATER TEMP Warm: 90°C Indicates the engine coolant temperature in °C. Default value: 80°C. In the event of a malfunction, perform the trouble diagnosis for DTC P0115 ETC SENSOR. Indicates the intake air temperature in °C. This information is provided by the IAT sensor. Default value: 30°C. In the event of a malfunction, perform the trouble diagnosis for DTC P0070 IAT SENSOR. 12V < BATTERY VOL < 14.4V In the event of a malfunction, perform the trouble diagnosis for CHARGING SYSTEM. Display and notes Trouble diagnosis 2 Intake air temperature PR059: INLET AIR TEMP Cold = EXT AIR TEMP Warm: 30°C 3 Battery voltage PR074: BATTERY VOL Test Condition: Engine at Idle Order Function 1 Engine coolant temperature 2 External air temperature Parameter or status check or action WATER TEMP Warm: 90°C Indicates the engine coolant temperature in °C. Default value: 80°C. In the event of a malfunction, perform the trouble diagnosis for DTC P0115 ETC SENSOR. PR061: EXT AIR TEMP Indicates the ambient air temperature in °C. This information is provided by BCM via CAN communication line. In the event of a malfunction, perform the trouble diagnosis for DTC P0100 MAF SENSOR. Indicates the intake air temperature in °C. This information is provided by the IAT sensor. Default value: 30°C. In the event of a malfunction, perform the trouble diagnosis for DTC P0070 IAT SENSOR. 12 V < BATTERY VOL < 14.4V In the event of a malfunction, perform the trouble diagnosis for CHARGING SYSTEM. PR064: 3 Intake air temperature PR059: INLET AIR TEMP Cold = EXT AIR TEMP Warm: 30°C 4 Battery voltage PR074: BATTERY VOL AIR CIRC SUBFUNCTION (TURBOCHARGING/INLET.) Test Condition: Engine Stopped and Ignition Switch ON Order 1 Function Intake air temperature Parameter or status check or action PR059: INLET AIR TEMP Cold = EXT AIR TEMP Warm: 30°C Display and notes Indicates the intake air temperature in °C. This information is provided by the IAT sensor. Default value: 30°C. EC-1690 Trouble diagnosis In the event of a malfunction, perform the trouble diagnosis for DTC P0070 IAT SENSOR. TROUBLE DIAGNOSIS [K9K] Order 2 Function Parameter or status check or action Display and notes PR035: ATOMOS PRESS Indicates the ambient barometric pressure in mbar. The sensor is incorporated in the ECM. PR032: INLET PRESS Indicates the pressure in the turbocharger in mbar. Intake air pressure Trouble diagnosis If not consistent, check ATOMOS PRESS, INLET PRESS (in DATA MONITOR mode) and local ambient barometric pressure, with the engine stopped and ignition switch ON. 3 Air flow PR132: AIR FLOW Mass air flow estimated by the ECM. NONE. 4 Intake air temperature sensor voltage PR081: INLET TMP S V Indicates the voltage delivered by the ECM to supply the intake air temperature sensor. NONE. 5 Engine speed PR055: ENGINE SPEED Indicates the engine's rotational speed in rpm. In the event of a malfunction, perform the trouble diagnosis for DTC P0335 CKP SENSOR. 1 Function Intake air temperature 3 4 5 Intake temperature sensor voltage Engine speed ATOMOS PRESS Indicates the ambient barometric pressure in mbar. The sensor is incorporated in the ECM. PR032: INLET PRESS Indicates the pressure in the turbocharger in mbar. PR132: AIR FLOW 350 < Cold< 400 mg/piston stroke 300 < Warm < 350 mg/piston stroke Air flow estimated by the ECM. PR081: INLET TMP S V Indicates the voltage delivered by the computer to supply the inlet temperature sensor NONE. PR055: ENGINE SPEED Cold: 900 rpm V Warm: 805 rpm Indicates the engine's rotational speed in rpm. In the event of a malfunction, perform the trouble diagnosis for DTC P0335 CKP SENSOR. In the event of a malfunction, perform the trouble diagnosis for DTC P0070 IAT SENSOR. If not consistent, check ATOMOS PRESS, INLET PRESS (in DATA MONITOR mode) and local ambient barometric pressure, with the engine stopped and ignition switch ON. Function 1 Engine coolant temperature WATER TEMP Warm: 90°C Function 1 Engine coolant temperature Display and notes Indicates the engine coolant temperature in °C. Default value: 80°C Parameter or status check or action PR064: WATER TEMP Warm: 90°C I NONE. L Trouble diagnosis In the event of a malfunction, perform the trouble diagnosis for DTC P0115 ECT SENSOR. Test Condition: Engine at Idle Order H K Parameter or status check or action PR064: G J ENGINE COOLING SUB FUNCTION Test Condition: Engine Stopped and Ignition Switch ON Order E Trouble diagnosis Indicates the intake air temperature in °C. This information is provided by the IAT sensor. Default value: 30°C. Air circuit pressure Air flow Display and notes INLET AIR TEMP Cold = EXT AIR TEMP Warm: 30°C PR035: 2 C F Parameter or status check or action PR059: EC D Test Condition: Engine at Idle Order A Display and notes Indicates theengine coolant temperature in °C. Default value: 80 °C. EC-1691 Trouble diagnosis In the event of a malfunction, perform the trouble diagnosis for DTC P0115 ECT SENSOR. M TROUBLE DIAGNOSIS [K9K] DRIVER PARAMETERS SUB FUNCTION Test Condition: Engine Stopped and Ignition Switch ON Order 1 2 Function Accelerator pedal position Accelerator pedal position sensor voltage Parameter or status check or action PR030: ACCEL/PDL POS 0% PR086: PL PTNMR T1 V 16% PR088: PL PTNMR T2 V 7% Display and notes Trouble diagnosis Indicates the percentage of the accelerator pedal position between no load and full load position. 0% < ACCEL/PDL POS < 100% In the event of a malfunction, perform the trouble diagnosis for APP SENSOR (DTC P0225, P0651 and P2120) and DTC P0641 SENSOR POWER SUPPLY. Indicates the voltage supply percentage for the accelerator pedal position sensor 1 and 2. 10% < PL PTNMR T1 V < 20% 5% < PL PTNMR T2 V < 15% In the event of a malfunction, perform the trouble diagnosis for APP SENSOR (DTC P0225, P0651 and P2120) and DTC P0641 SENSOR POWER SUPPLY. Display and notes Trouble diagnosis Test Condition: Engine at Idle Order 1 2 Function Accelerator pedal position Accelerator pedal position sensor voltage Parameter or status check or action PR030: ACCEL/PDL POS 0% PR086: PL PTNMR T1 V 16% PR088: PL PTNMR T2 V 7% Indicates the percentage of the accelerator pedal position between no load and full load position. 0% < ACCEL/PDL POS < 100% Indicates the voltage supply percentage for the accelerator pedal position sensor 1 and 2. 10% < PL PTNMR T1 V < 20% 5% < PL PTNMR T2 V < 15% In the event of a malfunction, perform the trouble diagnosis for APP SENSOR (DTC P0225, P0651 and P2120) and DTC P0641 SENSOR POWER SUPPLY. ANTIPOLLUTION/OBD SUBFUNCTION Test Condition: Engine Stopped and Ignition Switch ON Order Function Parameter or status check or action Display and notes Trouble diagnosis Indicates the condition of the EGR volume control. 1 EGR volume control ET008: EGR SOL/V CNT INACTIVE ● INACTIVE: The valve is not controlled by the ECM. ● ACTIVE: The valve is controlled by the ECM. NONE. 2 Ambient barometric pressure PR035: ATOMOS PRESS Indicates the ambient barometric pressure in mbar. The sensor is incorporated in the ECM. If not consistent, check ATOMOS PRESS, INLET PRESS (in DATA MONITOR mode) and local ambient barometric pressure, with the engine stopped and ignition switch ON. 3 Mass air flow PR132: AIR FLOW Air flow estimated by the ECM. NONE. 4 Fuel flow PR017: FUEL FLOW 0.0 mg/piston stroke Indicates the fuel flow out of the fuel pump in mg/piston stroke. NONE. EGR/V OPN REF Warm or cold = - 50 Indicates a theoretical EGR volume control valve opening value for optimum engine operation. EGR/V OPN REF = EGR PO RECOPY NOTE. 5 EGR volume control valve control PR005: EC-1692 TROUBLE DIAGNOSIS [K9K] Order 6 Function EGR volume control valve position feedback Parameter or status check or action PR051: EGR PO RECOPY Warm or cold = - 50 Display and notes Indicates the actual value of the EGR volume control valve position. EGR PO RECOPY = EGR/V OPN REF Trouble diagnosis NOTE. EC Indicates the EGR volume control valve control position sensor voltage according to the valve position. 7 8 9 EGR volume control valve control position sensor voltage Accelerator pedal position Engine coolant temperature PR077: PR030: PR064: EGR POS SE VO 1.09 V ACCEL/PDL POS 0% WATER TEMP Warm: 90°C ● INACTIVE: The valve is not controlled by the ECM ● ACTIVE: The valve is controlled by the ECM. 0.5V < EGR POS SE VO < 4.8V A C D NOTE. E Indicates the percentage of the accelerator pedal position between no load and full load position. ACCEL/PDL POS = 0% In the event of a malfunction, perform the trouble diagnosis for APP SENSOR (DTC P0225, P0651 and P2120) and DTC P0641 SENSOR POWER SUPPLY. Indicates the engine coolant temperature in °C. Default value: 80°C. In the event of a malfunction, perform the trouble diagnosis for DTC P0115 ECT SENSOR. H Trouble diagnosis I F G Test Condition: Engine at Idle Parameter or status check or action Order Display and notes Indicates the condition of the EGR volume control. 1 2 3 EGR volume control Ambient barometric pressure Air flow 4 Fuel flow 5 EGR volume control valve control 6 EGR volume control valve position feedback ET008: EGR SOL/V CNT INACTIVE ● INACTIVE: The valve is not controlled by the ECM. ● ACTIVE: The valve is controlled by the ECM. Indicates the ambient barometric pressure in mbar. The sensor is incorporated in the ECM. J NONE. K If not consistent, check ATOMOS PRESS, INLET PRESS (in DATA MONITOR mode) and local ambient barometric pressure, with the engine stopped and ignition switch ON. PR035: ATOMOS PRESS PR132: AIR FLOW 350 < Cold < 400 mg/piston stroke 300 < Warm< 350 mg/piston stroke Air flow estimated by the ECM. NONE. PR017: FUEL FLOW 10 < Cold < 12 mg/piston stroke 4 < Warm < 6 mg/piston stroke Indicates the fuel flow out of the fuel pump in mg/piston stroke. NONE. PR005: EGR/V OPN REF Warm: 20% Indicates a theoretical EGR volume control valve opening value for optimum engine operation. NONE. PR051: EGR PO RECOPY Warm: approx. 20% Indicates the actual value of the EGR volume control valve position. Default value: 30% NONE. EC-1693 L M TROUBLE DIAGNOSIS [K9K] Parameter or status check or action Order Display and notes Trouble diagnosis Indicates the EGR volume control valve control position sensor voltage according to the valve position. 7 EGR volume control valve control position sensor voltage PR077: EGR POS SE VO ● INACTIVE: The valve is not controlled by the ECM. ● ACTIVE: The valve is controlled by the ECM. 0.5 V < EGR POS SE VO < 4.8 V 8 Accelerator pedal position PR030: ACCEL/PDL POS 0% Indicates the percentage of the pedal position between no load and full load position 0 < ACCEL/PDL POS < 100% 9 Engine coolant temperature PR064: WATER TEMP Warm: 90°C Indicates the engine coolant temperature in °C. Default value: 80°C. NONE. In the event of a malfunction, perform the trouble diagnosis for APP SENSOR (DTC P0225, P0651 and P2120) and DTC P0641 SENSOR POWER SUPPLY. In the event of a malfunction, perform the trouble diagnosis for DTC P0115 ECT SENSOR. CONSULT-II Reference Value in Data Monitor Mode BBS0040Z Remarks: ● Specification data are reference values. ● Specification data are output/input values which are detected or supplied by the ECM at the connector. * Specification data may not be directly related to their components signals/values/operations. MONITOR ITEM CONDITION SPECIFICATION ● Run engine and compare CONSULT-II value with the tachometer indication. ● Engine speed: Idle ● Air conditioner switch: OFF ● Shift lever: Neutral position ● No load ● Ignition switch: ON (Engine stopped) WATER TEMP ● Engine: After warming up More than 70°C (158°F) FUEL TEMP ● Engine: After warming up More than 40°C (104°F) BATTERY VOL ● Ignition switch: ON (Engine stopped) 11 - 14V ENGINE SPEED IDLE REG REF ACCEL/PDL POS Almost the same speed as the tachometer indication Approximately 800 rpm Accelerator pedal: Fully released Approximately 0% Altitude Approx. 0m: Approx. 100.62 kPa (1.0062 bar, 1.026 kg/cm2 , 14.59 psi) Approx. 1,000 m: Approx. 88.95 kPa ATMOS PRESS ● (0.8895 bar, 0.907 kg/cm2 , 12.90 psi) Approx. 1,500 m: Approx. 83.16 kPa Ignition switch: ON (0.8316 bar, 0.848 kg/cm2 , 12.06 psi) Approx. 2,000 m: Approx. 78.36 kPa (0.7836 bar, 0.799 kg/cm2 , 11.36 psi) ● Engine: After warming up ● Air conditioner switch: OFF ● Shift lever: Neutral position ● No load ● Engine: After warming up ● Air conditioner switch: OFF ● Shift lever: Neutral position ● No load INLET PRESS AIR FLOW Idle Approximately 980 mbar 2,000 rpm Approximately 1,010 mbar Idle Approximately 200 mg/cp 2,000 rpm Approximately 270 mg/cp EC-1694 TROUBLE DIAGNOSIS [K9K] MONITOR ITEM VEHICLE SPEED CONDITION ● Turn drive wheels and compare CONSULT-II value with the speedometer indication Almost the same speed as the speedometer indication ● Engine: After warming up Idle Approximately 230 bar ● Air conditioner switch: OFF ● Shift lever: Neutral position 2,000 rpm Approximately 450 bar ● No load ● Engine: After warming up Idle Approximately 230 bar ● Air conditioner switch: OFF ● Shift lever: Neutral position 2,000 rpm Approximately 450 bar ● No load ● Engine: After warming up Idle Approximately 4.9 mg/cp ● Air conditioner switch: OFF ● Shift lever: Neutral position ● No load ● Engine: After warming up ● Air conditioner switch: OFF ● Shift lever: Neutral position ● No load ● Engine: After warming up ● Air conditioner switch: OFF ● Shift lever: Neutral position ● No load ● Engine: After warming up ● Air conditioner switch: OFF ● Shift lever: Neutral position ● No load ● Engine: After warming up ● Air conditioner switch: OFF ● Shift lever: Neutral position ● No load ● RAIL PRESSURE RAIL PRES SET FUEL FLOW EGR PO RECOPY EGR/V OPN REEF REFGERNT PRSS PL PTNMR T2 V A EC C D E 2,000 rpm Approximately 3.5 mg/cp F Idle Approximately -50 % G Idle Approximately -50 % H I Idle Approximately 5.7 bar J Idle Approximately 0 W K Ignition switch: ON (Engine stopped) Accelerator pedal: Fully released Approximately 15 % L ● Ignition switch: ON (Engine stopped) Accelerator pedal: Fully released Approximately 6 % ● Engine: After warming up ● Air conditioner switch: OFF ● Shift lever: Neutral position ● No load ● Engine: After warming up ● Air conditioner switch: OFF ● Shift lever: Neutral position ● No load PWR ABSOB A/C PL PTNMR T1 V SPECIFICATION EGR POS SE VO INLET TMP S V M Idle Approximately 3.56 V Idle Approximately 1.6 V EC-1695 TROUBLE DIAGNOSIS [K9K] MONITOR ITEM CONDITION ● Engine: After warming up ● Air conditioner switch: OFF ● Shift lever: Neutral position ● No load ● Engine: After warming up ● Air conditioner switch: OFF ● Shift lever: Neutral position ● No load RAIL PRES S V H R ATHD MX P SPECIFICATION Idle Approximately 1 V 2,000 rpm Approximately 1.5 V Idle Approximately 20 W EC-1696 TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT [K9K] TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT Description PFP:00006 A BBS00411 Intermittent incidents may occur. In many cases, the incident resolves itself (the part or circuit function returns to normal without intervention). It is important to realize that the symptoms described in the customer's com- EC plaint often do not recur on DTC visits. Realize also that the most frequent cause of intermittent incidents occurrences is poor electrical connections. Because of this, the conditions under which the incident occurred may not be clear. Therefore, circuit checks made as part of the standard diagnostic procedure may not indiC cate the specific malfunctioning area. Diagnostic Procedure BBS00412 1. INSPECTION START D Erase DTCs. Refer to EC-1628, "How to Erase DTC" . E >> GO TO 2. 2. CHECK GROUND TERMINALS F Check ground terminals for corroding or loose connection. Refer to EC-1703, "Ground Inspection" . OK or NG OK >> GO TO 3. NG >> Repair or replace. G H 3. SEARCH FOR ELECTRICAL INCIDENT Perform GI-25, "How to Perform Efficient Diagnosis for an Electrical Incident" , “INCIDENT SIMULATION TESTS”. OK or NG OK >> INSPECTION END NG >> Repair or replace. I J K L M EC-1697 POWER SUPPLY AND GROUND CIRCUIT [K9K] POWER SUPPLY AND GROUND CIRCUIT Wiring Diagram PFP:24110 BBS00413 MBWA1564E EC-1698 POWER SUPPLY AND GROUND CIRCUIT [K9K] Remarks: Specification data are reference values and are measured between each terminal and ground. CAUTION: Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM's transistor. Use a ground other than ECM terminals, such as the ground. TERMINAL NO. WIRE COLOR ITEM CONDITION 22 O Ignition switch [Ignition switch ON] 25 26 27 B B B ECM ground ● Warm-up condition ● Idle speed DATA (DC Voltage and Pulse Signal) A EC BATTERY VOLTAGE (11 - 14V) C Approximately 0V D Approximately 0V E [Engine is running] [Engine is running] 32 B ECM ground ● Warm-up condition ● Idle speed [Ignition switch ON] [Ignition switch OFF] ● 104 P ECM relay (self-shutoff) For a few seconds after turning ignition switch OFF [Ignition switch OFF] ● 109 110 G G Power supply for ECM More than a few seconds after turning ignition switch OFF [Ignition switch ON] Diagnostic Procedure F Approximately 1.4V G BATTERY VOLTAGE (11 - 14V) H BATTERY VOLTAGE (11 - 14V) BBS00414 1. INSPECTION START Start engine. Is engine running? Yes or No Yes >> GO TO 7. No >> GO TO 2. I J K 2. CHECK ECM POWER SUPPLY CIRCUIT-I 1. 2. L Turn ignition switch ON. Check voltage between ECM terminal 22 and ground with CONSULT-II or tester. M Voltage: Battery voltage OK or NG OK >> GO TO 4. NG >> GO TO 3. MBIB1461E EC-1699 POWER SUPPLY AND GROUND CIRCUIT [K9K] 3. DETECT MALFUNCTIONING PART Check the following. ● Harness connectors M1, E101 ● Fuse block (J/B) connector M7 ● 10A fuse ● Harness for open or short between ECM and fuse >> Repair open circuit or short to ground or short to power in harness or connectors. 4. CHECK GROUND CONNECTIONS 1. 2. Turn ignition switch OFF. Loosen and retighten ground screw on the body. Refer to EC-1703, "Ground Inspection" . – Body ground (1) – Priming pump (2) OK or NG OK >> GO TO 5. NG >> Repair or replace ground connections. MBIB1520E 5. CHECK ECM GROUND CIRCUIT FOR OPEN AND SHOR 1. 2. Disconnect ECM harness connector. Check harness continuity between ECM terminals 25, 26, 27, 32 and ground. Refer to Wiring Diagram. Continuity should exist. 3. Also check harness for short to power. OK or NG OK >> GO TO 6. NG >> Repair open circuit or short to power in harness or connectors. 6. CHECK ECM POWER SUPPLY CIRCUIT-II 1. 2. 3. Reconnect ECM harness connector. Turn ignition switch ON. Check voltage between IPDM E/R terminal 33 and ground with CONSULT-II or tester. Voltage: Battery voltage OK or NG OK >> Go to EC-1759, "DTC P0231 FUEL PUMP" . NG >> GO TO 7. MBIB1462E EC-1700 POWER SUPPLY AND GROUND CIRCUIT [K9K] 7. CHECK ECM POWER SUPPLY CIRCUIT-III 1. 2. 3. A Turn ignition switch OFF and wait at least 10 seconds. Turn ignition switch ON and then OFF. Check voltage between ECM terminals 109, 110 and ground with CONSULT-II or tester. Voltage: EC After turning ignition switch OFF, battery voltage will exist for a few seconds, then drop to approximately 0V. OK or NG OK >> GO TO 14. NG (Battery voltage does not exist)>>GO TO 8. NG (Battery voltage exists for more then a few seconds)>>GO TO 11. C D MBIB1463E 8. CHECK ECM POWER SUPPLY CIRCUIT-IV 1. 2. E F Turn ignition switch OFF and wait at least 10 seconds. Check voltage between ECM terminal 104 and ground with CONSULT-II or tester. G Voltage: Battery voltage OK or NG OK >> GO TO 9. NG >> GO TO 11. H I PBIB1171E J 9. CHECK ECM POWER SUPPLY CIRCUIT-V 1. 2. 3. Disconnect ECM harness connector. Disconnect IPDM E/R harness connector E7. Check harness continuity between ECM terminals 109, 110 and IPDM E/R terminal 32. Refer to Wiring Diagram. K L Continuity should exist. 4. Also check harness for short to ground and short to power. OK or NG OK >> GO TO 16. NG >> GO TO 10. 10. DETECT MALFUNCTIONING PART Check the following. Harness connectors E48, F101 ● Harness for open or short between ECM and IPDM E/R ● >> Repair open circuit or short to ground or short to power in harness or connectors. EC-1701 M POWER SUPPLY AND GROUND CIRCUIT [K9K] 11. CHECK ECM POWER SUPPLY CIRCUIT-VI 1. 2. 3. Disconnect ECM harness connector. Disconnect IPDM E/R harness connector E7. Check harness continuity between ECM terminal 104 and IPDM E/R terminal 29 under the following conditions. Refer to Wiring Diagram. MBIB1559E CONDITION 1: CONDITION 2: Continuity should exist. Continuity should not exist. 4. Also check harness for short to ground and short to power. OK or NG OK >> GO TO 13. NG >> GO TO 12. 12. DETECT MALFUNCTIONING PART Check the following. ● Harness connectors E48, F101 ● Diode E64 ● Harness for open or short between ECM and IPDM E/R >> Repair open circuit or short to ground or short to power in harness or connectors. 13. CHECK 20A FUSE 1. Disconnect 20 A fuse. 2. Check 20A fuse OK or NG OK >> GO TO 16. NG >> Replace 20A fuse. EC-1702 POWER SUPPLY AND GROUND CIRCUIT [K9K] 14. CHECK GROUND CONNECTIONS A 1. 2. Turn ignition switch OFF. Loosen and retighten ground screw on the body. Refer to EC-1703, "Ground Inspection" . – Body ground (1) – Priming pump (2) OK or NG OK >> GO TO 15. NG >> Repair or replace ground connections. EC C D MBIB1520E E 15. CHECK ECM GROUND CIRCUIT FOR OPEN AND SHORT 1. 2. Disconnect ECM harness connector. Check harness continuity between ECM terminals 25, 26, 27, 32 and ground. Refer to Wiring Diagram. F Continuity should exist. G 3. Also check harness for short to power. OK or NG OK >> GO TO 16. NG >> Repair open circuit or short to power in harness or connectors. H 16. CHECK INTERMITTENT INCIDENT I Refer to EC-1697, "TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT" . OK or NG OK >> Replace IPDM E/R. Refer to PG-18, "IPDM E/R (INTELLIGENT POWER DISTRIBUTION MODULE ENGINE ROOM)" . NG >> Repair open circuit or short to ground or short to power in harness or connectors. Ground Inspection J K BBS00416 Ground connections are very important to the proper operation of electrical and electronic circuits. Ground connections are often exposed to moisture, dirt and other corrosive elements. The corrosion (rust) can become an unwanted resistance. This unwanted resistance can change the way a circuit works. Electronically controlled circuits are very sensitive to proper grounding. A loose or corroded ground can drastically affect an electronically controlled circuit. A poor or corroded ground can easily affect the circuit. Even when the ground connection looks clean, there can be a thin film of rust on the surface. When inspecting a ground connection follow these rules: ● Remove the ground bolt or screw. ● Inspect all mating surfaces for tarnish, dirt, rust, etc. ● Clean as required to assure good contact. ● Reinstall bolt or screw securely. ● Inspect for “add-on” accessories which may be interfering with the ground circuit. ● If several wires are crimped into one ground eyelet terminal, check for proper crimps. Make sure all of the wires are clean, securely fastened and providing a good ground path. If multiple wires are cased in one eyelet make sure no ground wires have excess wire insulation. EC-1703 L M POWER SUPPLY AND GROUND CIRCUIT [K9K] For detailed ground distribution information, refer to PG-38, "Ground Distribution" . PBIB1870E EC-1704 DTC PC001 CAN COMMUNICATION LINE [K9K] DTC PC001 CAN COMMUNICATION LINE Description PFP:22693 A BBS0041O CAN (Controller Area Network) is a serial communication line for real time application. It is an on-vehicle multiplex communication line with high data communication speed and excellent error detection ability. Many elec- EC tronic control units are equipped onto a vehicle, and each control unit shares information and links with other control units during operation (not independent). In CAN communication, control units are connected with 2 communication lines (CAN H line, CAN L line) allowing a high rate of information transmission with less wiring. C Each control unit transmits/receives data but selectively reads required data only. On Board Diagnosis Logic DTC No. PC001 BBS0041P Trouble diagnosis name MULTIPLEX NETWORK (CAN COMMUNICATION LINE) ● 1.DEF: Carry out the multiplex network toruoble diagnosis NOTE: ● Special notes: – Malfunction indicator (Red) lights up. Possible cause ● Harness or connectors (CAN communication line is open or shorted) D E F G H I J K L M EC-1705 DTC PC001 CAN COMMUNICATION LINE [K9K] Wiring Diagram BBS0041R MBWA1568E EC-1706 DTC PC001 CAN COMMUNICATION LINE [K9K] Diagnostic Procedure BBS0041S A Go to LAN-27, "CAN Communication Unit" . EC C D E F G H I J K L M EC-1707 DTC P0016 CKP - CMP CORRELATION [K9K] DTC P0016 CKP - CMP CORRELATION On Board Diagnosis Logic DTC No. P0016 PFP:10328 BBS0041T Trouble diagnosis name Possible cause CRANKSHAFT POSITION - CAMSHAFT POSITION CORRELATION ● Harness or connectors (CMP sensor circuit is open or shorted.) ● Harness or connectors (CKP sensor circuit is open or shorted.) ● Camshaft position sensor ● Crankshaft position sensor ● Timing belt ● Signal plate NOTE: ● If DTC P0016 is displayed with DTC P0335 or P0340, first perform trouble diagnosis for DTC P0335 or P0340. Refer to EC-1774, "DTC P0335 CKP SENSOR" or EC-1778, "DTC P0340 CMP SENSOR" . ● Conditions for applying the diagnostic procedure to the stored DTCs: The DTC is declared present when cranking the engine or at idle speed. Diagnostic Procedure BBS0041V 1. CHECK CAMSHAFT POSITION SENSOR Refer to EC-1783, "Component Inspection" . OK or NG OK >> GO TO 2. NG >> Replace camshaft position sensor. 2. CHECK SPROCKET Visually check for chipping signal plate gear tooth. OK or NG OK >> GO TO 3. NG >> Remove debris and clean the signal plate or replace sprocket. 3. CHECK CRANKSHAFT POSITION SENSOR Refer to EC-1777, "Component Inspection" . OK or NG OK >> GO TO 4. NG >> Replace crankshaft position sensor. 4. CHECK GEAR TOOTH Visually check for chipping signal plate gear tooth. OK or NG OK >> GO TO 5. NG >> Replace the signal plate. 5. CHECK TIMING BELT Refer to EM-272, "TIMING BELT" . OK or NG OK >> GO TO 6. NG >> Replace timing belt. EC-1708 DTC P0016 CKP - CMP CORRELATION [K9K] 6. CHECK INTERMITTENT INCIDENT A Refer to EC-1697, "TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT" . EC >> INSPECTION END C D E F G H I J K L M EC-1709 DTC P0045 TC BOOST CONTROL SORENOID VALVE [K9K] DTC P0045 TC BOOST CONTROL SORENOID VALVE Description PFP:14956 BBS0041W The turbocharger boost control solenoid valve controls vacuum signal to the turbocharger boost control actuator. By changing the variable nozzle vane opening through the rods, the intake air volume is adjusted. MBIB1521E The turbocharger boost control solenoid valve (1) is moved by ON/ OFF pulse from the ECM. The longer the ON pulse, the charge air pressure rises. MBIB1522E On Board Diagnosis Logic DTC No. BBS0041X Trouble diagnosis name Possible cause ● Harness or connectors (The solenoid valve circuit is open or shorted.) C0.0: Open circuit oe short circuit to ground ● Turbocharger boost control solenoid valve CC.1: Short circuit to +12V ● Turbocharger ● Turbocharger boost sensor ● Air inlet circuit TURBOCHARGER BOOST CONTROL SOLENOID VALVE CIRCUIT P0045 ● ● NOTE: ● Conditions for applying the diagnostic procedure to the stored DTCs: The DTC is declared present when ignition switch is in the ON position. ● Special notes: – If this DTC is present, air flow regulation is cut, EGR voluime control valve is closed and turbocharger boost pressure regulation is cut. – Suspected injection message displayed on the instrument panel and reduced performance. – Malfunction indicator (Red) lights up. EC-1710 DTC P0045 TC BOOST CONTROL SORENOID VALVE [K9K] Wiring Diagram BBS0041Z A EC C D E F G H I J K L M MBWA1567E EC-1711 DTC P0045 TC BOOST CONTROL SORENOID VALVE [K9K] Specification data are reference valves, and are measured between each terminal and ground. Pulse signal is measured by CONSULT-II. CAUTION: Do not use ECM ground terminals when measuring input/output voltage. Doing so may damage the ECM's transistor. Use a ground other than ECM terminals, such as the ground. TERMINAL NO. WIRE COLOR ITEM CONDITION DATA (DC Voltage and Pulse Signal) 0 - 12.5V [Ignition switch ON] 35 R ● Warm-up condition ● Idle speed MBIB1504E Turbocharger boost control solenoid valve 0 - 12.5V [Ignition switch ON] ● Warm-up condition ● Engine speed: 2,000 rpm MBIB1505E [Ignition switch ON] [Ignition switch OFF] ● 104 P ECM relay (self-shutoff) For a few seconds after turning ignition switch OFF [Ignition switch OFF] ● 109 110 G G Power supply for ECM More than a few seconds after turning ignition switch OFF [Ignition switch ON] : Average voltage for pulse signal (Actual pulse signal can be confirmed by oscilloscope.) EC-1712 Approximately 1.4V BATTERY VOLTAGE (11 - 14V) BATTERY VOLTAGE (11 - 14V) DTC P0045 TC BOOST CONTROL SORENOID VALVE [K9K] Diagnostic Procedure BBS00420 1. CHECK TURBOCHARGER BOOST CONTROL SOLENOID VALVE POWER SUPPLY CIRCUIT 1. 2. 3. A Turn ignition switch OFF. Disconnect turbocharger boost control solenoid valve (1) harness connector. Turn ignition switch ON. EC C D MBIB1522E 4. Check voltage between turbocharger boost control solenoid valve terminals 2 and ground with CONSULT-II or tester. E F Voltage: Battery voltage OK or NG OK >> GO TO 3. NG >> GO TO 2. G H MBIB1101E 2. DETECT MALFUNCTIONING PART Check the following. ● Harness connectors E48, F101 ● Harness for open and short between turbocharger boost control solenoid valve and IPDM E/R I J K >> Repair open circuit or short to ground or short to power in harness or connectors. 3. CHECK TURBOCHARGER BOOST CONTROL SOLENOID VALVE OUTPUT SIGNAL CIRCUIT FOR L OPEN AND SHORT 1. 2. 3. Turn ignition switch OFF. Disconnect ECM harness connector. Check harness continuity between ECM terminal 35 and turbocharger boost control solenoid valve terminal 1. Refer to Wiring Diagram. Continuity should exist. 4. Also check harness for short to ground and short to power. OK or NG OK >> GO TO 4. NG >> Repair open circuit or short to ground or short to power in harness or connectors. 4. CHECK TURBOCHARGER BOOST CONTROL SOLENOID VALVE Refer to EC-1714, "Component Inspection" . OK or NG OK >> GO TO 5. NG >> Replace turbocharger boost control solenoid valve. EC-1713 M DTC P0045 TC BOOST CONTROL SORENOID VALVE [K9K] 5. CHECK OTHER ITEMS Check the following. ● Turbocharger ● Air inlet circuit (for obstructions, etc.) ● Turbocharger boost pressure sensor signal OK or NG OK >> GO TO 6. NG >> Repair or replace. 6. CHECK INTERMITTENT INCIDENT Refer to EC-1697, "TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT" . >> INSPECTION END Component Inspection BBS00421 TURBOCHARGER BOOST CONTROL SOLENOID VALVE 1. Disconnect turbocharger boost control solenoid valve (1) harness connector. MBIB1522E 2. Check harness continuity between turbocharger boost control solenoid valve terminals under the following conditions. Temperature °C (°F) Resistance kΩ -30 (-22) 18.6 ± 1.8 23 (73) 21 ± 2.1 110 (230) 18 ± 1.8 If NG, replace turbocharger boost control solenoid valve. MBIB1486E EC-1714 DTC P0070 IAT SENSOR [K9K] DTC P0070 IAT SENSOR Component Description PFP:22693 A BBS00422 The intake air temperature sensor (1) is built into mass air flow sensor. The sensor detects intake air temperature and transmits a signal to the ECM. The temperature sensing unit uses a thermistor which is sensitive to the change in temperature. Electrical resistance of the thermistor decreases in response to the temperature rise. EC C D MBIB1523E E On Board Diagnosis Logic DTC No. BBS00423 Trouble diagnosis name INTAKE AIR TEMPERATURE SENSOR CIRCUIT P0070 ● CO.1: Open circuit or short circuit to +12V ● CC.1: Short circuit to ground Possible cause ● Harness or connectors (The sensor circuit is open or shorted.) ● Intake air temperature sensor F G H I J K L M EC-1715 DTC P0070 IAT SENSOR [K9K] Wiring Diagram BBS00425 MBWA1547E EC-1716 DTC P0070 IAT SENSOR [K9K] Diagnostic Procedure BBS00426 1. CHECK GROUND CONNECTIONS A 1. 2. Turn ignition switch OFF. Loosen and retighten ground screw on the body. Refer to EC-1703, "Ground Inspection" . – Body ground (1) – Priming pump (2) OK or NG OK >> GO TO 2. NG >> Repair or replace ground connections. EC C D MBIB1520E E 2. CHECK INTAKE AIR TEMPERATURE SENSOR POWER SUPPLY CIRCUIT 1. Disconnect mass air flow sensor (intake air temperature sensor is built-into) (2) harness connector. – : Vehicle front Turbocharger boost sensor (1) EGR volume control valve (3) Turn ignition switch ON. – – 2. F G H I MBIB1524E 3. Check voltage between MAF sensor terminal 1 and ground with CONSULT-II or tester. J Voltage: Approximately 5.0V OK or NG OK >> GO TO 3. NG >> Repair harness or connectors. K L MBIB1464E 3. CHECK INTAKE AIR TEMPERATURE SENSOR GROUND CIRCUIT FOR OPEN AND SHORT 1. 2. 3. Turn ignition switch OFF. Disconnect ECM harness connector. Check harness continuity between MAF sensor terminal 2 and ECM terminal 70. Refer to Wiring Diagram. Continuity should exist. 4. Also check harness for short to ground and short to power. OK or NG OK >> GO TO 4. NG >> Repair open circuit or short to ground or short to power in harness or connectors. EC-1717 M DTC P0070 IAT SENSOR [K9K] 4. CHECK INTAKE AIR TEMPERATURE SENSOR Refer to EC-1718, "Component Inspection" . OK or NG OK >> GO TO 5. NG >> Replace mass air flow sensor (with intake air temperature sensor). 5. CHECK INTERMITTENT INCIDENT Refer to EC-1697, "TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT" . >> INSPECTION END Component Inspection BBS00427 INTAKE AIR TEMPERATURE SENSOR 1. 2. Check resistance between mass air flow sensor terminals 1 and 2 under the following conditions. Temperature °C (°F) Resistance kΩ -40 (-40) 50,000 ± 6,800 -10 (14) 9,500 ± 900 25 (77) 2,051 ± 120 50 (122) 810 ± 47 80 (176) 310 ± 17 If NG, replace mass air flow sensor (with intake air temperature sensor). Removal and Installation MBIB1487E BBS00428 MASS AIR FLOW SENSOR Refer to EM-245, "AIR CLEANER AND AIR DUCT" . EC-1718 DTC P0087 FUEL SYSTEM [K9K] DTC P0087 FUEL SYSTEM On Board Diagnosis Logic DTC No. P0087 PFP:22693 A BBS00429 Trouble diagnosis name FUEL FLOW CAPACITY FUNCTION Possible cause ● Fuel pump ● Fuel injector ● Fuel rail pressure sensor ● Fuel filter ● Air mixed with fuel ● Lack of fuel ● Fuel line EC C D NOTE: ● Special notes: – Malfunction indicator (Red) lights up. E Diagnostic Procedure BBS0042B 1. CHECK FUEL RAIL PRESSURE SENSOR Refer to EC-1664, "TEST 7: HIGH PRESSURE SYSTEM CHECK" . OK or NG OK >> GO TO 2. NG >> Replace fuel rail. F G H 2. CHECK FUEL INJECTOR Refer to EC-1662, "TEST 3: FUEL INJECTOR CHECK" . OK or NG OK >> GO TO 4. NG >> GO TO 3. I J 3. REPLACE FUEL INJECOR 1. 2. Replace fuel injector of malfunctioning cylinder. Perform Injector Adjustment Value Registration. Refer to EC-1625, "Injector Adjustment Value Registration" . K L >> INSPECTION END 4. CHECK FUEL PUMP M Refer to EC-1762, "Component Inspection" . OK or NG OK >> GO TO 5. NG >> Replace fuel pump. 5. CHECK FUEL FILTER Refer to EC-1666, "TEST 11: FUEL FILTER CHECK" . OK or NG OK >> GO TO 6. NG >> Replace fuel filter. EC-1719 DTC P0087 FUEL SYSTEM [K9K] 6. CHECK FUEL LINE Refer to EC-1660, "TEST 1: LOW PRESSURE CIRCUIT CHECK" . OK or NG OK >> GO TO 7. NG >> Repair fuel line. 7. PERFORM HIGH PRESSURE SYSTEM CHECK Refer to EC-1664, "TEST 7: HIGH PRESSURE SYSTEM CHECK" . >> INSPECTION END Removal and Installation BBS0042C FUEL INJECTOR Refer to EM-266, "FUEL INJECTOR" . FUEL PUMP Refer to EM-268, "HIGH PRESSURE PUMP" . EC-1720 DTC P0089 FUEL PUMP [K9K] DTC P0089 FUEL PUMP On Board Diagnosis Logic DTC No. PFP:16700 A BBS0042D Trouble diagnosis name Possible cause EC FUEL RAIL PRESSURE REGULATION FUNCTION P0089 ● 1.DEF: At minimum limit ● 2.DEF: At maximum limit ● 3.DEF: Below minimum threshold ● 4.DEF: Above maximum threshold ● 5.DEF: High flow current < minimum ● 5.DEF: High flow current > maximum ● 7.DEF: Low flow current < minimum ● 8.DEF: Low flow current > maximum ● Fuel pump ● Air mixed with fuel ● Lack of fuel ● Fuel rail pressure sensor C D E NOTE: ● Special notes: – Malfunction indicator (Red) lights up. F Diagnostic Procedure BBS0042F 1. CHECK FUEL RAIL PRESSURE SENSOR G Refer to EC-1664, "TEST 7: HIGH PRESSURE SYSTEM CHECK" . OK or NG OK >> GO TO 2. NG >> Replace fuel rail. H I 2. CHECK FUEL PUMP Perform EC-1762, "Component Inspection" . OK or NG OK >> GO TO 3. NG >> Replace Fuel pump. J K 3. CHECK FUEL FILTER Refer to EC-1666, "TEST 11: FUEL FILTER CHECK" . OK or NG OK >> GO TO 4. NG >> Replace fuel filter. L M 4. CHECK FUEL LINE Refer to EC-1665, "TEST 8: HIGH-PRESSURE CIRCUIT LEAK CHECK" . OK or NG OK >> GO TO 5. NG >> Repair fuel line. 5. PERFORM HIGH PRESSURE SYSTEM CHECK Refer to EC-1664, "TEST 7: HIGH PRESSURE SYSTEM CHECK" . >> INSPECTION END Removal and Installation BBS0042G FUEL PUMP Refer to EM-268, "HIGH PRESSURE PUMP" . EC-1721 DTC P0100 MAF SENSOR [K9K] DTC P0100 MAF SENSOR Component Description PFP:22693 BBS0042H The mass air flow sensor is placed in the stream of intake air. ● Intake air temperature sensor (1) MBIB1523E CONSULT-II Reference Value in Data Monitor Mode BBS0042I Specification data are reference values. MONITOR ITEM CONDITION ● Engine: After warming up ● Air conditioner switch: OFF ● Shift lever: Neutral position ● No load AIR FLOW SPECIFICATION Idle Approximately 200 mg/cp 2,000 rpm Approximately 270 mg/cp On Board Diagnosis Logic DTC No. BBS0042J Trouble diagnosis name Possible cause MASS AIR FLOW SENSOR CIRCUIT P0100 ● 1.DEF: Parmanent low lebel ● 2.DEF: Parmanent high lebel ● ● ● Harness or connectors (The sensor circuit is open or shorted.) 3.DEF: Below minimum threshold ● Mass air flow sensor 4.DEF: Above maximum threshold ● Air filter obstructed ● 5.DEF: Parmanent at minimum limit ● Intake air duct obstructed ● 6.DEF: Parmanent at maximum limit NOTE: ● If DTC P0100 is displayed with DTC P0235, first perform trouble diagnosis for DTC P0235. Refer to EC-1763, "DTC P0235 TC BOOST SENSOR" . ● If DTC P0100 is displayed with DTC P0641, first perform trouble diagnosis for DTC P0641. Refer to EC-1830, "DTC P0641 SENSOR POWER SUPPLY" . ● Conditions for applying the diagnostic procedure to the stored DTCs: The DTC is declared present with engine running. ● Special notes: – If this DTC is present, mass air flow sensor function will stop and EGR voluime control valve is closed. EC-1722 DTC P0100 MAF SENSOR [K9K] Wiring Diagram BBS0042L A EC C D E F G H I J K L M MBWA1548E EC-1723 DTC P0100 MAF SENSOR [K9K] Specification data are reference values, and are measured between each terminal and ground. CAUTION: Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM's transistor. Use a ground other than ECM terminals, such as the ground. TERMINAL NO. 50 WIRE COLOR L ITEM Sensor power supply (Mass air flow sensor) CONDITION DATA (DC Voltage) [Ignition switch: ON] Approximately 5.0V [Ignition switch: ON] Approximately 0.36V [Engine is running] 60 Y Mass air flow sensor ● Warm-up condition ● Idle speed Approximately 1.7V [Engine is running] ● Warm-up condition ● Engine speed: 2,500 rpm. Approximately 2.2V [Engine is running] 70 G Mass air flow sensor ground ● Warm-up condition ● Idle speed [Ignition switch ON] [Ignition switch OFF] ● 104 P ECM relay (self-shutoff) For a few seconds after turning ignition switch OFF [Ignition switch OFF] ● 109 110 G G Power supply for ECM More than a few seconds after turning ignition switch OFF [Ignition switch ON] Diagnostic Procedure Approximately 0.3V Approximately 1.4V BATTERY VOLTAGE (11 - 14V) BATTERY VOLTAGE (11 - 14V) BBS0042M 1. CHECK AIR FILTER Check that air filter is not obsstructed. Yes or No Yes >> Repair. No >> GO TO 2. 2. CHECK INTAKE AIR DUCT Check that intake air duct is not obsstructed. Yes or No Yes >> Repair. No >> GO TO 3. EC-1724 DTC P0100 MAF SENSOR [K9K] 3. CHECK GROUND CONNECTIONS A 1. 2. Turn ignition switch OFF. Loosen and retighten ground screw on the body. Refer to EC-1703, "Ground Inspection" . – Body ground (1) – Priming pump (2) OK or NG OK >> GO TO 4. NG >> Repair or replace ground connections. EC C D MBIB1520E E 4. CHECK MAFS POWER SUPPLY CIRCUIT 1. Disconnect mass air flow sensor (2) harness connector. – : Vehicle front Turbocharger boost sensor (1) EGR volume control valve (3) Turn ignition switch ON. – – 2. F G H MBIB1524E 3. I Check voltage between mass air flow sensor terminals 4, 5 and ground with CONSULT-II or tester. J Terminal 4: 5: Voltage Battery voltage Approximately 5.0V K OK or NG OK >> GO TO 6. NG >> GO TO 5. L MBIB1465E 5. DETECT MALFUNCTIONING PART M Check the following. ● Harness connectors E48, F101 ● Harness for open or short between mass air flow sensor and IPDM E/R ● Harness for open or short between mass air flow sensor and ECM >> Repair open circuit or short to ground or short to power in harness or connectors. EC-1725 DTC P0100 MAF SENSOR [K9K] 6. CHECK MAFS GROUND CIRCUIT FOR OPEN AND SHORT 1. 2. 3. Turn ignition switch OFF. Disconnect ECM harness connector. Check harness continuity between mass air flow sensor terminal 2 and ECM terminal 70. Refer to Wiring Diagram. Continuity should exist. 4. Also check harness for short to ground and short to power. OK or NG OK >> GO TO 7. NG >> Repair open circuit or short to ground or short to power in harness or connectors. 7. CHECK MAFS INPUT SIGNAL CIRCUIT FOR OPEN AND SHORT 1. Check harness continuity between mass air flow sensor terminal 6 and ECM terminal 60. Refer to Wiring Diagram. Continuity should exist. 2. Also check harness for short to ground and short to power. OK or NG OK >> GO TO 8. NG >> Repair open circuit or short to ground or short to power in harness or connectors. 8. CHECK MASS AIR FLOW SENSOR Refer to EC-1726, "Component Inspection" . OK or NG OK >> GO TO 9. NG >> Replace mass air flow sensor. 9. CHECK INTERMITTENT INCIDENT Refer to EC-1697, "TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT" . >> INSPECTION END Component Inspection BBS0042N MASS AIR FLOW SENSOR 1. 2. 3. Reconnect all harness connectors disconnected. Start engine and warm it up to normal operating temperature. Check voltage between ECM terminal 60 (Mass air flow sensor signal) and ground. Condition Voltage V Ignition switch ON (Engine stopped.) Approx. 0.36 Engine speed: Idle Approx. 1.7 Engine speed: 2,500 rpm Approx. 2.2 4. If NG, replace mass air flow sensor. SEC915C Removal and Installation BBS0042O MASS AIR FLOW SENSOR Refer to EM-245, "AIR CLEANER AND AIR DUCT" . EC-1726 DTC P0115 ECT SENSOR [K9K] DTC P0115 ECT SENSOR Description PFP:22693 A BBS0042P The engine coolant temperature sensor (1) is used to detect the engine coolant temperature. The sensor modifies a voltage signal from the ECM. The modified signal returns to the ECM as the engine coolant temperature input. The sensor uses a thermistor which is sensitive to the change in temperature. The electrical resistance of the thermistor decreases as temperature increases. EC C D MBIB1525E E On Board Diagnosis Logic DTC No. BBS0042Q Trouble diagnosis name ENGINE COOLANT TEMPERATURE SENSOR CIRCUIT P0115 ● CC.0: Short circuit to ground ● CO.1: Short circuit to +12V or open circuit Possible cause ● Harness or connectors (The sensor circuit is open or shorted.) ● Engine coolant temperature sensor F G NOTE: ● Special notes: – If this DTC is present, cooling fan motor is activated at low speed for vehicles fitted with air conditioning. H I J K L M EC-1727 DTC P0115 ECT SENSOR [K9K] Wiring Diagram BBS0042S MBWA1549E EC-1728 DTC P0115 ECT SENSOR [K9K] Diagnostic Procedure BBS0042T 1. CHECK GROUND CONNECTIONS A 1. 2. Turn ignition switch OFF. Loosen and retighten ground screw on the body. Refer to EC-1703, "Ground Inspection" . – Body ground (1) – Priming pump (2) Yes or No Yes >> GO TO 2. NG >> Repair or replace ground connections. EC C D MBIB1520E E 2. CHECK ECT SENSOR POWER SUPPLY CIRCUIT 1. 2. F Disconnect engine coolant temperature sensor (1) harness connector. Turn ignition switch ON. G H I MBIB1525E 3. Check voltage between ECT sensor terminal 3 and ground with CONSULT-II or tester. J Voltage: Approximately 5.0V OK or NG OK >> GO TO 3. NG >> Repair harness or connectors. K L MBIB1466E 3. CHECK ECT SENSOR GROUND CIRCUIT FOR OPEN AND SHORT 1. 2. 3. Turn ignition switch OFF. Disconnect ECM harness connector. Check harness continuity between ECT sensor terminal 2 and ECM terminal 63. Refer to Wiring Diagram. Continuity should exist. 4. Also check harness for short to ground and short to power. OK or NG OK >> GO TO 4. NG >> Repair open circuit or short to ground or short to power in harness or connectors. EC-1729 M DTC P0115 ECT SENSOR [K9K] 4. CHECK ENGINE COOLANT TEMPERATURE SENSOR Refer to EC-1730, "Component Inspection" . OK or NG OK >> GO TO 5. NG >> Replace engine coolant temperature sensor. 5. CHECK INTERMITTENT INCIDENT Refer to EC-1697, "TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT" . >> INSPECTION END Component Inspection BBS0042U ENGINE COOLANT TEMPERATURE SENSOR 1. 2. Check resistance between engine coolant temperature sensor terminals 2 and 3 as shown in the figure. Engine coolant temperature °C (°F) Resistance kΩ -40 (-40) 76,000 ± 7,000 -10 (14) 12,500 ± 1,130 25 (77) 2,252 ± 112 50 (122) 810 ± 40 80 (176) 280 ± 8 110 (230) 115 ± 3 120 (248) 88 ± 2 MBIB1488E If NG, replace engine coolant temperature sensor. Removal and Installation BBS0042V ENGINE COOLANT TEMPERATURE SENSOR Refer to EM-276, "CYLINDER HEAD" . EC-1730 DTC P0170 FUEL INJECTOR ADJUSTMENT VALUE [K9K] DTC P0170 FUEL INJECTOR ADJUSTMENT VALUE On Board Diagnosis Logic DTC No. P0170 PFP:22693 A BBS0042X Trouble diagnosis name INJECTOR ADJUSTMENT VALUE DATA ERROR Possible cause ● Injector Adjustment Value is not registered sufficiently NOTE: ● If DTC P0170 is displayed with DTC P0200, P0201, P0202, P0203, P0204, first perform trouble diagnosis for other DTC. Refer to EC-1740, "DTC P0200 FUEL INJECTOR" or EC-1745, "DTC P0201 P0204 FUEL INJECTOR" . EC C D Diagnostic Procedure BBS0042Z 1. PERFORM INJECTOR ADJUSTMENT VALUE REGISTRATION Perform Injector Adjustment Value Registration. Refer to EC-1625, "Injector Adjustment Value Registration" . >> INSPECTION END E F G H I J K L M EC-1731 DTC P0180 FUEL PUMP TEMPERATURE SENSOR [K9K] DTC P0180 FUEL PUMP TEMPERATURE SENSOR Description PFP:22693 BBS00430 Fuel pump temperature sensor is built in the fuel pump. The sensor detects the fuel temperature in the fuel pump and calibrates the fuel injection amount change by fuel temperature. CONSULT-II Reference Value in Data Monitor Mode BBS00431 Specification data are reference values. MONITOR ITEM FUEL TEMP SEN CONDITION ● SPECIFICATION Engine: After warming up More than 40°C (104°F) On Board Diagnosis Logic DTC No. BBS00432 Trouble diagnosis name FUEL PUMP TEMPERATURE SENSOR CIRCUIT P0180 ● CC.0: Short circuit to ground ● CO.1: Short circuit to +12V or open circuit EC-1732 Possible cause ● Harness or connectors (The sensor circuit is open or shorted.) ● Fuel pump temperature sensor DTC P0180 FUEL PUMP TEMPERATURE SENSOR [K9K] Wiring Diagram BBS00434 A EC C D E F G H I J K L M MBWA1550E EC-1733 DTC P0180 FUEL PUMP TEMPERATURE SENSOR [K9K] Specification data are reference values and are measured between each terminal and ground. CAUTION: Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM's transistor. Use a ground other than ECM terminals, such as the ground. TERMINAL NO. 54 WIRE COLOR P ITEM Fuel pump temperature sensor DATA (DC Voltage and Pulse Signal) CONDITION [Engine is running] ● Warm-up condition Approximately 0.3 - 5.0V Output voltage varies with fuel pump temperature [Engine is running] 64 G Fuel pump temperature sensor ground ● Warm-up condition ● Idle speed Approximately 0.3V Diagnostic Procedure BBS00435 1. CHECK GROUND CONNECTIONS 1. 2. Turn ignition switch OFF. Loosen and retighten ground screw on the body. Refer to EC-1703, "Ground Inspection" . – Body ground (1) – Priming pump (2) OK or NG OK >> GO TO 2. NG >> Repair or replace ground connections. MBIB1520E 2. CHECK FUEL PUMP TEMPERATURE SENSOR POWER SUPPLY CIRCUIT 1. 2. 3. Disconnect fuel pump temperature sensor harness connector. Turn ignition switch ON. Check voltage between fuel pump temperature sensor terminal 1 and ground with CONSULT-II or tester. Voltage: Approximately 5.0V OK or NG OK >> GO TO 3. NG >> Repair harness or connectors. PBIB2245E EC-1734 DTC P0180 FUEL PUMP TEMPERATURE SENSOR [K9K] 3. CHECK FUEL PUMP TEMPERATURE SENSOR GROUND CIRCUIT FOR OPEN AND SHORT 1. 2. 3. A Turn ignition switch OFF. Disconnect ECM harness connector. Check harness continuity between fuel pump temperature sensor terminal 2 and ECM terminal 64. Refer to Wiring Diagram. EC Continuity should exist. C 4. Also check harness for short to ground and short to power. OK or NG OK >> GO TO 4. NG >> Repair open circuit or short to ground or short to power in harness or connectors. D 4. CHECK FUEL PUMP TEMPERATURE SENSOR E Refer to EC-1735, "Component Inspection" . OK or NG OK >> GO TO 5. NG >> Replace fuel pump. F 5. CHECK INTERMITTENT INCIDENT G Refer to EC-1697, "TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT" . H >> INSPECTION END Component Inspection BBS004UO FUEL PUMP TEMPERATURE SENSOR 1. Check resistance between fuel pump temperature sensor terminals 1 and 2 as shown in the figure. Resistence: 2. I J 2.2 kΩ at 25°C (77°F) If NG, replace fuel pump. K L PBIB0417E Removal and Installation BBS00436 FUEL PUMP Refer to EM-268, "HIGH PRESSURE PUMP" . EC-1735 M DTC P0190 FRP SENSOR [K9K] DTC P0190 FRP SENSOR CONSULT-II Reference Value in Data Monitor Mode PFP:22693 BBS00438 Specification data are reference values. MONITOR CONDITION ● Engine: After warming up ● Air conditioner switch: OFF ● Shift lever: Neutral position ● No load ● Engine: After warming up ● Air conditioner switch: OFF ● Shift lever: Neutral position ● No load RAIL PRESSURE RAIL PRES SET SPECIFICATOIN Idle Approximately 230 bar 2,000 rpm Approximately 450 bar Idle Approximately 230 bar 2,000 rpm Approximately 450 bar On Board Diagnosis Logic DTC No. BBS00439 Trouble diagnosis name Possible cause FUEL RAIL PRESSURE SENSOR CIRCUIT P0190 ● 1.DEF: Inconsistency ● 2.DEF: Below minimum threshold ● 3.DEF: Above maximum threshold ● 4.DEF: Value outside of tolerance ● CC.0: Short circuit to ground ● CO.1: Short circuit to +12V or open circuit ● Harness or connectors (The sensor circuit is open or shorted.) ● Fuel rail pressure sensor NOTE: ● If DTC P0190 is displayed with DTC P0641, first perform trouble diagnosis for DTC P0641. Refer to EC-1830, "DTC P0641 SENSOR POWER SUPPLY" . ● Conditions for applying the diagnostic procedure to the stored DTCs: The DTC is declared present after the engine started. ● Special notes: – If this DTC is present, engine stops and is impossible to restarted. – Malfunction indicator (Red) lights up. EC-1736 DTC P0190 FRP SENSOR [K9K] Wiring Diagram BBS0043B A EC C D E F G H I J K L M MBWA1551E EC-1737 DTC P0190 FRP SENSOR [K9K] Specification data are reference values and are measured between each terminal and ground. CAUTION: Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM's transistor. Use a ground other than ECM terminals, such as the ground. TERMINAL NO. 47 WIRE COLOR L ITEM Sensor power supply (Fuel rail pressure sensor) CONDITION [Ignition switch ON] DATA (DC Voltage) Approximately 5.0V [Engine is running] 57 R Fuel rail pressure sensor ● Warm-up condition ● Idle speed Approximately 1.0V [Engine is running] ● Warm-up condition ● Engine speed is 2,000 rpm Approximately 1.5V [Engine is running] 67 B Sensor ground (Fuel rail pressure sensor) ● Warm-up condition ● Idle speed Diagnostic Procedure Approximately 0.45V BBS0043C 1. CHECK GROUND CONNECTION 1. 2. Turn ignition switch OFF. Loosen and retighten ground screw on the body. Refer to EC-1703, "Ground Inspection" . – Body ground (1) – Priming pump (2) OK or NG OK >> GO TO 2. NG >> Repair or replace ground connections. MBIB1520E 2. CHECK FUEL RAIL PRESSURE SENSOR POWER SUPPLY CIRCUIT 1. 2. 3. Disconnect fuel rail pressure sensor harness connector. Turn ignition switch ON. Check voltage between fuel rail pressure sensor terminal 3 ground with CONSULT-II or tester. Voltage: Approximately 5.0V OK or NG OK >> GO TO 3. NG >> Repair open circuit or short to ground or short to power in harness or connectors. MBIB1467E EC-1738 DTC P0190 FRP SENSOR [K9K] 3. CHECK FUEL RAIL PRESSURE SENSOR GROUND CIRCUIT FOR OPEN AND SHORT 1. 2. 3. A Turn ignition switch OFF. Disconnect ECM harness connector. Check harness continuity between fuel rail pressure sensor terminal 2 and ECM terminal 67. Refer to Wiring Diagram. EC Continuity should exist. C 4. Also check harness for short to ground and short to power. OK or NG OK >> GO TO 4. NG >> Repair open circuit or short to ground or short to power in harness or connectors. D 4. CHECK FUEL RAIL PRESSURE SENSOR INPUT SIGNAL CIRCUIT FOR OPEN AND SHORT 1. E Check harness continuity between ECM terminal 57 and fuel rail pressure sensor terminal 1. Refer to Wiring Diagram. F Continuity should exist. 2. Also check harness for short to ground and short to power. OK or NG OK >> GO TO 4. NG >> Repair open circuit or short to ground or short to power in harness connectors. G H 5. CHECK FUEL RAIL PRESSURE SENSOR Refer to EC-1739, "Component Inspection" . OK or NG OK >> GO TO 6. NG >> Replace fuel rail. I J 6. CHECK INTERMITTENT INCIDENT Refer to EC-1697, "TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT" . K >> INSPECTION END L Component Inspection BBS0043D FUEL RAIL PRESSURE SENSOR 1. 2. 3. 4. 5. Reconnect harness connector disconnected. Start engine and warm it up to normal operating temperature. Check voltage between ECM terminal 57 (Fuel rail pressure sensor signal) and ground under the following conditions. Condition Voltage V Idle Approximately 1.0 2,000 rpm Approximately 1.5 If the voltage is out of specification, disconnect fuel rail pressure sensor harness connector and connect it again. Then repeat above check. If NG, replace fuel rail. Removal and Installation M MBIB1539E BBS0043E FUEL RAIL Refer to EM-267, "INJECTOR RAIL" . EC-1739 DTC P0200 FUEL INJECTOR [K9K] DTC P0200 FUEL INJECTOR Component Description PFP:16600 BBS004UP The fuel injector is a small, precise solenoid valve. When the ECM supplies a ground to the fuel injector circuit, the coil in the fuel injector is energized. The energized coil pulls the needle valve back and allows fuel to flow through the fuel injector into the cylinder. The amount of fuel injected depends upon the injection pulse duration. Pulse duration is the length of time the fuel injector remains open. The ECM controls the injection pulse duration based on engine fuel needs. CONSULT-II Reference Value in Data Monitor Mode BBS004UQ Specification data are reference values. MONITOR ITEM CONDITION ● Engine: After warming up ● Air conditioner switch: OFF ● Shift lever: Neutral position ● No load FUEL FLOW SPECIFICATION Idle Approximately 4.9 mg/cp 2,000 rpm Approximately 3.5 mg/cp On Board Diagnosis Logic DTC No. BBS0043F Trouble diagnosis name FUEL INJECTOR CIRCUIT P0200 ● CC.0: Short circuit to ground ● CC.1: Short circuit to +12V Possible cause ● Harness or connectors (The fuel injector circuit is shorted.) ● Fuel injector NOTE: ● If DTC P0200 is displayed with DTC P0201, P0202, P0203, P0204, first perform trouble diagnosis for other DTC. Refer to EC-1745, "DTC P0201 - P0204 FUEL INJECTOR" . ● Conditions for applying the diagnostic procedure to the stored DTCs: The DTC is declared present with engine running. ● Special notes: – If this DTC is present, the engine stops. – Malfunction indicator (Red) lights up. EC-1740 DTC P0200 FUEL INJECTOR [K9K] Wiring Diagram BBS004TT A EC C D E F G H I J K L M MBWA1553E EC-1741 DTC P0200 FUEL INJECTOR [K9K] Specification data are reference values and are measured between each terminal and ground. Pulse signal is measured by CONSULT-II. CAUTION: Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM's transistor. Use a ground other than ECM terminals, such as the ground. TERMINAL NO. WIRE COLOR ITEM CONDITION [Engine is running] 73 75 77 79 B/P P/L G L Fuel injector No. 2 Fuel injector No. 4 Fuel injector No. 3 Fuel injector No. 1 ● Warm-up condition ● Idle speed DATA (DC Voltage and Pulse Signal) 0 - 9V NOTE: The pulse cycle changes depending on rpm at idle. MBIB1512E 0 - 9V [Engine is running] ● Warm-up condition ● Engine speed: 2,000 rpm MBIB1513E [Engine is running] 74 O 76 V 78 R 80 P Fuel injector power supply No. 2 Fuel injector power supply No. 4 Fuel injector power supply No. 3 Fuel injector power supply No. 1 ● Warm-up condition ● Idle speed 5 - 10V NOTE: The pulse cycle changes depending on rpm at idle. MBIB1514E 5 - 10V [Engine is running] ● Warm-up condition ● Engine speed: 2,000 rpm MBIB1515E : Average voltage for pulse signal (Actual pulse signal can be confirmed by oscilloscope.) EC-1742 DTC P0200 FUEL INJECTOR [K9K] Diagnostic Procedure BBS0043H 1. CHECK FUEL INJECTOR POWER SUPPLY FOR OPEN AND SHORT CIRCUIT 1. 2. 3. 4. A Turn ignition switch OFF. Disconnect fuel injector (1) harness connector. Disconnect ECM harness connector. Check harness continuity between the following terminals. Refer to Wiring Diagram. Terminal EC C Cylinder ECM Fuel injector 74 1 No.2 76 1 No.4 78 1 No.3 80 1 No.1 D MBIB1526E F Continuity should exist. 5. Also check harness for short to ground and short to power. OK or NG OK >> GO TO 2. NG >> Repair open circuit or short to ground or short to power in harness or connectors. 2. CHECK FUEL INJECOR OUTPUT SIGNAL CIRCUIT FOR OPEN AND SHORT 1. Check harness continuity between the following terminals. Refer to Wiring Diagram. Terminal G H I Cylinder ECM Fuel injector 73 2 No.2 75 2 No.4 77 2 No.3 79 2 No.1 J K L Continuity should exist. 2. Also check harness for short to ground and short to power. OK or NG OK >> GO TO 3. NG >> Repair open circuit or short to ground or short to power in harness or connectors. 3. CHECK INTERMITTENT INCIDENT Refer to EC-1697, "TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT" . OK or NG OK >> GO TO 4. NG >> Repair or open circuit or short to ground or short to power in harness or connectors. 4. REPLACE FUEL INJECOR 1. 2. E Replace fuel injector of malfunctioning cylinder. Perform Injector Adjustment Value Registration. Refer to EC-1625, "Injector Adjustment Value Registration" . >> INSPECTION END EC-1743 M DTC P0200 FUEL INJECTOR [K9K] Removal and Installation BBS004TV FUEL INJECTOR Refer to EM-266, "FUEL INJECTOR" . EC-1744 DTC P0201 - P0204 FUEL INJECTOR [K9K] DTC P0201 - P0204 FUEL INJECTOR Component Description PFP:16600 A BBS0043I The fuel injector is a small, precise solenoid valve. When the ECM supplies a ground to the fuel injector circuit, the coil in the fuel injector is energized. The energized coil pulls the needle valve back and allows fuel to flow EC through the fuel injector into the cylinder. The amount of fuel injected depends upon the injection pulse duration. Pulse duration is the length of time the fuel injector remains open. The ECM controls the injection pulse duration based on engine fuel needs. C CONSULT-II Reference Value in Data Monitor Mode BBS0043J Specification data are reference values. MONITOR ITEM CONDITION ● Engine: After warming up ● Air conditioner switch: OFF ● Shift lever: Neutral position ● No load FUEL FLOW Idle Approximately 4.9 mg/cp 2,000 rpm Approximately 3.5 mg/cp E On Board Diagnosis Logic DTC No. D SPECIFICATION BBS0043K Trouble diagnosis name Possible cause G NO. 1 CYLINDER FUEL INJECTOR CIRCUIT P0201 ● CO: Open circuit ● CC: Short circuit ● 1.DEF: At minimum stop ● 2.DEF: At maximum stop F H NO. 2 CYLINDER FUEL INJECTOR CIRCUIT P0202 ● CO: Open circuit ● CC: Short circuit ● 1.DEF: At minimum stop ● 2.DEF: At maximum stop I NO. 3 CYLINDER FUEL INJECTOR CIRCUIT P0203 ● CO: Open circuit ● CC: Short circuit ● 1.DEF: At minimum stop ● 2.DEF: At maximum stop ● Harness or connectors (The fuel injector circuit is open.) ● Fuel injector J K L NO. 4 CYLINDER FUEL INJECTOR CIRCUIT P0204 ● CO: Open circuit ● CC: Short circuit ● 1.DEF: At minimum stop ● 2.DEF: At maximum stop M NOTE: ● Conditions for applying the diagnostic procedure to the stored DTCs: The DTC is declared present with engine running. ● Special notes: – If this DTC is present, the idle speed is stuck at 1,000 rpm with engine noise, unstable engine speed, reduced engine performance. – Malfunction indicator (Red) lights up. – Malfunction indicator (Yellow) lights up. EC-1745 DTC P0201 - P0204 FUEL INJECTOR [K9K] Wiring Diagram BBS0043M MBWA1553E EC-1746 DTC P0201 - P0204 FUEL INJECTOR [K9K] Specification data are reference values and are measured between each terminal and ground. Pulse signal is measured by CONSULT-II. A CAUTION: Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM's transistor. Use a ground other than ECM terminals, such as the ground. EC TERMINAL NO. WIRE COLOR ITEM CONDITION C [Engine is running] 73 75 77 79 DATA (DC Voltage and Pulse Signal) B/P P/L G L Fuel injector No. 2 Fuel injector No. 4 Fuel injector No. 3 Fuel injector No. 1 ● Warm-up condition ● Idle speed 0 - 9V D NOTE: The pulse cycle changes depending on rpm at idle. E MBIB1512E 0 - 9V F [Engine is running] ● Warm-up condition ● Engine speed: 2,000 rpm G MBIB1513E H [Engine is running] 74 O 76 V 78 R 80 P Fuel injector power supply No. 2 Fuel injector power supply No. 4 Fuel injector power supply No. 3 Fuel injector power supply No. 1 ● Warm-up condition ● Idle speed 5 - 10V I NOTE: The pulse cycle changes depending on rpm at idle. J MBIB1514E 5 - 10V K [Engine is running] ● Warm-up condition ● Engine speed: 2,000 rpm L MBIB1515E M : Average voltage for pulse signal (Actual pulse signal can be confirmed by oscilloscope.) Diagnostic Procedure BBS0043N 1. CHECK DTC Make sure that which malfunction (DTC second line indication) is displayed. A CO or CC B 1.DEF or 2.DEF A or B A B >> GO TO 2. >> GO TO 5. EC-1747 DTC P0201 - P0204 FUEL INJECTOR [K9K] 2. CHECK FUEL INJECTOR POWER SUPPLY FOR OPEN AND SHORT CIRCUIT 1. 2. 3. 4. Turn ignition switch OFF. Disconnect fuel injector (1) harness connector. Disconnect ECM harness connector. Check harness continuity between the following terminals corresponding to the malfunctioning cylinder. Refer to Wiring Diagram. Terminal DTC Cylinder ECM Fuel injector P0201 80 1 No.1 P0202 74 1 No.2 P0203 78 1 No.3 P0204 76 1 No.4 MBIB1526E Continuity should exist. 5. Also check harness for short to ground and short to power. OK or NG OK >> GO TO 3. NG >> Repair open circuit or short to ground or short to power in harness or connectors. 3. CHECK FUEL INJECOR OUTPUT SIGNAL CIRCUIT FOR OPEN AND SHORT 1. Check harness continuity between the following terminals corresponding to the malfunctioning cylinder. Refer to Wiring Diagram. Terminal DTC Cylinder ECM Fuel injector P0201 79 2 No.1 P0202 73 2 No.2 P0203 77 2 No.3 P0204 75 2 No.4 Continuity should exist. 2. Also check harness for short to ground and short to power. OK or NG OK >> GO TO 4. NG >> Repair open circuit or short to ground or short to power in harness or connectors. EC-1748 DTC P0201 - P0204 FUEL INJECTOR [K9K] 4. CHECK FUEL INJECTOR CIRCUIT FOR SHORT A Check harness continuity between the following terminals corresponding to the malfunctioning cylinder. Refer to Wiring Diagram. P0201 P0202 P0203 P0204 EC Terminal DTC Cylinder Fuel injector ECM 2 Except 79 1 Except 80 2 Except 73 1 Except 74 2 Except 77 1 Except 78 2 Except 75 1 Except 76 No.1 No.2 C D No.3 E No.4 F Continuity should not exist. OK or NG OK >> GO TO 8. NG >> Repair circuit short in harness or connectors. 5. CHECK INJECTOR ADJUSTMENT VALUE G H Make sure that all injector adjustment values are registered correctly. Refer to EC-1625, "Injector Adjustment Value Registration" . OK or NG OK >> GO TO 6. NG >> Perform Injector Adjustment Value Registration. Refer to EC-1625, "Injector Adjustment Value Registration" . I J 6. CHECK KNOCK SENSOR SHIELD CIRCUIT FOR OPEN AND SHORT Check knock sensor shield circuit for open and short. Refer to EC-1771, "Wiring Diagram" . OK or NG OK >> GO TO 7. NG >> Repair open circuit or short to ground or short to power in harness or connectors. 7. CHECK KNOCK SENSOR INSTALLATION K L M Check that knock sensor is installed securely on the engine. Refer to EM-282, "OVERHAUL" . OK or NG OK >> GO TO 8. NG >> Repair open circuit or short to ground or short to power in harness or connectors. 8. CHECK INTERMITTENT INCIDENT Refer to EC-1697, "TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT" . OK or NG OK >> GO TO 9. NG >> Repair open circuit or short to ground or short to power in harness or connectors. EC-1749 DTC P0201 - P0204 FUEL INJECTOR [K9K] 9. REPLACE FUEL INJECOR 1. 2. Replace fuel injector of malfunctioning cylinder. Perform Injector Adjustment Value Registration. Refer to EC-1625, "Injector Adjustment Value Registration" . >> INSPECTION END Component Inspection BBS0043O FUEL INJECTOR 1. 2. Disconnect fuel injector harness connector. Check resistance between terminals as shown in the figure. Continuity should exist. 3. If NG, replace fuel injector. MBIB1253E Removal and Installation BBS0043P FUEL INJECTOR Refer to EM-266, "FUEL INJECTOR" . EC-1750 DTC P0225 APP SENSOR [K9K] DTC P0225 APP SENSOR Description PFP:22693 A BBS0043Q The accelerator pedal position sensor is installed on the upper end of the accelerator pedal assembly. The sensors detect the accelerator pedal position and sends a signal to the ECM. The ECM uses the signal to determine the amount of fuel to be injected. EC C D PBIB1741E E CONSULT-II Reference Value in Data Monitor Mode BBS0043R Specification data are reference values. MONITOR ITEM PL PTNMR T1 V PL PTNMR T2 V CONDITION Ignition switch: ON (Engine stopped) Accelerator pedal: Fully released Approximately 15 % ● Ignition switch: ON (Engine stopped) Accelerator pedal: Fully released Approximately 6 % On Board Diagnosis Logic DTC No. F SPECIFICATION ● G BBS0043S Trouble diagnosis name H Possible cause APP SENSOR 1 CIRCUIT ● CO.0: Open circuit or short circuit to ground ● CC.1: Short circuit to +12V ● 1.DEF: Inconsistency between APP sensors 1 and 2 ● 2.DEF: No signal ● 3.DEF: Blocked component P0225 ● Harness or connectors (The APP sensor 1 circuit is open or shorted.) ● Accelerator pedal position sensor (Accelerator pedal position sensor 1) NOTE: ● If DTC P0225 is displayed with DTC P0641, first perform trouble diagnosis for DTC P0641. Refer to EC-1830, "DTC P0641 SENSOR POWER SUPPLY" . ● Special notes: – If this DTC is present, the engine speed is maintained above 1,000 rpm, the engine performance is reduced, and malfuction indicator (Red) lights up. – If this DTC is present with DTC P2120, the engine speed is fixed at 1,800 rpm, the engine performance is reduced, and malfuction indicator (Red) lights up. EC-1751 I J K L M DTC P0225 APP SENSOR [K9K] Wiring Diagram BBS0043U LHD MODELS MBWA1554E EC-1752 DTC P0225 APP SENSOR [K9K] Specification data are reference values and are measured between each terminal and ground. CAUTION: Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM's transistor. Use a ground other than ECM terminals, such as the ground. TERMINAL NO. 6 WIRE COLOR L/R ITEM Sensor ground (Accelerator pedal position sensor 2) CONDITION DATA (DC Voltage and Pulse Signal) [Engine is running] ● Warm-up condition ● Idle speed 12 18 28 29 L/W Accelerator pedal position sensor 2 L Sensor power supply (Accelerator pedal position sensor 2) B Sensor ground (Accelerator pedal position sensor 1) R Sensor power supply (Accelerator pedal position sensor 1) Engine stopped ● Accelerator pedal: Fully released C D Approximately 0.4V E [Ignition switch ON] ● Engine stopped ● Accelerator pedal: Fully depressed [Ignition switch ON] Approximately 2.0V F Approximately 4.6V G [Engine is running] ● Warm-up condition ● Idle speed [Ignition switch ON] Approximately 0.24V H Approximately 5.0V I [Ignition switch ON] 30 W Accelerator pedal position sensor 1 ● Engine stopped ● Accelerator pedal: Fully released EC Approximately 0.3V [Ignition switch ON] ● A Approximately 0.76V J [Ignition switch ON] ● Engine stopped ● Accelerator pedal: Fully depressed Approximately 4.2V K L M EC-1753 DTC P0225 APP SENSOR [K9K] RHD MODELS MBWA1555E EC-1754 DTC P0225 APP SENSOR [K9K] Specification data are reference values and are measured between each terminal and ground. CAUTION: Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM's transistor. Use a ground other than ECM terminals, such as the ground. TERMINAL NO. 6 WIRE COLOR L/R ITEM Sensor ground (Accelerator pedal position sensor 2) CONDITION DATA (DC Voltage and Pulse Signal) [Engine is running] ● Warm-up condition ● Idle speed 12 18 28 29 L/W Accelerator pedal position sensor 2 L Sensor power supply (Accelerator pedal position sensor 2) B Sensor ground (Accelerator pedal position sensor 1) R Sensor power supply (Accelerator pedal position sensor 1) Engine stopped ● Accelerator pedal: Fully released C D Approximately 0.4V E [Ignition switch ON] ● Engine stopped ● Accelerator pedal: Fully depressed [Ignition switch ON] Approximately 2.0V F Approximately 4.6V G [Engine is running] ● Warm-up condition ● Idle speed [Ignition switch ON] Approximately 0.24V H Approximately 5.0V I [Ignition switch ON] 30 W Accelerator pedal position sensor 1 ● Engine stopped ● Accelerator pedal: Fully released EC Approximately 0.3V [Ignition switch ON] ● A Approximately 0.76V J [Ignition switch ON] ● Engine stopped ● Accelerator pedal: Fully depressed Diagnostic Procedure Approximately 4.2V K BBS0043V 1. CHCEK GROUND CONNECTIONS L 1. 2. Turn ignition switch OFF. Loosen and retighten ground screw on the body. Refer to EC-1703, "Ground Inspection" . – Body ground (1) – Priming pump (2) OK or NG OK >> GO TO 2. NG >> Repair or replace ground connections. M MBIB1520E EC-1755 DTC P0225 APP SENSOR [K9K] 2. CHECK APP SENSOR 1 POWER SUPPLY CIRCUIT 1. – – 2. Disconnect accelerator pedal position (APP) sensor harness connector (1). Accelerator pedal position sensor (2) Accelerator pedal (3) Turn ignition switch ON. MBIB1345E 3. Check voltage between APP sensor terminal 4 and ground with CONSULT-II or tester. Voltage: Approximately 5.3V OK or NG OK >> GO TO 4. NG >> GO TO 3. MBIB1468E 3. DETECT MALFUNCTIONING PART Check the following. ● Harness connectors M201, M8 (RHD models) ● Harness connectors M1, E101 (RHD models) ● Harness for open or short between APP sensor and ECM >> Repair open circuit or short to ground or short to power in harness or connectors. 4. CHECK APP SENSOR 1 GROUND CIRCUIT FOR OPEN AND SHORT 1. 2. 3. Turn ignition switch OFF. Disconnect ECM harness connector. Check harness continuity between APP sensor terminal 2 and ECM terminal 28. Refer to Wiring Diagram. Continuity should exist. 4. Also check harness for short to ground and short to power. OK or NG OK >> GO TO 6. NG >> GO TO 5. 5. DETECT MALFUNCTIONING PART Check the following. Harness connectors M201, M8 (RHD models) ● Harness connectors M1, E101 (RHD models) ● Harness for open or short between APP sensor and ECM ● >> Repair open circuit or short to ground or short to power in harness or connectors. EC-1756 DTC P0225 APP SENSOR [K9K] 6. CHECK APP SENSOR 1 INPUT SIGNAL CIRCUIT FOR OPEN AND SHORT 1. A Check harness continuity between ECM terminal 30 and APP sensor terminal 3. Refer to Wiring Diagram. EC Continuity should exist. 2. Also check harness for short to ground and short to power. OK or NG OK >> GO TO 8. NG >> GO TO 7. C 7. DETECT MALFUNCTIONING PART D Check the following. ● Harness connectors M201, M8 (RHD models) ● Harness connectors M1, E101 (RHD models) ● Harness for open or short between APP sensor and ECM E F >> Repair open circuit or short to ground or short to power in harness or connectors. 8. CHECK APP SENSOR G Refer to EC-1757, "Component Inspection" . OK or NG OK >> GO TO 9. NG >> Replace accelerator pedal assembly. H I 9. CHECK INTERMITTENT INCIDENT Refer to EC-1697, "TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT" . J >> INSPECTION END Component Inspection BBS0043W K ACCELERATOR PEDAL POSITION SENSOR 1. Disconnect APP sensor harness connector (1). ● Accelerator pedal position sensor (2) ● Accelerator pedal (3) L M MBIB1345E EC-1757 DTC P0225 APP SENSOR [K9K] 2. Check resistance between the APP sensor terminals 2 and 4, 1 and 5. Terminals 2 and 4: 1 and 5: 3. Resistance 1.7 ± 0.9 kΩ 2.4 ± 1.2 kΩ If NG, replace accelerator pedal assembly. MBIB1489E Removal and Installation BBS0043X ACCELERATOR PEDAL Refer to ACC-2, "ACCELERATOR CONTROL SYSTEM" . EC-1758 DTC P0231 FUEL PUMP [K9K] DTC P0231 FUEL PUMP Description PFP:22693 A BBS0043Y To control the amount of the fuel inhalation of the fuel pump, a plunger is built into the fuel pump. When the amount of the fuel inhalation of fuel increases, the fuel pump raises the fuel exhalation pressure. As a result, EC the fuel injection pressure is raised. When the load of the engine increases, the ECM sends a signal to the fuel pump to raise the injection pressure. CONSULT-II Reference Value in Data Monitor Mode BBS0043Z C Specification data are reference values. MONITOR ITEM CONDITION ● Engine: After warming up ● Air conditioner switch: OFF ● Shift lever: Neutral position ● No load FUEL FLOW SPECIFICATION Idle Approximately 4.9 mg/cp 2,000 rpm Approximately 3.5 mg/cp On Board Diagnosis Logic DTC No. E BBS00440 Trouble diagnosis name FUEL PUMP CONTROL CIRCUIT P0231 D ● ● CO.0: Open circuit or short circuit to ground ● CC.1: Short circuit to +12V F Possible cause ● Harness or connectors (The fuel pump circuit is open or shorted.) G Fuel pump NOTE: ● Special notes: – If this DTC is present, the fuel pump is fully opened and the engine is stopped to prevent it from revving. – Malfuction indicator (Red) lights up. H I J K L M EC-1759 DTC P0231 FUEL PUMP [K9K] Wiring Diagram BBS00442 MBWA1556E EC-1760 DTC P0231 FUEL PUMP [K9K] Specification data are reference values and are measured between each terminal and ground. Pulse signal is measured by CONSULT-II. A CAUTION: Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM's transistor. Use a ground other than ECM terminals, such as the ground. EC TERMINAL NO. WIRE COLOR ITEM CONDITION DATA (DC Voltage and Pulse Signal) C 0 - 12.5V [Engine is running] ● Warm-up condition ● Idle speed D E MBIB1506E 39 P Fuel pump 0 - 12.5V F [Engine is running] ● Warm-up condition ● Engine speed: 2,000 rpm G MBIB1507E [Ignition switch ON] [Ignition switch OFF] ● 104 P ECM relay (self-shutoff) For a few seconds after turning ignition switch OFF [Ignition switch OFF] ● 109 110 G G Power supply for ECM More than a few seconds after turning ignition switch OFF [Ignition switch ON] H Approximately 1.4V I BATTERY VOLTAGE (11 - 14V) J BATTERY VOLTAGE (11 - 14V) K : Average voltage for pulse signal (Actual pulse signal can be confirmed by oscilloscope.) Diagnostic Procedure BBS00443 1. CHECK FUEL PUMP POWER SUPPLY CIRCUIT 1. 2. 3. 4. L Turn ignition switch OFF. Disconnect fuel pump harness connector. Turn ignition switch ON. Check voltage between fuel pump terminal 2 and ground with CONSULT-II or tester. M Voltage: Battery voltage OK or NG OK >> GO TO 3. NG >> GO TO 2. PBIB2605E EC-1761 DTC P0231 FUEL PUMP [K9K] 2. DETECT MALFUNCTIONING PART Check the following. ● Harness connectors E48, F101 ● Harness for open or short between fuel pump and IPDM E/R >> Repair open circuit or short to ground or short to power in harness or connectors. 3. CHECK FUEL PUMP OUTPUT SIGNAL CIRCUIT FOR OPEN AND SHORT 1. 2. 3. Turn ignition switch OFF. Disconnect ECM harness connector. Check harness continuity between ECM terminal 39 and fuel pump terminal 1. Refer to Wiring Diagram. Continuity should exist. 4. Also check harness for short to ground and short to power. OK or NG OK >> GO TO 4. NG >> Repair open circuit or short to ground or short to power in harness or connectors. 4. CHECK FUEL PUMP Refer to EC-1762, "Component Inspection" . OK or NG OK >> GO TO 5. NG >> Replace fuel pump. 5. CHECK INTERMITTENT INCIDENT Refer to EC-1697, "TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT" . >> INSPECTION END Component Inspection BBS00444 FUEL PUMP 1. 2. Disconnect fuel pump harness connector. Check resistance between fuel pump terminals 1 and 2. Resistance: 5.3 ± 0.5Ω [at 20°C (68°F)] 3. If NG, replace fuel pump. PBIB0417E Removal and Installation BBS00445 FUEL PUMP Refer to EM-268, "HIGH PRESSURE PUMP" . EC-1762 DTC P0235 TC BOOST SENSOR [K9K] DTC P0235 TC BOOST SENSOR Component Description PFP:22693 A BBS00446 The turbocharger boost sensor detects pressure in the exit side of the charge air cooler. The sensor output voltage to the ECM increases as pressure increases. EC C D MBIB1527E E CONSULT-II Reference Value in Data Monitor Mode BBS00447 Specification data are reference values. MONITOR ITEM CONDITION ● Engine: After warming up ● Air conditioner switch: OFF ● Shift lever: Neutral position ● No load INLET PRESS Approximately 980 mbar 2,000 rpm Approximately 1,010 mbar On Board Diagnosis Logic DTC No. F SPECIFICATION Idle G BBS00448 Trouble diagnosis name Possible cause TURBOCHARGER BOOST SENSOR CIRCUIT ● 1.DEF: Parmanent low lebel ● 2.DEF: Parmanent high lebel ● 3.DEF: Below minimum threshold ● 4.DEF: Above maximum threshold ● 5.DEF: Inconsistency ● 6.DEF: Parmanent at maximum limit ● 7.DEF: Parmanent at minimum limit P0235 H I ● ● Harness or connectors (The sensor circuit is open or shorted.) J Turbocharger boost sensor K NOTE: ● If DTC P0235 is displayed with DTC P0641, first perform the trouble diagnosis for DTC P0641. Refer to EC-1830, "DTC P0641 SENSOR POWER SUPPLY" . ● Special notes: – Malfunction indicator (Red) lights up. EC-1763 L M DTC P0235 TC BOOST SENSOR [K9K] Wiring Diagram BBS0044A MBWA1557E EC-1764 DTC P0235 TC BOOST SENSOR [K9K] Specification data are reference values, and are measured between each terminal and ground. CAUTION: Do not use ECM ground terminals when measuring input/output voltage. Doing so may damage the ECM's transistor. Use a ground other than ECM terminals, such as the ground. TERMINAL NO. 48 WIRE COLOR V ITEM Sensor power supply (Turbocharger boost sensor) CONDITION [Ignition switch ON] A EC DATA (DC Voltage) Approximately 5.0V C Approximately 1.6V D Approximately 2.0V E Approximately 0.3V F [Engine is running] 58 O Turbocharger boost sensor ● Warm-up condition ● Idle speed [Engine is running] ● Warm-up condition ● Engine speed: 2,000 rpm [Engine is running] 68 G Sensor ground (Turbocharger boost sensor) ● Warm-up condition ● Idle speed Diagnostic Procedure BBS0044B G 1. CHECK GROUND CONNECTIONS 1. 2. Turn ignition switch OFF. Loosen and retighten ground screw on the body. Refer to EC-1703, "Ground Inspection" . – Body ground (1) – Priming pump (2) OK or NG OK >> GO TO 2. NG >> Repair or replace ground connections. H I J K MBIB1520E L M EC-1765 DTC P0235 TC BOOST SENSOR [K9K] 2. CHECK TURBOCHARGER BOOST SENSOR POWER SUPPLY CIRCUIT 1. 2. Disconnect turbocharge boost sensor (1) harness connector. Turn ignition switch ON. MBIB1528E 3. Check voltage between turbocharge boost sensor terminal 1 and ground with CONSULT-II or tester. Voltage: Approximately 5.0V OK or NG OK >> GO TO 3. NG >> Repair open circuit or short to ground or short to power in harness or connectors. MBIB1469E 3. CHECK TURBOCHAGER BOOST SENSOR GROUND CIRCUIT FOR OPEN AND SHORT 1. 2. 3. Turn ignition switch OFF. Disconnect ECM harness connector. Check harness continuity between turbocharger boost sensor terminal 2 and ECM terminal 68. Refer to Wiring Diagram. Continuity should exist. 4. Also check harness for short to ground and short to power. OK or NG OK >> GO TO 4. NG >> Repair open circuit or short to ground or short to power in harness or connectors. 4. CHECK TURBOCHAGER BOOST SENSOR INPUT SIGNAL CIRCUIT FOR OPEN AND SHORT 1. Check harness continuity between ECM terminals 58 and turbocharger boost sensor terminal 3. Refer to Wiring Diagram. Continuity should exist. 2. Also check harness for short to ground and short to power. OK or NG OK >> GO TO 5. NG >> Repair open circuit or short to ground or short to power in harness connectors. 5. CHECK INTERMITTENT INCIDENT Refer to EC-1697, "TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT" . OK or NG OK >> Replace turbocharger boost sensor. NG >> Repair open circuit or short to ground or short to power in harness connectors. EC-1766 DTC P0235 TC BOOST SENSOR [K9K] Removal and Installation BBS0044D A TURBOCHARGER BOOST SENSOR Refer to EM-247, "CHARGE AIR COOLER" . EC C D E F G H I J K L M EC-1767 DTC P0263, P0266, P0269, P0272 NO.1 - 4 CYLINDER MISFIRE [K9K] DTC P0263, P0266, P0269, P0272 NO.1 - 4 CYLINDER MISFIRE On Board Diagnosis Logic DTC No. P0263 P0266 P0269 P0272 Trouble diagnosis name PFP:22693 BBS0044T Possible cause NO. 1 CYLINDER MISFIRE NO. 2 CYLINDER MISFIRE NO. 3 CYLINDER MISFIRE NO. 4 CYLINDER MISFIRE ● Insufficient compression ● Incorrect valve clearance ● Intake air leak ● EGR volume control valve ● The fuel injector circuit is open or shorted ● Fuel injector NOTE: ● If DTC P0263, P0266, P0269 or P0272 is displayed with DTC P0201, P0202, P0203 or P0204, first perform the trouble diagnosis for DTC P0201, P0202, P0203 or P00204. Refer to EC-1745, "DTC P0201 - P0204 FUEL INJECTOR" . ● If DTC P0263, P0266, P0269 or P0272 is displayed with DTC P0089, first perform the trouble diagnosis for DTC P0089. Refer to EC-1721, "DTC P0089 FUEL PUMP" . ● Conditions for applying the diagnostic procedure to the stored DTCs: The DTC is declared present when the engine speed is at idle speed. ● Special notes: – If this DTC is present, the engine is maintained at 1,000 rpm and engine performance is reduced. – Malfuction indicator (Red) lights up. EC-1768 DTC P0263, P0266, P0269, P0272 NO.1 - 4 CYLINDER MISFIRE [K9K] Diagnostic Procedure BBS0044V 1. CHECK FOR INTAKE AIR LEAK A 1. Start engine and run it at idle speed. 2. Listen for the sound of the intake air leak. OK or NG OK >> GO TO 2. NG >> Discover air leak location and repair. EC C 2. CHECK FOR EGR VOLUME CONTROL VALVE D 1. Stop engine. 2. Visually check EGR volume comtrol valve. Refer to EM-251, "EGR UNIT" . OK or NG OK >> GO TO 3. NG >> Repair or replace. E F 3. CHECK FUEL INJECTOR G Refer to EC-1750, "Component Inspection" . OK or NG OK >> GO TO 5. NG >> GO TO 4. H 4. REPLACE FUEL INJECOR 1. 2. Replace fuel injector of malfunctioning cylinder. Perform Injector Adjustment Value Registration. Refer to EC-1625, "Injector Adjustment Value Registration" . I J >> INSPECTION END K 5. CHECK COMPRESSION PRESSURE Check compression pressure. OK or NG OK >> GO TO 6. NG >> Repair. L M 6. CHECK VALVE CLEARANCE Check valve clearance. Refer to EM-292, "Valve Clearance" . OK or NG OK >> GO TO 7. NG >> Repair. 7. CHECK INTERMITTENT INCIDENT Perform EC-1697, "TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT" . >> INSPECTION END EC-1769 DTC P0325 KNOCK SENSOR (KS) [K9K] DTC P0325 KNOCK SENSOR (KS) Component Description PFP:22060 BBS0044W The knock sensor (1) is attached to the cylinder block. It senses engine knocking using a piezoelectric element. A knocking vibration from the cylinder block is sensed as vibrational pressure. This pressure is converted into a voltage signal and sent to the ECM. ● Fuel rail (2) MBIB1529E On Board Diagnosis Logic BBS0044X The MIL will not light up for these diagnoses. DTC No. Trouble Diagnosis Name Possible Cause ● P0325 KNOCK SENSOR CIRCUIT ● Harness or connectors (The sensor circuit is open or shorted.) Knock sensor NOTE: ● If DTC P0325 is displayed with DTC P0115, P0180 or P2226, first perform the trouble diagnosis for DTC P0115, P0180 or P22264. Refer to EC-1727, "DTC P0115 ECT SENSOR" , EC-1732, "DTC P0180 FUEL PUMP TEMPERATURE SENSOR" or EC-1863, "DTC P2226 BARO SENSOR" . A malfunction for these sensors could lead to an incorrect touble diagnosis on the knock sensor. ● Conditions for applying the diagnostic procedure to the stored DTCs: The DTC is declared present when the engine speed is at idle speed. EC-1770 DTC P0325 KNOCK SENSOR (KS) [K9K] Wiring Diagram BBS0044Z A EC C D E F G H I J K L M MBWA1558E EC-1771 DTC P0325 KNOCK SENSOR (KS) [K9K] Specification data are reference values and are measured between each terminal and ground. CAUTION: Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM's transistor. Use a ground other than ECM terminals, such as the ground. TERMINAL NO. 41 44 WIRE COLOR — W ITEM Sensor ground (Knock sensor shield circuit) Knock sensor CONDITION [Engine is running] ● Idle speed [Engine is running] ● Idle speed DATA (DC Voltage) Approximately 0.2V Approximately 0.3V [Engine is running] 45 O Sensor ground (Knock sensor) ● Warm-up condition ● Idle speed Approximately 0.3V Diagnostic Procedure BBS00450 1. CHECK GROUND CONNECTIONS 1. 2. Turn ignition switch OFF. Loosen and retighten ground screw on the body. Refer to EC-1703, "Ground Inspection" . – Body ground (1) – Primimg pump (2) OK or NG OK >> GO TO 2. NG >> Repair or replace ground connections. MBIB1520E 2. CHECK KNOCK SENSOR GROUND CIRCUIT FOR OPEN AND SHORT 1. – 2. 3. Disconnect knock sensor (1) harness connector. Fuel rail (2) Disconnect ECM harness connector. Check harness continuity between knock sensor terminal 1 and ECM terminal 45. Refer to Wiring Diagram. Continuity should exist. 4. Also check harness for short to ground and short to power. OK or NG OK >> GO TO 3. NG >> Repair open circuit or short to ground or short to power in harness or connectors. 3. CHECK KNOCK SENSOR INPUT SIGNAL CIRCUIT FOR OPEN AND SHORT 1. Check harness continuity between knock sensor terminal 2 and ECM terminal 44. Refer to Wiring Diagram. Continuity should exist. 2. Also check harness for short to ground and short to power. OK or NG OK >> GO TO 4. NG >> Repair open circuit or short to ground or short to power in harness or connectors. EC-1772 MBIB1529E DTC P0325 KNOCK SENSOR (KS) [K9K] 4. CHECK KNOCK SENSOR A Check continuity between knock sensor terminals 1 and 2. Continuity should exist. EC OK or NG OK >> GO TO 5. NG >> Replace knock sensor. C 5. CHECK INTERMITTENT INCIDENT Refer to EC-1697, "TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT" . D >> INSPECTION END E Removal and Installation BBS00452 KNOCK SENSOR Refer to EM-282, "OVERHAUL" . F G H I J K L M EC-1773 DTC P0335 CKP SENSOR [K9K] DTC P0335 CKP SENSOR Description PFP:23731 BBS0044E The crankshaft position (CKP) sensor is located on the oil pan facing the gear teeth (cogs) of the signal plate. The ECM receives the voltage signal from crankshaft position sensor and detects the fluctuation of the engine revolution. MBIB1530E CONSULT-II Reference Value in Data Monitor Mode BBS0044F Specification data are reference values. MONITOR ITEM ENGINE SPEED CONDITION ● SPECIFICATION Run engine and compare CONSULT-II value with the tachometer indication. Almost the same speed as the tachometer indication On Board Diagnosis Logic DTC No. BBS0044G Trouble diagnosis name Possible cause CRANKSHAFT POSITION SENSOR CIRCUIT P0335 ● 1.DEF: Inconsistency ● 2.DEF: No signal ● 3.DEF: Too many additional teeth ● 4.DEF: Teeth missing ● 5.DEF: Additional teeth ● 6.DEF: Too many teeth missing ● Harness or connectors (The sensor circuit is open or shorted.) ● Crankshaft position sensor NOTE: ● Conditions for applying the diagnostic procedure to the stored DTCs: The DTC is declared present with the engine cranking or idling. ● Special notes: – If this DTC (with 1.DEF, 2.DEF, 3.DEF, 6.DEF) is present, the engine stops and malfunction indicator (Red) lights up. – If this DTC (with 4.DEF, 5.DEF) is present, the engine performance is reduced and malfunction indicator (Red) will not light up. EC-1774 DTC P0335 CKP SENSOR [K9K] Wiring Diagram BBS0044I A EC C D E F G H I J K L M MBWA1559E EC-1775 DTC P0335 CKP SENSOR [K9K] Specification data are reference values and are measured between each terminal and ground. Pulse signal is measured by CONSULT-II. CAUTION: Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM's transistor. Use a ground other than ECM terminals, such as the ground. TERMINAL NO. WIRE COLOR ITEM CONDITION [Engine is running] ● Warm-up condition ● Idle speed DATA (DC Voltage and Pulse Signal) 0 - 12.5V NOTE: The pulse cycle changes depending on rpm at idle. MBIB1508E 55 R Crankshaft position sensor 0 - 12.5V [Engine is running] ● Warm-up condition ● Engine speed: 2,000 rpm MBIB1509E [Engine is running] 65 B Crankshaft position sensor ground ● Warm-up condition ● Idle speed Approximately 0.3V : Average voltage for pulse signal (Actual pulse signal can be confirmed by oscilloscope.) Diagnostic Procedure BBS0044J 1. CHECK GROUND CONNECTIONS 1. 2. Turn ignition switch OFF. Loosen and retighten ground screw on the body. Refer to EC-1703, "Ground Inspection" . – Body ground (1) – Priming pump (2) OK or NG OK >> GO TO 2. NG >> Repair or replace ground connections. MBIB1520E EC-1776 DTC P0335 CKP SENSOR [K9K] 2. CHECK CKP SENSOR GROUND CIRCUIT FOR OPEN AND SHORT 1. 2. 3. A Disconnect crankshaft position (CKP) sensor (1) harness connector. Disconnect ECM harness connector. Check harness continuity between ECM terminal 65 and CKP sensor terminal 2. Refer to Wiring Diagram. EC C Continuity should exist. 4. Also check harness for and short to ground and short to power. OK or NG OK >> GO TO 3. NG >> Repair open circuit or short to ground or short to power in harness or connectors. D MBIB1531E E 3. CHECK CKP SENSOR INPUT SIGNALCIRCUIT FOR OPEN AND SHORT 1. F Check harness continuity between ECM terminal 55 and CKP sensor terminal 1. Refer to Wiring Diagram. Continuity should exist. G 2. Also check harness for and short to ground and short to power. OK or NG OK >> GO TO 4. NG >> Repair open circuit or short to ground or short to power in harness or connectors. H 4. CHECK CRANKSHAFT POSITION SENSOR I Refer to EC-1777, "Component Inspection" . OK or NG OK >> GO TO 5. NG >> Replace crankshaft position sensor. J 5. CHECK GEAR TOOTH K Visually check for chipping flywheel gear tooth. OK or NG OK >> GO TO 6. NG >> Replace signal plate. L 6. CHECK INTERMITTENT INCIDENT M Refer to EC-1697, "TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT" . >> INSPECTION END Component Inspection BBS0044K CRANKSHAFT POSITION SENSOR 1. 2. Disconnect crankshaft position sensor harness connector. Check resistance between crankshaft positon sensor terminals 1 and 2. Resistance: 760 Ω 3. If NG, replace crankshaft position sensor. Removal and Installation BBS0044L CRANKSHAFT POSITION SENSOR Refer to EM-257, "OIL PAN" . EC-1777 DTC P0340 CMP SENSOR [K9K] DTC P0340 CMP SENSOR Description PFP:23731 BBS0044M The camshaft position (CMP) sensor senses the retraction with camshaft to identify a particular cylinder. The camshaft position (CMP) sensor senses the piston position. The sensor consists of a permanent magnet and Hall IC. When engine is running, the high and low parts of the teeth cause the gap with the sensor to change. The changing gap causes the magnetic field near the sensor to change. Due to the changing magnetic field, the voltage from the sensor changes. MBIB1532E On Board Diagnosis Logic DTC No. P0340 BBS0044N Trouble diagnosis name CAMSHAFT POSITION SENSOR CIRCUIT ● 1.DEF: Signal absent Possible cause ● Harness or connectors (The sensor circuit is open or shorted.) ● Camshaft position sensor ● Timing belt ● Signal plate NOTE: ● Conditions for applying the diagnostic procedure to the stored DTCs: The DTC is declared present with the engine cranking or idling. EC-1778 DTC P0340 CMP SENSOR [K9K] Wiring Diagram BBS0044P A EC C D E F G H I J K L M MBWA1560E EC-1779 DTC P0340 CMP SENSOR [K9K] Specification data are reference values and are measured between each terminal and ground. Pulse signal is measured by CONSULT-II. CAUTION: Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM's transistor. Use a ground other than ECM terminals, such as the ground. TERMINAL NO. WIRE COLOR ITEM CONDITION [Engine is running] ● Warm-up condition ● Idle speed DATA (DC Voltage and Pulse Signal) 0 - 1V NOTE: The pulse cycle changes depending on rpm at idle. MBIB1510E 56 Y Camshaft position sensor 0 - 1V [Engine is running] ● Warm-up condition ● Engine speed: 2,000 rpm MBIB1511E [Engine is running] 66 L Sensor ground (Camshaft position sensor) ● Warm-up condition ● Idle speed [Ignition switch ON] [Ignition switch OFF] ● 104 P ECM relay (self-shutoff) For a few seconds after turning ignition switch OFF [Ignition switch OFF] ● 109 110 G G Power supply for ECM More than a few seconds after turning ignition switch OFF [Ignition switch ON] Approximately 0.3V Approximately 1.4V BATTERY VOLTAGE (11 - 14V) BATTERY VOLTAGE (11 - 14V) : Average voltage for pulse signal (Actual pulse signal can be confirmed by oscilloscope.) Diagnostic Procedure BBS0044Q 1. CHECK GROUND CONNECTIONS 1. 2. Turn ignition switch OFF. Loosen and retighten ground screw on the body. Refer to EC-1703, "Ground Inspection" . – Body ground (1) – Priming pump (2) OK or NG OK >> GO TO 2. NG >> Repair or replace ground connections. MBIB1520E EC-1780 DTC P0340 CMP SENSOR [K9K] 2. CHECK CMP SENSOR POWER SUPPLY CIRCUIT 1. 2. A Disconnect camshaft position (CMP) sensor (1) harness connector. Turn ignition switch ON. EC C D MBIB1533E 3. E Check voltage between CMP sensor terminal 3 and ground with CONSULT-II or tester. Voltage: Approximately 5.0V F OK or NG OK >> GO TO 4. NG >> GO TO 3. G MBIB1010E H 3. DETECT MALFUNCTIONING PART Check the following. ● Harness connectors E48, F101 ● Harness continuity between camshaft position sensor and IPDM E/R I J >> Repair open circuit or short to ground or short to power in harness or connectors. 4. CHECK CMP SENSOR GROUND CIRCUIT FOR OPEN AND SHORT 1. 2. 3. Turn ignition switch OFF. Disconnect ECM harness connector. Check harness continuity between ECM terminal 66 and CMP sensor terminal 1. Refer to Wiring Diagram. Continuity should exist. 4. Also check harness for short to ground and short to power. OK or NG OK >> GO TO 5. NG >> Repair open circuit or short to ground or short to power in harness or connectors. 5. CHECK CMP SENSOR INPUT SIGNAL CIRCUIT FOR OPEN AND SHORT 1. Check harness continuity between ECM terminal 56 and CMP sensor terminal 2. Refer to Wiring Diagram. Continuity should exist. 2. Also check harness for short to ground and short to power. OK or NG OK >> GO TO 6. NG >> Repair open circuit or short to ground or short to power in harness or connectors. EC-1781 K L M DTC P0340 CMP SENSOR [K9K] 6. CHECK CAMSHAFT POSITION SENSOR Refer to EC-1783, "Component Inspection" . OK or NG OK >> GO TO 7. NG >> Replace camshaft position sensor. 7. CHECK SPROCKET Visually check for chipping signal plate gear tooth. OK or NG OK >> GO TO 8. NG >> Repair or replace sprocket. 8. CHECK TIMING BELT Refer to EM-272, "TIMING BELT" . OK or NG OK >> GO TO 8. NG >> Replace timing belt. 9. CHECK INTERMITTENT INCIDENT Refer to EC-1697, "TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT" . >> INSPECTION END EC-1782 DTC P0340 CMP SENSOR [K9K] Component Inspection BBS0044R A CAMSHAFT POSITION SENSOR 1. 2. 3. Reconnect all harness connectors disconnected. Start engine and warm it up to normal operating temperature. Measure the voltage signal between ECM terminal 56 and ground with CONSULT-II or tester under the followng conditions. CONDITION [Engine is running] ● Warm-up condition ● Idle speed EC DATA (DC Voltage and Pulse Signal) C 0 - 1V D NOTE: The pulse cycle changes depending on rpm at idle. E MBIB1540E MBIB1510E F 0 - 1V [Engine is running] ● Warm-up condition ● Engine speed: 2,000 rpm G H MBIB1511E 4. If NG, replace camshaft position sensor. Removal and Installation BBS0044S I CAMSHAFT POSITION SENSOR Refer to EM-272, "TIMING BELT" . J K L M EC-1783 DTC P0380 GLOW CONTROL UNIT [K9K] DTC P0380 GLOW CONTROL UNIT On Board Diagnosis Logic DTC No. P0380 PFP:22693 BBS00453 Trouble diagnosis name Possible cause ● Harness or connectors (The glow control unit circuit is open.) ● Glow control unit GLOW PLUG DIAGNOSTIC CONNECTION EC-1784 DTC P0380 GLOW CONTROL UNIT [K9K] Wiring Diagram BBS00455 A EC C D E F G H I J K L M MBWA1561E EC-1785 DTC P0380 GLOW CONTROL UNIT [K9K] Diagnostic Procedure BBS00456 1. CHECK GLOW CONTROL UNIT POWER SUPPLY CIRCUIT 1. 2. 3. Turn ignition switch OFF. Disconnect glow control unit harness connecetor. Check voltage between glow control unit terminal 3 and ground with CONSULT-II or tester. Voltage: Battery voltage OK or NG OK >> GO TO 3. NG >> GO TO 2. MBIB1470E 2. DETECT MALFUNCTIONING PART Check the following. ● Harness connectors E49, F103 ● 60A fusible link ● Harness for open and short between glow control unit and battery >> Repair open circuit or short to ground or short to power in harness or connectors. 3. CHECK GLOW CONTROL UNIT OUTPUT SIGNAL CIRCUIT FOR OPEN AND SHORT 1. 2. Disconnect ECM harness connector. Check harness continuity between ECM terminal 90 and glow control unit terminal 9. Refer to Wiring Diagram. Continuity should exist. 3. Also check harness for short to ground and short to power. OK or NG OK >> GO TO 4. NG >> Repair open circuit or short to ground or short to power in harness or connectors. 4. CHECK GLOW CONTROL UNIT INPUT SIGNAL CIRCUIT FOR OPEN AND SHORT 1. Check harness continuity between ECM terminal 98 and glow control unit terminal 8. Refer to Wiring Diagram. Continuity should exist. 2. Also check harness for short to ground and short to power. OK or NG OK >> GO TO 5. NG >> Repair open circuit or short to ground or short to power in harness or connectors. EC-1786 DTC P0380 GLOW CONTROL UNIT [K9K] 5. CHECK GLOW PLUG CIRCUIT 1. 2. A Disconnect glow plug harness connectors. Check harness continuity between glow control unit terminals 1, 2, 6, 7 and glow plug teminal 1. Refer to Wiring Diagram. EC Continuity should exist. 3. Also check harness for short to ground and short to power. OK or NG OK >> GO TO 6. NG >> Repair open circuit or short to ground or short to power in harness or connectors. C D 6. CHECK INTERMITTENT INCIDENT Refer to EC-1697, "TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT" . OK or NG OK >> Replace glow control unit NG >> Repair or replace. E F G H I J K L M EC-1787 DTC P0382 GLOW CONTROL UNIT [K9K] DTC P0382 GLOW CONTROL UNIT On Board Diagnosis Logic DTC No. PFP:22693 BBS00458 Trouble diagnosis name GLOW CONTROL UNIT CIRCUIT P0382 ● CC.1: Short circuit to +12V ● CO.0: Open circuit or short circuit to ground Possible cause ● Harness or connectors (The glow control unit circuit is open or shorted.) ● Glow control unit NOTE: ● Special note: – If this DTC is present, engine starting is difficult (or impossible when cold). – If this DTC (with CO.0) is present, continuous operation of the glow plugs permanently controlled with risk of being damaged and risk of damaging the engine. EC-1788 DTC P0382 GLOW CONTROL UNIT [K9K] Wiring Diagram BBS0045A A EC C D E F G H I J K L M MBWA1561E EC-1789 DTC P0382 GLOW CONTROL UNIT [K9K] Diagnostic Procedure BBS0045B 1. CHECK GLOW CONTROL UNIT POWER SUPPLY CIRCUIT 1. 2. 3. Turn ignition switch OFF. Disconnect glow control unit harness connecetor. Check voltage between glow control unit terminal 3 and ground with CONSULT-II or tester. Voltage: Battery voltage OK or NG OK >> GO TO 3. NG >> GO TO 2. MBIB1470E 2. DETECT MALFUNCTIONING PART Check the following. ● Harness connectors E49, F103 ● 60A fusible link ● Harness for open and short between glow control unit and battery >> Repair open circuit or short to ground or short to power in harness or connectors. 3. CHECK GLOW CONTROL UNIT OUTPUT SIGNAL CIRCUIT FOR OPEN AND SHORT 1. 2. Disconnect ECM harness connector. Check harness continuity between ECM terminal 90 and glow control unit terminal 9. Refer to Wiring Diagram. Continuity should exist. 3. Also check harness for short to ground and short to power. OK or NG OK >> GO TO 4. NG >> Repair open circuit or short to ground or short to power in harness or connectors. 4. CHECK GLOW CONTROL UNIT INPUT SIGNAL CIRCUIT FOR OPEN AND SHORT 1. Check harness continuity between ECM terminal 98 and glow control unit terminal 8. Refer to Wiring Diagram. Continuity should exist. 2. Also check harness for short to ground and short to power. OK or NG OK >> GO TO 5. NG >> Repair open circuit or short to ground or short to power in harness or connectors. 5. CHECK INTERMITTENT INCIDENT Refer to EC-1697, "TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT" . OK or NG OK >> Replace glow control unit NG >> Repair or replace. EC-1790 DTC P0400 EGR FUNCTION [K9K] DTC P0400 EGR FUNCTION CONSULT-II Reference Value in Data Monitor Mode PFP:14710 A BBS0045E Specification data are reference values. MONITOR ITEM CONDITION EGR PO RECOPY EGR/V OPN REEF ● Engine: After warming up ● Air conditioner switch: OFF ● Shift lever: Neutral position ● No load ● Engine: After warming up ● Air conditioner switch: OFF ● Shift lever: Neutral position ● No load ● Engine: After warming up ● Air conditioner switch: OFF ● Shift lever: Neutral position ● No load EGR POS SE VO Idle D Idle Approximately -50 % E Idle Approximately 3.56 V EGR VOLUME CONTROL VALVE CIRCUIT ● 1.DEF: Parameter at minimum level ● 2.DEF: Parameter at maximum level ● 3.DEF: Inconsistency ● 4.DEF: Valve jammed ● 5.DEF: Valve clogged F BBS0045F Trouble diagnosis name P0400 C Approximately -50 % On Board Diagnosis Logic DTC No. EC SPECIFICATION G Possible cause ● Harness or connectors (The EGR volume control valve circuit is open or shorted.) ● EGR volume control valve stuck ● EGR volume control valve control position sensor ● EGR passage clogged NOTE: ● Conditions for applying the diagnostic procedure to the stored DTCs: The DTC is declared present with engine running. ● Special notes: – If this DTC is present, the engine will be unsteady, with popssible stalling. Starting malfunctions, or even impossible when cold. – Malfunction indicator (Red) lights up. – Malfunction indicator (Yellow) lights up. H I J K L M EC-1791 DTC P0400 EGR FUNCTION [K9K] Wiring Diagram BBS0045H MBWA1562E EC-1792 DTC P0400 EGR FUNCTION [K9K] Specification data are reference values and are measured between each terminal and ground. CAUTION: Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM's transistor. Use a ground other than ECM terminals, such as the ground. TERMINAL NO. WIRE COLOR ITEM CONDITION DATA (DC Voltage and Pulse Signal) [Engine is running] 37 B ● Warm-up condition ● Idle speed EGR volume control valve Warm-up condition ● Engine speed: 2,000 rpm C D Approximately 0.78V E [Engine is running] 40 49 W SB EGR volume control valve Sensor power supply (EGR volume control valve control position sensor) ● Warm-up condition ● Idle speed Approximately 0.7 - 1.9 F [Engine is running] ● Warm-up condition ● Engine speed: 2,000 rpm [Ignition switch ON] EC Approximately 1.1V [Engine is running] ● A Approximately 1.5 - 1.9V G Approximately 5.0V H [Engine is running] 59 69 L P EGR volume control valve control position sensor Sensor ground (EGR volume control valve control position sensor) ● Warm-up condition ● Idle speed Approximately 4.1V I [Engine is running] ● Warm-up condition ● Engine speed: 2,000 rpm Approximately 3.3V J [Engine is running] ● Warm-up condition ● Idle speed Approximately 0.5V K L M EC-1793 DTC P0400 EGR FUNCTION [K9K] Diagnostic Procedure BBS0045I 1. CHECK EGR VOLUME CONTROL VALVE CONTROL CIRCUIT 1. 2. – 3. 4. Turn ignition switch OFF. Disconnect EGR volume control valve (1) harness connector. Brake fluid reservoir (2) Disconnect ECM harness connector. Check harness continuity between ECM terminals and EGR volume control valve terminals as follows. Refer to Wiring Diagram. ECM terminal EGR volume control valve terminal 37 2 40 6 49 1 59 5 69 3 Continuity should exist. 5. Also check harness for short to ground and short to power. OK or NG OK >> GO TO 2. NG >> Repair open circuit or short to ground or short to power in harness or connectors. 2. CHECK EGR VOLUME CONTROL VALVE Refer to EC-1799, "Component Inspection" . OK or NG OK >> GO TO 3. NG >> Replace EGR volume control valve. 3. CHECK EGR VOLUME CONTROL VALVE CONTROL POSITION SENSOR Refer to EC-1799, "Component Inspection" . OK or NG OK >> GO TO 4. NG >> Replace EGR volume control valve. 4. CHECK EGR PASSAGE Check the following for clogging and cracks. EGR tube ● EGR hose ● EGR cooler OK or NG OK >> GO TO 5. NG >> Repair or replace EGR passage. ● 5. CHECK INTERMITTENT INCIDENT Refer to EC-1697, "TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT" . >> INSPECTION END EC-1794 MBIB1535E DTC P0403 EGR VOLUME CONTROL VALVE [K9K] DTC P0403 EGR VOLUME CONTROL VALVE CONSULT-II Reference Value in Data Monitor Mode PFP:14710 A BBS0045M Specification data are reference values. MONITOR ITEM CONDITION EGR PO RECOPY EGR/V OPN REEF ● Engine: After warming up ● Air conditioner switch: OFF ● Shift lever: Neutral position ● No load ● Engine: After warming up ● Air conditioner switch: OFF ● Shift lever: Neutral position ● No load ● Engine: After warming up ● Air conditioner switch: OFF ● Shift lever: Neutral position ● No load EGR POS SE VO Idle D Idle Approximately -50 % E Idle Approximately 3.56 V F BBS0045N Trouble diagnosis name EGR VOLUME CONTROL VALVE CIRCUIT P0403 C Approximately -50 % On Board Diagnosis Logic DTC No. EC SPECIFICATION ● CC.1: Short circuit to +12V ● CO.0: Open circuit or short circuit to ground ● CO: Open circuit ● 1.DEF: Overheat detection G Possible cause ● Harness or connectors (The EGR volume control valve circuit is open or shorted.) ● EGR volume control valve stuck closed ● EGR volume control valve control positiom sensor NOTE: ● Conditions for applying the diagnostic procedure to the stored DTCs: The DTC is declared present with engine running at idle speed. ● Special notes: – If this DTC is present, the engine is difficult to start, or even impossible when cold. – Malfunction indicator (Red) lights up. – Malfunction indicator (Yellow) lights up. H I J K L M EC-1795 DTC P0403 EGR VOLUME CONTROL VALVE [K9K] Wiring Diagram BBS0045P MBWA1562E EC-1796 DTC P0403 EGR VOLUME CONTROL VALVE [K9K] Specification data are reference values and are measured between each terminal and ground. CAUTION: Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM's transistor. Use a ground other than ECM terminals, such as the ground. TERMINAL NO. WIRE COLOR ITEM CONDITION DATA (DC Voltage and Pulse Signal) [Engine is running] 37 B ● Warm-up condition ● Idle speed EGR volume control valve Warm-up condition ● Engine speed: 2,000 rpm C D Approximately 0.78V E [Engine is running] 40 49 W SB EGR volume control valve Sensor power supply (EGR volume control valve control position sensor) ● Warm-up condition ● Idle speed Approximately 0.7 - 1.9 F [Engine is running] ● Warm-up condition ● Engine speed: 2,000 rpm [Ignition switch ON] EC Approximately 1.1V [Engine is running] ● A Approximately 1.5 - 1.9V G Approximately 5.0V H [Engine is running] 59 69 L P EGR volume control valve control position sensor Sensor ground (EGR volume control valve control position sensor) ● Warm-up condition ● Idle speed Approximately 4.1V I [Engine is running] ● Warm-up condition ● Engine speed: 2,000 rpm Approximately 3.3V J [Engine is running] ● Warm-up condition ● Idle speed Approximately 0.5V K L M EC-1797 DTC P0403 EGR VOLUME CONTROL VALVE [K9K] Diagnostic Procedure BBS0045Q 1. CHECK EGR VOLUME CONTROL VALVE CONTROL CIRCUIT 1. 2. – 3. 4. Turn ignition switch OFF. Disconnect EGR volume control valve (1) harness connector. Brake fluid reservoir (2) Disconnect ECM harness connector. Check harness continuity between ECM terminals and EGR volume control valve terminals as follows. Refer to Wiring Diagram. ECM terminal EGR volume control valve terminal 37 2 40 6 49 1 59 5 69 3 Continuity should exist. 5. Also check harness for short to ground and short to power. OK or NG OK >> GO TO 2. NG >> Repair open circuit or short to ground or short to power in harness or connectors. 2. CHECK EGR VOLUME CONTROL VALVE Refer to EC-1799, "Component Inspection" . OK or NG OK >> GO TO 3. NG >> Replace EGR volume control valve. 3. CHECK EGR VOLUME CONTROL VALVE CONTROL POSITION SENSOR Refer to EC-1799, "Component Inspection" . OK or NG OK >> GO TO 4. NG >> Replace EGR volume control valve. 4. CHECK EGR PASSAGE Check the following for clogging and cracks. EGR tube ● EGR hose ● EGR cooler OK or NG OK >> GO TO 5. NG >> Repair or replace EGR passage. ● 5. CHECK INTERMITTENT INCIDENT Refer to EC-1697, "TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT" . >> INSPECTION END EC-1798 MBIB1535E DTC P0403 EGR VOLUME CONTROL VALVE [K9K] Component Inspection BBS0045R A EGR VOLUME CONTROL VALVE 1. 2. Disconnect EGR volume control valve (1) harness connector. ● Brake fluid reservoir (2) Check resistance between EGR volume control valve terminals 2 and 6. EC Resistance: 8 ± 2.3 Ω at 25°C (77°F) C If NG, replace EGR volume control valve. D MBIB1535E EGR VOLUME CONTROL VALVE CONTROL POSITION SENSOR 1. 2. E Disconnect EGR volume control valve (1) harness connector. ● Brake fluid reservoir (2) Check resistance between EGR volume control valve terminals 1 and 3. F Continuity should exist. G If NG, replace EGR volume control valve. H MBIB1535E Removal and Installation BBS0045S EGR VOLUME CONTROL VALVE I Refer to EM-251, "EGR UNIT" . J K L M EC-1799 DTC P0409 EGR VOLUME CONTROL VALVE CONTROL POSITION SENSOR [K9K] DTC P0409 EGR VOLUME CONTROL VALVE CONTROL POSITION SENSOR PFP:22693 CONSULT-II Reference Value in Data Monitor Mode BBS0047K Specification data are reference values. MONITOR ITEM EGR PO RECOPY EGR/V OPN REEF CONDITION ● Engine: After warming up ● Air conditioner switch: OFF ● Shift lever: Neutral position ● No load ● Engine: After warming up ● Air conditioner switch: OFF ● Shift lever: Neutral position ● No load ● Engine: After warming up ● Air conditioner switch: OFF ● Shift lever: Neutral position ● No load EGR POS SE VO SPECIFICATION Idle Approximately -50 % Idle Approximately -50 % Idle Approximately 3.56 V On Board Diagnosis Logic DTC No. BBS0047L Trouble diagnosis name EGR VOLUME CONTROL VALVE CONTROL POSITION SENSOR CIRCUIT P0409 ● 1.DEF: Above maximum threshold ● 1.DEF: Below minimum threshold Possible Cause ● Harness or connectors (The EGR volume control valve control position sensor circuit is open or shorted.) ● EGR volume control valve control position sensor ● EGR volume control valve stuck NOTE: ● If this DTC is displayed with DTC P0641, first perform the trouble diagnosis for DTC P0641. Refer to EC-1830, "DTC P0641 SENSOR POWER SUPPLY" . EC-1800 DTC P0409 EGR VOLUME CONTROL VALVE CONTROL POSITION SENSOR [K9K] Wiring Diagram BBS0047N A EC C D E F G H I J K L M MBWA1562E EC-1801 DTC P0409 EGR VOLUME CONTROL VALVE CONTROL POSITION SENSOR [K9K] Specification data are reference values and are measured between each terminal and ground. CAUTION: Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM's transistor. Use a ground other than ECM terminals, such as the ground. TERMINAL NO. WIRE COLOR ITEM CONDITION DATA (DC Voltage and Pulse Signal) [Engine is running] 37 B ● Warm-up condition ● Idle speed EGR volume control valve Approximately 1.1V [Engine is running] ● Warm-up condition ● Engine speed: 2,000 rpm Approximately 0.78V [Engine is running] 40 49 W SB EGR volume control valve Sensor power supply (EGR volume control valve control position sensor) ● Warm-up condition ● Idle speed Approximately 0.7 - 1.9 [Engine is running] ● Warm-up condition ● Engine speed: 2,000 rpm [Ignition switch ON] Approximately 1.5 - 1.9V Approximately 5.0V [Engine is running] 59 69 L P EGR volume control valve control position sensor Sensor ground (EGR volume control valve control position sensor) ● Warm-up condition ● Idle speed Approximately 4.1V [Engine is running] ● Warm-up condition ● Engine speed: 2,000 rpm Approximately 3.3V [Engine is running] ● Warm-up condition ● Idle speed EC-1802 Approximately 0.5V DTC P0409 EGR VOLUME CONTROL VALVE CONTROL POSITION SENSOR [K9K] Diagnostic Procedure BBS0047O 1. CHECK EGR VOLUME CONTROL VALVE CONTROL CIRCUIT 1. 2. – 3. 4. A Turn ignition switch OFF. Disconnect EGR volume control valve (1) harness connector. Brake fluid reservoir (2) Disconnect ECM harness connector. Check harness continuity between ECM terminals and EGR volume control valve terminals as follows. Refer to Wiring Diagram. EC C D ECM terminal EGR volume control valve terminal 37 2 40 6 49 1 59 5 69 3 Continuity should exist. MBIB1535E E F G 5. Also check harness for short to ground and short to power. OK or NG OK >> GO TO 2. NG >> Repair open circuit or short to ground or short to power in harness or connectors. 2. CHECK EGR VOLUME CONTROL VALVE H I Refer to EC-1804, "Component Inspection" . OK or NG OK >> GO TO 3. NG >> Replace EGR volume control valve. J 3. CHECK EGR VOLUME CONTROL VALVE CONTROL POSITION SENSOR K Refer to EC-1804, "Component Inspection" . OK or NG OK >> GO TO 4. NG >> Replace EGR volume control valve. L 4. CHECK EGR PASSAGE M Check the following for clogging and cracks. ● EGR tube ● EGR hose ● EGR cooler OK or NG OK >> GO TO 5. NG >> Repair or replace EGR passage. 5. CHECK INTERMITTENT INCIDENT Refer to EC-1697, "TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT" . >> INSPECTION END EC-1803 DTC P0409 EGR VOLUME CONTROL VALVE CONTROL POSITION SENSOR [K9K] Component Inspection BBS004UR EGR VOLUME CONTROL VALVE 1. 2. Disconnect EGR volume control valve (1) harness connector. ● Brake fluid reservoir (2) Check resistance between EGR volume control valve terminals 2 and 6. Resistance: 8 ± 2.3 Ω at 25°C (77°F) If NG, replace EGR volume control valve. MBIB1535E EGR VOLUME CONTROL VALVE CONTROL POSITION SENSOR 1. 2. Disconnect EGR volume control valve (1) harness connector. ● Brake fluid reservoir (2) Check resistance between EGR volume control valve terminals 1 and 3. Continuity should exist. If NG, replace EGR volume control valve. MBIB1535E Removal and Installation BBS004US EGR VOLUME CONTROL VALVE Refer to EM-251, "EGR UNIT" . EC-1804 DTC P0487 EGR VOLUME CONTROL VALVE CONTROL POSITION SENSOR [K9K] DTC P0487 EGR VOLUME CONTROL VALVE CONTROL POSITION SENSOR PFP:22693 CONSULT-II Reference Value in Data Monitor Mode BBS0047R Specification data are reference values. MONITOR ITEM EGR PO RECOPY EGR/V OPN REEF EC CONDITION ● Engine: After warming up ● Air conditioner switch: OFF ● Shift lever: Neutral position ● No load ● Engine: After warming up ● Air conditioner switch: OFF ● Shift lever: Neutral position ● No load ● Engine: After warming up ● Air conditioner switch: OFF ● Shift lever: Neutral position ● No load EGR POS SE VO SPECIFICATION Idle D Idle Approximately -50 % E Idle F Approximately 3.56 V BBS0047S Trouble diagnosis name EGR VOLUME CONTROL VALVE CONTROL POSITION SENSOR CIRCUIT P0487 C Approximately -50 % On Board Diagnosis Logic DTC No. A ● CO.0: Short circuit to ground or open circuit ● CC.1: Short circuit to +12V G Possible Cause ● Harness or connectors (The EGR volume control valve control position sensor circuit is open or shorted.) H ● EGR volume control valve control position sensor I ● EGR volume control valve stuck NOTE: ● If this DTC is displayed with DTC P0641, first perform the trouble diagnosis for DTC P0641. Refer to EC-1830, "DTC P0641 SENSOR POWER SUPPLY" . ● Special notes: – Malfunction indicator (Yellow) lights up. J K L M EC-1805 DTC P0487 EGR VOLUME CONTROL VALVE CONTROL POSITION SENSOR [K9K] Wiring Diagram BBS0047U MBWA1562E EC-1806 DTC P0487 EGR VOLUME CONTROL VALVE CONTROL POSITION SENSOR [K9K] Specification data are reference values and are measured between each terminal and ground. CAUTION: Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM's transistor. Use a ground other than ECM terminals, such as the ground. TERMINAL NO. WIRE COLOR ITEM CONDITION DATA (DC Voltage and Pulse Signal) [Engine is running] 37 B ● Warm-up condition ● Idle speed EGR volume control valve Warm-up condition ● Engine speed: 2,000 rpm C D Approximately 0.78V E [Engine is running] 40 49 W SB EGR volume control valve Sensor power supply (EGR volume control valve control position sensor) ● Warm-up condition ● Idle speed Approximately 0.7 - 1.9 F [Engine is running] ● Warm-up condition ● Engine speed: 2,000 rpm [Ignition switch ON] EC Approximately 1.1V [Engine is running] ● A Approximately 1.5 - 1.9V G Approximately 5.0V H [Engine is running] 59 69 L P EGR volume control valve control position sensor Sensor ground (EGR volume control valve control position sensor) ● Warm-up condition ● Idle speed Approximately 4.1V I [Engine is running] ● Warm-up condition ● Engine speed: 2,000 rpm Approximately 3.3V J [Engine is running] ● Warm-up condition ● Idle speed Approximately 0.5V K L M EC-1807 DTC P0487 EGR VOLUME CONTROL VALVE CONTROL POSITION SENSOR [K9K] Diagnostic Procedure BBS0047V 1. CHECK EGR VOLUME CONTROL VALVE CONTROL CIRCUIT 1. 2. – 3. 4. Turn ignition switch OFF. Disconnect EGR volume control valve (1) harness connector. Brake fluid reservoir (2) Disconnect ECM harness connector. Check harness continuity between ECM terminals and EGR volume control valve terminals as follows. Refer to Wiring Diagram. ECM terminal EGR volume control valve terminal 37 2 40 6 49 1 59 5 69 3 Continuity should exist. 5. Also check harness for short to ground and short to power. OK or NG OK >> GO TO 2. NG >> Repair open circuit or short to ground or short to power in harness or connectors. 2. CHECK EGR VOLUME CONTROL VALVE Refer to EC-1809, "Component Inspection" . OK or NG OK >> GO TO 3. NG >> Replace EGR volume control valve. 3. CHECK EGR VOLUME CONTROL VALVE CONTROL POSITION SENSOR Refer to EC-1809, "Component Inspection" . OK or NG OK >> GO TO 4. NG >> Replace EGR volume control valve. 4. CHECK EGR PASSAGE Check the following for clogging and cracks. EGR tube ● EGR hose ● EGR cooler OK or NG OK >> GO TO 5. NG >> Repair or replace EGR passage. ● 5. CHECK INTERMITTENT INCIDENT Refer to EC-1697, "TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT" . >> INSPECTION END EC-1808 MBIB1535E DTC P0487 EGR VOLUME CONTROL VALVE CONTROL POSITION SENSOR [K9K] Component Inspection BBS004UT A EGR VOLUME CONTROL VALVE 1. 2. Disconnect EGR volume control valve (1) harness connector. ● Brake fluid reservoir (2) Check resistance between EGR volume control valve terminals 2 and 6. EC Resistance: 8 ± 2.3 Ω at 25°C (77°F) C If NG, replace EGR volume control valve. D MBIB1535E EGR VOLUME CONTROL VALVE CONTROL POSITION SENSOR 1. 2. E Disconnect EGR volume control valve (1) harness connector. ● Brake fluid reservoir (2) Check resistance between EGR volume control valve terminals 1 and 3. F Continuity should exist. G If NG, replace EGR volume control valve. H MBIB1535E Removal and Installation BBS004UU EGR VOLUME CONTROL VALVE I Refer to EM-251, "EGR UNIT" . J K L M EC-1809 DTC P0500 VSS [K9K] DTC P0500 VSS Description PFP:32702 BBS0045T The vehicle speed signal is sent to the combination meter from the “ABS actuator and electric unit (control unit)” by CAN communication line. The combination meter then sends a signal to the ECM by CAN communication line. On Board Diagnosis Logic DTC No. P0500 BBS0045U Trouble diagnosis name Possible cause ● Harness or connectors (The CAN communication line is open or shorted) ● Harness or connectors (The vehicle speed signal circuit is open or shorted) ● Wheel sensor ● Combination meter ● ABS actuator and electric unit (control unit) VEHICLE SPEED INFORMATION Diagnostic Procedure BBS0045X 1. CHECK DTC WITH “ABS ACTUATOR AND ELECTRIC UNIT (CONTROL UNIT)” Refer to BRC-8, "TROUBLE DIAGNOSIS" or BRC-49, "TROUBLE DIAGNOSIS" . OK or NG OK >> GO TO 2. NG >> Repair or replace. 2. CHECK COMBINATION METER Refer to DI-4, "COMBINATION METERS" . >> INSPECTION END EC-1810 DTC P0530 REFRIGERANT PRESSURE SENSOR [K9K] DTC P0530 REFRIGERANT PRESSURE SENSOR Component Description PFP:22693 A BBS0045Y The refrigerant pressure sensor (1) is installed at the condenser of the air conditioner system. The sensor uses an electrostatic volume pressure transducer to convert refrigerant pressure to voltage. The voltage signal is sent to ECM, and ECM controls cooling fan system. EC C D MBIB1536E E CONSULT-II Reference Value in Data Monitor Mode BBS0045Z Specification data are reference values. MONITOR ITEM CONDITION ● Engine: After warming up ● Air conditioner switch: OFF ● Shift lever: Neutral position ● No load REFGERNT PRSS Idle Approximately 5.7 bar On Board Diagnosis Logic DTC No. Trouble diagnosis name ● CO.1: Short circuit to +12V or open circuit ● CC.0: Short circuit to ground G BBS00460 REFRIGERANT PRESSURE SENSOR CIRCUIT P0530 F SPECIFICATION H Possible cause ● Harness or connectors (The sensor circuit is open or shorted.) ● Refrigerant pressure sensor NOTE: ● If DTC P0530 is displayed with DTC P0641, first perform the trouble diagnosis for DTC P0643.1 Refer to EC-1830, "DTC P0641 SENSOR POWER SUPPLY" . I J K L M EC-1811 DTC P0530 REFRIGERANT PRESSURE SENSOR [K9K] Wiring Diagram BBS00462 MBWA1563E EC-1812 DTC P0530 REFRIGERANT PRESSURE SENSOR [K9K] Specification data are reference values and are measured between each terminal and ground. CAUTION: Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM's transistor. Use a ground other than ECM terminals, such as the ground. TERMINAL NO. 83 WIRE COLOR W A EC ITEM Sensor power supply (Refrigerant pressure sensor) CONDITION [Ignition switch: ON] DATA (DC Voltage) Approximately 5.0V C Approximately 2.3V D [Engine is running] 89 BR Refrigerant pressure sensor ● Warm-up condition ● Both A/C switch and blower fan switch: ON (Compressor operates.) E [Engine is running] 107 Y Sensor ground (Refrigerant pressure sensor) ● Warm-up condition ● Idle speed Approximately 0.3V F Diagnostic Procedure BBS00463 1. CHECK GROUND CONNECTIONS G 1. 2. Turn ignition switch OFF. Loosen and retighten ground screw on the body. Refer to EC-1703, "Ground Inspection" . – Body ground (1) – Priming pump (2) OK or NG OK >> GO TO 2. NG >> Repair or replace ground connections. H I J MBIB1520E K L M EC-1813 DTC P0530 REFRIGERANT PRESSURE SENSOR [K9K] 2. CHECK REFRIGERANT PRESSURE SENSOR POWER SUPPLY CIRCUIT 1. 2. Disconnect refrigerant pressure sensor (1) harness connector. Turn ignition switch ON. MBIB1536E 3. Check voltage between refrigerant pressure sensor terminal 3 and ground with CONSULT-II or tester. Voltage: Approximately 5.0V OK or NG OK >> GO TO 4. NG >> GO TO 3. MBIB1471E 3. DETECT MALFUNCTIONING PART Check the following. ● Harness connectors E48, F101 ● Harness for open or short between ECM and refrigerant pressure sensor >> Repair harness or connectors. 4. CHECK REFRIGERANT PRESSURE SENSOR GROUND CIRCUIT FOR OPEN AND SHORT 1. 2. 3. Turn ignition switch OFF. Disconnect ECM harness connector. Check harness continuity between refrigerant pressure sensor terminal 1 and ECM terminal 107. Refer to Wiring Diagram. Continuity should exist. 4. Also check harness for short to ground and short to power. OK or NG OK >> GO TO 6. NG >> GO TO 5. 5. DETECT MALFUNCTIONING PART Check the following. ● Harness connectors E48, F101 ● Harness for open or short between ECM and refrigerant pressure sensor >> Repair open circuit or short to ground or short to power in harness or connectors. EC-1814 DTC P0530 REFRIGERANT PRESSURE SENSOR [K9K] 6. CHECK REFRIGERANT PRESSURE SENSOR INPUT SIGNAL CIRCUIT FOR OPEN AND SHORT 1. A Check harness continuity between ECM terminal 89 and refrigerant pressure sensor terminal 2. Refer to Wiring Diagram. EC Continuity should exist. 2. Also check harness for short to ground and short to power. OK or NG OK >> GO TO 8. NG >> GO TO 7. C 7. DETECT MALFUNCTIONING PART D Check the following. ● Harness connectors E48, F101 ● Harness for open or short between ECM and refrigerant pressure sensor E F >> Repair open circuit or short to ground or short to power in harness or connectors. 8. CHECK INTERMITTENT INCIDENT G Refer to EC-1697, "TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT" . OK or NG OK >> Replace refrigerant pressure sensor. NG >> Repair or replace. Removal and Installation H BBS00464 REFRIGERANT PRESSURE SENSOR I Refer to ATC-135, "REFRIGERANT LINES" or MTC-81, "REFRIGERANT LINES" . J K L M EC-1815 DTC P0560 BATTERY VOLTAGE [K9K] DTC P0560 BATTERY VOLTAGE On Board Diagnosis Logic DTC No. PFP:22693 BBS00465 Trouble diagnosis name Possible cause ● Battery ● Battery terminal ● Alternator ● Incorrect jump starting BATTERY VOLTAGE P0560 ● 1.DEF: Above maximum threshold ● 2.DEF: Below threshold NOTE: ● Conditions for applying the diagnostic procedure to the stored DTCs: The DTC is declared present when the engine is running at above 1,000 rpm. ● Special notes: – Malfunction indicator (Red) lights up. EC-1816 DTC P0560 BATTERY VOLTAGE [K9K] Wiring Diagram BBS004U4 A EC C D E F G H I J K L M MBWA1571E EC-1817 DTC P0560 BATTERY VOLTAGE [K9K] Remarks: Specification data are reference values and are measured between each terminal and ground. CAUTION: Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM's transistor. Use a ground other than ECM terminals, such as the ground. TERMINAL NO. 22 WIRE COLOR O ITEM Ignition switch CONDITION [Ignition switch ON] Diagnostic Procedure DATA (DC Voltage and Pulse Signal) BATTERY VOLTAGE (11 - 14V) BBS00467 1. CHECK BATTERY VOLTAGE 1. 2. Turn ignition switch ON. Check battery voltage. Voltage: Above 11V OK or NG OK >> GO TO 2. NG >> Recharge the battery. 2. CHECK BATTERY TERMINALS 1. Turn ignition switch OFF. 2. Check battery terminals condition. OK or NG OK >> GO TO 3. NG >> Repair the battery terminals. 3. CHECK BATTERY AND ALTERNATOR Check that the proper type of battery and type of alternator are installed. Refer to, SC-5, "BATTERY" and SC-15, "CHARGING SYSTEM" . OK or NG OK >> GO TO 4. NG >> Replace with a proper one. 4. CHECK ECM POWER SUPPLY CIRCUIT 1. 2. Turn ignition switch ON. Check voltage between ECM terminal 22 and groound with CONSULT-II or tester. Voltage: Above 11V OK or NG OK >> GO TO 6. NG >> GO TO 5. MBIB1461E EC-1818 DTC P0560 BATTERY VOLTAGE [K9K] 5. DETECT MALFUNCTIONING PART A Check the following. ● Fuse block (J/B) connector M7 ● 10A fuse ● Harness connectors M1, E101 ● Harness for open or short between ECM and fuse block (J/B) EC C >> Repair open circuit or short to ground or short to power in harness or connectors. 6. CHECK ELECTRICAL PARTS DAMAGE D Check the following for damage. ● Wiring harness and harness connectors for burn ● Fuses for short OK or NG OK >> INSPECTION END NG >> Repair or replace malfunctioning part. E F G H I J K L M EC-1819 DTC P0571 BRAKE SWITCH [K9K] DTC P0571 BRAKE SWITCH Description PFP:22693 BBS00468 Brake switch signal is applied to the ECM through the stop lamp switch when the brake pedal is depressed. This signal is used mainly to decrease the engine speed when the vehicle is driving. On Board Diagnosis Logic DTC No. BBS0046A Trouble diagnosis name BRAKE SWITCH CIRCUIT P0571 ● CO.0: Open circuit or short circuit to ground ● 1.DEF: Signal absent Possible cause ● Harness or connectors (Stop lamp switch circuit is open or shorted.) ● Stop lamp switch NOTE: ● Conditions for applying the diagnostic procedure to the stored DTCs: The DTC is declared present when the ignition switch is turned ON, when deceleratig or when the brake pedal is depressed. EC-1820 DTC P0571 BRAKE SWITCH [K9K] Wiring Diagram BBS0046C A EC C D E F G H I J K L M MBWA1565E EC-1821 DTC P0571 BRAKE SWITCH [K9K] Specification data are reference values and are measured between each terminal and ground. CAUTION: Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM's transistor. Use a ground other than ECM terminals, such as the ground. TERMINAL NO. WIRE COLOR ITEM CONDITION [Ignition switch: ON] ● 5 R Stop lamp switch Brake pedal: Fully released [Ignition switch: ON] ● Brake pedal: Slightly depressed DATA (DC Voltage) Approximately 0V BATTERY VOLTAGE (11 - 14V) Diagnostic Procedure BBS0046D 1. CHECK STOP LAMP SWITCH POWER SUPPLY CIRCUIT 1. 2. – 3. Turn ignition switch OFF. Disconnect stop lamp switch (1) harness connector. Brake pedal (2) Turn ignition switch ON. MBIB1346E 4. Check voltage between stop lamp switch terminal 3 and ground with CONSULT-II or tester. Voltage: Battery voltage OK or NG OK >> GO TO 3. NG >> GO TO 2. MBIB1558E 2. DETECT MALFUNCTIONING PART Check the following. Harness connectors M1, E101 (RHD models) ● Harness connectors M8, M201 (RHD models) ● 10A fuse ● Fuse block (J/B) connector E7 ● Harness for open and short between stop lamp switch and IPDM E/R ● >> Repair open circuit or short to ground or short to power in harness or connectors. EC-1822 DTC P0571 BRAKE SWITCH [K9K] 3. CHECK STOP LAMP SWITCH INPUT SIGNAL CIRCUIT FOR OPEN AND SHORT 1. 2. 3. Turn ignition switch OFF. Disconnect ECM harness connector. Check harness continuity between ECM terminal 5 and stop lamp switch terminal 4. Refer to Wiring Diagram. Continuity should exist. A EC C 4. Also check harness for short to ground and short to power. OK or NG OK >> GO TO 5. NG >> GO TO 4. 4. DETECT MALFUNCTIONING PART D E Check the following. ● Harness connectors M1, E101 (RHD models) ● Harness connectors M8, M201 (RHD models) ● Harness for open and short between stop lamp switch and ECM F G >> Repair open circuit or short to ground or short to power in harness or connectors. 5. CHECK STOP LAMP SWITCH H Refer to EC-1824, "Component Inspection" . OK or NG OK >> GO TO 6. NG >> Replace stop lamp switch. I 6. CHECK INTERMITTENT INCIDENT J Refer to EC-1697, "TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT" . K >> INSPECTION END L M EC-1823 DTC P0571 BRAKE SWITCH [K9K] Component Inspection BBS0046E STOP LAMP SWITCH 1. Disconnect stop lamp switch (1) harness connector. ● Brake pedal (2) MBIB1346E 2. Check continuity between stop lamp switch terminals 3 and 4 under the following conditions. Conditions Brake pedal: Fully released Brake pedal: Slightly depressed Continuity Should not exist Should exist If NG, adjust stop lamp switch installation, refer to BR-6, "BRAKE PEDAL" , and perform step 2 again. PBIB2103E EC-1824 DTC P0604 ECM [K9K] DTC P0604 ECM Description PFP:22693 A BBS0046F The ECM consists of a microcomputer and connectors for signal input and output and for power supply. The ECM controls the engine. EC C D MBIB1517E E On Board Diagnosis Logic DTC No. P0604 BBS0046G Trouble diagnosis name ECM MEMORY Possible cause ● F ECM NOTE: ● Conditions for applying the diagnostic procedure to the stored DTCs: The DTC is declared present with engine running. ● Special notes: – If this DTC is present, it is impossible to stop and restart the engine. – Malfunction indicator (Red) lights up. Diagnostic Procedure G H BBS0046I 1. CHECK INJECTOR ADJUSTMENT VALUE I Check that all injector adjustment values are resistered correctly. OK or NG OK >> GO TO 2. NG >> Enter all injector adjustment values correctly. Refer to EC-1625, "Injector Adjustment Value Registration" . J K 2. REPLACE ECM 1. 2. 3. Replace ECM. Perform initialization of NATS system and registration of all NATS ignition key IDs. Refer to BL-218, "ECM Re-communicating Function" . Perform Injector Adjustment Value Registration. Refer to EC-1625, "Injector Adjustment Value Registration" . >> INSPECTION END EC-1825 L M DTC P0606 ECM [K9K] DTC P0606 ECM Description PFP:23710 BBS0046J The ECM consists of a microcomputer and connectors for signal input and output and for power supply. The ECM controls the engine. MBIB1517E On Board Diagnosis Logic DTC No. BBS0046K Trouble diagnosis name Possible cause ECM P0606 ● 1.DEF: Analogue/digital converter ● 2.DEF: Injection calibration data ● 3.DEF: Memory self-test ● 4.DEF: Non refreshed watchdog ● 5.DEF: Interference on the injector control line ● 6.DEF: Watachdog activation ● ECM NOTE: ● Special note: – If this DTC is present, the engine speed is set to 1,300 rpm, alouder sound is heard comimg from the engine and malfunction indiocator (Red) lights up. – When engine is stopped, malfunction indicator (Red) lights up. Diagnostic Procedure BBS0046M 1. CHECK DTC Make sure that which malfunction (DTC second line indication) is displayed. A 1.DEF, 3.DEF, 4.DEF or 6.DEF B 2.DEF C 5.DEF A, B or C A >> GO TO 2. B >> GO TO 3. C >> GO TO 5. 2. REPLACE ECM 1. 2. 3. Replace ECM. Perform initialization of NATS system and registration of all NATS ignition key IDs. Refer to BL-218, "ECM Re-communicating Function" . Perform Injector Adjustment Value Registration. Refer to EC-1625, "Injector Adjustment Value Registration" . >> INSPECTION END EC-1826 DTC P0606 ECM [K9K] 3. CHECK INJECTOR ADJUSTMENT VALUE A Check that all injector adjustment values are resistered correctly. OK or NG EC OK >> GO TO 4. NG >> Enter all injector adjustment values correctly. Refer to EC-1625, "Injector Adjustment Value Registration" . C REPLACE ECM 4. 1. 2. 3. Replace ECM. Perform initialization of NATS system and registration of all NATS ignition key IDs. Refer to BL-218, "ECM Re-communicating Function" . Perform Injector Adjustment Value Registration. Refer to EC-1625, "Injector Adjustment Value Registration" . >> INSPECTION END D E F 5. CHECK INJECTOR CONTROL CIRCUIT Check injector control circuit for open and short. Refer to EC-1741, "Wiring Diagram" . OK or NG OK >> GO TO 6. NG >> Repair or replace harness or connectors. 6. REPLACE ECM 1. 2. 3. G H I Replace ECM. Perform initialization of NATS system and registration of all NATS ignition key IDs. Refer to BL-218, "ECM Re-communicating Function" . Perform Injector Adjustment Value Registration. Refer to EC-1625, "Injector Adjustment Value Registration" . J K >> INSPECTION END L M EC-1827 DTC P062F ECM [K9K] DTC P062F ECM Description PFP:22693 BBS004UK The ECM consists of a microcomputer and connectors for signal input and output and for power supply. The ECM controls the engine. MBIB1517E On Board Diagnosis Logic DTC No. BBS004UL Trouble diagnosis name Possible cause ECM EEPROM MEMORY P062F ● 1.DEF: Writing to EEPROM memory ● 1.DEF: Reading to EEPROM memory ● ECM NOTE: ● Conditions for applying the diagnostic procedure to the stored DTCs: The DTC is declared present with engine running. ● Special notes: – If this DTC is present, it is impossible to stop and restart the engine. – Malfunction indicator (Red) lights up. – Malfunction indicator (Yellow) lights up. Diagnostic Procedure BBS004UM 1. CHECK BATTERY CABLE Check the battery cable for damage. OK or NG OK >> GO TO 2. NG >> Repair or replace. 2. CHECK BATTERY VALTAGE Check the battery voltage. Voltage: Above 11V OK or NG OK >> GO TO 3. NG >> Repair or replace. 3. CHECK POWER SUPPLY AND GROUND CIRCUIT Check the ECM power supply and ground circuit. Perform EC-1699, "Diagnostic Procedure" . OK or NG OK >> GO TO 4. NG >> Repair or replace. EC-1828 DTC P062F ECM [K9K] 4. REPLACE ECM 1. 2. 3. A Replace ECM. Perform initialization of NATS system and registration of all NATS ignition key IDs. Refer to BL-218, "ECM EC Re-communicating Function" . Perform Injector Adjustment Value Registration. Refer to EC-1625, "Injector Adjustment Value Registration" . C >> INSPECTION END D E F G H I J K L M EC-1829 DTC P0641 SENSOR POWER SUPPLY [K9K] DTC P0641 SENSOR POWER SUPPLY On Board Diagnosis Logic DTC No. PFP:22693 BBS0046N Trouble diagnosis name Possible cause ● Harness or connectors (The APP sensor 1 power supply circuit is shorted.) (Fuel rail pressure sensor circuit is shorted.) (Turbosharger boost sensor circuit is shorted.) (EGR volume control valve control position sensor circuit is shorted.) (Mass air flow sensor circuit is shorted.) (Refrigerant pressure sensor circuit is shorted.) ● Accelerator pedal position sensor (Accelerator pedal position sensor 1) ● Fuel rail pressure sensor ● Turbosharger boost sensor ● EGR volume control valve control position sensor ● Mass air flow sensor ● Refrigerant pressure sensor SENSOR POWER SUPPLY CIRCUIT P0641 ● 1.DEF: Parameter at minimum level ● 2.DEF: Parameter at maximum level NOTE: ● If DTC P0641 is displayed with DTC P0100, P0190, P0225, P0235, P0409, P0487, P0530, P0651, P2120, first perform trouble diagnosis for DTC P0641. ● Special notes: – If this DTC is present, the engine stops immediately and cannnot be restarted. – Malfuction indicator (Red) lights up. EC-1830 DTC P0641 SENSOR POWER SUPPLY [K9K] Wiring Diagram BBS0046P A LHD MODELS EC C D E F G H I J K L M MBWA1573E EC-1831 DTC P0641 SENSOR POWER SUPPLY [K9K] Specification data are reference values and are measured between each terminal and ground. CAUTION: Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM's transistor. Use a ground other than ECM terminals, such as the ground. TERMINAL NO. 6 WIRE COLOR L/R ITEM Sensor ground (Accelerator pedal position sensor 2) CONDITION DATA (DC Voltage and Pulse Signal) [Engine is running] ● Warm-up condition ● Idle speed Approximately 0.3V [Ignition switch ON] 12 L/W Accelerator pedal position sensor 2 ● Engine stopped ● Accelerator pedal: Fully released [Ignition switch ON] ● Engine stopped ● Accelerator pedal: Fully depressed 18 L Sensor power supply (Accelerator pedal position sensor 2) 28 B Sensor ground (Accelerator pedal position sensor 1) ● Warm-up condition ● Idle speed Sensor power supply (Accelerator pedal position sensor 1) [Ignition switch ON] 29 R Approximately 0.4V [Ignition switch ON] Approximately 2.0V Approximately 4.6V [Engine is running] Approximately 0.24V Approximately 5.0V [Ignition switch ON] 30 W Accelerator pedal position sensor 1 ● Engine stopped ● Accelerator pedal: Fully released Approximately 0.76V [Ignition switch ON] ● Engine stopped ● Accelerator pedal: Fully depressed Approximately 4.2V 47 L Sensor power supply (Fuel rail pressure sensor) [Ignition switch ON] Approximately 5.0V 48 V Sensor power supply (Turbocharger boost sensor) [Ignition switch ON] Approximately 5.0V 49 SB Sensor power supply (EGR volume control valve position sensor) [Ignition switch ON] Approximately 5.0V 50 L Sensor power supply (Mass air flow sensor) [Ignition switch ON] Approximately 5.0V 83 W Sensor power supply (Refrigerant pressure sensor) [Ignition switch ON] Approximately 5.0V EC-1832 DTC P0641 SENSOR POWER SUPPLY [K9K] RHD MODELS A EC C D E F G H I J K L M MBWA1574E EC-1833 DTC P0641 SENSOR POWER SUPPLY [K9K] Specification data are reference values and are measured between each terminal and ground. CAUTION: Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM's transistor. Use a ground other than ECM terminals, such as the ground. TERMINAL NO. 6 WIRE COLOR L/R ITEM Sensor ground (Accelerator pedal position sensor 2) CONDITION DATA (DC Voltage and Pulse Signal) [Engine is running] ● Warm-up condition ● Idle speed Approximately 0.3V [Ignition switch ON] 12 L/W Accelerator pedal position sensor 2 ● Engine stopped ● Accelerator pedal: Fully released [Ignition switch ON] ● Engine stopped ● Accelerator pedal: Fully depressed 18 L Sensor power supply (Accelerator pedal position sensor 2) 28 B Sensor ground (Accelerator pedal position sensor 1) ● Warm-up condition ● Idle speed Sensor power supply (Accelerator pedal position sensor 1) [Ignition switch ON] 29 R Approximately 0.4V [Ignition switch ON] Approximately 2.0V Approximately 4.6V [Engine is running] Approximately 0.24V Approximately 5.0V [Ignition switch ON] 30 W Accelerator pedal position sensor 1 ● Engine stopped ● Accelerator pedal: Fully released Approximately 0.76V [Ignition switch ON] ● Engine stopped ● Accelerator pedal: Fully depressed Approximately 4.2V 47 L Sensor power supply (Fuel rail pressure sensor) [Ignition switch ON] Approximately 5.0V 48 V Sensor power supply (Turbocharger boost sensor) [Ignition switch ON] Approximately 5.0V 49 SB Sensor power supply (EGR volume control valve position sensor) [Ignition switch ON] Approximately 5.0V 50 L Sensor power supply (Mass air flow sensor) [Ignition switch ON] Approximately 5.0V 83 W Sensor power supply (Refrigerant pressure sensor) [Ignition switch ON] Approximately 5.0V EC-1834 DTC P0641 SENSOR POWER SUPPLY [K9K] Diagnostic Procedure BBS0046Q 1. CHECK GROUND CONNECTIONS A 1. 2. Turn ignition switch OFF. Loosen and retighten ground screw on the body. Refer to EC-1703, "Ground Inspection" . – Body ground (1) – Priming pump (2) OK or NG OK >> GO TO 2. NG >> Repair or replace ground connections. EC C D MBIB1520E E 2. CHECK APP SENSOR 1 POWER SUPPLY CIRCUIT-I 1. – – 2. F Disconnect accelerator pedal position (APP) sensor harness connector (1). Accelerator pedal position sensor (2) Accelerator pedal (3) Turn ignition switch ON. G H I MBIB1345E 3. Check voltage between APP sensor terminal 4 and ground with CONSULT-II or tester. J Voltage: Approximately 5.0V OK or NG OK >> GO TO 7. NG >> GO TO 3. K L MBIB1468E 3. CHECK APP SENSOR 1 POWER SUPPLY CIRCUIT-II 1. 2. 3. Turn ignition switch OFF. Disconnect ECM harness connecor. Check harness continuity between APP sensor terminal 4 and ECM terminal 29. Refe to Wiring Diagram. Continuity should exist. OK or NG OK >> GO TO 5. NG >> GO TO 4. EC-1835 M DTC P0641 SENSOR POWER SUPPLY [K9K] 4. DETECT MALFUNCTIONING PART Check the following. ● Harness connectors M201, M8 (RHD models) ● Harness connectors M1, E101 (RHD models) ● Harness for open or short between APP sensor and ECM >> Repair open circuit or short to ground or short to power in harness or connectors. 5. CHECK SENSOR POWER SUPPLY CIRCUITS Check the following. Harness for short to power and short to ground, between the following terminals. ECM terminal Sensor terminal Reference Wiring Diagram 29 APP sensor terminal 4 EC-1831 47 Fuel rail pressure sensor terminal 3 EC-1737 48 Turbocharger boost sensor terminal 1 EC-1764 49 EGR volume control valve control position sensor terminal 1 EC-1801 50 Mass air flow sensor terminal 5 EC-1723 83 Refrigerant pressure sensor terminal 3 EC-1812 OK or NG OK >> GO TO 6. NG >> Repair short to ground or short to power in harness or connectors. 6. CHECK COMPONENTS Check the following. Fuel rail pressure sensor (Refer to EC-1739, "Component Inspection" .) ● Turbocharger boost sensor (Refer to EC-1765, "Diagnostic Procedure" .) ● EGR volume control valve control position sensor (Refer to EC-1799, "Component Inspection" .) ● Mass air flow sensor (Refer to EC-1726, "Component Inspection" .) ● Refrigerant pressure sensor (Refer to ATC-85, "COMPONENT INSPECTION" or MTC-51, "COMPONENT INSPECTION" .) OK or NG OK >> GO TO 7. NG >> Replace malfunctioning component. ● 7. CHECK APP SENSOR Refer to EC-1757, "Component Inspection" . OK or NG OK >> GO TO 8. NG >> Replace accelerator pedal assembly. 8. CHECK INTERMITTENT INCIDENT Refer to EC-1697, "TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT" . >> INSPECTION END EC-1836 DTC P0651 APP SENSOR [K9K] DTC P0651 APP SENSOR Description PFP:22693 A BBS004U5 The accelerator pedal position sensor is installed on the upper end of the accelerator pedal assembly. The sensors detect the accelerator pedal position and sends a signal to the ECM. The ECM uses the signal to determine the amount of fuel to be injected. EC C D PBIB1741E E CONSULT-II Reference Value in Data Monitor Mode BBS004U6 Specification data are reference values. MONITOR ITEM PL PTNMR T1 V PL PTNMR T2 V CONDITION Ignition switch: ON (Engine stopped) Accelerator pedal: Fully released Approximately 15 % ● Ignition switch: ON (Engine stopped) Accelerator pedal: Fully released Approximately 6 % On Board Diagnosis Logic DTC No. Trouble diagnosis name ● CO.1: Open circuit or short circuit to +12V ● CC.0: Short circuit to ground G BBS004U7 H Possible cause ● APP SENSOR 2 CIRCUIT P0651 F SPECIFICATION ● ● Harness or connectors (The APP sensor 2 circuit is open or shorted.) I Accelerator pedal position sensor (Accelerator pedal position sensor 2) NOTE: ● If DTC P0651 is displayed with DTC P0641, first perform trouble diagnosis for DTC P0641. Refer to EC-1830, "DTC P0641 SENSOR POWER SUPPLY" . ● Special notes: – If this DTC is present, the engine idle speed is set to 1,000 rpm, the engine performance is reduced, and – Malfunction indicator (Red) lights up. J K L M EC-1837 DTC P0651 APP SENSOR [K9K] Wiring Diagram BBS004U8 LHD MODELS MBWA1554E EC-1838 DTC P0651 APP SENSOR [K9K] Specification data are reference values and are measured between each terminal and ground. CAUTION: Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM's transistor. Use a ground other than ECM terminals, such as the ground. TERMINAL NO. 6 WIRE COLOR L/R ITEM Sensor ground (Accelerator pedal position sensor 2) CONDITION DATA (DC Voltage and Pulse Signal) [Engine is running] ● Warm-up condition ● Idle speed 12 18 28 29 L/W Accelerator pedal position sensor 2 L Sensor power supply (Accelerator pedal position sensor 2) B Sensor ground (Accelerator pedal position sensor 1) R Sensor power supply (Accelerator pedal position sensor 1) Engine stopped ● Accelerator pedal: Fully released C D Approximately 0.4V E [Ignition switch ON] ● Engine stopped ● Accelerator pedal: Fully depressed [Ignition switch ON] Approximately 2.0V F Approximately 4.6V G [Engine is running] ● Warm-up condition ● Idle speed [Ignition switch ON] Approximately 0.24V H Approximately 5.0V I [Ignition switch ON] 30 W Accelerator pedal position sensor 1 ● Engine stopped ● Accelerator pedal: Fully released EC Approximately 0.3V [Ignition switch ON] ● A Approximately 0.76V J [Ignition switch ON] ● Engine stopped ● Accelerator pedal: Fully depressed Approximately 4.2V K L M EC-1839 DTC P0651 APP SENSOR [K9K] RHD MODELS MBWA1555E EC-1840 DTC P0651 APP SENSOR [K9K] Specification data are reference values and are measured between each terminal and ground. CAUTION: Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM's transistor. Use a ground other than ECM terminals, such as the ground. TERMINAL NO. 6 WIRE COLOR L/R ITEM Sensor ground (Accelerator pedal position sensor 2) CONDITION DATA (DC Voltage and Pulse Signal) [Engine is running] ● Warm-up condition ● Idle speed 12 18 28 29 L/W Accelerator pedal position sensor 2 L Sensor power supply (Accelerator pedal position sensor 2) B Sensor ground (Accelerator pedal position sensor 1) R Sensor power supply (Accelerator pedal position sensor 1) Engine stopped ● Accelerator pedal: Fully released C D Approximately 0.4V E [Ignition switch ON] ● Engine stopped ● Accelerator pedal: Fully depressed [Ignition switch ON] Approximately 2.0V F Approximately 4.6V G [Engine is running] ● Warm-up condition ● Idle speed [Ignition switch ON] Approximately 0.24V H Approximately 5.0V I [Ignition switch ON] 30 W Accelerator pedal position sensor 1 ● Engine stopped ● Accelerator pedal: Fully released EC Approximately 0.3V [Ignition switch ON] ● A Approximately 0.76V J [Ignition switch ON] ● Engine stopped ● Accelerator pedal: Fully depressed Diagnostic Procedure Approximately 4.2V K BBS004U9 1. CHCEK GROUND CONNECTIONS L 1. 2. Turn ignition switch OFF. Loosen and retighten ground screw on the body. Refer to EC-1703, "Ground Inspection" . – Body ground (1) – Priming pump (2) OK or NG OK >> GO TO 2. NG >> Repair or replace ground connections. M MBIB1520E EC-1841 DTC P0651 APP SENSOR [K9K] 2. CHECK APP SENSOR 2 POWER SUPPLY CIRCUIT 1. – – 2. Disconnect accelerator pedal position (APP) sensor harness connector (1). Accelerator pedal position sensor (2) Accelerator pedal (3) Turn ignition switch ON. MBIB1345E 3. Check voltage between APP sensor terminal 5 and ground with CONSULT-II or tester. Voltage: Approximately 5.0V OK or NG OK >> GO TO 4. NG >> GO TO 3. PBIB1597E 3. DETECT MALFUNCTIONING PART Check the following. ● Harness connectors M201, M8 (RHD models) ● Harness connectors M1, E101 (RHD models) ● Harness for open or short between APP sensor and ECM >> Repair open circuit or short to ground or short to power in harness or connectors. 4. CHECK APP SENSOR 2 GROUND CIRCUIT FOR OPEN AND SHORT 1. 2. 3. Turn ignition switch OFF. Disconnect ECM harness connector. Check harness continuity between APP sensor terminal 1 and ECM terminal 6. Refer to Wiring Diagram. Continuity should exist. 4. Also check harness for short to ground and short to power. OK or NG OK >> GO TO 6. NG >> GO TO 5. 5. DETECT MALFUNCTIONING PART Check the following. Harness connectors M201, M8 (RHD models) ● Harness connectors M1, E101 (RHD models) ● Harness for open or short between APP sensor and ECM ● >> Repair open circuit or short to ground or short to power in harness or connectors. EC-1842 DTC P0651 APP SENSOR [K9K] 6. CHECK APP SENSOR 2 INPUT SIGNAL CIRCUIT FOR OPEN AND SHORT 1. A Check harness continuity between ECM terminal 12 and APP sensor terminal 6. Refer to Wiring Diagram. EC Continuity should exist. 2. Also check harness for short to ground and short to power. OK or NG OK >> GO TO 8. NG >> GO TO 7. C 7. DETECT MALFUNCTIONING PART D Check the following. ● Harness connectors M201, M8 (RHD models) ● Harness connectors M1, E101 (RHD models) ● Harness for open or short between APP sensor and ECM E F >> Repair open circuit or short to ground or short to power in harness or connectors. 8. CHECK APP SENSOR G Refer to EC-1843, "Component Inspection" . OK or NG OK >> GO TO 9. NG >> Replace accelerator pedal assembly. H I 9. CHECK INTERMITTENT INCIDENT Refer to EC-1697, "TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT" . J >> INSPECTION END Component Inspection BBS004UA K ACCELERATOR PEDAL POSITION SENSOR 1. Disconnect APP sensor harness connector (1). ● Accelerator pedal position sensor (2) ● Accelerator pedal (3) L M MBIB1345E EC-1843 DTC P0651 APP SENSOR [K9K] 2. Check resistance between the APP sensor terminals 2 and 4, 1 and 5. Terminals 2 and 4: 1 and 5: 3. Resistance 1.7 ± 0.9 kΩ 2.4 ± 1.2 kΩ If NG, replace accelerator pedal assembly. MBIB1489E Removal and Installation BBS004UB ACCELERATOR PEDAL Refer to ACC-2, "ACCELERATOR CONTROL SYSTEM" . EC-1844 DTC P0685 ECM RELAY [K9K] DTC P0685 ECM RELAY On Board Diagnosis Logic DTC No. PFP:22693 A BBS0046V Trouble diagnosis name ECM RELAY CIRCUIT P0685 ● 1.DEF: Permanent low signal ● 2.DEF: Permanent high signal Possible cause ● Harness or connectors (The ECM relay circuit is shorted.) ● ECM relay EC C D E F G H I J K L M EC-1845 DTC P0685 ECM RELAY [K9K] Wiring Diagram BBS0046X MBWA1572E EC-1846 DTC P0685 ECM RELAY [K9K] Specification data are reference values and are measured between each terminal and ground. CAUTION: Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM's transistor. Use a ground other than ECM terminals, such as the ground. TERMINAL NO. WIRE COLOR ITEM CONDITION [Ignition switch ON] [Ignition switch OFF] ● 104 P ECM relay (self-shutoff) For a few seconds after turning ignition switch OFF [Ignition switch OFF] ● 109 110 G G Power supply for ECM More than a few seconds after turning ignition switch OFF [Ignition switch ON] Diagnostic Procedure A EC DATA (DC Voltage) C Approximately 1.4V D BATTERY VOLTAGE (11 - 14V) E BATTERY VOLTAGE (11 - 14V) BBS0046Y F 1. CHECK ECM POWER SUPPLY CIRCUIT-I 1. 2. 3. Turn ignition switch OFF and wait at least 10 seconds. Turn ignition switch ON and then OFF. Check voltage between ECM terminals 109, 110 and ground with CONSULT-II or tester. Voltage: G H After turning ignition switch OFF, battery voltage will exist for a few seconds, then drop to approximately 0V. OK or NG OK >> GO TO 9. NG (Battery voltage does not exist)>>GO TO 2. NG (Battery voltage exists for more then a few seconds)>>GO TO 5. I J MBIB1463E K 2. CHECK ECM POWER SUPPLY CIRCUIT-II 1. 2. Turn ignition switch OFF and wait at least 10 seconds. Check voltage between ECM terminal 104 and ground with CONSULT-II or tester. L M Voltage: Battery voltage OK or NG OK >> GO TO 3. NG >> GO TO 5. PBIB1171E EC-1847 DTC P0685 ECM RELAY [K9K] 3. CHECK ECM POWER SUPPLY CIRCUIT-III 1. 2. 3. Disconnect ECM harness connector. Disconnect IPDM E/R harness connector E7. Check harness continuity between ECM terminals 109, 110 and IPDM E/R terminal 32. Refer to Wiring Diagram. Continuity should exist. 4. Also check harness for short to ground and short to power. OK or NG OK >> GO TO 8. NG >> GO TO 4. 4. DETECT MALFUNCTIONING PART Check the following. ● Harness connectors E48, F101 ● Harness for open or short between ECM and IPDM E/R >> Repair open circuit or short to ground or short to power in harness or connectors. 5. CHECK ECM POWER SUPPLY CIRCUIT-IV 1. 2. 3. Disconnect ECM harness connector. Disconnect IPDM E/R harness connector E7. Check harness continuity between ECM terminal 104 and IPDM E/R terminal 29 under the following conditions. Refer to Wiring Diagram. MBIB1559E CONDITION 1: CONDITION 2: Continuity should exist. Continuity should not exist. 4. Also check harness for short to ground and short to power. OK or NG OK >> GO TO 7. NG >> GO TO 6. 6. DETECT MALFUNCTIONING PART Check the following. ● Harness connectors E48, F101 ● Diode E64 ● Harness for open or short between ECM and IPDM E/R >> Repair open circuit or short to ground or short to power in harness or connectors. EC-1848 DTC P0685 ECM RELAY [K9K] 7. CHECK 20A FUSE A 1. Disconnect 20 A fuse. 2. Check 20A fuse OK or NG OK >> GO TO 8. NG >> Replace 20A fuse. EC C 8. CHECK INTERMITTENT INCIDENT Refer to EC-1697, "TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT" . OK or NG OK >> Replace IPDM E/R. Refer to PG-18, "IPDM E/R (INTELLIGENT POWER DISTRIBUTION MODULE ENGINE ROOM)" . NG >> Repair open circuit or short to ground or short to power in harness or connectors. 9. CHECK INTERMITTENT INCIDENT D E F Refer to EC-1697, "TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT" . G >> INSPECTION END H I J K L M EC-1849 DTC P0703 BRAKE SWITCH [K9K] DTC P0703 BRAKE SWITCH Description PFP:22693 BBS00470 Brake switch signal is applied to the ECM through the stop lamp switch when the brake pedal is depressed. This signal is used mainly to decrease the engine speed when the vehicle is driving. On Board Diagnosis Logic DTC No. BBS00472 Trouble diagnosis name BRAKE SWITCH CIRCUIT P0703 ● 1.DEF: Signal absent ● 2.DEF: Inconsistency Possible cause ● Harness or connectors (Stop lamp switch circuit is open or shorted.) ● Stop lamp switch NOTE: ● Conditions for applying the diagnostic procedure to the stored DTCs: The DTC is declared present when the ignition switch is ON, when decelerating or when the brake pedal is depressed. EC-1850 DTC P0703 BRAKE SWITCH [K9K] Wiring Diagram BBS00474 A EC C D E F G H I J K L M MBWA1565E EC-1851 DTC P0703 BRAKE SWITCH [K9K] Specification data are reference values and are measured between each terminal and ground. CAUTION: Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM's transistor. Use a ground other than ECM terminals, such as the ground. TERMINAL NO. WIRE COLOR ITEM CONDITION [Ignition switch: ON] ● 5 R Stop lamp switch Brake pedal: Fully released [Ignition switch: ON] ● Brake pedal: Slightly depressed DATA (DC Voltage) Approximately 0V BATTERY VOLTAGE (11 - 14V) Diagnostic Procedure BBS00475 1. CHECK STOP LAMP SWITCH POWER SUPPLY CIRCUIT 1. 2. – 3. Turn ignition switch OFF. Disconnect stop lamp switch (1) harness connector. Brake pedal (2) Turn ignition switch ON. MBIB1346E 4. Check voltage between stop lamp switch terminal 3 and ground with CONSULT-II or tester. Voltage: Battery voltage OK or NG OK >> GO TO 3. NG >> GO TO 2. MBIB1558E 2. DETECT MALFUNCTIONING PART Check the following. Harness connectors M1, E101 (RHD models) ● Harness connectors M8, M201 (RHD models) ● 10A fuse ● Fuse block (J/B) connector E7 ● Harness for open and short between stop lamp switch and IPDM E/R ● >> Repair open circuit or short to ground or short to power in harness or connectors. EC-1852 DTC P0703 BRAKE SWITCH [K9K] 3. CHECK STOP LAMP SWITCH INPUT SIGNAL CIRCUIT FOR OPEN AND SHORT 1. 2. 3. Turn ignition switch OFF. Disconnect ECM harness connector. Check harness continuity between ECM terminal 5 and stop lamp switch terminal 4. Refer to Wiring Diagram. Continuity should exist. A EC C 4. Also check harness for short to ground and short to power. OK or NG OK >> GO TO 5. NG >> GO TO 4. 4. DETECT MALFUNCTIONING PART D E Check the following. ● Harness connectors M1, E101 (RHD models) ● Harness connectors M8, M201 (RHD models) ● Harness for open and short between stop lamp switch and ECM F G >> Repair open circuit or short to ground or short to power in harness or connectors. 5. CHECK STOP LAMP SWITCH H Refer to EC-1854, "Component Inspection" . OK or NG OK >> GO TO 6. NG >> Replace stop lamp switch. I 6. CHECK INTERMITTENT INCIDENT J Refer to EC-1697, "TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT" . K >> INSPECTION END L M EC-1853 DTC P0703 BRAKE SWITCH [K9K] Component Inspection BBS00476 STOP LAMP SWITCH 1. Disconnect stop lamp switch (1) harness connector. ● Brake pedal (2) MBIB1346E 2. Check continuity between stop lamp switch terminals 3 and 4 under the following conditions. Conditions Brake pedal: Fully released Brake pedal: Slightly depressed Continuity Should not exist Should exist If NG, adjust stop lamp switch installation, refer to BR-6, "BRAKE PEDAL" , and perform step 2 again. PBIB2103E EC-1854 DTC P2120 APP SENSOR [K9K] DTC P2120 APP SENSOR Description PFP:22693 A BBS00477 The accelerator pedal position sensor is installed on the upper end of the accelerator pedal assembly. The sensors detect the accelerator pedal position and sends a signal to the ECM. The ECM uses the signal to determine the amount of fuel to be injected. EC C D PBIB1741E E CONSULT-II Reference Value in Data Monitor Mode BBS00478 Specification data are reference values. MONITOR ITEM PL PTNMR T1 V PL PTNMR T2 V CONDITION Ignition switch: ON (Engine stopped) Accelerator pedal: Fully released Approximately 15 % ● Ignition switch: ON (Engine stopped) Accelerator pedal: Fully released Approximately 6 % On Board Diagnosis Logic DTC No. Trouble diagnosis name ● CO.0: Open circuit or short circuit to ground ● CC.1: Short circuit to +12V G BBS00479 ● Harness or connectors (The APP sensor 2 circuit is open or shorted.) I Accelerator pedal position sensor (Accelerator pedal position sensor 2) NOTE: ● If DTC P2120 is displayed with DTC P0641, first perform trouble diagnosis for DTC P0641. Refer to EC-1830, "DTC P0641 SENSOR POWER SUPPLY" . ● If DTC P2120 is displayed with DTC P0651, first perform trouble diagnosis for DTC P0651. Refer to EC-1837, "DTC P0651 APP SENSOR" . ● Special notes: – If this DTC is present, the engine speed is maintained above 1,000 rpm, and malfuction indicator (Red) lights up. – If this DTC is present with DTC P0225, the engine idle speed is fixed at 1,800 rpm, and malfuction indicator (Red) lights up. EC-1855 H Possible cause ● APP SENSOR 2 CIRCUIT P2120 F SPECIFICATION ● J K L M DTC P2120 APP SENSOR [K9K] Wiring Diagram BBS0047B LHD MODELS MBWA1554E EC-1856 DTC P2120 APP SENSOR [K9K] Specification data are reference values and are measured between each terminal and ground. CAUTION: Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM's transistor. Use a ground other than ECM terminals, such as the ground. TERMINAL NO. 6 WIRE COLOR L/R ITEM Sensor ground (Accelerator pedal position sensor 2) CONDITION DATA (DC Voltage and Pulse Signal) [Engine is running] ● Warm-up condition ● Idle speed 12 18 28 29 L/W Accelerator pedal position sensor 2 L Sensor power supply (Accelerator pedal position sensor 2) B Sensor ground (Accelerator pedal position sensor 1) R Sensor power supply (Accelerator pedal position sensor 1) Engine stopped ● Accelerator pedal: Fully released C D Approximately 0.4V E [Ignition switch ON] ● Engine stopped ● Accelerator pedal: Fully depressed [Ignition switch ON] Approximately 2.0V F Approximately 4.6V G [Engine is running] ● Warm-up condition ● Idle speed [Ignition switch ON] Approximately 0.24V H Approximately 5.0V I [Ignition switch ON] 30 W Accelerator pedal position sensor 1 ● Engine stopped ● Accelerator pedal: Fully released EC Approximately 0.3V [Ignition switch ON] ● A Approximately 0.76V J [Ignition switch ON] ● Engine stopped ● Accelerator pedal: Fully depressed Approximately 4.2V K L M EC-1857 DTC P2120 APP SENSOR [K9K] RHD MODELS MBWA1555E EC-1858 DTC P2120 APP SENSOR [K9K] Specification data are reference values and are measured between each terminal and ground. CAUTION: Do not use ECM ground terminals when measuring input/output voltage. Doing so may result in damage to the ECM's transistor. Use a ground other than ECM terminals, such as the ground. TERMINAL NO. 6 WIRE COLOR L/R ITEM Sensor ground (Accelerator pedal position sensor 2) CONDITION DATA (DC Voltage and Pulse Signal) [Engine is running] ● Warm-up condition ● Idle speed 12 18 28 29 L/W Accelerator pedal position sensor 2 L Sensor power supply (Accelerator pedal position sensor 2) B Sensor ground (Accelerator pedal position sensor 1) R Sensor power supply (Accelerator pedal position sensor 1) Engine stopped ● Accelerator pedal: Fully released C D Approximately 0.4V E [Ignition switch ON] ● Engine stopped ● Accelerator pedal: Fully depressed [Ignition switch ON] Approximately 2.0V F Approximately 4.6V G [Engine is running] ● Warm-up condition ● Idle speed [Ignition switch ON] Approximately 0.24V H Approximately 5.0V I [Ignition switch ON] 30 W Accelerator pedal position sensor 1 ● Engine stopped ● Accelerator pedal: Fully released EC Approximately 0.3V [Ignition switch ON] ● A Approximately 0.76V J [Ignition switch ON] ● Engine stopped ● Accelerator pedal: Fully depressed Diagnostic Procedure Approximately 4.2V K BBS0047C 1. CHCEK GROUND CONNECTIONS L 1. 2. Turn ignition switch OFF. Loosen and retighten ground screw on the body. Refer to EC-1703, "Ground Inspection" . – Body ground (1) – Priming pump (2) OK or NG OK >> GO TO 2. NG >> Repair or replace ground connections. M MBIB1520E EC-1859 DTC P2120 APP SENSOR [K9K] 2. CHECK APP SENSOR 2 POWER SUPPLY CIRCUIT 1. – – 2. Disconnect accelerator pedal position (APP) sensor harness connector (1). Accelerator pedal position sensor (2) Accelerator pedal (3) Turn ignition switch ON. MBIB1345E 3. Check voltage between APP sensor terminal 5 and ground with CONSULT-II or tester. Voltage: Approximately 5.0V OK or NG OK >> GO TO 4. NG >> GO TO 3. PBIB1597E 3. DETECT MALFUNCTIONING PART Check the following. ● Harness connectors M201, M8 (RHD models) ● Harness connectors M1, E101 (RHD models) ● Harness for open or short between APP sensor and ECM >> Repair open circuit or short to ground or short to power in harness or connectors. 4. CHECK APP SENSOR 2 GROUND CIRCUIT FOR OPEN AND SHORT 1. 2. 3. Turn ignition switch OFF. Disconnect ECM harness connector. Check harness continuity between APP sensor terminal 1 and ECM terminal 6. Refer to Wiring Diagram. Continuity should exist. 4. Also check harness for short to ground and short to power. OK or NG OK >> GO TO 6. NG >> GO TO 5. 5. DETECT MALFUNCTIONING PART Check the following. Harness connectors M201, M8 (RHD models) ● Harness connectors M1, E101 (RHD models) ● Harness for open or short between APP sensor and ECM ● >> Repair open circuit or short to ground or short to power in harness or connectors. EC-1860 DTC P2120 APP SENSOR [K9K] 6. CHECK APP SENSOR 2 INPUT SIGNAL CIRCUIT FOR OPEN AND SHORT 1. A Check harness continuity between ECM terminal 12 and APP sensor terminal 6. Refer to Wiring Diagram. EC Continuity should exist. 2. Also check harness for short to ground and short to power. OK or NG OK >> GO TO 8. NG >> GO TO 7. C 7. DETECT MALFUNCTIONING PART D Check the following. ● Harness connectors M201, M8 (RHD models) ● Harness connectors M1, E101 (RHD models) ● Harness for open or short between APP sensor and ECM E F >> Repair open circuit or short to ground or short to power in harness or connectors. 8. CHECK APP SENSOR G Refer to EC-1861, "Component Inspection" . OK or NG OK >> GO TO 9. NG >> Replace accelerator pedal assembly. H I 9. CHECK INTERMITTENT INCIDENT Refer to EC-1697, "TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT" . J >> INSPECTION END Component Inspection BBS0047D K ACCELERATOR PEDAL POSITION SENSOR 1. Disconnect APP sensor harness connector (1). ● Accelerator pedal position sensor (2) ● Accelerator pedal (3) L M MBIB1345E EC-1861 DTC P2120 APP SENSOR [K9K] 2. Check resistance between the APP sensor terminals 2 and 4, 1 and 5. Terminals 2 and 4: 1 and 5: 3. Resistance 1.7 ± 0.9 kΩ 2.4 ± 1.2 kΩ If NG, replace accelerator pedal assembly. MBIB1489E Removal and Installation BBS0047E ACCELERATOR PEDAL Refer to ACC-2, "ACCELERATOR CONTROL SYSTEM" . EC-1862 DTC P2226 BARO SENSOR [K9K] DTC P2226 BARO SENSOR Description PFP:22693 A BBS0047F The barometric pressure sensor is built into ECM. The sensor detects ambient barometric pressure and sends the voltage signal to the microcomputer. EC C D MBIB1517E E On Board Diagnosis Logic DTC No. BBS0047G Trouble diagnosis name Possible cause F BAROMETRIC PRESSURE SENSOR CIRCUIT P2226 ● CC.1: Shoet circuit to +12V ● CO.0: Short circuit to ground or open circuit ● ECM G Diagnostic Procedure BBS0047I 1. REPLACE ECM 1. 2. 3. Replace ECM. Perform initialization of NATS system and registration of all NATS ignition key IDs. Refer to BL-218, "ECM Re-communicating Function" . Perform Injector Adjustment Value Registration. Refer to EC-1625, "Injector Adjustment Value Registration" . H I J >> INSPECTION END K L M EC-1863 COOLING FAN [K9K] COOLING FAN System Description Sensor PFP:21486 BBS004UC Input Signal to ECM Crankshaft position sensor (POS) Camshaft position sensor (PHASE) Engine speed Battery Battery voltage Wheel sensor Vehicle speed* Engine coolant temperature sensor Engine coolant temperature Air conditioner switch Air conditioner ON signal* Refrigerant pressure sensor Refrigerant pressure ECM function Cooling fan control Actuator IPDM E/R (Cooling fan relays) *: This signal is sent to ECM through CAN communication line. The ECM controls the cooling fan corresponding to the vehicle speed, engine coolant temperature, refrigerant pressure, and air conditioner ON signal. The control system has 3-step control [HIGH/LOW/OFF]. EC-1864 COOLING FAN [K9K] COOLING FAN OPERATION A EC C D E F G H I J K L M MBIB1472E EC-1865 COOLING FAN [K9K] Wiring Diagram BBS004UG MBWA1566E EC-1866 COOLING FAN [K9K] Diagnostic Procedure BBS004UH 1. CHECK COOLING FAN OPERATION A Perform IPDM E/R auto active test and check cooling fan motors operation, refer to PG-22, "Auto Active Test" . EC 2. Make sure that cooling fan operates at each speed (Low/High). OK or NG C OK >> INSPECTION END NG >> GO TO 2. 1. 2. CHECK IPDM E/R POWER SUPPLY CIRCUIT 1. 2. 3. D Turn ignition switch OFF. Disconnect IPDM E/R harness connector E6. Check voltage between IPDM E/R terminal 14 and ground with CONSULT-II or tester. E Voltage: Battery voltage F OK or NG OK >> GO TO 4. NG >> GO TO 3. G H MBIB1556E 3. DETECT MALFUNCTIONING PART I Check the following. ● 40A fusible link ● Harness for open or short between IPDM E/R and battery >> Repair open circuit or short to ground in harness or connectors. J K 4. CHECK IPDM E/R GROUND CIRCUIT FOR OPEN AND SHORT 1. 2. Disconnect IPDM E/R harness connectors E11 and E12. Check harness continuity between IPDM E/R terminals 3, 54 and ground. Refer to Wiring Diagram. L M Continuity should exist. 3. Also check harness for short to power. OK or NG OK >> GO TO 5. NG >> Repair open circuit or short to power in harness or connectors. EC-1867 COOLING FAN [K9K] 5. CHECK COOLING FAN MOTOR CIRCUIT FOR OPEN AND SHORT 1. 2. Disconnect cooling fan motor harness connector. Check harness continuity between the following terminals. Cooling fan motor terminal 1 and IPDM E/R terminal 12, Cooling fan motor terminal 1 and IPDM E/R terminal 10, Cooling fan motor terminal 2 and ground. Refer to Wiring diagram. Continuity should exist. 3. Also check harness for short to ground and short to power. OK or NG OK >> GO TO 7. NG >> GO TO 6. 6. DETECT MALFUNCTIONING PART Check the following. ● Resistor E62 ● Harness for open or short between cooling fan motor and IPDM E/R ● Harness for open or short between cooling fan motor and ground >> Repair open circuit or short to ground in harness or connectors. 7. CHECK COOLING FAN MOTOR Refer to EC-1868, "Component Inspection" . OK or NG OK >> GO TO 8. NG >> Replace cooling fan motor. 8. CHECK INTERMITTENT INCIDENT Perform EC-1697, "TROUBLE DIAGNOSIS FOR INTERMITTENT INCIDENT" . OK or NG OK >> Replace IPDM E/R. Refer to PG-18, "IPDM E/R (INTELLIGENT POWER DISTRIBUTION MODULE ENGINE ROOM)" . NG >> Repair or replace harness or connector. Component Inspection BBS004UJ COOLING FAN MOTOR 1. 2. 3. Disconnect cooling fan motor harness connector. Supply cooling fan motor terminals with battery voltage and check operation. If NG, replace cooling fan motor. MBIB1557E EC-1868 MI & DATA LINK CONNECTORS [K9K] MI & DATA LINK CONNECTORS Wiring Diagram PFP:24814 A BBS00417 EC C D E F G H I J K L M MBWA1569E EC-1869 SERVICE DATA AND SPECIFICATIONS (SDS) [K9K] SERVICE DATA AND SPECIFICATIONS (SDS) PFP:00100 BBS004U1 Engines Vehicles Type E11 Suffix 274 K9K 276 Bore (mm, in) Stroke (mm, in) Displacement cm 3 (cu in) Compression ratio Catalytic converter Emission control standard 76 (2.99) 80.5 (3.17) 1,461 (89.15) 18.25/1 228 Euro 4 ENGINE SPEED (rpm) SMOKE OPACITY IDLE SPEED Max. - no load Max. - under load Homologation value Max. - legal 800 ± 50 4,500 ± 150 5,000 ± 150 2.26 m-1 (46%) 3 m-1 (73%) DESCRIPTION MARQUE/TYPE SPECIAL NOTES High pressure pump DELPHI Located on the high pressure pump 0 to 1,400 bars continuous pressure Fuel rail fuel pressure sensor DELPHI Incorporated into the fuel rail Non measurable resistance Fuel injector DELPHI Solenoid injector Maximum pressure 1600 bar Non measurable resistance Fuel pump DELPHI Resistance: 5.3 ± 0.5 Ω at 20°C ECM DELPHI ECM (computer) (112 terminals) Glow control unit NAGARES BED 7-12 With pre-postheating function controlled by the ECM Glow plug BERU or CHAMPION Resistance: Less than 0.6 Ω connector disconnected Double track potentiometer Resistance: Accelerator pedal position sensor CTS ● sensor 1: terminals 2 and 4: 1.7 ± 0.9 kΩ ● sensor 2: terminals 5 and 1: 2.4 ± 1.2 kΩ Intake air temperature sensor JAEGER CTN thermistor Resistance: 50,000 ± 6,800 Ω at - 40°C 9,500 ± 900 Ω at - 10°C 2,051 ± 120 Ω at 25°C 810 ± 47 Ω at 50°C 310 ± 17 Ω at 80°C Fuel pump temperature sensor DELPHI Located on the high pressure pump CTN thermistor Resistance: 2.2 kΩ at 25° C Engine coolant temperature sensor ELTH CTN thermistor Resistance: 76,000 ± 7,000Ω at - 40° C 12,500 ± 1,130 Ω at - 10°C 2,252 ± 112 Ω at 25° C 810 ± 40 Ω at 50° C 280 ± 8 Ω at 80° C 115 ± 3 Ω at 110°C 88 ± 2 Ω at 120° C Crankshaft position sensor MGI Variable reluctance sensor Resistance: 760 Ω Barometric pressure sensor DELPHI Built into the ECM Turbocharger boost sensor BOSCF/LDF6 20-300 Non measurable resistance Camshaft position sensor SAGEM Hall effect sensor Knock sensor SAGEM Non measurable resistance EC-1870 SERVICE DATA AND SPECIFICATIONS (SDS) [K9K] DESCRIPTION EGR volume control valve MARQUE/TYPE PIERBURG SPECIAL NOTES Resistance: ● Turbocharger boost control solenoid valve BITRON A terminals 2 and 6: 8 ± 2.3 Ω at 25°C Resistance: 18.6 ± 1.8 Ω at -30°C 21 ± 2.1 Ω at 23°C 18 ± 1.8 Ω at 110°C EC C D E F G H I J K L M EC-1871 SERVICE DATA AND SPECIFICATIONS (SDS) [K9K] EC-1872 EXTERIOR & INTERIOR I BODY SECTION EI EXTERIOR & INTERIOR A B C D CONTENTS PRECAUTIONS .......................................................... 2 Precautions for Supplemental Restraint System (SRS) “AIR BAG” and “SEAT BELT PRE-TENSIONER” .................................................................. 2 PrecautionsforProcedureswithoutCowlTopCover..... 2 Precautions .............................................................. 2 CLIP AND FASTENER ............................................... 3 Clip and Fastener ..................................................... 3 FRONT BUMPER ....................................................... 4 Removal and Installation .......................................... 4 REMOVAL ............................................................. 6 INSTALLATION ..................................................... 7 REAR BUMPER ......................................................... 8 Removal and Installation .......................................... 8 REMOVAL ............................................................. 9 INSTALLATION ..................................................... 9 FRONT GRILLE ........................................................ 10 Removal and Installation ........................................ 10 REMOVAL ........................................................... 10 INSTALLATION ................................................... 10 FRONT DEFLECTOR ................................................11 Removal and Installation .........................................11 REMOVAL ............................................................11 INSTALLATION ....................................................11 COWL TOP ............................................................... 12 Removal and Installation ........................................ 12 REMOVAL ........................................................... 12 INSTALLATION ................................................... 13 FENDER PROTECTOR ............................................ 14 Removal and Installation ........................................ 14 MUDGUARD ............................................................. 15 Removal and Installation ........................................ 15 ROOF SIDE MOLDING ............................................ 16 Removal and Installation ........................................ 16 REMOVAL ........................................................... 16 INSTALLATION ................................................... 16 WINDSHIELD MOLDING .......................................... 17 Removal and Installation ........................................ 17 REMOVAL ........................................................... 17 INSTALLATION ................................................... 18 DOOR OUTSIDE MOLDING ..................................... 19 Removal and Installation ........................................ 19 REMOVAL ........................................................... 19 INSTALLATION ................................................... 19 DOOR FINISHER ...................................................... 20 Removal and Installation ........................................ 20 REMOVAL ........................................................... 21 INSTALLATION ................................................... 21 BACK DOOR TRIM ................................................... 22 Removal and Installation ........................................ 22 REMOVAL ........................................................... 22 INSTALLATION ................................................... 23 LICENSE PLATE FINISHER ..................................... 24 Removal and Installation ........................................ 24 REMOVAL ........................................................... 24 INSTALLATION ................................................... 25 BODY SIDE TRIM ..................................................... 26 Removal and Installation ........................................ 26 REMOVAL ........................................................... 26 INSTALLATION ................................................... 27 REAR PARCEL SHELF FINISHER .......................... 28 Component Parts Location ..................................... 28 FLOOR TRIM ............................................................ 29 Removal and Installation ........................................ 29 REMOVAL ........................................................... 29 INSTALLATION ................................................... 29 HEADLINER .............................................................. 30 Removal and Installation ........................................ 30 REMOVAL ........................................................... 30 INSTALLATION ................................................... 31 LUGGAGE FLOOR TRIM ......................................... 32 Removal and Installation ........................................ 32 REMOVAL ........................................................... 33 INSTALLATION ................................................... 33 EI-1 E F G H EI J K L M PRECAUTIONS PFP:00001 PRECAUTIONS Precautions for Supplemental Restraint System (SRS) “AIR BAG” and “SEAT BELT PRE-TENSIONER” BIS000T5 The Supplemental Restraint System such as “AIR BAG” and “SEAT BELT PRE-TENSIONER”, used along with a front seat belt, helps to reduce the risk or severity of injury to the driver and front passenger for certain types of collision. Information necessary to service the system safely is included in the SRS and SB section of this Service Manual. WARNING: ● To avoid rendering the SRS inoperative, which could increase the risk of personal injury or death in the event of a collision which would result in air bag inflation, all maintenance must be performed by an authorized NISSAN/INFINITI dealer. ● Improper maintenance, including incorrect removal and installation of the SRS, can lead to personal injury caused by unintentional activation of the system. For removal of Spiral Cable and Air Bag Module, see the SRS section. ● Do not use electrical test equipment on any circuit related to the SRS unless instructed to in this Service Manual. SRS wiring harnesses can be identified by yellow and/or orange harnesses or harness connectors. Precautions for Procedures without Cowl Top Cover BIS000T6 When performing the procedure after removing cowl top cover, cover the lower end of windshield with urethane, etc. PIIB3706J Precautions BIS000T7 When removing or disassembling any part, be careful not to damage or deform it. Protect parts, which may get in the way with cloth. ● When removing parts with a screwdriver or other tool, protect parts by wrapping them with vinyl or tape. ● Keep removed parts protected with cloth. ● If a clip is deformed or damaged, replace it. ● If an unreusable part is removed, replace it with a new one. ● Tighten bolts and nuts firmly to the specified torque. ● After re-assembly has been completed, make sure each part functions correctly. ● Remove stains in the following way. Water-soluble stains: Dip a soft cloth in warm water, and then squeeze it tightly. After wiping the stain, wipe with a soft dry cloth. Oil stain: Dissolve a synthetic detergent in warm water (density of 2 to 3% or less), dip the cloth, then clean off the stain with the cloth. Next, dip the cloth in fresh water and squeeze it tightly. Then clean off the detergent completely. Then wipe the area with a soft dry cloth. ● Do not use any organic solvent, such as thinner or benzine. ● EI-2 CLIP AND FASTENER CLIP AND FASTENER Clip and Fastener PFP:76906 A BIS000T8 B C D E F G H EI J K L M SIIA0315E EI-3 FRONT BUMPER FRONT BUMPER Removal and Installation ● PFP:F2022 BIS000T9 Bumper fascia is made of plastic. Do not use excessive force and be sure to protect it from exposure to oil. EI-4 FRONT BUMPER A B C D E F G H EI J K L M MIIB9318E 1. Bumper fascia 2. Front emblem 3. Front deflector 4. Towing cover 5. Bumper stay RH 6. Bumper side bracket RH 7. Bumper energy absorber 8. Bumper reinforcement 9. Bumper stay LH EI-5 FRONT BUMPER 10. Grommet 11. Bumper side bracket LH 12. Front air guide 13. Hook lock support stay 14. Radiator core upper support 15. Radiator core lower support 16. Front grille 17. Bumper under cover 18. Guide 19. Front fog lamp (if equipped) 20. Fog lamp finisher (if equipped) 21. Bumper fascia finisher (model without front fog lamp) : Pawl : Refer to text REMOVAL 1. 2. 3. 4. 5. Remove front mud guard (if equipped). Refer to EI-15, "MUDGUARD" . Remove fender protector fixing bolts. Remove partially fender protectors (right, left) to access to bumper fascia mountings bolts. Refer to EI-14, "FENDER PROTECTOR" . Remove front bumper lowers clips. Squeeze the front grille fasteners LH and RH to the outside direction (arrow direction 1) and push forward to release (arrow direction 2). Remove mountings bolts from both side of front bumper. PIIB5089J 6. Raise the front bumper and pull to release it from the front fender on both sides. PIIB2537J 7. Disconnect front fog lamps harness connectors (if equipped) on both sides. 8. Remove the front bumper assembly from the vehicle. NOTE: This operation requires two workers 9. Remove front fog lamp finisher (if equipped). Refer to LT-87, "Removal and Installation" . 10. Remove front fog lamp (if equipped). Refer to LT-87, "Removal and Installation" . 11. Remove the front bumper energy absorber. EI-6 PIIB2538J FRONT BUMPER 12. Remove clip from bumper reinforcement on both sides. A B C PIIB2539J D 13. Remove bolts from hook lock support stay. E F G PIIB5569J 14. Remove four mountings nuts on the LH and two mountings nuts on the RH of bumper reinforcement, and remove the bumper reinforcement from the body. 15. Remove bumper stay LH and RH, bumper side brackets LH and RH, front air guide LH and RH. INSTALLATION H EI Install in the reverse order of removal. NOTE: After installation, adjust the clearance. J Portion Clearance mm (in) Front grille - Hood A-A 6.5 ± 2.0 (0.256 ± 0.079) Front grille - Hood B-B 6.5 ± 2.0 (0.256 ± 0.079) Front grille - Head lamp C-C 2.5 ± 1.5 (0.098 ± 0.059) Front bumper - Head lamp D-D 2.0 ± 1.6 (0.079 ± 0.063) Front bumper - Front fender E-E 0.0 + 1.0 (0.000 + 0.039) K L M EI-7 REAR BUMPER REAR BUMPER Removal and Installation PFP:H5022 BIS000TA Bumper fascia is made of plastic. Do not use excessive force and be sure to protect it from exposure to oil. MIIB9319E 1. Reflector LH 2. Rear fog lamp 3. Reflector RH 4. Bumper fascia 5. Rear combination lamp LH 6. Rear combination lamp RH 7. Rear fender cover LH 8. Bumper fascia protector LH 9. Bumper fascia energy absorber 10. Bumper fascia protector RH 11. Bumper fascia stay LH 12. Grommet 13. Bumper fascia stay RH 14. Rear fender cover RH 15. Rear panel (lower) 16. Bumper fascia retainer 17. Air extractor LH 18. Air extractor RH 19. Bumper fascia bracket LH 20. Bumper fascia bracket RH 21. Grommet : Pawl EI-8 REAR BUMPER REMOVAL 1. 2. 3. A Remove lower fixing bolts from rear combination lamp LH and RH. Remove rear bumper lowers clips. Remove rear bumper mountings bolts LH and RH on the rear fender. B C MIIB9320E 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. D Pull the rear bumper fascia to outside vehicle direction and disengage the fascia from the side of the vehicle. E Remove bumper fascia mountings bolts LH and RH on the rear gate. Remove rear mudguard LH and RH (if equipped). Refer to EIF 15, "MUDGUARD" . Remove partially the bumper fascia to disconnect the rear fog lamp harness connector. G NOTE: This operation requires two workers. PIIB2547J Remove the bumper fascia from the rear side of the vehicle. H Disengage clip securing the rear fender cover LH and RH to the rear fender. Remove the rear fog lamp. Refer to LT-97, "Removal and Installation" . Remove the reflex reflector LH and RH. EI Remove fascia bumper energy absorber. Remove rear panel (lower), bumper fascia protector LH and RH, bumper fascia stay LH and RH, bumper J fascia bracket LH and RH, air extractor LH and RH. INSTALLATION Install in the reverse order of removal. NOTE: Before installation check bumper fascia bracket LH and RH for break. K L M MIIB9323E NOTE: After installation, adjust the clearance. Portion Clearance mm (in) Rear fender - Rear bumper A-A 0.0 + 1.0 (0.000 + 0.039) Rear fender cover - Rear bumper B-B 0.0 + 1.0 (0.000 + 0.039) Back door - Rear bumper C-C 6.0 ± 2.0 (0.236 ± 0.079) EI-9 FRONT GRILLE FRONT GRILLE Removal and Installation PFP:62310 BIS000TB REMOVAL 1. 2. Remove front grille mounting clips. Refer to EI-4, "FRONT BUMPER" . Squeeze the front grille fasteners LH and RH to the outside direction (arrow direction 1) and push forward to release (arrow direction 2). PIIB5089J 3. Push the front grille from back side to disengage pawls from the front bumper. INSTALLATION Install in the reverse order of removal. EI-10 FRONT DEFLECTOR FRONT DEFLECTOR Removal and Installation PFP:96015 A BIS000TC B C D E F G H EI MIIB9327E 1. J Front deflector REMOVAL 1. 2. Remove mountings clips from the front bumper. Remove the front deflector. K INSTALLATION L Install in the reverse order of removal. M EI-11 COWL TOP COWL TOP Removal and Installation PFP:66100 BIS000TD PIIB4890J 1. Front fender cover 2. Side seal rubber and foam 3. Front washer hose 4. Plastic retainer* 5. Cowl top 6. Cowl top seal rubber 7. Vehicle identification cover 8. Cowl top sealing 9. Front wiper motor and link 10. Cowl top extension 11. Dash insulator 12. Plastic nuts *: Refer to text : Pawl : Plastic clip : Always replace after every disassembly REMOVAL 1. 2. 3. Remove front wiper motor rand link (LH and RH). Refer to WW-43, "Removal and Installation of Front Wiper Drive Assembly" . Disconnect the Front washer hose. Remove front fender cover (LH and RH). PIIB2555J EI-12 COWL TOP 4. 5. 6. Remove plastic retainer as follow. ● Expand and maintain the central clip to upper and lower direction. ● Pull the plastic clip to vehicle front direction to release the clip. Remove plastic clips from cowl top on left and right side. Remove side seal rubber (LH and RH) and foams. A B C PIIB2815J D 7. 8. Separate front wiper harness from the cowl top extension. Remove plastic nuts and fixing screws from the cowl top extension and remove cowl top extension. E F G PIIB2556J INSTALLATION Install in the reverse order of removal. NOTE: If the cowl top is reused, discard and replace the cowl top sealing by a new one. H EI J K L M EI-13 FENDER PROTECTOR FENDER PROTECTOR Removal and Installation PFP:63840 BIS000TE MIIB9333E 1. Fender protector 2. Spring nut : Front bumper fascia : Front mud guard (if equipped) EI-14 MUDGUARD MUDGUARD Removal and Installation PFP:63854 A BIS0014Z B C D E F G H EI MIIB9337E 1. Front mudguard (if fitted) 2. Rear mudguard (if fitted) J K L M EI-15 ROOF SIDE MOLDING ROOF SIDE MOLDING Removal and Installation PFP:73854 BIS000TF MIIB9335E 1. Roof side molding 2. Ended cap 3. Double sided tape 4. Roof panel flange 5. Roof panel 6. Body side outer panel : Always replace after every disassembly REMOVAL 1. 2. Use a plastic knife, etc., and lift up the end of roof side molding (back end), remove clip, and peel off double-sided tape to remove it. Remove the double-sided tape remaining on roof side molding back and vehicle body. NOTE: Double-sided tape can be easily removed using double-sided tape removal agent. PIIB4893J INSTALLATION NOTE: When only installing roof side molding, conduct the following procedure from Step 3. 1. Clean the roof side molding clip attachment surface (body side). 2. Bond roof side molding clip (body side) to vehicle body and let sit for 40 min. 3. Apply primer (Sumitomo3M N200 or comparable product) to roof side molding back double-sided tape application area. 4. Apply double-sided tape to roof side molding back (position in figure). 5. After butting roof side molding front end against window seal molding, push in molding from front to back end, and then affix to body using double-sided tape. EI-16 WINDSHIELD MOLDING WINDSHIELD MOLDING Removal and Installation PFP:72750 A BIS000TG B C D E F G MIIB0062E CAUTION: Be careful when handling adhesive and primer. H REMOVAL 1. 2. Remove cowl top cover. Refer to EI-12, "COWL TOP" . Peel off double-sided tape and remove front fender covers (LH/ RH) from front fenders (LH/RH). EI J K MIIB9073E 3. 4. 5. Apply protective tape along the contour of windshield molding and cut molding lip with cutter knife. Tear off excess molding from end of molding to glass. With pliers, draw out all the remaining molding left in flanged area of body to remove it completely from adhering surface on glass. M MIIB0064E EI-17 L WINDSHIELD MOLDING INSTALLATION 1. Apply primer between glass and panel then apply enough adhesive to allow molding adhesion. NOTE: ● The essential function of primers is to strengthen adhesion between glass and painted surface. ● There are 2 types of primer. Never confuse the application methods. Primer M ··· for painted surfaces Primer G ··· for glass ● If primer M overflows onto a painted surface other than bonding area, quickly remove it with white gasoline. 2. Apply primer to entire perimeter of molding area shown in the figure. 3. Align molding positioning mark (center of molding: white) with glass top edge center spacer positioning mark, push in so that molding's lower chin hooks onto glass, then continuing pushing toward the outside. CAUTION: After installing molding, make sure there are no non-standard conditions, such as a lip sticking out or wave in molding. MIIB0065E MIIB0066E 4. 5. Remove protective tape. Remove double-sided tape from front fender cover and apply primer (Sumitomo 3M K520) to double-sided tape application position shown in the figure. Then apply new double-sided tape and install front fender. MIIB9074E 6. Install cowl top cover. Refer to EI-12, "COWL TOP" . EI-18 DOOR OUTSIDE MOLDING DOOR OUTSIDE MOLDING Removal and Installation PFP:82820 A BIS000TH B C D E F G H EI PIIB4894J 1. Front door outside molding 4. Grommet 2. Rear door outside molding 3. J Front fender finisher : Plastic clip K REMOVAL 1. 2. Fully open the door glass. Take the door outside molding end by fingers and pull to disengage the plastic clip from the door outer panel. Insert a clip remover between the door outer panel and outside molding end if there is a risk to deform the door outside molding. 3. Pull upward to remove the door outside molding from the door outer panel. CAUTION: After removal, visually inspect molding, and if it is deformed, replace it with a new one. L M PIIB3386J INSTALLATION Install in the reverse order of removal. EI-19 DOOR FINISHER DOOR FINISHER Removal and Installation PFP:80900 BIS000TJ MIIB9329E 1. Power door switch finisher (front door) 2. Front door finisher 3. Inside handle escutcheon 4. Pull handle 5. Pull handle cap 6. Power door switch finisher (rear door) 7. Rear door finisher 8. Rear door corner cover 9. Front door corner cover* 10. Dust cover* *: Refer to GW section : Pawl : molded clip : Metal clip EI-20 DOOR FINISHER REMOVAL 1. 2. 3. A Fully open door glass. Pull up inside handle lever, and then spread inside handle escutcheon top and bottom to release top and bottom hooks. Slide inside handle escutcheon backwards, disengage bottom, and remove from door finisher. B C D MIIB0070E 4. 5. 6. Insert a clip remover wrapped with tape into back of power window switch finisher, hold up the back end, and disengage metal clips. Hold up front side, remove inserted area, and remove. Pull back rear side, remove inserted area, and remove. Separate the power window switch finisher back harness connector and remove it. E F G PIIB4900J 7. 8. 9. Remove door pull handle cap and screw. Remove front door corner cover. Refer to GW-101, "Removal and Installation" . Insert clip driver or clip clamp remover into door finisher back clip and remove clip. NOTE: Insert a clip driver or clip clamp remover into the part shown by the arrow (between the body side panel and the clips). Remove finisher. H EI J K L MIIB0072E 10. Pull door finisher upwards to remove it from door panel. INSTALLATION Note the following, and install in the reverse order of removal. CAUTION: When installing finisher, confirm clips are accurately aligned with the holes on body side panel, then press in. EI-21 M BACK DOOR TRIM BACK DOOR TRIM Removal and Installation PFP:90900 BIS000TK MIIB9326E 1. Back door side finisher LH 2. Back door side finisher RH 3. Back door finisher : Metal clip REMOVAL 1. 2. 3. Insert a suitable tool between the back door inner panel and back door finisher, to access to mountings clips. Using a clip remover, remove clips from the back door panel. Disengage metal clips from the back door panel and remove back door finisher, and separate back door finisher from back door side finisher LH and RH. MIIB9324E 4. 5. Insert a suitable tool between the back door inner panel and back door side finisher and to disengage metal clips. Remove back door side finisher. MIIB9325E EI-22 BACK DOOR TRIM INSTALLATION Note the following, and install in the reverse order of removal. CAUTION: When installing, confirm clips are accurately aligned with the holes on body side panel, then press in. A B C D E F G H EI J K L M EI-23 LICENSE PLATE FINISHER LICENSE PLATE FINISHER Removal and Installation PFP:84810 BIS00150 MIIB9328E 1. License plate finisher 2. License plate lamp and back door switch actuator harness REMOVAL 1. 2. 3. Remove the back door finisher. Refer to EI-22, "BACK DOOR TRIM" . Remove nuts securing the license plate finisher to the back door panel. Pull the license plate finisher to downward direction to disengage fixing clips from the back door panel. MIIB9321E EI-24 LICENSE PLATE FINISHER 4. 5. 6. Release license plate lamp LH (1) and RH (2) from holder (3), and disconnect harness connector. Remove screws securing the holder to the license plate finisher (5) and disconnect back door lock switch actuator (4). Separate license plate lamp and back door switch actuator harness from the holder. NOTE: For easier installation, locate the position of harness and component. A B C MIIB9322E D INSTALLATION Install in the reverse order of removal, paying attention to following points: ● Before installation of back door finisher, close the back door and check the correct operation of back door lock switch actuator. ● Check the correct operation of license plate lamp LH and RH. E F G H EI J K L M EI-25 BODY SIDE TRIM BODY SIDE TRIM Removal and Installation PFP:76913 BIS000TN MIIB9332E 1. Front pillar garnish 2. Front body side welt 3. Dashboard side finisher 4. Rear parcel shelf holder 5. Center pillar lower garnish 6. Rear pillar garnish 7. Rear body side welt 8. Center pillar upper garnish 9. Ledge : Insertion : Pawl : Plastic clip : Metal clip : Refer to text REMOVAL Front Body Side Welt Remove front body side welt from vehicle. Dashboard Side Finisher 1. 2. Remove front body side welt from vehicle. Pull dash side finisher slanted backwards to remove it. Front Pillar Garnish 1. 2. Remove partially front body side welt. Remove the mounting clips, pull the front pillar garnish from inside the passenger room, and remove it. EI-26 BODY SIDE TRIM Center Pillar Lower Garnish 1. 2. Remove partially front and rear body side welt. Spread the area engaged in the center pillar flange, remove front side first and then remove rear side in the same manner. B Center Pillar Upper Garnish 1. 2. 3. 4. A Remove partially front and rear body side welt. Remove center pillar lower garnish. Remove front seat belt shoulder anchor. Refer to SB-3, "Removal and Installation of Front Seat Belt" . Pull center pillar upper garnish from inside passenger room, disengage clips as instructed in the figure, and remove garnish from vehicle. C D E F G MIIB0074E Rear Pillar Garnish 1. 2. 3. 4. Remove partially rear body side welt. Remove Luggage side finisher. Refer to EI-33, "Luggage Side Finisher" . Remove rear seat belt upper anchor. Refer to SB-4, "Removal and Installation of Rear Seat Belt" . Release clips and remove rear pillar garnish. H EI INSTALLATION Install in the reverse order of removal. J K L M EI-27 REAR PARCEL SHELF FINISHER REAR PARCEL SHELF FINISHER Component Parts Location PFP:79910 BIS0015D MIIB9334E 1. Rear parcel shelf finisher EI-28 FLOOR TRIM FLOOR TRIM Removal and Installation PFP:74902 A BIS000TQ B C D E F G H EI MIIB9330E 1. Floor carpet 2. Steering column shaft cover 3. Front floor spacer LH 4. Front floor spacer RH 5. Front floor center LH 6. Front floor center RH 7. Rear floor spacer LH 8. Rear floor spacer RH J K : Clip REMOVAL 1. 2. 3. 4. 5. 6. 7. 8. 9. Remove front seats (LH/RH) and rear seat cushion. Refer to SE-7, "FRONT SEAT" and SE-12, "REAR SEAT" in SE section. Remove center console. Refer to IP-13, "Removal And Installation" in IP section. Remove air bag sensor unit harness connector and harness clips. Refer to SRS-48, "DIAGNOSIS SENSOR UNIT" in SRS section. Remove instrument panel stay cover. Refer to IP-5, "Removal and Installation" in IP section. Remove center pillar lower garnish (LH/RH). Refer to EI-26, "Removal and Installation" in EI section. Remove partially body side welts (LH/RH). Remove dash side finishers (LH/RH). Refer to EI-26, "BODY SIDE TRIM" in EI section. Remove carpet hook. Remove floor carpet from vehicle. INSTALLATION Install in the reverse order of removal. EI-29 L M HEADLINER HEADLINER Removal and Installation PFP:73910 BIS000TR MIIB9336E 1. Headliner 2. Assist grip 3. Room lamp 4. Room harness 5. Sunvisor holder 6. Harness 7. Room lamp 8. Sunvisor 9. Cap 10. Assist grip 11. Adhesive 12. Microphone spacer (if equipped) 13. Spacer : Pawl : Plastic clip : Metal clip : Always replace after every disassembly REMOVAL 1. 2. 3. 4. Remove front pillar garnish. Refer to EI-26, "BODY SIDE TRIM" in EI section. Remove back door weatherstrip. Remove luggage side upper finishers (LH/RH). Refer to EI-32, "LUGGAGE FLOOR TRIM" in EI section. Remove center pillar upper garnish (5-door vehicles) and lock pillar upper garnish (3-door vehicles). Refer to EI-26, "BODY SIDE TRIM" in EI section. EI-30 HEADLINER 5. Remove assist grip. NOTE: When removing assist grip, insert a thin screwdriver, etc., into the clip and move the clip outside. A B C MIIB0078E D 6. 7. 8. Remove sunvisors (LH/RH). Remove room lamp (with map lamp function). Refer to LT-171, "MAP LAMP, PERSONAL LAMP" . Remove sunvisor holder. NOTE: Insert a screwdriver into the cutout and rotate 90° to remove. E F G SIIA0224J 9. Remove vehicle rear clips. 10. Peel off headliner adhesive and remove headliner from back door opening. CAUTION: The roof panel could be deformed, so do not strongly pull the headliner. H EI J K MIIB0079E L INSTALLATION 1. 2. Remove any adhesive left on the vehicle side. Apply adhesive to headliner. Adhesive: 3. 4. 5. M Yokohama Rubber Hammer Tight YM-21, or BETAMATE 7138 Move front seats (LH/RH) toward front of vehicle, and fix headrests (LH/RH) in top position. Place the headliner front section on the headrest and fasten the headliner rear section with the clips. After installing sunvisor holder, install in the reverse order of removal. MIIB9106E EI-31 LUGGAGE FLOOR TRIM LUGGAGE FLOOR TRIM Removal and Installation PFP:84999 BIS000TW MIIB9331E 1. Luggage floor lid RR 2. Luggage floor lid FR 3. 4. Luggage floor carpet 5. Trunk room lamp 6. Rope hook 7. Cap 8. Luggage side finisher 9. Mask 10. Hook : Pawl : Plastic clip : Metal clip EI-32 Luggage rear kick plate LUGGAGE FLOOR TRIM REMOVAL Luggage Side Finisher 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. A Remove rear parcel shelf. Refer to EI-28, "REAR PARCEL SHELF FINISHER" . Remove luggage floor lid FR and RR. Remove luggage floor carpet. Remove luggage rear plate. Refer to EI-33, "Luggage Rear Kickplate" . Remove cigar lighter (if equipped) and disconnect harness connector. Remove Trunk room lamp. Refer to LT-172, "LUGGAGE ROOM LAMP" . Remove cap and remove bolts securing the luggage side finisher to the rear fender inner panel. Remove hook and rope hook. Remove plastic clips securing the luggage side finisher to rear fender inner panel. Remove metal clips securing the luggage side finisher to rear fender inner panel. Separate the luggage side finisher from the rear pillar garnish. Remove luggage side finisher. Luggage Rear Kickplate 1. 2. 3. 4. 5. B C D E F Remove rear parcel shelf finisher. Remove luggage floor lid FR and RR. Remove partially back door weather strip. Remove luggage side finisher. Remove luggage rear kickplate. G H INSTALLATION Install in the reverse order of removal. EI J K L M EI-33 LUGGAGE FLOOR TRIM EI-34 ENGINE MECHANICAL B ENGINE SECTION EM ENGINE MECHANICAL A EM C D CONTENTS CR PRECAUTIONS .......................................................... 7 Precautions for Draining Coolant ............................. 7 Precautions for Disconnecting Fuel Piping .............. 7 Precautions for Removal and Disassembly ............. 7 Precautions for Inspections, Repairs, and Replacement ......................................................................... 7 Precautions for Assembling and Installing ............... 7 Parts Requiring Angle Tightening ............................. 7 Precautions for Liquid Gasket .................................. 8 REMOVAL OF LIQUID GASKET SEALING .......... 8 LIQUID GASKET APPLICATION PROCEDURE..... 8 PREPARATION ........................................................... 9 Special Service Tools ............................................... 9 Commercial Service Tools .......................................11 NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING .............................................. 12 NVH Troubleshooting —Engine Noise ................... 12 Use the Chart Below to Help You Find the Cause of the Symptom. ..................................................... 13 DRIVE BELTS ........................................................... 14 Checking drive Belts .............................................. 14 Tension Adjustment ................................................ 14 ALTERNATOR AND A/C COMPRESSOR BELT (WITH A/C MODELS) ......................................... 15 ALTERNATOR BELT (WITHOUT A/C MODELS)... 15 WATER PUMP BELT .......................................... 16 Removal and Installation ........................................ 16 REMOVAL ........................................................... 16 INSTALLATION ................................................... 16 Removal and Installation of Drive Belt Idler Pulley... 16 REMOVAL ........................................................... 17 INSTALLATION ................................................... 17 AIR CLEANER AND AIR DUCT ............................... 18 Removal and Installation ........................................ 18 REMOVAL ........................................................... 18 INSTALLATION ................................................... 19 Changing Air Cleaner Filter .................................... 21 REMOVAL ........................................................... 21 INSTALLATION ................................................... 21 INTAKE MANIFOLD ................................................. 22 Removal and Installation ........................................ 22 REMOVAL ........................................................... 22 INSTALLATION ................................................... 23 EXHAUST MANIFOLD AND THREE WAY CATALYST .......................................................................... 24 Removal and Installation ........................................ 24 REMOVAL ........................................................... 24 INSPECTION AFTER REMOVAL ....................... 25 INSTALLATION ................................................... 25 OIL PAN AND OIL STRAINER ................................. 26 Removal and Installation ........................................ 26 REMOVAL ........................................................... 26 INSTALLATION ................................................... 27 INSPECTION AFTER INSTALLATION ................ 28 IGNITION COIL ......................................................... 29 Removal and Installation ........................................ 29 REMOVAL ........................................................... 29 INSTALLATION ................................................... 29 SPARK PLUG (PLATINUM-TIPPED TYPE) ............. 30 Removal and Installation ........................................ 30 REMOVAL ........................................................... 30 INSPECTION AFTER REMOVAL ....................... 30 INSTALLATION ................................................... 31 FUEL INJECTOR AND FUEL TUBE ........................ 32 Removal and Installation ........................................ 32 REMOVAL ........................................................... 32 INSTALLATION ................................................... 33 INSPECTION AFTER INSTALLATION ................ 34 ROCKER COVER ..................................................... 35 Removal and Installation ........................................ 35 REMOVAL ........................................................... 35 INSTALLATION ................................................... 36 CAMSHAFT .............................................................. 38 Removal and Installation ........................................ 38 REMOVAL ........................................................... 38 INSTALLATION ................................................... 41 INSPECTION AFTER REMOVAL ....................... 44 EM-1 E F G H I J K L M INSPECTION AFTER INSTALLATION ................ 47 Valve Clearance ...................................................... 47 INSPECTION ....................................................... 47 ADJUSTMENT .................................................... 49 TIMING CHAIN .......................................................... 50 Removal and Installation ........................................ 50 REMOVAL ........................................................... 51 INSPECTION AFTER REMOVAL ........................ 53 INSTALLATION .................................................... 53 INSPECTION AFTER INSTALLATION ................ 56 OIL SEAL .................................................................. 57 Removal and Installation of Valve Oil Seal ............. 57 REMOVAL ........................................................... 57 INSTALLATION .................................................... 57 Removal and Installation of Front Oil Seal ............. 57 REMOVAL ........................................................... 57 INSTALLATION .................................................... 58 Removal and Installation of Rear Oil Seal .............. 58 REMOVAL ........................................................... 58 INSTALLATION .................................................... 58 CYLINDER HEAD ..................................................... 60 On Vehicle Inspection ............................................. 60 COMPRESSION PRESSURE INSPECTION ...... 60 Removal and Installation ........................................ 61 REMOVAL ........................................................... 61 INSPECTION AFTER REMOVAL ........................ 62 INSTALLATION .................................................... 62 Disassembly and Assembly .................................... 63 DISASSEMBLY ................................................... 64 ASSEMBLY ......................................................... 64 INSPECTION AFTER DISASSEMBLY ................ 65 ENGINE ASSEMBLY ................................................ 70 Removal and Installation ........................................ 70 REMOVAL ........................................................... 71 INSTALLATION .................................................... 73 INSPECTION AFTER INSTALLATION ................ 73 CYLINDER BLOCK ................................................... 74 Disassembly and Assembly .................................... 74 DISASSEMBLY ................................................... 75 ASSEMBLY ......................................................... 77 How to Select Piston and Bearing .......................... 82 DESCRIPTION .................................................... 82 HOW TO SELECT PISTON ................................. 83 HOW TO SELECT MAIN BEARING .................... 84 Inspection After Disassembly ................................. 85 CRANKSHAFT SIDE CLEARANCE .................... 85 CONNECTING ROD SIDE CLEARANCE ........... 85 PISTON AND PISTON PIN CLEARANCE .......... 85 PISTON RING SIDE CLEARANCE ..................... 86 PISTON RING END GAP .................................... 86 CONNECTING ROD BEND AND TORSION ....... 87 CONNECTING ROD BEARING HOUSING DIAMETER (BIG END) ........................................ 87 CONNECTING ROD BUSHING OIL CLEARANCE DIAMETER (SMALL END) ....................... 87 CYLINDER BLOCK DISTORTION ...................... 88 INNER DIAMETER OF MAIN BEARING HOUS- ING .......................................................................88 PISTON TO CYLINDER BORE CLEARANCE ...89 OUTER DIAMETER OF CRANKSHAFT JOURNAL ......................................................................90 OUTER DIAMETER OF CRANKSHAFT PIN ......90 OUT-OF-ROUND AND TEPER OF CRANKSHAFT .................................................................90 CRANKSHAFT RUNOUT ....................................91 OIL CLEARANCE OF CONNECTING ROD BEARING .............................................................91 OIL CLEARANCE OF MAIN BEARING ...............92 CRUSH HEIGHT OF MAIN BEARING OR CONNECTING ROD BEARING ...................................92 FLYWHEEL RUNOUT .........................................93 SERVICE DATA AND SPECIFICATIONS (SDS) ......94 Standard and Limit ..................................................94 GENERAL SPECIFICATIONS .............................94 INTAKE MANIFOLD AND EXHAUST MANIFOLD ...................................................................94 DRIVE BELTS ......................................................95 SPARK PLUG ......................................................95 CYLINDER HEAD ................................................95 VALVE ..................................................................96 CAMSHAFT AND CAMSHAFT BEARING ...........99 CYLINDER BLOCK ..............................................99 PISTON, PISTON RING AND PISTON PIN ...... 100 CONNECTING ROD .......................................... 101 CRANKSHAFT ................................................... 101 MAIN BEARING ................................................. 101 CONNECTING ROD BEARING ......................... 102 MISCELLANEOUS COMPONENTS .................. 102 Tightening Torque ................................................. 103 HR PRECAUTIONS ....................................................... 105 Precautionsfor ProcedureswithoutCowl TopCover. 105 Precautions for Draining Engine Coolant .............. 105 Precautions for Disconnecting Fuel Piping ........... 105 Precautions for Removal and Disassembly .......... 105 Precautions for Inspection, Repair and Replacement ...................................................................... 105 Precautions for Assembly and Installation ............ 105 Parts Requiring Angle Tightening ......................... 105 Precautions For Liquid Gasket .............................. 106 REMOVAL OF LIQUID GASKET ....................... 106 LIQUID GASKET APPLICATION PROCEDURE.106 PREPARATION ....................................................... 108 Special Service Tools ............................................ 108 Commercial Service Tools .................................... 110 NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING ............................................ 112 NVH Troubleshooting — Engine Noise ................. 112 Use the Chart Below to Help You Find the Cause of the Symptom. .................................................... 113 DRIVE BELTS .......................................................... 114 Checking Drive Belts ............................................. 114 Tension Adjustment ............................................... 114 Removal and Installation ....................................... 115 EM-2 REMOVAL ..........................................................115 INSTALLATION ..................................................115 Removal and Installation of Drive Belt Idler Pulley..116 REMOVAL ..........................................................116 INSTALLATION ..................................................117 AIR CLEANER AND AIR DUCT ..............................118 Components ..........................................................118 Removal and Installation .......................................118 REMOVAL ..........................................................118 INSTALLATION ..................................................119 Changing Air Cleaner Filter ...................................119 REMOVAL ..........................................................119 INSPECTION AFTER REMOVAL ......................119 INSTALLATION ..................................................119 INTAKE MANIFOLD ............................................... 120 Components ......................................................... 120 Removal and Installation ...................................... 121 REMOVAL ......................................................... 121 INSTALLATION ................................................. 122 EXHAUST MANIFOLD ........................................... 124 Components ......................................................... 124 Removal and Installation ...................................... 125 REMOVAL ......................................................... 125 INSPECTION AFTER REMOVAL ..................... 126 INSTALLATION ................................................. 126 OIL PAN AND OIL STRAINER ............................... 127 Components ......................................................... 127 Removal and Installation ...................................... 127 REMOVAL ......................................................... 127 INSTALLATION ................................................. 128 INSPECTION AFTER INSTALLATION ............. 131 IGNITION COIL ....................................................... 132 Components ......................................................... 132 Removal and Installation ...................................... 132 REMOVAL ......................................................... 132 INSTALLATION ................................................. 132 SPARK PLUG (PLATINUM-TIPPED TYPE) ........... 133 Components ......................................................... 133 Removal and Installation ...................................... 133 REMOVAL ......................................................... 133 INSPECTION AFTER REMOVAL ..................... 133 INSTALLATION ................................................. 134 FUEL INJECTOR AND FUEL TUBE ...................... 135 Components ......................................................... 135 Removal and Installation ...................................... 135 REMOVAL ......................................................... 135 INSTALLATION ................................................. 137 INSPECTION AFTER INSTALLATION ............. 139 ROCKER COVER ................................................... 140 Components ......................................................... 140 Removal and Installation ...................................... 140 REMOVAL ......................................................... 140 INSTALLATION ................................................. 141 TIMING CHAIN ........................................................ 142 Components ......................................................... 142 Removal and Installation ...................................... 143 REMOVAL ......................................................... 143 INSPECTION AFTER REMOVAL ..................... 146 INSTALLATION ................................................. 146 INSPECTION AFTER INSTALLATION .............. 150 CAMSHAFT ............................................................ 151 Components ......................................................... 151 Removal and Installation ...................................... 151 REMOVAL ......................................................... 151 INSPECTION AFTER REMOVAL ..................... 157 INSTALLATION ................................................. 161 INSPECTION AFTER INSTALLATION .............. 165 Valve Clearance ................................................... 166 INSPECTION .................................................... 166 ADJUSTMENT .................................................. 168 OIL SEAL ................................................................ 170 Removal and Installation of Valve Oil Seal ........... 170 REMOVAL ......................................................... 170 INSTALLATION ................................................. 170 Removal and Installation of Front Oil Seal ........... 171 REMOVAL ......................................................... 171 INSTALLATION ................................................. 171 Removal and Installation of Rear Oil Seal ............ 172 REMOVAL ......................................................... 172 INSTALLATION ................................................. 172 CYLINDER HEAD ................................................... 173 On-Vehicle Service ............................................... 173 CHECKING COMPRESSION PRESSURE ....... 173 Components ......................................................... 174 Removal and Installation ...................................... 174 REMOVAL ......................................................... 174 INSPECTION AFTER REMOVAL ..................... 175 INSTALLATION ................................................. 176 INSPECTION AFTER INSTALLATION .............. 176 Components ......................................................... 177 Disassembly and Assembly .................................. 178 DISASSEMBLY ................................................. 178 ASSEMBLY ....................................................... 178 Inspection After Disassembly ............................... 179 VALVE DIMENSIONS ........................................ 179 VALVE GUIDE CLEARANCE ............................ 179 VALVE GUIDE REPLACEMENT ....................... 180 VALVE SEAT CONTACT ................................... 181 VALVE SEAT REPLACEMENT ......................... 181 VALVE SPRING SQUARENESS ....................... 182 VALVE SPRING DIMENSIONS AND VALVE SPRING PRESSURE LOAD ............................. 182 ENGINE ASSEMBLY .............................................. 184 Components ......................................................... 184 Removal and Installation ...................................... 184 REMOVAL ......................................................... 185 INSTALLATION ................................................. 187 INSPECTION AFTER INSTALLATION .............. 188 CYLINDER BLOCK ................................................ 189 Components ......................................................... 189 Disassembly and Assembly .................................. 190 DISASSEMBLY ................................................. 190 EM-3 A EM C D E F G H I J K L M ASSEMBLY ....................................................... 193 How to Select Piston and Bearing ........................ 199 DESCRIPTION .................................................. 199 HOW TO SELECT CONNECTING ROD BEARING .................................................................... 199 HOW TO SELECT MAIN BEARING .................. 202 Inspection After Disassembly ............................... 206 CRANKSHAFT END PLAY ................................ 206 CONNECTING ROD SIDE CLEARANCE ......... 206 PISTON TO PISTON PIN OIL CLEARANCE .... 206 PISTON RING SIDE CLEARANCE ................... 207 PISTON RING END GAP .................................. 207 CONNECTING ROD BEND AND TORSION ..... 208 CONNECTING ROD BIG END DIAMETER ...... 208 CONNECTING ROD BUSHING OIL CLEARANCE ................................................................. 208 CYLINDER BLOCK DISTORTION .................... 209 MAIN BEARING HOUSING INNER DIAMETER. 209 PISTON TO CYLINDER BORE CLEARANCE . 210 CRANKSHAFT MAIN JOURNAL DIAMETER ... 211 CRANKSHAFT PIN JOURNAL DIAMETER ...... 211 OUT-OF-ROUND AND TAPER OF CRANKSHAFT ............................................................... 211 CRANKSHAFT RUNOUT .................................. 211 CONNECTING ROD BEARING OIL CLEARANCE ................................................................. 211 MAIN BEARING OIL CLEARANCE ................... 212 MAIN BEARING CRUSH HEIGHT .................... 213 CONNECTING ROD BEARING CRUSH HEIGHT ............................................................. 213 MAIN BEARING CAP BOLT OUTER DIAMETER. 213 CONNECTING ROD BOLT OUTER DIAMETER. 214 FLYWHEEL DEFLECTION ................................ 214 SERVICE DATA AND SPECIFICATIONS (SDS) .... 215 Standard and Limit ................................................ 215 GENERAL SPECIFICATIONS ........................... 215 DRIVE BELT ...................................................... 215 EXHAUST MANIFOLD ...................................... 215 SPARK PLUG (PLATINUM-TIPPED TYPE) ...... 215 CYLINDER HEAD ............................................. 215 VALVE ................................................................ 216 CAMSHAFT AND CAMSHAFT BEARING ........ 220 CYLINDER BLOCK ........................................... 220 PISTON, PISTON RING AND PISTON PIN ...... 221 CONNECTING ROD ......................................... 222 CRANKSHAFT .................................................. 222 MAIN BEARING ................................................ 224 CONNECTING ROD BEARING ........................ 225 K9K APPLICATION NOTICE .......................................... 226 How to Check Vehicle Type .................................. 226 PRECAUTIONS ....................................................... 227 Precautions for Drain Coolant .............................. 227 Precautions for Disconnecting Fuel Piping ........... 227 Precautions for Removal and Disassembly .......... 227 Precautions for Inspection, Repair and Replacement ...................................................................... 227 Precautions for Assembly and Installation ............ 227 Parts Requiring Angular Tightening ...................... 227 Precautions For Liquid Gasket .............................. 228 REMOVAL OF LIQUID GASKET ....................... 228 LIQUID GASKET APPLICATION PROCEDURE.228 Precautions for Diesel Equipment ......................... 229 CLEANLINESS .................................................. 229 SPECIAL FEATURES ........................................ 231 PREPARATION ....................................................... 233 Special Service Tools ............................................ 233 Commercial Service Tools .................................... 236 IDENTIFICATION INFORMATION .......................... 238 Engine Identification .............................................. 238 NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING ............................................ 239 NVH Troubleshooting —Engine Noise .................. 239 Use the Chart Below to Help You Find the Cause of the Symptom. .................................................... 240 ENGINE ROOM COVER ......................................... 241 Removal and Installation ....................................... 241 REMOVAL .......................................................... 241 INSTALLATION .................................................. 241 DRIVE BELTS .......................................................... 242 Checking Drive Belts ............................................. 242 Tension Adjustment ............................................... 242 MODELS WITH A/C COMPRESSOR ................ 242 MODELS WITHOUT A/C COMPRESSOR ........ 242 Removal and Installation ....................................... 243 REMOVAL .......................................................... 243 INSTALLATION .................................................. 243 AIR CLEANER AND AIR DUCT .............................245 Removal and Installation ....................................... 245 REMOVAL .......................................................... 245 INSTALLATION .................................................. 245 Changing Air Cleaner Filter ................................... 246 REMOVAL .......................................................... 246 INSTALLATION .................................................. 246 CHARGE AIR COOLER .......................................... 247 Removal and Installation (For 50kW) .................... 247 REMOVAL .......................................................... 247 INSPECTION AFTER REMOVAL ...................... 248 INSTALLATION .................................................. 248 Removal and Installation (For 65kW) .................... 249 REMOVAL .......................................................... 249 INSPECTION AFTER REMOVAL ...................... 250 INSTALLATION .................................................. 250 EGR UNIT ................................................................ 251 Removal and Installation ....................................... 251 REMOVAL .......................................................... 251 INSTALLATION .................................................. 252 EXHAUST MANIFOLD, TURBOCHARGER, CATALYST ........................................................................ 253 Removal and Installation ....................................... 253 REMOVAL .......................................................... 253 INSTALLATION .................................................. 254 EM-4 INSPECTION AFTER INSTALLATION ............. 254 Disassembly and Assembly ................................. 255 DISASSEMBLY ................................................. 255 INSPECTION AFTER DISASSEMBLY ............. 255 ASSEMBLY ....................................................... 256 OIL PAN .................................................................. 257 Removal and Installation ...................................... 257 REMOVAL ......................................................... 257 INSPECTION AFTER REMOVAL ..................... 259 INSTALLATION ................................................. 259 INSPECTION AFTER INSTALLATION ............. 259 GLOW PLUG .......................................................... 260 Removal and Installation ...................................... 260 REMOVAL ......................................................... 260 INSTALLATION ................................................. 260 VACUUM PUMP ..................................................... 261 Removal and Installation ...................................... 261 INSPECTION BEFORE REMOVAL .................. 261 REMOVAL ......................................................... 261 INSTALLATION ................................................. 261 HIGH PRESSURE PIPES ....................................... 262 Removal and Installation ...................................... 262 REMOVAL ......................................................... 262 INSTALLATION ................................................. 263 FUEL INJECTOR .................................................... 266 Removal and Installation ...................................... 266 REMOVAL ......................................................... 266 INSTALLATION ................................................. 266 INJECTOR RAIL ..................................................... 267 Removal and Installation ...................................... 267 REMOVAL ......................................................... 267 INSTALLATION ................................................. 267 HIGH PRESSURE PUMP ....................................... 268 Removal and Installation ...................................... 268 REMOVAL ......................................................... 268 INSTALLATION ................................................. 269 ROCKER COVER ................................................... 270 Removal and Installation ...................................... 270 REMOVAL ......................................................... 270 INSTALLATION ................................................. 271 TIMING BELT .......................................................... 272 Removal and Installation ...................................... 272 REMOVAL ......................................................... 272 INSTALLATION ................................................. 275 CYLINDER HEAD ................................................... 276 Removal and Installation ...................................... 276 REMOVAL ......................................................... 276 INSTALLATION ................................................. 277 Disassembly and Assembly ................................. 277 DISASSEMBLY ................................................. 277 INSPECTION AFTER DISASSEMBLY ............. 277 ASSEMBLY ....................................................... 278 ENGINE ASSEMBLY .............................................. 279 Removal and Installation ...................................... 279 REMOVAL ......................................................... 280 INSTALLATION ................................................. 281 INSPECTION AFTER INSTALLATION ............. 281 OVERHAUL ............................................................ 282 Tightening Torques ............................................... 282 UPPER ENGINE ............................................... 282 BOTTOM ENGINE ............................................ 282 Standard Replacement ......................................... 283 PREPARING USED ENGINE ............................ 283 Disassembly ......................................................... 284 REMOVING THE UPPER ENGINE ................... 284 POSITIONING THE BELT AT THE TIMING POINT ............................................................... 285 DISASSEMBLY OF THE CYLINDER HEAD ..... 288 Cleaning ............................................................... 291 Inspection ............................................................. 291 GASKET FACE ................................................. 291 CAMSHAFT END PLAY .................................... 291 Valve Clearance ................................................... 292 CHECKING AND ADJUSTING THE VALVE CLEARANCE .................................................... 292 Assembly .............................................................. 293 ASSEMBLY OF THE CYLINDER HEAD ........... 293 Disassembly of The Bottom Engine ..................... 297 REMOVAL ......................................................... 297 Assembly .............................................................. 301 INSTALLATION OF OIL JETS ........................... 301 METHOD FOR INSTALLING THE OIL COOLER AND OIL FILTER ............................................... 302 Removing The Piston Pins ................................... 302 CONNECTING ROD BEARING ........................ 303 ON THE CONNECTING ROD BODY ................ 303 ON THE CONNECTING ROD CAP .................. 304 INSTALLATION OF MAIN BEARING ................ 306 ON THE CYLINDER BLOCK ............................ 306 ON THE BEARING CAPS ................................. 307 INSTALLATION OF NO. 1 BEARING ................ 308 CONNECTING RODS / PISTON ASSEMBLY . 308 DIRECTION FOR INSTALLATION THE SNAP RINGS ON THE PISTON .................................. 308 INSTALLATION OF THE SNAP RINGS ............ 308 CHECKING PISTON PROTRUSION ................ 309 INSTALLATION OF REAR OIL SEAL RETAINER AND OIL PUMP ................................................. 310 INSTALLATION OF THE CRANKSHAFT SEAL GASKETS ......................................................... 311 INSTALLATION OF THE CYLINDER HEAD ..... 315 TIMING ADJUSTMENT ..................................... 316 BASIC INSPECTION .............................................. 321 Cylinder Head ....................................................... 321 CYLINDER HEAD TIGHTENING PROCEDURE. 321 THICKNESS OF THE CYLINDER HEAD GASKET ................................................................... 321 INSPECTION OF THE PISTON PROTRUSION. 321 VALVE ............................................................... 322 VALVE SEAT ..................................................... 322 VALVE GUIDE ................................................... 322 VALVE SPRING ................................................. 324 PISTON ............................................................. 324 INSPECTION OF VALVE CLEARANCE ........... 324 CAMSHAFT ....................................................... 325 Piston .................................................................... 326 PISTON MARKING ........................................... 326 TABLE OF PISTON PIN HEIGHT ..................... 326 EM-5 A EM C D E F G H I J K L M MEASURING THE PISTON DIAMETER ........... 326 PISTON RING ................................................... 327 PISTON RING END GAP .................................. 327 Connecting Rod .................................................... 327 DIRECTION OF INSTALLATION OF THE CONNECTING ROD IN RELATION TO THE PISTON. 328 DIRECTION FOR INSTALLATION THE SNAP RINGS ON THE PISTON .................................. 328 Crankshaft ............................................................ 328 WORKING OUT THE CLASS OF MAIN BEARING (ORIGINAL FITMENT) ............................... 329 Cylinder Block ....................................................... 329 TABLE OF CYLINDER BLOCK MAIN BEARING HOUSING INNER DIAMETERS ........................ 329 MATCHING THE MAIN BEARING ..................... 330 Main Bearing and Cap .......................................... 330 MAIN BEARING ................................................. 330 CONNECTING ROD BEARING ......................... 331 Preparing the engine to be on the stand ............... 331 Parts To Be Replaced After Removal ................... 332 Installation of Thread Inserts ................................. 333 EM-6 PRECAUTIONS [CR] PRECAUTIONS Precautions for Draining Coolant [CR] ● PFP:00001 A BBS002MS Drain coolant only after the engine has cooled down. Precautions for Disconnecting Fuel Piping ● ● ● Before starting work, make sure no fire or spark producing items are in the work area. Release fuel pressure before disassembly. After disconnecting pipes, plug openings to stop fuel leakage. Precautions for Removal and Disassembly ● ● ● ● ● ● ● ● ● ● ● – – ● – – – ● ● BBS002MW BBS002MX Use an angle wrench when attaching the following parts. Cylinder head bolt Main bearing cap bolt Connecting rod cap nut The specified torque written for these parts is not the final tightening value, but is the torque used for tightening before angle tightening. When tightening, make sure there is no debris on the threads or mating surfaces, and lubricate the threads with engine oil. EM-7 D E F BBS002MV Always use a torque wrench when tightening nuts and bolts. Unless otherwise specified, tighten nuts and bolts from inside to outside in crisscross pattern. Tighten them gradually and evenly in two to three steps. Always replace gasket, packing, oil seals, and O-rings with new ones. Thoroughly wash, clean, and blow dry each part. Be sure that engine oil and coolant passages are free of clogs. Remove any dirt and lint on sliding and mating surfaces. Before assembly, apply ample amount of engine oil to sliding surfaces. If coolant was drained, bleed air from the system. Follow the procedure below to make sure there are no fuel leaks. Turn the ignition switch to ON (do not start engine), and with fuel pressure applied in the fuel line, check to make sure there are no fuel leaks from the connection. Start the engine, and at in creased speed, check again to see if there are any fuel leaks from the connection. After assembly, start engine and increase the engine speed, then check coolant, fuel, oil, grease, and exhaust gas for leakage. Parts Requiring Angle Tightening ● BBS002MU Thoroughly inspect each part following inspection procedure, then correct or replace as necessary. Inspect new parts in the same way, and replace if necessary. Precautions for Assembling and Installing ● C Use correct special service tool in the specified position. Always pay attention to safety. Be careful not to damage surface accuracy of mating or sliding surfaces. To prevent foreign material from entering the engine, close openings with appropriate tape as necessary. Arrange disassembled parts in their normal positions in order to simplify locating the cause of damage or excessive wear and to insure correct reassembly. The removal order of nuts and bolts should in principle move diagonally from the outside. Locations for which order is stipulated should follow that order. Precautions for Inspections, Repairs, and Replacement ● EM BBS002MT G H I J K L M PRECAUTIONS [CR] Precautions for Liquid Gasket BBS002MY REMOVAL OF LIQUID GASKET SEALING ● ● Unscrew nuts and bolts. Use a seal cutter to cut the liquid gasket and remove the joined parts. CAUTION: Be careful not to damage the mating surfaces. In positions where a seal cutter is difficult to use, lightly tap with a plastic hammer and remove. CAUTION: When using a screwdriver, be careful not to scratch the mating surfaces. PBIC0275E LIQUID GASKET APPLICATION PROCEDURE 1. 2. 3. Using a scraper (1), remove any old liquid gasket remaining on the gasket application surface and its mating surface. ● Remove any old liquid gasket remaining in the gasket application groove and on the threads of bolts and bolt holes. Using white gasoline, wipe the gasket application surface and its mating surface to remove any moisture, oil, and foreign material. Set the genuine liquid gasket in a tube presser. PBIC1289E 4. Apply a continuous bead of liquid gasket to the specified position at the specified diameter. ● Apply liquid gasket in the application groove. EMA0622D Apply liquid gasket inside bolt holes. There may be times when application to the exterior is required, so follow those instructions if such are found in the text. ● Attaching should be done within 5 minutes after gasket application. ● Immediately wipe off any protruding liquid gasket. ● Do nor retighten nuts and bolts after installation. ● After finishing work, wait at least 30 minutes before refilling engine oil and coolant. CAUTION: Follow all specific instructions in this manual. ● EM-8 SEM164F PREPARATION [CR] PREPARATION Special Service Tools PFP:00002 A BBS002MZ Tool number Tool name Description KV10111100 Seal cutter EM Removing parts attached with liquid gasket C D ZZA0013D KV10117100 Heated oxygen sensor wrench Removing and Installing heated oxygen sensor For 22 mm (0.87 in) width hexagon nut E F NT379 KV10105630 Ring gear stopper Removing and installing crankshaft pulley Removing and installing flywheel, drive plate G H ZZA1005D KV10105610 Stopper plate Removing and installing crankshaft pulley I J K ZZA0009D KV10112100 Angle wrench Tightening bolts for bearing cap, cylinder head, etc. L M NT014 ST10120000 Cylinder head bolt wrench Loosening and tightening cylinder head bolt a: 13 mm (0.51 in) dia. b: 12 mm (0.47 in) c: 10 mm (0.39 in) NT583 KV101092S0 Valve spring compressor set 1. KV10116200 Valve spring compressor set 2. KV10109220 Adapter Removing and installing valve mechanism ZZA0993D EM-9 PREPARATION [CR] Tool number Tool name Description KV10107902 Valve oil seal puller Removing valve oil seal NT011 KV10115600 Valve oil seal drift Installing valve oil seal ZZA0996D EM03470000 Piston ring compressor piston assembly into cylinder bore NT044 1. ST15243000 Valve seat drift 2. KV11103710 Adapter 3. KV11103720 Adapter Installing valve seat PBIC1120E KV10107400 Piston pin Press stand 1. KV10107310 Center shaft 2. ST03140030 Stand 3. ST13040030 Spring 4. KV10107320 Cap 5. ST13040050 Drift Disassembling and assembling piston with connecting rod NT013 WS39930000 Tube presser Pressing the tube of liquid gasket NT052 EM-10 PREPARATION [CR] Commercial Service Tools BBS002N0 A Tool name Description Spark plug wrench Removing and installing spark plug EM C NT047 Crankshaft pulley puller Removing crankshaft pulley D E PBIC0887E Manual lift table caddy Removing and installing engine F G H ZZA1210D Valve seat cutter set Finishing valve seat dimensions I J NT048 Piston ring expander Removing and installing piston ring K L NT030 Valve guide drift Removing and installing valve guide Intake & Exhaust: a: 9.5 mm (0.374 in) dia. b: 5.5 mm (0.217 in) dia. NT015 Valve guide reamer Reaming valve guide 1 or hole for oversize valve guide 2 Intake & Exhaust: d1 : 5.0 mm (0.217 in) dia. d2 : 9.675 mm (0.381 in) dia. NT016 EM-11 M NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING [CR] NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING NVH Troubleshooting —Engine Noise PFP:00003 BBS002N1 PBIC1413E EM-12 NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING [CR] Use the Chart Below to Help You Find the Cause of the Symptom. BBS002N2 A 1. Locate the area where noise occurs. 2. Confirm the type of noise. 3. Specify the operating condition of engine. 4. Check specified noise source. If necessary, repair or replace these parts. EM C Operating condition of engine Location of noise Top of engine Rocker cover Cylinder head Type of noise Front of engine When starting When idling When racing C A — A B Rattle C A — A B Slap or rap Knock Knock Front of engine Timing chain cover After warmup Ticking or clicking Slap or knock Crankshaft pulley Cylinder block (Side of engine) Oil pan Before warmup Tapping or ticking — A A A A A — B B A — — C — — B B B A B B B B B B While driving Source of noise Check item D — Tappet noise Valve clearance EM-47 C Camshaft bearing noise Camshaft journal clearance Camshaft runout EM-45 EM-44 — Piston pin noise Piston and piston pin clearance Connecting rod bushing clearance EM-85 EM-87 A Piston slap noise Piston-to-bore clearance Piston ring side clearance Piston ring end gap Connecting rod bend and torsion EM-89 EM-86 EM-86 EM-87 B Connecting rod bearing noise Connecting rod bushing clearance (Small end) Connecting rod bearing clearance (Big end) EM-87 EM-87 C Main bearing noise Main bearing oil clearance Crankshaft runout EM-92 EM-91 K B Timing chain and chain tensioner noise Timing chain cracks and wear Timing chain tensioner operation EM-53 EM-51 L C Drive belts (Sticking or slipping) Drive belts deflection A Creaking A B A B A B Drive belts (Slipping) Idler pulley bearing operation Squall Creak A B — B A B Water pump noise Water pump operation A: Closely related B: Related — C: Sometimes related B — —: Not related EM-13 E F G H I J M Squeaking or fizzing B Reference page EM-14 CO-17 DRIVE BELTS [CR] DRIVE BELTS Checking drive Belts ● ● ● ● PFP:02117 BBS002N3 Inspection should be done only when engine is cold or over 30 minutes after the engine is stopped. Turn the crankshaft pulley two times clockwise, and make sure tension on all pulleys is equal before doing the test. Visually check the belts for wear, damage, and cracks on inside and edges. When measuring deflection, apply 98.1 N (10 kg, 22lb) at the marked point. PBIC1414E PBIC1415E CAUTION: When measuring belt tension immediately after the belt is installed, first set the tension to the standard, rotate the crankshaft for more than two turns in order to eliminate variance in the belt tension between pulleys, then measure and adjust tension to the standard again. Deflection [mm (in)] [When pressed by force of 98.1N (10 kg, 22lb)] Tension [N (kg, lb)] Location New Alternator and A/C compressor belt Alternator belt Water pump belt 603 - 691 (61.5 - 70.5, 135.6 - 155.3) 603 - 691 (61.5 - 70.5, 135.6 - 155.3) 446 - 534 (45.5 - 54.5, 100.3 - 120.0) At adjustment 495 - 583 (50.5 - 59.5, 111.3 - 131.1) 495 - 583 (50.5 - 59.5, 111.3 - 131.1) 348 - 436 (35.5 - 44.5, 78.2 - 98.0) Tension Adjustment Location Limit Measuring point New belt At adjustment Limit A 6.6 - 7.8 (0.260 0.307) 7.3 - 8.5 (0.287 0.335) 13.8 (0.543) B 5.6 - 6.6 (0.220 0.260) 7.1 - 8.3 (0.280 0.327) 11.9 (0.469) A 3.1 - 4.1 (0.122 0.161) 9.8 - 10.6 (0.386 0.417) 13.8 (0.543) C 6.7 - 7.3 (0.264 0.287) 7.6 - 8.6 (0.299 0.339) 12.4 (0.448) D 4.7 - 5.6 (0.185 0.220) 7.0 - 7.7 (0.276 0.303) 8.6 (0.339) 196 (20, 44.1) 196 (20, 44.1) 137 (14, 30.9) BBS002N4 Location of adjuster and tightening method Alternator and A/C compressor drive belt Adjusting bolt on idler pulley Water pump belt Adjusting bolt on idler pulley EM-14 DRIVE BELTS [CR] CAUTION: ● When the belt is replaced with new one, adjust the belt tension to the value for “New belt”, A because new belt will not fully seat in the pulley groove. ● When tension of the belt being used exceeds “Limit”, adjust it to the value for “At adjustment”. ● When installing a belt, make sure that it is correctly engaged with the pulley groove. EM ● Do not allow oil or engine coolant to get on the belt. ● Do not twist or bend the belt strongly. C ALTERNATOR AND A/C COMPRESSOR BELT (WITH A/C MODELS) 1. 2. 3. 4. 5. 6. Remove RH front fender protector. Loosen lock nut (1). Tighten lock nut (1) with fingers. Loosen lock nut (1) half a turn counter-clockwise. Adjust the belt tension by turning the adjuster bolt (2). For the specified belt tension, refer to EM-14, "Checking drive Belts" . Tighten lock nut (1). D E F Nut (1) : : 24.5 - 31.4 N·m (2.5 - 3.2 kg-m, 18 - 23 ft-lb) 7. 8. G Turn the crankshaft pulley two times clockwise. Check that the belt tension is within the standard. Refer to MA27, "Checking Drive Belts" . H I PBIC1290E J ALTERNATOR BELT (WITHOUT A/C MODELS) 1. 2. 3. 4. 5. 6. K Remove RH front fender protector. Loosen lock nut (1). Tighten lock nut (1) with fingers. Loosen lock nut (1) half a turn counter-clockwise. Adjust the belt tension by turning the adjuster bolt (2). For the specified belt tension, refer to EM-14, "Checking drive Belts" . Tighten lock nut (1). L M Nut (1) : : 24.5 - 31.4 N·m (2.5 - 3.2 kg-m, 18 - 23 ft-lb) 7. 8. Turn the crankshaft pulley two times clockwise. Check that the belt tension is within the standard. Refer to MA27, "Checking Drive Belts" . PBIC1416E EM-15 DRIVE BELTS [CR] WATER PUMP BELT 1. 2. 3. 4. 5. Remove RH front fender protector. Loosen lock nut (3). Tighten lock nut (3) with fingers. Adjust the belt tension by turning the adjuster bolt (4). For the specified belt tension, refer to EM-14, "Checking drive Belts" . Tighten lock nut (3). Nut (3) : : 24.5 - 31.4 N·m (2.5 - 3.2 kg-m, 18 - 23 ft-lb) 6. 7. Turn the crankshaft pulley two times clockwise. Check that the belt tension is within the standard. Refer to MA-27, "Checking Drive Belts" . Removal and Installation BBS002N5 REMOVAL ● Fully loosen each belt while referring to EM-14, "Tension Adjustment" . Remove them one by one, starting with the one in the front. INSTALLATION 1. 2. 3. 4. Install belts to the pulley in the reverse order of removal. CAUTION: ● Make sure the belt is securely inside the groove on each pulley. ● Make sure there is no oil, grease, or coolant in pulley grooves. Adjust tension of each belt. CAUTION: ● When measuring belt tension immediately after the belt is installed, first set the tension to the standard, rotate the crankshaft for more than two turns in order to eliminate variance in the belt tension between pulleys, then measure and adjust tension to the standard. ● When measuring belt tension, hand tighten idler pulley lock nut to eliminate any looseness. Tighten the lock nut of adjustment parts to the specified torque. Make sure that tension of each belt is within the standard. Removal and Installation of Drive Belt Idler Pulley BBS002N6 PBIC1417E 1. Adjuster bolt (for water pump belt) 2. Idler pulley assembly EM-16 3. Shaft DRIVE BELTS [CR] 4. Cover 7. Cover 5. Spacer 8. Bracket 6. Idler pulley 9. Adjuster bolt (for alternator and A/C compressor belt) REMOVAL 1. 2. 3. 4. EM Remove drive belts. Refer to EM-16, "Removal and Installation" . Pull the adjuster bolt out from the shaft. Move the idler pulley assembly along the bracket slide groove and remove by turning the shaft end at the wider part of the groove. (For alternator and A/C compressor belt) Remove the lock nut and remove the shaft by pulling towards the rear of the engine. (For water pump belt) 2. 3. 4. C D INSTALLATION 1. A Install belts to pulley in reverse order of removal. CAUTION: ● Make sure belt is correctly engaged with the pulley groove. ● Check for oil and coolant on belt and each pulley groove. Adjust belt tension. Refer to EM-14, "Tension Adjustment" . Tighten each adjusting bolt and nut to the specified torque. Make sure that tension of each belt is within the standard. E F G H I J K L M EM-17 AIR CLEANER AND AIR DUCT [CR] AIR CLEANER AND AIR DUCT Removal and Installation PFP:16500 BBS002N7 PBIC1418E 1. EVAP canister purge volume control solenoid valve 2. Vacuum hose 3. Vacuum hose 4. Manifold absolute pressure sensor 5. O-ring 6. Vacuum hose 7. Air cleaner case (upper) 8. Gasket 9. Air cleaner case (lower) 10. Gasket 11. Clip 12. Air duct 13. Gasket 14. Gasket 15. Electric throttle control actuator 16. Air cleaner body 17. Air cleaner filter 18. Gasket REMOVAL NOTE: The steps 1 to 2 can be skipped, moving straight to the step 3 (separation of harnesses and hoses, etc. cannot be skipped) 1. Remove the harness connector and then the manifold absolute pressure sensor. CAUTION: ● Handle manifold absolute pressure sensor with care. Avoid impacts. ● Make sure no foreign matter is attached to the sensor (oils, chemicals, etc.) 2. Remove the harness connector and vacuum hose and then the EVAP canister purge volume control solenoid valve. CAUTION: Handle EVAP canister purge volume control solenoid valve with care. Avoid impacts. 3. Remove air duct. EM-18 AIR CLEANER AND AIR DUCT [CR] Remove the clips, and with air duct (2) turned to nearly 90 degrees, pull off from the air cleaner body (1). Remove the clips, pull the air cleaner body down then forward, and then remove the air cleaner body and the air cleaner filter. NOTE: Removal and disassembly of the air cleaner case (upper) and (lower) follows below. Move the transaxle breather hose. Remove the air cleaner case assembly in the following order. ● The entire air cleaner case (upper and lower) is referred to as the air cleaner case assembly. Separate the harness connector from the electronic throttle control actuator. Separate the brake booster vacuum hose. Loosen bolts in the reverse of the order shown in figure. Remove the air cleaner case assembly by raising. ● Slowly raise the force evenly on the intake manifold joint to lift it and remove the air cleaner case assembly. CAUTION: ● To avoid damaging parts, do not use sudden force. ● Block the intake manifold openings with tape to make sure no foreign particles get inside it while you are removing the air cleaner case assembly. ● 4. 5. 6. a. b. c. 7. A EM C PBIC1293E D E F G PBIC1419E 8. Loosen the bolts in reverse of the order shown in the figure and separate the air cleaner case (upper) and (lower). H I J K PBIC1420E 9. Remove the electronic throttle control actuator from the air cleaner case (upper). ● Turn the air cleaner case (upper) over on the protective sheet to make sure the surface does not get scratched. ● The electronic throttle control actuator should be handled with the following precautions in mind. CAUTION: ● Handle electronic throttle control actuator with care. Avoid impacts. ● Do not disassemble or adjust. INSTALLATION 1. a. b. c. Install the electronic throttle control actuator (1) to the air cleaner case (upper) (2) in the following procedure: Install the gasket (3) to the connector base. Attach the gasket (4) to the outer groove on the throttle bore on the side of the air cleaner case (upper) (2). Install electronic throttle control actuator. ● There is no pre-determined order in which the mounting bolts should be tightened. ● Perform the “Throttle Valve Closed Position Learning” when harness connector of the electric throttle control actuator is EM-19 PBIC1294E L M AIR CLEANER AND AIR DUCT [CR] 2. disconnected. Refer to EC-69, "Throttle Valve Closed Position Learning" (WITH EURO-OBD), EC-486, "Throttle Valve Closed Position Learning" (WITHOUT EURO-OBD). ● Perform the “Idle Air Volume Learning” and “Throttle Valve Closed Position Learning” when the electric throttle control actuator is replaced. Refer to EC-69, "Idle Air Volume Learning" and EC-69, "Throttle Valve Closed Position Learning" (WITH EURO-OBD), EC-486, "Idle Air Volume Learning" and EC486, "Throttle Valve Closed Position Learning" (WITHOUT EURO-OBD). Assemble the air cleaner case (upper) and (lower). ● Tighten bolts evenly in two steps in the order shown in figure. 1st step : 1.9 - 2.2 N·m (0.20 - 0.22 kg-m, 17 - 19 in-lb) 2nd step : 3.8 - 4.4 N·m (0.40 - 0.44 kg-m, 35 - 38 in-lb) PBIC1420E 3. a. b. c. Attach the air cleaner case assembly in the following order. Attach the gasket (for the intake manifold (1) and the PCV path (2)) ● Attach for the intake manifold so that the case protrusion (4) fit into the cutout hole (3) on the side of the gasket. ● Make sure foreign particles do not attach to the gasket or the sealing area. Insert the air cleaner case assembly into the intake manifold. ● At the same time, insert the bottom path protrusions into the PCV path holes on the rocker cover. PBIC1295E CAUTION: Insert straight, making sure the axis is lined up, to prevent the gaskets from being crooked or twisted. Tighten bolts in the numerical order shown in figure. ● Tighten bolts evenly in several steps. CAUTION: Tighten after making sure the positioning of bolts 5 and 6 is true. PBIC1419E 4. 5. 6. 7. Install air cleaner body and air cleaner filter. Refer to EM-21, "Changing Air Cleaner Filter" . Attach air duct. Attach EVAP canister purge volume control solenoid valve. Attach the manifold absolute pressure sensor. ● Make sure no foreign particles attach to the flange, O-ring, or attachment hole. ● Tighten the mounting bolt after making sure it is fully inserted into the mounting hole. EM-20 AIR CLEANER AND AIR DUCT [CR] Changing Air Cleaner Filter BBS002N8 A REMOVAL 1. 2. 3. 4. Remove air duct. Refer to EM-18, "REMOVAL" . Remove clips (2) of air cleaner body (1). After moving the air cleaner body downward, remove it by pulling it forward. ● While pressing down the radiator upper hose, remove air cleaner body (1). Remove air cleaner filter from the air cleaner body. NOTE: In some cases the air cleaner filter might remain in the air cleaner case (upper). EM C D PBIC1296E INSTALLATION 1. 2. 3. E Set the air cleaner filter on the air cleaner case (upper) (1). Insert the two projections (3) on the air cleaner body (2) into the two notch holes (4) on the rear of the air cleaner case (upper) (1), then lift up and fasten with the clip. Attach air duct. F G H PBIC1297E I J K L M EM-21 INTAKE MANIFOLD [CR] INTAKE MANIFOLD Removal and Installation PFP:14003 BBS002N9 PBIC1421E 1. Support bracket 4. Intake manifold 2. Gasket 3. Stud bolt REMOVAL 1. 2. 3. 4. Remove air duct and air cleaner case assembly. Refer to EM-18, "AIR CLEANER AND AIR DUCT" . Remove the PCV hose (between the intake manifold and the rocker cover) from the intake manifold side. Remove the support bracket mounting bolt (No. 1 port upper engine front side) Loosen nuts and bolts in the reverse of the order shown in the figure to remove the intake manifold. CAUTION: Disregard No. 6 shown in figure in the loosening order. PBIC1422E NOTE: Removal and installation of No. 5 nut is made easier by inserting the tool into the recommended cutout part (2) on the No. 1 port (1). (The same applies to No. 4 nut) PBIC1298E EM-22 INTAKE MANIFOLD [CR] INSTALLATION ● A Install in the reverse order of removal paying attention to the following. Attachment of the Intake Manifold ● ● ● Check for damage or foreign material on the mounting surfaces. Tighten nuts and bolts in numerical order shown in figure. NOTE: No. 6 in the figure shows the 2nd tightening of No. 1 bolt. When installing support bracket, refer to EM-22, "Removal and Installation" . EM C D PBIC1422E E F G H I J K L M EM-23 EXHAUST MANIFOLD AND THREE WAY CATALYST [CR] EXHAUST MANIFOLD AND THREE WAY CATALYST Removal and Installation PFP:14004 BBS002NA PBIC1423E 1. Bracket 2. Gasket 3. Exhaust manifold 4. Heated oxygen sensor 1 5. Exhaust manifold cover 6. Stud bolt 7. Three way catalyst (manifold) 8. Three way catalyst cover 9. Support REMOVAL 1. 2. 3. 4. 5. 6. 7. 8. a. b. Remove air duct. Refer to EM-18, "AIR CLEANER AND AIR DUCT" . Remove RH front fender protector. Remove alternator and A/C compressor belt. Refer to EM-14, "DRIVE BELTS" . Remove A/C compressor with piping connected, move A/C compressor to body side and secure it onto body with a rope. Remove exhaust front tube connection at front. Refer to EX-3, "EXHAUST SYSTEM" . Remove RH engine mount stay and alternator bracket. Loosen the lower bolt and move the alternator to the front of the vehicle. As needed, remove the heated oxygen sensor 1 in the following order. NOTE: Steps 2 to 7 above are not needed for heated oxygen sensor 1 removal. Separate the harness connector and remove it from bracket. Using heated oxygen sensor wrench (special service tool), remove heated oxygen sensor 1. CAUTION: ● Handle it carefully, avoid any chance of impact caused by PBIC1424E dropping. EM-24 EXHAUST MANIFOLD AND THREE WAY CATALYST [CR] Do not over torque the heated oxygen sensor. Doing so may cause damage to the heated oxygen sensor, resulting in the MI coming on. A 9. Remove exhaust manifold cover. 10. Remove the three way catalyst cover. EM 11. Loosen nuts and bolts in the reverse of the order shown in figure to remove the exhaust manifold and three way catalyst. CAUTION: C Be careful not to damage the A/C piping. ● D PBIC1425E E 12. Separate the exhaust manifold and three way catalyst. CAUTION: Avoid impacts to three way catalyst. F INSPECTION AFTER REMOVAL Surface Distortion G ● Using a reliable straightedge (1) and feeler gauge (2), check distortion of mounting surface on exhaust manifold. Limit ● H : 0.3 mm (0.012 in) If it exceeds the limit, replace the exhaust manifold. I J PBIC1299E INSTALLATION ● K Install in the reverse order of removal paying attention to the following. Installation of Exhaust Manifold and Three Way Catalyst ● ● L Check for damage or foreign material on the mounting surfaces. Tighten nuts in numerical order shown in figure. M PBIC1425E Installation of Heated Oxygen Sensor 1 CAUTION: ● Do not over torque the heated oxygen sensor. Doing so may cause damage to the heated oxygen sensor, resulting in the MI coming on. EM-25 OIL PAN AND OIL STRAINER [CR] OIL PAN AND OIL STRAINER Removal and Installation PFP:11110 BBS002NB PBIC1426E 1. Oil pan (upper) 2. Transaxle connecting bolt 3. Oil strainer 4. Drain plug 5. Washer 6. Oil pan (lower) 7. Rear plate cover 8. Transaxle connecting bolt REMOVAL NOTE: Installation and removal of manual transmission vehicle oil pan (upper) require removal of the transaxle. 1. Remove RH front fender protector. 2. Drain the engine oil. 3. Remove the oil pan (lower) in the following order. a. Loosen bolts in the reverse of the order shown in figure. b. Insert seal cutter (special service tool) between oil pan (upper) and oil pan (lower). Slide seal cutter by tapping on the side of the tool with a hammer. Remove oil pan (lower). CAUTION: Exercise care not to damage mating surface. NOTE: The following is the order for removing the oil pan (upper). 4. Remove the oil level gauge. PBIC1427E 5. Remove drive belts. Refer to EM-14, "DRIVE BELTS" . 6. Remove the A/C compressor with piping connected and move the A/C compressor aside. CAUTION: Hang it with rope and temporarily tighten to body to avoid putting stress on air conditioner piping. 7. Remove the exhaust front tube. Refer to EX-3, "EXHAUST SYSTEM" . EM-26 OIL PAN AND OIL STRAINER [CR] 8. Remove three way catalyst support. Refer to EM-24, "EXHAUST MANIFOLD AND THREE WAY CATALYST" . A 9. Remove the transaxle in the following order. a. Mount engine slingers on cylinder head. Refer to EM-71, "REMOVAL" . EM b. Lift with a hoist and position engine. c. Remove transaxle. Refer to MT-7, "Removal" . 10. Remove oil pan (upper) with the following procedure. C a. Loosen oil pan (upper) mounting bolts in the reverse of the order shown in figure. D E F PBIC1428E b. c. Insert a flathead offset screwdriver into the cutout (1) shown in figure and create a crack between the oil pan and cylinder block. Insert seal cutter (special service tool) between oil pan (upper) and cylinder block. Slide seal cutter by tapping on the side of the tool with a hammer. Remove oil pan (upper). CAUTION: Exercise care not to damage mating surface. G H I PBIC1429E J 11. Remove oil strainer. INSTALLATION 1. 2. a. K Install oil strainer. NOTE: Do not use O-ring, gasket, or other seal parts. Attach the oil pan (upper) in the following order. Apply the liquid gasket to the position shown in figure. Use Genuine Liquid Gasket or equivalent. CAUTION: ● For bolt holes with marks (3 locations), apply liquid gasket outside the holes. ● Apply a bead of 5.5 to 6.5 mm (0.127 - 0.256 in) in diameter to area “A” and “B”. L M PBIC1430E EM-27 OIL PAN AND OIL STRAINER [CR] b. Tighten bolts in the numerical order shown in figure. NOTE: See below for mounting positions of bolts Under head 70 mm (2.76 in) Under head 90 mm (3.54 in) Under head 25 mm (0.98 in) 3. 4. a. : 4, 8, 12 : 9,10 : Other than the above Install transaxle assembly. Install oil pan (lower) in the following procedure: Apply the liquid gasket to the position shown in figure. Use Genuine Liquid Gasket or equivalent. PBIC1428E PBIC1431E b. Tighten bolts in the numerical order shown in figure. PBIC1427E 5. 6. Install oil pan drain plug. ● For washer installation direction, refer to components figure on EM-26, "Removal and Installation" . Reinstall removed parts in reverse order of removal. CAUTION: Engine oil should be filled at least 30 minutes after the oil pan is installed. INSPECTION AFTER INSTALLATION ● ● Check engine oil level. Refer to LU-6, "ENGINE OIL" . Warm up engine and check the oil amount and no leakage of oil. Refer to LU-6, "ENGINE OIL" . EM-28 IGNITION COIL [CR] IGNITION COIL Removal and Installation PFP:22448 A BBS002NC EM C D E F PBIC1432E 1. Ignition coil 2. Spark plug H REMOVAL 1. 2. 3. G Remove air duct and air cleaner case assembly. Refer to EM-18, "AIR CLEANER AND AIR DUCT" . Disconnect harness connector from the ignition coil. Remove ignition coil. CAUTION: ● Handle ignition coil with care. Avoid impacts. ● Do not disassemble. I J INSTALLATION K Install in the reverse order of removal. L M EM-29 SPARK PLUG (PLATINUM-TIPPED TYPE) [CR] SPARK PLUG (PLATINUM-TIPPED TYPE) Removal and Installation PFP:22401 BBS002ND REMOVAL 1. 2. Remove ignition coil. Refer to EM-29, "IGNITION COIL" . Remove spark plugs with a spark plug wrench. CAUTION: Handle spark plug with care. Avoid impacts. SMA581C INSPECTION AFTER REMOVAL ● ● – – ● – – Use standard type spark plug for normal condition. The hot type spark plug is suitable when fouling occurs with the standard type spark plug under conditions such as: Frequent engine starts Low ambient temperatures The cold type spark plug is suitable when spark plug knock occurs with the standard type spark plug under conditions such as: Extended highway driving Frequent high engine revolution Make NGK Champion Standard type LFR5AP-11 REC10PYC4 Hot type LFR4AP-11 — Cold type LFR6AP-11 — Gap (Nominal) : 1.1 mm (0.043 in) CAUTION: ● Do not use a wire brush for cleaning. ● If plug tip is covered with carbon, spark plug cleaner may be used. Cleaner air pressure: Less than 588 kPa (6 kg/cm2 , 85 psi) Cleaning time: Less than 20 seconds SMA773C EM-30 SPARK PLUG (PLATINUM-TIPPED TYPE) [CR] ● Checking and adjusting plug gap is not required between change intervals. A EM C SMA806CA D INSTALLATION Install in the reverse order of removal. Spark plug E : 19.6 - 29.4 N·m (2.0 - 3.0 kg-m, 15 - 21 ft-lb) F G H I J K L M EM-31 FUEL INJECTOR AND FUEL TUBE [CR] FUEL INJECTOR AND FUEL TUBE Removal and Installation PFP:16600 BBS002NE PBIC1433E 1. O-ring (brown) 2. Clip 3. O-ring (black) 4. Fuel tube 5. Fuel feed hose 6. Fuel injector REMOVAL 1. 2. 3. 4. 5. 6. Release fuel pressure. Refer to EC-71, "FUEL PRESSURE RELEASE" (WITH EURO-OBD), EC-488, "FUEL PRESSURE RELEASE" (WITHOUT EURO-OBD). Remove air duct and air cleaner case assembly. Refer to EM-18, "AIR CLEANER AND AIR DUCT" . Remove intake manifold support bracket. Remove the fuel hose on the side of the fuel tube. CAUTION: Attach a plug to the removed hose to prevent fuel leaks. Separate the fuel injector harness and move to a position where it will not get in the way of work. ● If it is stuck or otherwise difficult to remove, remove the fuel injector and fuel tube assembly from the cylinder head and separate fuel injector harness in a better position. Loosen bolts in the reverse of the order shown in the figure and then remove the fuel injector and fuel tube assembly. CAUTION: ● Make sure the fuel injector nozzle does not touch the other parts. ● Take out without tipping, as this will cause fuel to leak. PBIC1434E EM-32 FUEL INJECTOR AND FUEL TUBE [CR] 7. a. b. Remove the fuel injector (2) from the fuel tube (1) in the following order. Open and pull out the clip (3). Remove fuel injector from the fuel tube by pulling straight. CAUTION: ● Be careful not to damage the nozzle. ● Do not drop or impact the fuel injector. ● Do not disassemble or adjust fuel injector. A EM C PBIC1301E D INSTALLATION 1. Keep in mind the following points when attaching the O-ring to the fuel injector. CAUTION: ● The upper and lower O-rings are different, so use caution when attaching them. Fuel tube side Nozzle side E : Black : Brown F Handle O-ring with bare hands. Never wear gloves. ● Lubricate O-ring with engine oil. ● Do not clean O-ring with solvent. ● Make sure the O-ring and its mating part are free of foreign material. ● When installing the O-ring, be careful not to scratch it with tools or your fingernails. Also be careful not to twist or stretch O-ring. If O-ring is stretched while it is being attached, do not insert it into fuel tube immediately. Install the fuel injector onto the fuel tube in the following procedure: Insert the clip (3) into the clip mounting groove (2) on the fuel injector (1). ● Insert clip cutout (5) into fuel injector protrusion (4). CAUTION: ● Always replace clip with new one. ● Make sure the clip does not interfere with the O-ring. If it does, replace the O-ring. With the clip assembly as is, insert the fuel injector (1) into the fuel tube (6). ● Make sure the axis is lined up when inserting. ● Insert clip cutout (8) into fuel tube protrusion (7). ● Make sure the flange (10) on the fuel tube fits securely in the clip flange groove (9). Make sure the fuel injector does not spin or come off. ● 2. a. b. c. PBIC1302E EM-33 G H I J K L M FUEL INJECTOR AND FUEL TUBE [CR] 3. Install fuel tube and injector assembly onto cylinder head. CAUTION: Make sure the injector nozzle does not touch the other parts. ● Tighten bolts evenly in two steps in the order shown in figure. 1st step : 11.8 - 13.8 N·m (1.2 - 1.4 kg-m, 9 - 10 ft-lb) 2ne step : 20.8 - 28.2 N·m (2.1 - 2.9 kg-m, 16 - 20 ft-lb) 4. 5. PBIC1434E Connect fuel feed hose.· CAUTION: Securely tighten the hose clamp at a position where it does not get in the way of the bulge. Install intake manifold support bracket. ● Tighten mounting bolts in the following order. – Tighten bolts temporarily in numerical order shown in the figure. – Tighten bolts to the specification in numerical order shown in the figure. Bolt 1 : 6.9 - 9.5 N·m (0.7 - 0.96 kg-m, 61 - 84 in-lb) Bolts 2 and 3 PBIC1572E : 8.4 - 10.8 N·m (0.86 - 1.1 kg-m, 75 - 95 in-lb) 6. Reinstall removed parts in reverse order of removal. INSPECTION AFTER INSTALLATION ● 1. 2. Follow the procedure below to make sure there are no fuel leaks. Turn the ignition switch to ON (do not start engine), and with fuel pressure applied in the fuel line, check to make sure there no fuel leaks from the connection. Start the engine, and with the increased speed, check again to see if there are any fuel leaks from the connection. EM-34 ROCKER COVER [CR] ROCKER COVER Removal and Installation PFP:13264 A BBS002NF EM C D E F G H I PBIC1436E 1. Harness bracket 2. Grommet 3. PCV control valve 4. PCV hose 5. Oil filler cap 6. Intake valve timing control solenoid valve 7. O-ring 8. Rocker cover 9. Rocker cover oil seal 10. Gasket 3. 4. 5. 6. 7. K 11. Gasket REMOVAL 1. 2. J L Remove air duct and air cleaner case assembly. Refer to EM-18, "AIR CLEANER AND AIR DUCT" . Remove RH engine mount stay. Refer to EM-70, "Removal and Installation" . NOTE: It is not necessary to support the engine using a jack. Remove ignition coil. Refer to EM-29, "IGNITION COIL" . Remove ignition coil harness bracket. Disconnect PCV hose and intake valve timing control sorenoid valve harness connector. Remove the PCV control valve if necessary. Remove the intake valve timing control solenoid valve if necessary. CAUTION: ● Handle intake valve timing control solenoid valve with care. Avoid impacts. ● Do not disassemble. EM-35 M ROCKER COVER [CR] 8. Loosen bolts in the reverse of the order shown in the figure to remove rocker cover. PBIC1437E 9. Remove the rocker cover oil seal using a screwdriver. CAUTION: Be careful not to damage the rocker cover. INSTALLATION 1. Install rocker cover oil seal. ● Using drift with outer diameter 97 mm (3.82 in) and inner diameter 83 mm (3.27 in) to 88 mm (3.46 in), press oil seal in. ● Press-fit the oil seal evenly to the mounting surface. PBIC1303E 2. a. b. Install the rocker cover in the following procedure: Install the gasket (1) to the No. 1 camshaft bracket upper surface. ● Match up the positioning pins (2) and gasket holes in the direction of the shape of the camshaft bracket when attaching. Install the gasket to the rocker cover mounting groove. MBIB9034E c. Apply the liquid gasket to the position shown in figure. Use Genuine Liquid Gasket or equivalent. PBIC0555E EM-36 ROCKER COVER [CR] d. Tighten bolts evenly in two steps in the order shown in the figure, to the specified torque. ● See below for mounting positions of bolts Under head 45 mm (1.77 in) Under head 20 mm (0.79 in) A : 1, 2 (inside bolts) EM : Other than above (outside bolts) C PBIC1437E 3. 4. 5. Install intake valve timing control solenoid valve. ● Make sure no foreign particles attach to the flange, O-ring, or attachment hole. ● Tighten the mounting bolt after making sure it is fully inserted into the mounting hole. Install PCV control valve. ● Insert until the flange is flush with the grommet. Reinstall removed parts in reverse order of removal. D E F G H I J K L M EM-37 CAMSHAFT [CR] CAMSHAFT Removal and Installation PFP:13001 BBS002NG PBIC1438E 1. Camshaft bracket (No. 2 - 5) 4. Camshaft (exhaust) 5. Valve lifter 6. Camshaft sprocket (intake) 7. Camshaft sprocket (exhaust) 8. Chain tensioner 9. Cylinder head front cover 10. Timing chain 2. Camshaft bracket (No. 1) 11. Cylinder head 3. Camshaft (intake) 12. O-ring 13. Camshaft position sensor (PHASE) REMOVAL 1. 2. 3. 4. 5. 6. 7. Remove RH front fender protector. Secure the engine position using one of the following methods. Remove RH engine mount stay and engine mount bracket (upper). Refer to EM-70, "Removal and Installation" . ● Mount engine slingers and hook with hoist. Refer to EM-70, "Removal and Installation" . ● Support the oil pan bottom with a jack stand, etc. Remove rocker cover. Refer to EM-35, "ROCKER COVER" . Remove the camshaft position sensor (PHASE) from the back of the cylinder head if necessary. CAUTION: ● Handle camshaft position sensor (PHASE) with care. Avoid impacts. ● The tip of the sensor is magnetic, so do not let metal dust get on it or place it next to objects which can be affected by magnets. Remove RH headlamp. Refer to LT-32, "Removal and Installation" . Remove the cylinder head front cover. Following the procedure below, place cylinder No. 1 at TDC of its compression stroke EM-38 CAMSHAFT [CR] a. b. c. d. Turn the crankshaft pulley clockwise. When doing this, make sure both the intake and exhaust cam noses on cylinder No. 1 are facing out- A wards. (No. 1 cylinder at TDC of its compression stroke) Confirm mating marks (1) stamped on intake and exhaust sprockets are located as shown. EM ● If there is no position mark at the position in the figure, turn the crankshaft pulley once more to position them as in the figure. C Make sure mating marks on intake and exhaust camshaft sprockets are located as shown in the figure, then paint mating marks on the timing chain links. D PBIC1306E E 8. a. Make sure the intake camshaft sprocket is in the most advanced position. CAUTION: Installation and removal of the intake camshaft sprocket must be done in the most advanced position for the following reasons, so make sure you follow the procedure exactly. ● The sprocket (1) and vane (camshaft coupling) (3) are designed to spin and move within the range of a certain angle. ● With the engine stopped the vane (3) is in the most retarded position. It will not spin because it is locked to the sprocket side by the internal lock pin (2). ● If the camshaft sprocket mounting bolts are turned in the situation described above (the most retarded position), the lock pin (2) will become damaged and cause malfunctions because of the increased horizontal load (cutting PBIC1439E force) on the lock pin (2). ● Put the intake camshaft sprocket in the most advance position in the following steps. CAUTION: The chain tensioner must not be removed before doing this step. NOTE: The spinning direction in the following description is as seen from the engine front. Immobilize the hexagonal part of the camshaft with a wrench (1) to prevent the intake camshaft from moving. F G H I J K L M PBIC1308E EM-39 CAMSHAFT [CR] b. Apply air pressure with an air gun (2) to the advanced angle side oil passage of the intake valve timing control on the top surface of the No. 1 camshaft bracket (1). Compression pressure : 300 kPa (3.00 bar, 3 kg/cm2 , 43.5 psi) or more c. d. e. NOTE: The air pressure is used to move the lock pin into the disengage position. ● Keep applying air pressure until step “e” is completed. PBIC1309E CAUTION: ● Be sure not to damage the oil passage with the tip of the air gun. ● Wipe all the oil off on the top surface of the No. 1 camshaft bracket to prevent oil from being blown with the air, and the area around the air gun should be covered with a rag when applying air pressure. Eye protection should be worn as needed. Turn the intake camshaft slowly counter-clockwise in direction A (towards the intake manifold). ● Keep the air pressure on. CAUTION: Also be sure the wrench immobilizing the camshaft does not come loose. While doing the above, once you hear a click (the sound of the internal lock pin disengaging) from inside the intake camshaft sprocket, start turning the intake camshaft in the opposite direction, direction B (clockwise: towards the exhaust manifold) and PBIC1440E to the most advanced angle position. ● Keep the air pressure on. ● If there is no click, as soon as the vane (camshaft coupling) starts moving independently of the camshaft sprocket, the lock pin has become disengaged. ● If the lock pin does not become disengaged, shake the wrench immobilizing the camshaft slightly. ● If this still does not help in disengaging the lock pin, tap the intake camshaft front very lightly with a plastic hammer. Once the vane starts to spin and then the camshaft sprocket starts to spin with the camshaft, it has reached the most advanced position, so stop. ● Make sure the most advanced position locating intake valve timing control advance mark (1) of vane (3) and alignment mark (2) of sprocket (4) as shown in the figure. PBIC1634E EM-40 CAMSHAFT [CR] 9. Attach the stopper pin (1) such as a paper clip to secure the plunger in the full compressed position and remove the chain tensioner (2). A EM C PBIC1312E D 10. Keeping the wrench on the camshaft hexagonal part, loosen the mounting bolts and remove the intake and exhaust camshaft sprockets. CAUTION: ● Make sure the tools do not come in contact with the A/C piping. ● Do not loosen mounting bolts with securing anything other than the camshaft hexagonal part or with tensioning the timing chain. NOTE: With the front cover attached, the timing chain and crankshaft sprocket will not come off, so there is no need to take steps to maintain the timing chain tension. E F G EMD0826D The intake camshaft sprocket should be handled with the following precautions in mind. CAUTION: ● When removing intake camshaft sprocket, using adhesive tape or equivalent, prevent vane from rotating so that lock pin will not rejoin in the most retarded position. ● Handle it carefully, and avoid any chance of impact caused by dropping. ● Do not disassemble. (Do not loosen the four front bolts.) NOTE: While removing the intake camshaft sprocket, if the lock pin has been rejoined in the most retarded position, do the following to restore it. a. Reinstall the intake camshaft sprocket to the intake camshaft and tighten the mounting bolts enough to prevent air leaking out when the air pressure is applied later. CAUTION: To prevent internal lock pin from damaging, keep the torque on the mounting bolts to the minimum required to prevent air from escaping. b. Apply the air pressure, disengage the lock pin following step 8, and turn the vane to the most advanced position. (The timing chain need not be attached for this step.) c. Remove the intake camshaft sprocket from camshaft. 11. Remove camshaft brackets. ● Loosen bolts in several steps in reverse order shown in the figure. 12. Remove camshaft. CAUTION: Do not deform or damage intake camshaft rear end signal plate. 13. Remove valve lifter. ● Identify installation position of each valve. Arrange removed valve lifters so they cannot be mixed up. PBIC0969E H ● INSTALLATION 1. Install valve lifter. EM-41 I J K L M CAMSHAFT [CR] 2. ● Install it in its original positions. Install camshaft. ● You can distinguish between the intake and the exhaust by looking at the different shapes of the front and rear ends of the camshaft. MBIB0204E ● Install the camshaft front ends dowel pin hole (1) and dowel pin (2) so that they are positioned as shown in the figure. PBIC1316E 3. Install camshaft brackets. ● Completely remove any foreign material on bottom surfaces of camshaft brackets and top surface of cylinder head. ● Referring to the marks on top of the camshaft bracket, install so that it is in the same position and facing the same direction as when removed. MBIB0206E 4. a. Tighten camshaft bracket bolts in the following order. Bolt sizes vary with installation position. Refer to the following when installing bolts. Bolt color 1 - 10 11, 12 b. : Black : Gold First tighten bolts 9 through 12, then tighten bolts 1 through 8 in numerical order. PBIC0969E : 2.0 N·m (0.2 kg-m, 18 in-lb) c. Tighten all bolts in numerical order shown in the figure. : 5.9 N·m (0.6 kg-m, 52 in-lb) d. Retighten all bolts in numerical order shown in the figure. : 9.0 - 11.8 N·m (0.92 - 1.2 kg-m, 80 - 104 in-lb) 5. Install the intake camshaft sprocket in the following procedure: EM-42 CAMSHAFT [CR] ● Make sure the most advanced position checking intake valve timing control advance mark (1) of vane (3) and alignment mark (2) of sprocket (4) are located as shown in the figure. A EM C PBIC1634E D a. Install timing chain (2) by aligning its mating mark (3) (marked when timing chain is removed) with mark (4) on camshaft sprocket (1). ● Install by aligning the dowel pin on the back of the camshaft sprocket with dowel pin hole on the camshaft. E F G PBIC1317E b. Keeping the camshaft hexagonal part still with the wrench (2), tighten the mounting bolt for the intake camshaft sprocket (1). H I J PBIC1318E c. 6. a. b. c. Remove adhesive tape or equivalent from camshaft sprocket. Install the exhaust camshaft sprocket (1) in the following procedure: Install timing chain (2) by aligning its mating mark (3) (marked when timing chain is removed) with mark (4) on camshaft sprocket (1). ● Install by aligning the dowel pin groove of the sprocket with dowel pin on the camshaft. Keeping the camshaft hexagonal part still with the wrench, tighten the mounting bolt for the exhaust camshaft sprocket. Make sure the markings for the intake and the exhaust camshaft sprockets and the timing chain are all lined up. EM-43 K L M PBIC1319E CAMSHAFT [CR] 7. Install chain tensioner (2). ● Install the stopper pin (1) with plunger secured. ● After installation, remove the stopper pin (1) and release the plunger. ● Make sure again that mating marks on the intake and exhaust camshaft sprockets and mating marks on timing chain are aligned. PBIC1312E 8. Turn the crankshaft pulley (1) slowly clockwise to return the intake camshaft sprocket to the most retarded position. PBIC1322E ● ● When first turning the crankshaft the intake camshaft sprocket will turn. Once it is turned more, and the vane (camshaft) also turns, then it has reached the most retarded position. After spinning the crankshaft slightly in a counterclockwise direction, you can make sure the lock pin has joined by seeing if the vane and the sprocket move together. 9. Install the cylinder head front cover. ● Evenly apply the liquid gasket to the position shown in figure. Use Genuine Liquid Gasket or equivalent. ● Install so that the cylinder head front cover matches up with the dowel pin on the cylinder head side. 10. Install camshaft position sensor (PHASE). ● Make sure no foreign particles attach to the flange, O-ring, or attachment hole. ● Tighten the mounting bolt after making sure it is fully inserted into the mounting hole. 11. Inspect and adjust valve clearance. Refer to EM-47, "Valve Clearance" . 12. Reinstall removed parts in reverse order of removal. PBIC1441E INSPECTION AFTER REMOVAL Camshaft Runout ● ● ● Put V block on precise flat bed, and support No. 2 and No. 5 journal of camshaft. CAUTION: Do not support journal No. 1 (on the side of the camshaft sprocket) because it has a different diameter from the other four locations. Set a dial gauge (1) vertically onto journal No. 3. Rotate the camshaft in one direction by hand and read indication on the gauge. (Total indication reading) Limit ● : 0.04 mm (0.0016 in) or less PBIC1323E If exceeds the limit, replace the camshaft. EM-44 CAMSHAFT [CR] Camshaft Cam Height ● Standard CR14DE Intake Exhaust ● A Measure with a micrometer (1). EM : 40.359 - 40.549 mm (1.5889 - 1.5964 in) : 39.743 - 39.933 mm (1.5647 - 1.5722 in) C If it exceeds the standard, replace the camshaft. PBIC1324E D Camshaft Journal Clearance Outer Diameter of Camshaft Journal ● Measure with a micrometer (1). E Standard No. 1 : 27.935 - 27.955 mm (1.0998 - 1.1006 in) No. 2 to No. 5 : 23.450 - 23.470 mm (0.9232 - 0.9240 in) F G H PBIC1325E Inner Diameter of Camshaft Journal ● Tighten camshaft bracket bolts to the specified torque. ● Using an inside micrometer (1), measure inner diameter of the camshaft bracket. I J Standard No. 1 : 28.000 - 28.021 mm (1.1024 - 1.1032 in) No. 2 to No. 5 : 23.500 - 23.525 mm (0.9252 - 0.9262 in) K L PBIC1326E Calculation of Camshaft Journal Clearance (Journal clearance) = (inner diameter of camshaft bracket) - (outer diameter of camshaft journal). Standard No. 1 : 0.045 - 0.086 mm (0.0018 - 0.0034 in) No. 2 to No. 5 : 0.030 - 0.071 mm (0.0012 - 0.0028 in) If clearance exceeded the standard, replace the camshaft and/or the cylinder head. Refer to the standard values for each individual part. NOTE: Since the camshaft brackets and the cylinder head are machined together, replacement must be done using the cylinder head assembly. ● EM-45 M CAMSHAFT [CR] Camshaft End Play ● Set a dial gauge (1) to the camshaft front end in thrust direction. Move the camshaft back and forth (axially) and read indication on the gauge. Standard ● ● : 0.070 - 0.143 mm (0.0028 - 0.0056 in) When out of the standard, replace with new camshaft and measure again. When out of the standard again, replace with new cylinder head. PBIC1327E Camshaft Sprocket Runout ● ● Put V block on precise flat bed, and support No. 2 and No. 5 journal of camshaft. Using a dial gauge, measure camshaft sprocket runout. Limit Intake Exhaust ● : 0.20 mm (0.0079 in) : 0.15 mm (0.0059 in) If it exceeds the limit, replace camshaft sprocket. KBIA1493J Valve Lifter Check for cracks and wear on valve lifter surface. ● If anything above is found, replace valve lifter. KBIA1597J Valve Lifter Clearance Outer Diameter of Valve Lifter ● Measure with a micrometer (1). Standard : 29.960 - 29.975 mm(1.1795 - 1.1801 in) dia. PBIC1328E EM-46 CAMSHAFT [CR] Valve Lifter Hole Diameter ● Using an inside micrometer (1), measure the valve lifter hole diameter in cylinder head. Standard A : 30.000 - 30.021 mm (1.1811 - 1.1819 in) dia. EM C PBIC1329E Calculation of valve lifter clearance (Valve lifter clearance) = (valve lifter hole diameter) - (outer diameter of valve lifter) Standard ● E : 0.025 - 0.061 mm (0.0010 - 0.0024 in) If clearance exceeded the standard, replace either one or both of valve lifter and cylinder head. Refer to the standard values for valve lifter outer diameter and hole diameter. INSPECTION AFTER INSTALLATION Inspection of Camshaft Sprocket (INT) Oil Groove Valve Clearance BBS002NH INSPECTION 1. Whenever the camshaft and valve related parts are removed and installed or replaced, or symptoms due to changes in valve clearance as a result of aging (poor starting, rough idle, unusual noise) are obvious, check valve clearance with the following procedure: Warm up engine and stop it. EM-47 F G CAUTION: ● Perform this inspection only when DTC P0011 is detected in self-diagnostic results of CONSULT-II and it is directed according to inspection procedure of EC section. Refer to EC-104, "SELF-DIAG RESULTS MODE" (WITH EURO-OBD) or EC-521, "SELF-DIAG RESULTS MODE" (WITHOUT EURO-OBD). ● Check when the engine is cold so as to prevent burns from any splashing engine oil. 1. Check the engine oil level. Refer to LU-6, "ENGINE OIL" . 2. Perform the following procedure so as to prevent the engine from being unintentionally started while checking. a. Release fuel pressure. Refer to EC-71, "FUEL PRESSURE RELEASE" (WITH EURO-OBD) or EC-488, "FUEL PRESSURE RELEASE" (WITHOUT EURO-OBD). b. Disconnect ignition coil and injector harness connectors. 3. Remove intake valve timing control solenoid valve. Refer to EM-35, "ROCKER COVER" . 4. Crank the engine, and then make sure that engine oil comes out from intake valve timing control cover oil hole. End crank after checking. WARNING: Be careful not to touch rotating parts (drive belt, idler pulley, and crankshaft pulley, etc.). CAUTION: Engine oil may squirt from intake valve timing control solenoid valve installation hole during cranking. Use a shop cloth to prevent the engine components and the vehicle. Do not allow engine oil to get on rubber components such as drive belt or engine mount insulators. Immediately wipe off any splashed engine oil. ● Clean oil groove between oil strainer and intake valve timing control solenoid valve if engine oil does not come out from intake valve timing control cover oil hole. Refer to LU-5, "LUBRICATION SYSTEM" . 5. Remove components between intake valve timing control solenoid valve and camshaft sprocket (INT), and then check each oil groove for clogging. ● Clean oil groove if necessary. Refer to LU-5, "LUBRICATION SYSTEM" . 6. After inspection, install removed parts. ● D H I J K L M CAMSHAFT [CR] 2. 3. 4. Remove the following parts. ● RH front fender protector ● Rocker cover; Refer to EM-35, "ROCKER COVER" . Turn the crankshaft pulley clockwise. When doing this, make sure both the intake and exhaust cam noses on cylinder No. 1 are facing outwards. (No. 1 cylinder at TDC of its compression stroke) ● If they are not facing out, turn the crankshaft pulley further. It is OK to do step 6 first (checking when No. 4 cylinder at TDC of its compression stroke). 5. Referring to the figure, measure valve clearances of valves with × in table below using a feeler gauge (1). Cylinder No. 1 cylinder at TDC of its compression stroke. No. 1 No. 2 INT × × EXH × No. 3 No. 4 × PBIC1442E PBIC1331E Valve clearance standard: Hot Intake : 0.314 - 0.426 mm (0.012 - 0.017 in) Exhaust : 0.338 - 0.462 mm (0.013 - 0.018 in) Cold* Intake : 0.29 - 0.37 mm (0.011 - 0.015 in) Exhaust : 0.32 - 0.40 mm (0.013 - 0.016 in) 6. 7. *: Approximately 20°C (68°F) (Reference data) When adjusted for cold engine, the standard values for warm engine must be checked to see if they are correct, too. Rotate crankshaft by 360° clockwise (when viewed from font) to align No. 4 cylinder at TDC of its compression stroke. Referring to the figure, measure valve clearances of valves with × in table below. Cylinder No. 4 cylinder at TDC of its compression stroke. 8. No. 1 No. 2 INT EXH No. 3 No. 4 × × × × Adjustment of places outside range of standard values is done as follows. PBIC1443E EM-48 CAMSHAFT [CR] ADJUSTMENT A NOTE: ● The adjustment is made by selecting the thickness of the head of the valve lifter. (An adjuster shim is not used) ● The set thickness for the valve filter is measured at normal temperature, but any changes in dimension EM because of temperature differences maybe ignored. Accordingly, adjustment should use values for a warmed up engine (ready for inspection). 1. Remove camshaft. Refer to EM-38, "Removal and Installation" . C 2. Remove the valve lifters for parts which are outside the range of standard values. 3. Using a micrometer (1), measure thickness of the removed valve lifter center part. D E F PBIC1333E G 4. Measure the thickness of the valve lifter to be replaced using the following formula. How to determine valve lifer thickness t = Valve lifter thickness to be replaced t1 = Removed valve lifter thickness C1 = Valve clearance measurement C2 = Standard valve clearance Intake Exhaust ● : t = t1 + (C1 - C2 ) H I : 0.37 mm (0.015 in) : 0.40 mm (0.016 in) J New valve lifter thickness (1) can be identified by stamp marks (2) on the reverse side (inside of cylindrical part). K Stamp mark Valve lifter thickness 00 02 · · 68 3.00 mm (0.1181 in) 3.02 mm (0.1189 in) · · 3.68 mm (0.1449 in) L M ● 5. 6. 7. 8. 9. Valve lifter thickness settings: Thickness 3.00 - 3.68 mm (0.1181 PBIC1334E - 0.1449 in) in 0.02 mm (0.0008 in) intervals and 35 types. Install selected valve lifter. Install camshaft. Refer to EM-38, "Removal and Installation" . Manually turn crankshaft a few turns. Make sure that the valve clearance is within the standard using the reference value when engine is cold. After restoring, make sure the valve clearance is within the range of standard values with the engine warmed up. EM-49 TIMING CHAIN [CR] TIMING CHAIN Removal and Installation PFP:13028 BBS002NI PBIC1444E 1. Cylinder head front cover 2. Camshaft sprocket (intake) 3. Camshaft sprocket (exhaust) 4. Chain tensioner 5. Slack guide 6. Front cover 7. Front oil seal 8. Crankshaft pulley 9. Timing chain 10. Tension guide 11. Dowel pin 12. Oil pump drive spacer 13. Crankshaft sprocket 14. O-ring EM-50 TIMING CHAIN [CR] REMOVAL Operation Description A 1. Remove engine and transaxle assembly from the vehicle. Refer to EM-70, "Removal and Installation" . 2. Separate engine from transaxle. Refer to MT-7, "REMOVAL AND INSTALLATION" . EM 3. Remove parts remaining in step 3 and proceed to step 5. NOTE: The reason for doing work with the engine by itself is stated below. C ● It is necessary to remove the transaxle when removing and installing the oil pan (upper). ● For this reason, the entirety of the supporting engine mount disappears when removing and installing the front cover. D 1. Remove RH front wheel and RH front fender protector. 2. Drain the engine oil. 3. Remove the following parts. E ● Drive belts and drive belt idler pulleys; Refer to EM-14, "DRIVE BELTS" . ● Rocker cover; Refer to EM-35, "ROCKER COVER" . ● Exhaust front tube; Refer to EX-3, "EXHAUST SYSTEM" . F ● Starter motor; Refer to SC-51, "Removal and Installation (CR Engine Models)" . ● Oil pan (lower and upper) and oil strainer; Refer to EM-26, "OIL PAN AND OIL STRAINER" . G ● RH headlamp; Refer to LT-32, "Removal and Installation" . 4. Using the following procedure, remove the RH engine mount stay and the RH engine mount brackets (upper and lower). H a. The engine should be immobilized using any one of the following methods. ● Mount engine slingers and hook with hoist. Refer to EM-70, "Removal and Installation" . ● Support the transaxle bottom with a jack stand, etc. I CAUTION: Make sure the transaxle is not scratched while the bottom is being supported. b. Remove RH engine mount stay and RH engine mount bracket (upper and lower). Refer to EM-70, J "Removal and Installation" . 5. Remove alternator. Refer to SC-15, "CHARGING SYSTEM" . 6. Remove cylinder head front cover. Refer to EM-38, "CAMSHAFT" . K 7. Remove the cylinder head auxiliary bolts (1). L M PBIC1335E 8. a. b. Set No. 1 cylinder at TDC on its compression stroke. Turn the crankshaft pulley clockwise. When doing this, make sure both the intake and exhaust cam noses on cylinder No. 1 are facing outwards. (No. 1 cylinder at TDC of its compression stroke) EM-51 TIMING CHAIN [CR] c. Confirm mating marks (1) stamped on intake and exhaust sprockets are rotated as shown. ● If there is no position mark in the figure, turn the crankshaft pulley once more to position them as in the figure. PBIC1306E 9. a. b. Remove the crankshaft pulley in the following order. Using the starter motor mounting hole, attach a ring gear stopper (special service tool) and secure the crankshaft. ● You can also secure the crankshaft counterweight using hammer handle, etc., after removing the oil pan (upper). Make sure no foreign matter gets inside the engine. Loosen crankshaft bolt and pull it out. CAUTION: Do not remove the mounting bolts as they will be used as a supporting point for the pulley puller. PBIC1445E c. Place the crankshaft pulley puller (1) tab on the crank pulley hole, and pull the crankshaft pulley (2) through. CAUTION: Do not put the pulley tab on the crank pulley wide-diameter pulley, as this will damage the internal dampers. 10. Remove the idler pulley bracket assembly for drive belts from the front cover. Refer to EM-14, "DRIVE BELTS" . PBIC1338E 11. Remove the front cover in the following order. a. To give more freedom to the front cover position during installation and removal, pull out the oil pump drive spacer (2) over the front oil seal (1). ● Pull out straight, using long nosed pliers or two screwdrivers, etc. CAUTION: Be careful not to damage oil pump drive spacer surface. PBIC1339E EM-52 TIMING CHAIN [CR] b. Remove front cover carefully. ● Remove bolts A to C shown in the figure. CAUTION: ● To prevent the front of the cylinder head gasket from getting bent or damaged, remove so that it comes apart cleanly from the front cover top and the gasket bottom. ● Replace the cylinder head gasket with a new one if it is damaged. A EM C KBIA1502J D c. Remove O-ring from the cylinder block. 12. Remove the front cover dowel pins (1) from the cylinder block. ● After warming with an industrial drier (2), use locking pliers (3) to pull out the dowel pins. NOTE: This step is in preparation for installing the front cover. If the timing chain is to be removed, it can be done later. E F G PBIC1340E 13. Remove the front oil seal from the front cover. ● Insert a screwdriver behind the oil seal and pull up to remove. 14. Secure the intake camshaft sprocket in the most advanced position. Refer to EM-38, "CAMSHAFT" . NOTE: The following steps are for removing the timing chain and other related parts. 15. Remove chain tensioner. Refer to EM-38, "CAMSHAFT" . 16. Remove camshaft sprocket. Refer to EM-38, "CAMSHAFT" . NOTE: No markings are needed between the camshaft sprocket and timing chain. 17. Remove timing chain, the timing chain slack guide, and the tension guide. 18. Remove the crankshaft sprocket. H I J K L INSPECTION AFTER REMOVAL Make sure there are no noticeable cracks or wear on the timing chain, and replace if there are. M PBIC0282E INSTALLATION CAUTION: ● Completely remove liquid gasket attached to mounting surfaces using a scraper, and clean off with white gasoline. ● After installation, wipe off any extra liquid gasket. 1. Install the timing chain and related parts in the following steps. EM-53 TIMING CHAIN [CR] See the figure for positions sprockets, timing chain (1), and installation of other parts. ● Attach each sprocket with its mating mark towards the engine front. Install timing chain and crankshaft sprocket (2). ● You can make sure the No. 1 cylinder is at the TDC of its compression stroke by checking if the crankshaft key is straight up. ● Place the timing chain on the front of the camshaft to make sure it does not fall. Install timing chain slack guide (3) and the tension guide (4). Install camshaft sprockets. Refer to EM-38, "CAMSHAFT" . ● Align the mating marks on camshaft sprocket and timing chain here. ● a. b. c. PBIC1341E d. e. f. g. h. i. 2. Install chain tensioner. Refer to EM-38, "CAMSHAFT" . Check again to make sure all the mating marks are in place. Temporarily install the oil pump drive spacer, the crankshaft pulley, and the crankshaft pulley bolt, and make it so that the crankshaft can be turned. Turn the crankshaft clockwise viewing from engine front. Place intake side camshaft in the most retarded position. Refer to EM-38, "CAMSHAFT" . Turn the crankshaft a few more times clockwise and make sure nothing is wrong with it. Remove the parts installed in step f. Install front oil seal to front cover. ● Make sure the oil seal lettering is towards the engine front. ● Using suitable drift, press oil seal in until it is flush with end surface of mounting position. ● Do this without damaging the outer diameter of the oil seal. PBIC1446E 3. a. b. Install the front cover with the following procedure: Install O-ring (1) to the cylinder block. Apply liquid gasket to the contact area between the bottom of the cylinder head gasket (2) and the cylinder block (two places in the figure) using a screwdriver. Use Genuine Liquid Gasket or equivalent. PBIC1342E EM-54 TIMING CHAIN [CR] c. d. Evenly apply the liquid gasket to the back of the front cover as per the position in the figure. Apply a thin, even layer of liquid gasket to the entire upper surface of the front cover. Use Genuine Liquid Gasket or equivalent. A EM C PBIC1447E D e. f. g. h. With the inner rotor internal diameter part of the oil pump resting on the top of the crankshaft [with a space between the top of the front cover and the bottom of the cylinder head gasket (3)], bring the front cover (1) as close as possible to the cylinder block. (To the left in the figure) To make sure the front cover comes into contact with the cylinder head gasket (3) bottom and the cylinder block (2) front at the same time, lift it diagonally and set it in the mounting position. (To the right in the figure) CAUTION: ● Be careful not to damage the cylinder head gasket (3). ● Attach using caution not to let the liquid gasket get cut off by getting attached to unnecessary parts. Temporarily secure the front cover so it does not move using several bolts. Press fit dowel pins (1) to the cylinder block through the front cover. E F G PBIC1343E H I J K PBIC1344E i. j. k. Temporarily tighten the front cover bolts. ● A [Under head length: 25 mm (0.98 in)], B [Under head length: 40 mm (1.57 in)], C [Under head length: 50 mm (1.97 in)] L M Temporarily tighten the cylinder head auxiliary bolts. Tighten front cover bolts and the cylinder head auxiliary bolts to the specified torque. KBIA1502J EM-55 TIMING CHAIN [CR] 4. Install oil pump drive spacer (1). ● When installing, align with flat face of oil pump inner rotor. ● If they are not aligned properly, turn the inner rotor with a screwdriver until they do. CAUTION: Be careful not to damage the oil seal lip. PBIC1345E 5. 6. 7. 8. 9. Install the drive belt idler pulley bracket assembly. Refer to EM-14, "DRIVE BELTS" . Install crankshaft pulley. ● When installing, make sure the front oil seal lip does not fold back and the garter spring of oil seal lip does not fall. ● Secure the crankshaft as in “REMOVAL” and tighten the bolts. CAUTION: The bolt seats have a special lubricant applied in order to stabilize torque, so do not wipe off or apply oil. Install the cylinder head front cover. ● Evenly apply the liquid gasket to the position shown in figure. Use Genuine Liquid Gasket or equivalent Install RH engine mount bracket and RH engine mount stay. Refer toEM-70, "Removal and Installation" . Reinstall removed parts in reverse order of removal. PBIC1441E INSPECTION AFTER INSTALLATION ● ● In order to allow liquid gasket to be cured, perform inspection at least 30 minutes after the last step in which parts sealed with liquid gasket are installed. With engine warmed up, check each part for engine oil leakage. EM-56 OIL SEAL [CR] OIL SEAL Removal and Installation of Valve Oil Seal PFP:12279 A BBS002NJ REMOVAL 1. 2. 3. 4. 5. Remove camshaft. Refer to EM-38, "CAMSHAFT" . Remove valve lifter. Refer to EM-38, "CAMSHAFT" . Turn the crankshaft, put the cylinder to have the oil seal removed in the TDC position to prevent the valve from falling into the cylinder. CAUTION: When rotating the crankshaft, make sure the timing chain does not get caught in the front cover. Using a valve spring compressor (special service tool), remove the valve collet, valve spring retainer, and valve spring. EM C D SEM914F E Using a valve oil seal puller (special service tool), remove the valve oil seal. F G H SEM909F INSTALLATION 1. 2. 3. I Apply engine oil to the new valve oil seal joint and seal lip. Using a valve oil seal drift (special service tool), press fit the valve oil seal to the height shown in the figure. Reinstall removed parts in reverse order of removal. J K L PBIC0576E Removal and Installation of Front Oil Seal REMOVAL 1. 2. Remove the following parts. ● RH front fender protector ● Drive belt; Refer to EM-14, "DRIVE BELTS" . ● Crankshaft pulley; Refer to EM-50, "TIMING CHAIN" . Using a screwdriver, remove the front oil seal. CAUTION: Be careful not to damage the front cover or the crankshaft. EM-57 BBS002NK M OIL SEAL [CR] INSTALLATION 1. 2. Apply engine oil to the new front oil seal joint and seal lip. Using a suitable drift (1), press fit until the front end of front oil seal is level with the mounting surface. ● Suitable drift (1) : outer diameter 50 mm (1.97 in), inner diameter 44 mm (1.73 in). CAUTION: ● Be careful not to damage the front cover or the crankshaft. ● Press in straight, making sure the oil seal does not curl or tilt. PBIC1346E See the figure for the direction the front oil seal should be fitted. Reinstall removed parts in reverse order of removal. ● 3. SEM715A Removal and Installation of Rear Oil Seal BBS002NL REMOVAL 1. 2. 3. 4. Remove transaxle assembly. Refer to MT-7, "REMOVAL AND INSTALLATION" . Remove clutch cover and clutch disc. Refer to CL-11, "CLUTCH DISC, CLUTCH COVER AND FLYWHEEL" . Remove flywheel. Refer to EM-74, "CYLINDER BLOCK" . Using a screwdriver, remove the rear oil seal. CAUTION: Be careful not to damage the mounting surface. INSTALLATION 1. Using a suitable drift (1), press fit until the rear end of front oil seal is level with the mounting surface. ● Suitable drift (1): outer diameter 102 mm (4.02 in), inner diameter 90 mm (3.54 in). CAUTION: ● Do not touch the grease applied to the oil seal lip. ● Be careful not to damage the rear oil seal retainer or the crankshaft. ● Press in straight, making sure the oil seal does not curl or tilt. EM-58 PBIC1347E OIL SEAL [CR] ● Press rear oil seal (2) into rear oil seal retainer (3) so that it does not project from the end. A EM C PBIC1348E D 2. Reinstall removed parts in reverse order of removal. E F G H I J K L M EM-59 CYLINDER HEAD [CR] CYLINDER HEAD On Vehicle Inspection PFP:11041 BBS002NM COMPRESSION PRESSURE INSPECTION 1. 2. a. b. c. Warm up engine thoroughly. Then, stop it. Release fuel pressure with the following procedure. Remove rear seat assembly. Open the inspection hole cover. Disconnect fuel level sensor unit, fuel filter, and fuel pump assembly connector, and start engine. Refer to FL-4, "FUEL LEVEL SENSOR UNIT, FUEL FILTER AND FUEL PUMP ASSEMBLY" . d. After you stop the engine, crank it two or three times to consume the fuel in the pipes. CAUTION: After release the fuel pressure and until the compression pressure inspection, leave the harness connector off. 3. Remove ignition coil and spark plug from all the cylinders. Refer to EM-29, "IGNITION COIL" and EM-30, "SPARK PLUG (PLATINUM-TIPPED TYPE)" . 4. Attach a engine tachometer (not required in use of CONSULT-II). 5. Install compression tester (1) with adapter onto spark plug hole. PBIC1349E Use compression tester whose picking up end inserted to spark plug hole is smaller than 20 mm (0.79 in) in diameter. Otherwise, it may be caught by cylinder head during removal. With accelerator pedal fully depressed, turn ignition switch to “START” for cranking. When the gauge pointer stabilizes, read the compression pressure and engine rpm. Perform these steps to check each cylinder. ● 6. [kPa (bar, kg/cm2 , psi)/350rpm] Engine type CR14DE Standard 1,383 (13.83, 14.1, 201) Minimum 1,187 (11.87, 12.1, 172) SEM387C Difference limit among cylinders 98 (0.98, 1.0, 14) CAUTION: Always use a fully charged battery to obtain specified engine speed. ● If the engine speed is out of specified range, check battery liquid for proper gravity. Check engine speed again with normal battery gravity. ● If compression pressure is below minimum value, check valve clearances and parts associated with combustion chamber (Valve, valve seat, piston, piston ring, cylinder bore, cylinder head, cylinder head gasket). After the checking, measure compression pressure again. ● If some cylinders have low compression pressure, pour small amount of engine oil into the spark plug hole of the cylinder to re-check it for compression. – If the added engine oil improves the compression, the piston rings may be worn out or damaged. Check the piston rings and replace if necessary. – If the compression pressure remains at low level despite the addition of engine oil, the valves may be malfunctioning. Check the valves for damage. Replace the valve or valve seat accordingly. EM-60 CYLINDER HEAD [CR] If two adjacent cylinders have respectively low compression pressure and their compression remains low even after the addition of engine oil, the gasket is leaking. In such a case, replace the cylinder head gasket. After inspection, install removed parts in reverse order of removal. ● 7. Removal and Installation BBS002NN A EM C D E F G PBIC1448E 1. Cylinder head assembly 2. Cylinder head bolt 3. Washer 4. Cylinder head auxiliary bolt 5. Cylinder head auxiliary bolt 6. Gasket H I REMOVAL 1. 2. 3. Release the fuel pressure. Refer to EC-71, "FUEL PRESSURE RELEASE" (WITH EURO-OBD), EC-488, "FUEL PRESSURE RELEASE" (WITHOUT EURO-OBD). Drain engine coolant. Refer to CO-8, "ENGINE COOLANT" . Remove the following components and related parts. ● RH front fender protector ● Alternator and A/C compressor drive belt; Refer to EM-14, "DRIVE BELTS" . ● Air duct and air cleaner case assembly; Refer to EM-18, "AIR CLEANER AND AIR DUCT" . ● Intake manifold; Refer to EM-22, "INTAKE MANIFOLD" . ● Fuel injector and fuel tube assembly; Refer to EM-32, "FUEL INJECTOR AND FUEL TUBE" . ● Radiator upper hose and lower hose; Refer to CO-12, "RADIATOR" . ● Alternator and alternator bracket; Refer to SC-39, "Removal and Installation (CR Engine Models)" . ● Exhaust manifold and three way catalyst assembly; Refer to EM-24, "EXHAUST MANIFOLD AND THREE WAY CATALYST" . ● Ignition coil; Refer to EM-29, "IGNITION COIL" . ● Rocker cover; Refer to EM-35, "ROCKER COVER" . ● Camshaft; Refer to EM-38, "CAMSHAFT" . CAUTION: For the method for maintaining engine position, select the method which supports the bottom of the oil pan. ● Heated oxygen sensor harness bracket; Refer to EM-24, "EXHAUST MANIFOLD AND THREE WAY CATALYST" . ● Water outlet, thermostat, engine coolant temperature sensor and heater pipe; Refer to CO-19, "THERMOSTAT" . ● Water suction pipe mounting bolt; Refer to CO-17, "WATER PUMP" . EM-61 J K L M CYLINDER HEAD [CR] 4. 5. Loosen bolts in the reverse order shown in the figure and then remove the cylinder head assembly. Remove cylinder head gasket. PBIC1449E INSPECTION AFTER REMOVAL Cylinder Head Bolt Outer Diameter ● Cylinder head bolts are tightened by plastic zone tightening method. Whenever the size difference between d1 and d2 exceeds the limit, replace them with new one. Limit (d1 - d2) ● : 0.12 mm (0.0047 in) If reduction of outer diameter appears in a position other than d2, use it as d2 point. PBIC1450E INSTALLATION 1. Evenly apply the liquid gasket to the position in the figure and then install the cylinder head gasket. Use Genuine Liquid Gasket or equivalent. PBIC0573E 2. a. b. c. d. e. Attach the cylinder head assembly and then tighten bolts 1 to 10 in the order shown in the figure. CAUTION: For step c, loosen them in reverse of the order in the figure. NOTE: Bolts 11 to 13 should be tightened in step 3 after tightening bolts 1 to 10. Apply new engine oil to threads and seat surfaces of bolts. Tighten at 61.7 - 71.7 N·m (6.3 - 7.3 kg-m, 46 - 52 ft-lb). Loosen completely to 0 N·m (0 kg-m). PBIC1449E Tighten at 22.5 - 32.5 N·m (2.3 - 3.3 kg-m, 17 - 23 ft-lb). Tighten with 90 - 95 degrees clockwise [Target: 90 degrees]. (Angle tightening) CAUTION: Check and confirm the tightening angle by using angle wrench (special service tool). Avoid judgment by visual inspection without the tool. EM-62 CYLINDER HEAD [CR] ● Check tightening angle indicated on the angle wrench indicator plate. A EM C PBIC0574E D 3. Tighten auxiliary bolts (11 to 13) in the numerical order shown in the figure. E F G PBIC1449E 4. Reinstall removed parts in reverse order of removal. H Disassembly and Assembly BBS002NO I J K L M PBIC1451E 1. Spark plug 2. Valve collet 3. Valve spring retainer 4. Valve spring 5. Valve spring seat 6. Valve oil seal 7. Valve guide 8. Cylinder head 9. Valve seat (INT) EM-63 CYLINDER HEAD [CR] 10. Valve (INT) 11. Valve (EXH) 12. Valve seat (EXH) 13. Spark plug tube DISASSEMBLY 1. 2. Remove spark plugs with a spark plug wrench. Remove valve lifter. ● Mark position on valve lifter for assembly. 3. Remove valve collet. ● Compress the valve spring with a valve spring compressor (special service tool). Remove valve collet with a magnetic driver. CAUTION: When working, take care not to damage valve lifter holes. 4. Remove valve spring retainer and valve spring. 5. Push the valve stem toward the combustion chamber side and remove the valve. ● Before removal, check valve guide clearance. Refer to EMPBIC1015E 66, "Valve Guide Clearance" . ● Mark position on valve for assembly. 6. Remove valve oil seal. ● Use valve oil seal puller (special service tool). 7. Remove valve spring seat. 8. When valve seat replacement is necessary, refer to EM-67, "Replacement of Valve Seat" . 9. When valve guide replacement is necessary, refer to EM-66, "Valve Guide Replacement" . 10. Remove spark plug tube, as necessary. ● Using a pair of pliers, pull spark plug tube out of cylinder SEM909F head. CAUTION: ● Take care not to damage cylinder head. ● Once removed, a spark plug tube will be deformed and cannot be reused. Do not remove it unless absolutely necessary. ASSEMBLY 1. 2. 3. 4. 5. Install valve guide. Refer to EM-66, "Valve Guide Replacement" . Install valve seat. Refer to EM-67, "Replacement of Valve Seat" . Install valve oil seal. ● Using a valve oil seal drift (special service tool), install to the dimensions specified in the figure. Install valve spring seat. Install valve. ● Valves of larger diameter are for intake side. PBIC0576E 6. 7. 8. Install valve spring. Install valve spring retainer. Install valve collet. ● Use a valve spring compressor (special service tool) to compress the valve spring, then install collet with a magnetic finger. EM-64 CYLINDER HEAD [CR] ● After installing valve component parts, tap valve stem tip with a plastic hammer to assure a proper fit. Install valve lifter. ● Install it in its original positions. 10. Install spark plug tube. ● Press-fit into cylinder head in the following order. a. Remove the old liquid gasket which has become attached to the cylinder head mounting hole. b. Apply the liquid gasket to the area around the spark plug tube press-fit. ● Use Genuine Liquid Gasket or equivalent. c. Using a drift, press-fit spark plug tube so that its height “H” is as specified in the figure. 9. Standard press-fit height “H” : 41.0 - 42.0 mm (1.614 - 1.654 in) KBIA1248E A EM C D E CAUTION: ● Press-fit, making sure not to deform the spark plug tube. ● After press-fitting, wipe off liquid gasket protruding onto cylinder head upper face. 11. Install spark plug. ● Use a spark plug wrench. G INSPECTION AFTER DISASSEMBLY Cylinder Head Distortion H 1. 2. F Using a scraper, wipe off oil, scale, gasket, sealant, and carbon deposits from surface of cylinder head. CAUTION: Do not allow gasket fragments to enter oil or engine coolant passages. Check flatness of the cylinder head lower surface. Measure distortion in six directions shown in figure, at several points in each direction. Limit ● I J : 0.1 mm (0.004 in) K if it exceeds the limit, replace the cylinder head. PBIC0075E Valve Dimensions ● ● L Check dimensions of each valve. For dimensions, refer to EM96, "VALVE" . If dimensions are out of the standard, replace valve. M SEM188A EM-65 CYLINDER HEAD [CR] Valve Guide Clearance Check valve guide clearance before removing the valve guide. 1. Make sure valve stem diameter is within the standard. 2. Push the valve out toward combustion chamber for approximately 15 mm (0.59 in). Measure runout while pushing the valve toward the dial gauge (1). 3. The half of the dial gauge reading is the valve guide clearance. Standard Intake Exhaust : 0.020 - 0.053 mm (0.0008 - 0.0021 in) : 0.040 - 0.073 mm (0.0016 - 0.0029 in) PBIC1352E Valve Guide Replacement When valve guide is removed, replace with oversized [0.2 mm (0.008 in)] valve guide. 1. To remove valve guide, heat cylinder head to 110 to 130°C (230 to 266°F) by soaking in heated oil. SEM008A 2. Drive out valve guide with a press [under a 20 kN (2 ton, 2.2 US ton, 2.0 lmp ton) pressure] or hammer and suitable tool. SEM931C 3. Ream cylinder head valve guide hole. Valve guide hole diameter (for service parts): Intake and exhaust : 9.685 - 9.696 mm (0.3813 - 0.3817 in) dia. SEM932C EM-66 CYLINDER HEAD [CR] 4. Heat cylinder head to 110 to 130°C (230 to 266°F) by soaking in heated oil. A EM C SEM008A D 5. Press valve guide from camshaft side to dimensions as in illustration. CAUTION: Cylinder head contains heat. When working, wear protective equipment to avoid getting burned. E F G PBIC0577E 6. H Using valve guide reamer, apply reamer finish to valve guide. Standard Intake and exhaust : 5.500 - 5.518 mm (0.2165 - 0.2172 in) dia. I J K SEM932C Valve Seat Contact ● ● ● ● After confirming that the dimensions of valve guides and valves are within specifications, perform this procedure. Apply prussian blue (or white lead) onto contacting surface of valve seat to check the condition of the valve contact on the surface. Check if the contact area band is continuous all around the circumference. If not, grind to adjust valve fitting and check again. If the contacting surface still has N.G conditions even after the re-check, replace valve seat. L M EMA0487D Replacement of Valve Seat When valve seat is removed, replace with oversized [0.5 mm (0.020 in)] valve seat. 1. Bore out old seat until it collapses. Boring should not continue beyond the bottom face of the seat recess in cylinder head. Set the machine depth stop to ensure this. EM-67 CYLINDER HEAD [CR] 2. Ream cylinder head recess diameter for service valve seat. Oversize [0.5 mm (0.020 in)]: Intake: 29.000 - 29.016 mm (1.1417 - 1.1424 in) Exhaust: 24.000 - 24.016 mm (0.9449 - 0.9455 in) ● ● Be sure to ream in circles concentric to the valve guide center. This will enable valve seat to fit correctly. SEM795A 3. Heat cylinder head to 110 to 130°C (230 to 266°F) by soaking in heated oil. SEM008A 4. Provide valve seats cooled well with dry ice. Force fit valve seat into cylinder head. CAUTION: ● Avoid directly to touching cold valve seats. ● Cylinder head contains heat. When working, wear protective equipment to avoid getting burned. PBIC0579E 5. Using valve seat cutter set (commercial service tool) or valve seat grinder, finish the seat to the specified dimensions. CAUTION: When using valve seat cutter, firmly grip the cutter handle with both hands. Then, press on the contacting surface all around the circumference to cut in a single drive. Improper pressure on with the cutter or cutting many different times may result in stage valve seat. SEM934C EM-68 CYLINDER HEAD [CR] Grind to obtain the dimensions indicated in figure. Standard: D1 dia. D2 dia. D3 dia. D4 dia. D5 dia. 6. 7. A : 25.4 mm (1.000 in) : 27.0 - 27.2 mm (1.062 - 1.070 in) : 28.7 - 28.9 mm (1.129 - 1.137 in) : 22.0 - 22.2 mm (0.866 - 0.874 in) : 23.7 - 23.9 mm (0.933 - 0.940 in) Using compound, grind to adjust valve fitting. Check again for normal contact. EM C PBIC0974E D Valve Spring Squareness Set try square (1) along the side of valve spring and rotate the spring. Measure the maximum clearance between the top face of spring and try square (1). Limit ● E : 1.6 mm (0.063 in) F if exceeds the limit, replace the valve spring. G PBIC1355E Valve Spring Dimensions and Valve Spring Pressure Load ● Check valve spring pressure load at specified spring height. Standard Free height Installation height Installation load Height during valve open Load with valve open ● H I : 53.3 mm (2.098 in) : 32.82 mm (1.2921 in) J : 149 - 165 N (15.2 - 16.8 kg, 33.5 37 lb) : 24.73 mm (0.9736 in) K SEM113 : 228 - 250 N (23.3 - 25.5 kg, 51.3 56.2 lb) L If the dimensions exceed the standard, replace the valve spring. M EM-69 ENGINE ASSEMBLY [CR] ENGINE ASSEMBLY Removal and Installation PFP:10001 BBS002NP MBIB9032E LH engine mount bracket (vehicle side) 3. LH engine mount bracket (transaxle side) RH engine mount stay 5. (The shape may not be the same as figure) RH engine mount insulator 6. RH engine mount bracket (upper) RH engine mount bracket (lower) Rear engine mount bracket 9. Rear torque rod 1. LH engine mount insulator 4. 7. 2. 8. 10. Engine mounting bracket rear WARNING: ● Situate vehicle on a flat and solid surface. ● Place chocks at front and back of rear wheels. ● For engines not equipped with engine slingers, attach proper slingers and bolts described in PARTS CATALOG. CAUTION: ● Always be careful to work safely, avoid forceful or uninstructed operations. ● Do not start working until exhaust system and engine coolant are cool enough. ● If items or work required are not covered by the engine main body section, refer to the applicable sections. ● Always use the support point specified for lifting. ● Use either 2-pole lift type or separate type lift as best you can. If board-on type is used for unavoidable reasons, support at the rear axle jacking point with transmission jack or similar tool before starting work, in preparation for the backward shift of center of gravity. ● For supporting points for lifting and jacking point at rear axle, refer to GI-40, "Garage Jack, Safety Stand and 2-Pole Lift" . EM-70 ENGINE ASSEMBLY [CR] REMOVAL A Description of work Remove engine and transaxle assembly from vehicle, and separate engine and transaxle. Preparation EM 1. When engine can be hoisted, remove engine hood. 2. Release fuel pressure. Refer to EC-71, "FUEL PRESSURE RELEASE" (WITH EURO-OBD), EC-488, "FUEL PRESSURE RELEASE" (WITHOUT EURO-OBD). C 3. Drain engine coolant. Refer to CO-8, "ENGINE COOLANT" . 4. Remove the following parts. ● RH and LH front wheel D ● RH and LH front fender protector ● Exhaust front tube; Refer to EX-3, "EXHAUST SYSTEM" . ● Drive belt; Refer toEM-14, "DRIVE BELTS" . E ● Air duct; Refer to EM-18, "AIR CLEANER AND AIR DUCT" . ● Battery ● Radiator; Refer to CO-12, "RADIATOR" . F Engine room LH 5. Disconnect the harness connectors and terminals from the following parts. G NOTE: ● Remove the ECM (1) from the bracket and disconnect the two harness connectors. H CAUTION: Avoid impacts to ECM. ● Disconnect the intermediate connector (2) for the main harI ness between the vehicle and the engine room below the ECM. PBIC1356E ● Disconnect the harness connectors on the battery positive J terminal (3). ● Disconnect the ground wire on the transaxle (4) side. 6. Disconnect heater hose. Plug the hose immediately to prevent engine coolant from draining. K 7. Disconnect the shift cable from the transaxle. Refer to MT-12, "CONTROL LINKAGE" . 8. Disconnect the clutch tube from the transaxle side and temporarily fasten to vehicle. L ● Install the plug to prevent the clutch fluid from leaking. 9. Remove the crankshaft position sensor (POS) from the transaxle. CAUTION: M Handle it carefully, avoid any chance of impact caused by dropping. Engine room front and RH 10. Remove the ground wire between the alternator bracket and the vehicle. 11. Remove RH engine mount stay, alternator bracket, and alternator. 12. Remove A/C compressor from engine with piping connected, and temporarily install it to vehicle with rope to avoid putting stress on air conditioner pipes. 13. Remove fuel tube protector. Refer to EM-32, "FUEL INJECTOR AND FUEL TUBE" . 14. Disconnect fuel hose. Plug the hose immediately to prevent fuel from draining. Vehicle underbody 15. Remove the ABS wheel sensor from the steering knuckle. 16. Remove brake caliper from steering knuckle. Temporarily fix on vehicle side with rope or so to avoid putting stress on brake hose. Refer to BR-21, "FRONT DISC BRAKE" . 17. Remove RH and LH drive shafts. Refer to FAX-10, "FRONT DRIVE SHAFT" . EM-71 ENGINE ASSEMBLY [CR] 18. Remove rear torque rod (1). MBIB1377E Removal 19. Install engine slinger to cylinder head front left side (1) and rear right side (2) and support the engine position with a hoist. NOTE: Front side and rear side engine slinger are common parts. : 16.6 - 23.5 N·m (1.7 - 2.3 kg-m, 13 - 17 in) ● For front side, remove harness bracket under fuel tube protector and mount by using harness bracket mounting hole. Refer to EM-32, "FUEL INJECTOR AND FUEL TUBE" . PBIC1358E 20. Lift to a height sufficient to allow easy work, support the bottom of the engine with either a manual lift table caddy (commercial service tool) or two suitable jacks, and adjust the tension of the hoist. CAUTION: ● Put a piece of wood or something similar as the supporting surface, secure a completely stable condition. ● Make sure the hanging chain or hanging hook does not come into contact with the A/C piping or the vehicle (cowl top). Also make sure they do not get in the way by moving while the work is being done. PBIC1454E 21. Remove the RH engine mount bracket (upper) (1) mounting bolts (2). 22. Remove the LH engine mount bolt-securing nut (3). MBIB9050E 23. Carefully lower the manual lift table caddy or suitable jack, (or carefully raise the lift), and remove the engine and transaxle assembly from the vehicle. ● If you are going to lower the engine side, do this in tandem with the hoist. CAUTION: ● This should be done making sure it does not come in contact with the vehicle. ● Check that all connection points have been disconnected. ● Make sure the hanging chain or hanging hook does not come into contact with the A/C piping or the vehicle (cowl top). EM-72 ENGINE ASSEMBLY [CR] During engine and transaxle assembly removal, always be careful to prevent the vehicle from falling off the lift due to changes in the center of gravity. A ● If necessary, support the rear side of the vehicle with jack to prevent it from falling off. Separation Work EM ● On level ground, separate engine and transaxle with the following procedure: CAUTION: During the operation, securely support the engine by placing a piece of wood under the engine oil pan, C transaxle oil pan, and suspension member, and suspend the engine slingers by hoist. 24. Remove the starter motor. Refer to SC-51, "Removal and Installation (CR Engine Models)" . 25. Separate the engine and the transaxle. Refer to MT-7, "REMOVAL AND INSTALLATION" . D ● INSTALLATION Install in the reverse order of removal while being careful of the following. ● Do not allow the engine mount insulator to be damaged and be careful no oil gets on it. ● For a part with a specified installation orientation, refer to component figure in EM-70, "Removal and Installation" . ● Make sure all mount insulators are seated properly, then tighten nuts and bolts. E F INSPECTION AFTER INSTALLATION ● ● – – ● ● ● ● Before starting engine, check the levels of engine coolant, lubrications and working oils. If less than required quantity, fill to the specified level. Use procedure below to check for fuel leakage. Turn ignition switch ON (with engine stopped). With fuel pressure applied to fuel piping, check for fuel leakage at connection points. Start engine. With engine speed increased, check again for fuel leakage at connection points. Run engine to check for unusual noise and vibration. Warm up engine thoroughly to make sure there is no leakage of engine coolant, lubricants, working oil, fuel and exhaust gas. Bleed air from passages in pipes and tubes of applicable lines, such as in cooling system. After cooling down engine, again check amounts of engine coolant, lubricants, oil, and fluid. Refill to specified level, if necessary. G H I J K L M EM-73 CYLINDER BLOCK [CR] CYLINDER BLOCK Disassembly and Assembly PFP:11010 BBS002NQ PBIC1455E EM-74 CYLINDER BLOCK [CR] 1. Rear oil seal 2. Rear oil seal retainer 3. Knock sensor 4. Cylinder block 5. Oil level gauge guide 6. Top ring 7. Second ring 8. Oil ring 9. Piston A 10. Piston pin 11. Connecting rod 12. Connecting rod bearing 13. Thrust bearing 14. Main bearing 15. Crankshaft 16. Key 17. Connecting rod cap 18. Connecting rod nut 19. Main bearing cap bolt 20. Main bearing cap 21. Rear plate 22. Flywheel (M/T models) 23. Adapter (A/T models) 24. Drive plate (A/T models) 25. O-ring 26. Crankshaft position sensor (POS) EM D DISASSEMBLY 1. 2. a. b. C Remove engine and transaxle assembly from the vehicle and separate transaxle from the vehicle. Refer to EM-70, "Removal and Installation" . Install engine to engine stand in the following procedure. NOTE: We will use as an example the engine stand (commercial service tool) specified to support the cylinder block rear (transaxle mounting surface). Remove clutch cover and clutch disc. Refer to CL-11, "CLUTCH DISC, CLUTCH COVER AND FLYWHEEL" . Remove the flywheel. ● Using a ring gear stopper (special service tool), secure the crankshaft, loosen the bolts diagonally and remove. E F G H I J PBIC1456E c. K CAUTION: Make sure signal plate (1) are not damaged or deformed. NOTE: Figure shows the drive plate. Remove rear plate. L M PBIC1360E d. Lift engine using a hoist and mount it on an engine stand (1). ● For installation of engine slingers, refer to EM-70, "Removal and Installation" . PBIC1361E EM-75 CYLINDER BLOCK [CR] 3. 4. Drain engine oil and engine coolant from engine. Remove following components and related parts. ● Air cleaner case assembly; Refer to EM-18, "AIR CLEANER AND AIR DUCT" . ● Intake manifold; Refer to EM-22, "INTAKE MANIFOLD" . ● Fuel injector and fuel tube assembly; Refer to EM-32, "FUEL INJECTOR AND FUEL TUBE" . ● Ignition coil; Refer to EM-29, "IGNITION COIL" . ● Rocker cover; Refer to EM-35, "ROCKER COVER" . ● Oil pan and oil strainer; Refer to EM-26, "OIL PAN AND OIL STRAINER" . ● Front cover and timing chain; Refer to EM-50, "TIMING CHAIN" . ● Camshaft; Refer to EM-38, "CAMSHAFT" . ● Cylinder head assembly; Refer to EM-61, "Removal and Installation" . ● Oil filter; Refer to LU-9, "OIL FILTER" . ● Oil pressure switch; Refer to LU-6, "OIL PRESSURE CHECK" . 5. Remove knock sensor. CAUTION: Avoid impact such as a dropping. 6. Remove oil level gauge guide, if necessary. CAUTION: Once removed, it cannot be reused. Do not remove it unless absolutely necessary. 7. Remove rear oil seal retainer. ● Remove by inserting a screwdriver between main bearing cap and rear oil seal retainer. 8. Remove rear oil seal from rear oil seal retainer. ● Remove by driving it out using a screwdriver. CAUTION: Make sure the rear oil seal retainer is not damaged. 9. Remove piston and connecting rod assembly. ● Before removing connecting rod, check connecting rod side clearance. Refer to EM-85, "CONNECTING ROD SIDE CLEARANCE" . a. Position the crankshaft pin corresponding to the connecting rod to be removal onto the bottom dead center. b. Remove connecting rod cap. c. Push the piston and connecting rod assembly out toward cylinder head side with handle of a hammer. 10. Remove connecting rod bearings from connecting rod and connecting rod cap. EMG0025D CAUTION: When removing, check each part, and arrange them in a way that prevents mixing them up. 11. Remove piston rings from piston. ● Use piston ring expander (1). CAUTION: ● Be careful not to damage piston. ● Do not expand piston rings excessively. It can damage piston rings. ● Before removal of piston ring, check piston ring side clearance. Refer to EM-86, "PISTON RING SIDE CLEARANCE" . PBIC1362E EM-76 CYLINDER BLOCK [CR] 12. Remove piston from connecting rod. ● Use a piston pin press stand and a press to remove the piston pin. NOTE: The joint between the connecting rod and the piston pin is a press fit. CAUTION: Be careful not to damage the piston and connecting rod. A EM C PBIC1574E D 13. Remove the main bearing cap in the following order. a. Loosen and remove bolts in several steps in reverse of the numerical order shown in figure. ● Before loosening main bearing cap bolts, measure the crankshaft side clearance. Refer to EM-85, "CRANKSHAFT SIDE CLEARANCE" . b. Tapping lightly with a plastic hammer, remove the main bearing cap. 14. Remove crankshaft. 15. Remove main bearing and thrust bearing from cylinder block PBIC1457E and main bearing cap. CAUTION: Identify installation position of each part. Arrange removed parts so as not to mix them up. E F G H ASSEMBLY 1. 2. Thoroughly clean engine coolant and oil passages in cylinder block, as well as inside of crank case and cylinder bores, with compressed air. If the plug (1) in figure is removed, apply liquid gasket to the plug screw. Use Genuine Liquid Gasket or equivalent. ● Do not reuse washer. Replace it with a new washer. ● Tighten to the specified torque. I J K : 58.8 - 68.6 N·m (6.0 - 6.9 kg-m, 44 - 50 ft-lb) PBIC1363E 3. a. b. Install main bearings and thrust bearings. Clean bearing mounting surfaces on cylinder block and main bearing cap to remove any foreign material, dust, and oil on them. Install thrust bearings (1) on both sides of cylinder block No. 3 housing (2). ● Install thrust bearing with its oil groove (3) facing crankshaft arm side (outer side). M PBIC1364E EM-77 L CYLINDER BLOCK [CR] c. Install main bearing (1) in paying attention to the direction. Install main bearing with oil groove and oil hole (2) to cylinder block, and the one without oil groove and oil hole to main bearing cap (5). ● Before installing the main bearing, lubricate bearing surface (inside) with new engine oil. Do not apply engine oil to back surface, but thoroughly clean it. ● When installing, align the bearing stopper (3) to the notch (4). ● Make sure that oil holes in cylinder block and main bearing are aligned. Install crankshaft to cylinder block. ● Rotate crankshaft by hand and make sure it turns smoothly. Install main bearing cap. ● Install main bearing cap with its front mark (1) facing front of engine. NOTE: Since it is machined together with the cylinder block, it cannot be replaced on its own. ● 4. 5. PBIC1365E PBIC1366E 6. a. b. c. Tighten main bearing cap bolts in numerical order shown in figure with the following steps. Lubricate threads and seat surface of each bolt with new engine oil. Tighten it to 24.5 - 30.3 N·m (2.5 - 3.0 kg-m, 18 - 22 ft-lb). Tighten with 95 - 100 degrees clockwise [Target: 95 degrees].(Angle tightening) PBIC1457E ● ● ● Use an angle wrench (special service tool) to check tightening angle. CAUTION: Check tightening angle with an angle wrench. Do not visually check the tightening angle. After tightening main bearing cap bolts, rotate crankshaft by hand and make sure that it turns smoothly. Check crankshaft side clearance. Refer to EM-85, "CRANKSHAFT SIDE CLEARANCE" . PBIC1458E 7. Install the piston onto the connecting rod in the following procedure: EM-78 CYLINDER BLOCK [CR] a. Set so that the piston front mark (1) on the piston head and the connecting rod cylinder number (2) engraving are in the position shown in figure. A EM C PBIC1367E D b. Press fit the piston pin using the piston pin press stand (special service tool). NOTE: The joint between the connecting rod and the piston pin is a press fit. ● After finishing work, make sure the piston moves freely. E F G PBIC1574E 8. Install piston rings with piston ring expander as shown in the figure. CAUTION: ● Be careful not to damage piston. ● Make sure the piston ring does not spread out too much and break. H I J PBIC1582E ● ● Against the piston front mark (1), position end gaps of each piston ring as shown in figure. Install top ring and second ring with stamp mark side facing up. K L M PBIC1368E 9. Install connecting rod bearing to connecting rod and connecting rod cap. ● When installing connecting rod bearing, lubricate bearing surface (inside) with new engine oil. Do not apply engine oil to back surface, but thoroughly clean it. ● Install connecting rod bearing by aligning the stopper protrusion (1) with notch (2) on connecting rod. PBIC1369E EM-79 CYLINDER BLOCK [CR] 10. Install piston and connecting rod assembly to crankshaft. ● Position the crankshaft pin corresponding to the connecting rod to be removal onto the bottom dead center. ● Apply enough engine oil to cylinder bore, piston and crankshaft pin. ● Install connecting rod to cylinder position corresponding to cylinder No. stamped on it. ● Using a piston ring compressor (special service tool) (1), install piston so that piston grade number on piston head faces toward engine front. PBIC1370E CAUTION: Be careful not to damage the cylinder wall and crankshaft pin, resulting from an interference of the connecting rod big end. 11. Install connecting rod cap. ● Be sure that cylinder No. (1) on connecting rod and connecting rod cap match. PBIC1371E 12. Tighten connecting rod nuts in following steps. a. Lubricate threads and seat surface of connecting rod nuts and bolts with new engine oil. b. Tighten at 13.7 - 15.7 N·m (1.4 - 1.6 kg-m, 10.1 - 11.5 ft-lb). c. Tighten with 45 - 50 degrees clockwise [Target: 45 degrees]. (Angle tightening) CAUTION: Check tightening angle with an angle wrench (special service tool). Do not visually check the tightening angle. ● After the nuts were tightened, rotate crankshaft by hand and PBIC1459E make sure that it turns smoothly. ● Check connecting rod side clearance. Refer to EM-85, "CONNECTING ROD SIDE CLEARANCE" . 13. Install rear oil seal. ● Make sure the area surrounding the oil seal is not damaged, and use an oil seal drift to press fit. ● Press fit until the end of rear oil seal is level with the edges of the retainer. PBIC1460E EM-80 CYLINDER BLOCK [CR] 14. Install rear oil seal retainer. ● Evenly apply the liquid gasket to the position shown in figure. Use Genuine Liquid Gasket or equivalent. ● Install so that it matches up with the dowel pin on the cylinder block side. A EM C PBIC1461E D 15. Install oil level gauge guide (1). ● Press fit the oil level gauge guide (1) into the cylinder block with the assembly reference surface on the plate set as shown in the figure. ● Apply sealant to the press fit areas. CAUTION: Replace used oil level gauges with new ones. E F G H I J PBIC1372E 16. Install knock sensor. ● Install connector so that it is positioned towards the engine front. CAUTION: ● Handle it carefully to avoid impact. If any impact is applied, replace it with new one. ● Confirm no foreign material adhere to cylinder block and knock sensor mounting surfaces. ● Be sure to use specified bolts. ● Do not hold connector when tightening bolts. PBIC1373E ● Make sure installed sensor connector is away from contact with other parts. 17. For the following, install the parts disassembled in step 4 in the reverse order. 18. Secure the position of the engine with the hoist, remove the bolts, and lower from the engine stand. 19. Install rear plate. EM-81 K L M CYLINDER BLOCK [CR] 20. Install the flywheel (1). ● Install so that signal plate (4) is towards the back of the engine. ● Install by aligning the dowel pin hole (6) with the dowel pin (5) on the back of the crankshaft. CAUTION: Make sure signal plate (4) are not damaged or deformed. PBIC1374E ● Using a ring gear stopper (special service tool), secure the crankshaft, and tighten the bolts diagonally. PBIC1456E 21. Reinstall removed parts remained in reverse order of removal. How to Select Piston and Bearing BBS002NR DESCRIPTION Selection points ● ● ● Between cylinder block and crankshaft Between cylinder block and piston Selection parts Selection items Selection methods Main bearing Main bearing grade (Bearing thickness) Determined by cylinder block bearing housing grade (inner diameter of housing) and crankshaft journal grade (outer diameter of journal). Piston and piston pin assembly Note: Piston and piston pin are a set. They make up one part as an assembly. Piston grade (Piston outer diameter) Piston grade = cylinder bore grade (inner diameter of bore) The identification grade stamped on each part is the grade for the dimension measured in new condition. This grade cannot apply to reused parts. For reused or repaired parts, measure the dimension accurately. Determine the grade by comparing the measurement with the values of each selection table. For details of the measurement method of each part, the reuse standards and the selection method of the selective fitting parts, refer to the text. EM-82 CYLINDER BLOCK [CR] HOW TO SELECT PISTON When New Cylinder Block is Used ● A Check cylinder bore grade (1, 2, or 3) on cylinder block bottom rear surface and select piston of the same grade. EM C D PBIC1463E E NOTE: The piston head shape varies from engine to engine, as do their positions shown in figure. F G H PBIC1462E When Cylinder Block is Reused 1. 2. 3. Measure cylinder bore inner diameter. Determine the bore grade by comparing the measurement with the values under the cylinder bore inner diameter of the “Piston Selection Table”. Select the piston of the same grade. I J Piston selection Table CR14DE K Unit: mm (in) Grade 1 2 3 Inner diameter of cylinder bore 73.000 - 73.010 (2.8740 - 2.8744) 73.010 - 73.020 (2.8744 - 2.8748) 73.020 - 73.030 (2.8748 - 2.8752) Outer diameter of piston 72.980 - 72.990 (2.8732 - 2.8736) 72.990 - 73.000 (2.8736 - 2.8740) 73.000 - 73.010 (2.8740 - 2.8744) EM-83 L M CYLINDER BLOCK [CR] HOW TO SELECT MAIN BEARING When New Cylinder Block and Crankshaft are Used 1. “Main Bearing Selection Table” rows correspond to bearing housing grade (0, 1, 2, or 3) on cylinder block bottom rear surface. PBIC1463E 2. 3. Apply journal diameter grade (0, 1, 2, or 3) stamped on crankshaft front side to column in “Main Bearing Selection Table”. Select main bearing (STD 1 to 7) at the point where selected row and column meet in the following selection table. PBIC1464E When Cylinder Block and Crankshaft are Reused 1. 2. 3. 4. Measure inner diameter of cylinder block main bearing housing and outer diameter of crankshaft journal. Find measured dimension in “Cylinder block bearing housing inner diameter” row of “Main Bearing Selection Table”. Find the measured dimension in “Crankshaft main journal diameter” column in the following selection table. Select main bearing (STD 1 to 7) at the point where selected row and column meet in the following selection table. Main bearing Selection Table Units: mm (in) Cylinder block main bearing housing inner diameter Crankshaft journal diameter 44.970/44.966 (1.7705/1.7703) 44.966/44.962 (1.7703/1.7702) 44.962/44.958 (1.7702/1.7700) 44.958/44.954 (1.7700/1.7698) - 49.004/49.000 (1.9293/1.9291) 49.008/49.004 (1.9294/1.9293) 49.012/49.008 (1.9296/1.9294) 49.016/49.012 (1.9298/1.9296) - 0 1 2 3 ● Bearing grade No. ● Bearing thickness ● Identification color STD1 2.002/2.006 (0.0788/0.0790) Red STD 2 2.004/2.008 (0.0789/0.0791) Green STD 3 2.006/2.010 (0.0790/0.0791) Yellow STD 4 2.008/2.012 (0.0791/0.0792) Blue ● Bearing grade No. ● Bearing thickness ● Identification color STD 2 2.004/2.008 (0.0789/0.0791) Green STD 3 2.006/2.010 (0.0790/0.0791) Yellow STD 4 2.008/2.012 (0.0791/0.0792) Blue STD 5 2.010/2.014 (0.0791/0.0793) Pink ● Bearing grade No. ● Bearing thickness ● Identification color STD 3 2.006/2.010 (0.0790/0.0791) Yellow STD 4 2.008/2.012 (0.0791/0.0792) Blue STD 5 2.010/2.014 (0.0791/0.0793) Pink STD 6 2.012/2.016 (0.0792/0.0794) White ● Bearing grade No. ● Bearing thickness ● Identification color STD 4 2.008/2.012 (0.0791/0.0792) Blue STD 5 2.010/2.014 (0.0791/0.0793) Pink STD 6 2.012/2.016 (0.0792/0.0794) White STD 7 2.014/2.018 (0.0793/0.0794) Blue/yellow Grade (stamped) 0 1 2 3 EM-84 CYLINDER BLOCK [CR] Undersize Bearing Usage Guide A If specified oil clearance cannot be obtained by standard size main bearing, use undersize (US) bearing. ● When using undersize bearing, install it, measure bearing inner diameter, and grind journal to obtain specified oil clearance. EM Bearing undersize table ● Unit: mm (in) Size Thickness US 0.25 (0.0098) 2.123 - 2.131 (0.836 - 0.839) C CAUTION: Keep fillet R when grinding crankshaft journal (1) in order to use undersize bearing (All journals). D PBIC1375E Inspection After Disassembly BBS002NS CRANKSHAFT SIDE CLEARANCE ● ● F Using a dial gauge (1), measure the clearance between the thrust bearings and the crankshaft arm when the crankshaft is moved fully forward or backward. Standard Limit E G : 0.060 - 0.260 mm (0.0024 - 0.0102 in) : 0.3 mm (0.012 in) H If the measured value exceeds the limit, replace the thrust bearings, and measure again. If it still exceeds the limit, replace the crankshaft also. I PBIC1376E CONNECTING ROD SIDE CLEARANCE ● Standard Repair limit ● J Measure side clearance between connecting rod and crankshaft arm with feeler gauge (1). : 0.050 - 0.420 mm (0.0020 - 0.0165 in) : 0.5 mm (0.0197 in) K If the measured value exceeds the limit, replace the connecting rod, and measure again. If it still exceeds the limit, replace the crankshaft also. L M PBIC1377E PISTON AND PISTON PIN CLEARANCE Inner Diameter of Piston Pin ● Measure the inner diameter of piston pin bore with an inside micrometer (1). Standard : 18.008 - 18.012 mm (0.7090 - 0.7091 in) PBIC1378E EM-85 CYLINDER BLOCK [CR] Outer Diameter of Piston Pin ● Using a micrometer (1), measure piston pin outer diameter. Standard : 17.996 - 18.000 mm (0.7085 - 0.7087 in) PBIC1379E Piston and Piston pin Clearance (Piston pin clearance) = (Piston pin bore diameter) – (Outer diameter of piston pin) Standard ● ● : 0.008 - 0.016 mm (0.0003 - 0.0006 in) If clearance exceeds the standard, replace piston and piston pin assembly. When replacing piston and piston pin assembly, refer to EM-83, "HOW TO SELECT PISTON" PISTON RING SIDE CLEARANCE ● Measure side clearance of piston ring and piston ring groove with feeler gauge (1). Standard: Top ring 2nd ring Oil ring Limit: Top ring 2nd ring ● : 0.040 - 0.080 mm (0.0016 - 0.0031 in) : 0.025 - 0.070 mm (0.0010 - 0.0028 in) : 0.030 - 0.140 mm (0.0021 - 0.0055 in) : 0.11 mm (0.0043 in) : 0.1 mm (0.0039 in) PBIC1380E If out of specification, replace piston and/or piston ring assembly. PISTON RING END GAP ● ● Check if inner diameter of cylinder bore is within specification. Refer to EM-89, "PISTON TO CYLINDER BORE CLEARANCE" . Insert piston ring (1) until middle of cylinder with piston (2), and measure gap. Standard: Top ring 2nd ring Oil ring Limit: Top ring 2nd ring Oil ring ● : 0.18 - 0.33 mm (0.0071 - 0.0130 in) : 0.50 - 0.65 mm (0.0197 - 0.0256 in) : 0.20 - 0.70 mm (0.0079 - 0.0276 in) PBIC1381E : 0.57 mm (0.0224 in) : 0.85 mm (0.0335 in) : 0.96 mm (0.0378 in) If out of specification, replace piston ring. If gap still exceeds the limit even with a new ring, re-bore cylinder and use oversized piston and piston ring. EM-86 CYLINDER BLOCK [CR] CONNECTING ROD BEND AND TORSION ● A Check connecting rod bend and torsion with a connecting rod aligner. Bend: Limit : 0.15 mm (0.0059 in) per 100 mm (3.94 in) length Torsion: Limit : 0.30 mm (0.0118 in) per 100 mm (3.94 in) length EM C SEM038F ● D If it exceeds the limit, replace connecting rod assembly. E F G SEM003F H CONNECTING ROD BEARING HOUSING DIAMETER (BIG END) ● Install the connecting rod cap without the connecting rod bearing installed. After tightening the connecting rod bolt to the specified torque, measure the connecting rod big end inner diameter using an inside micrometer (1). Refer to EM-77, "ASSEMBLY" for the tightening procedure. Standard ● I J : 43.000 - 43.013 mm (1.6929 - 1.6934 in) dia. If it exceeds the standard, replace the connecting rod. K PBIC1382E L CONNECTING ROD BUSHING OIL CLEARANCE DIAMETER (SMALL END) Inner Diameter of Connecting Rod Bushing (Small End) ● Using an inside micrometer (1), measure inner diameter of bushing. Standard M : 17.962 - 17.978 mm (0.7072 - 0.7078 in) dia. PBIC1383E EM-87 CYLINDER BLOCK [CR] Outer Diameter of Piston Pin ● Using a micrometer (1), measure piston pin outer diameter. Standard : 17.996 - 18.000 mm (0.7996 - 0.7087 in) dia. PBIC1379E Connecting Rod Bushing Oil Clearance (Small End) (Connecting rod small end oil clearance) = (Inner diameter of connecting rod small end) – (Outer diameter of piston pin) Standard ● ● : –0.018 - –0.038 mm (–0.0007 - –0.0015 in) If the measured value exceeds the standard, replace the connecting rod assembly and/or piston and piston pin assembly. If replacing the piston and piston pin assembly, refer to EM-83, "HOW TO SELECT PISTON" . CYLINDER BLOCK DISTORTION ● ● Using a scraper, remove gasket on the cylinder block surface, and also remove oil, scale, carbon, or other contamination. CAUTION: Be careful not to allow gasket flakes to enter the oil or coolant passages. Measure the distortion on the block upper face at some different points in 6 directions. Limit ● : 0.1 mm (0.004 in) If out of the distortion limit, replace the cylinder block. PBIC0121E INNER DIAMETER OF MAIN BEARING HOUSING ● ● Install the main bearing cap with the main bearings removed, and tighten the mounting bolts to the specified torque. Refer to EM-77, "ASSEMBLY" for the tightening procedure. Using a bore gauge (1), measure the inner diameter of the main bearing housing. Standard ● : 49.000 - 49.016 mm (1.9291 - 1.9298 in) dia. If out of specification, replace cylinder block and main bearing cap as an assembly. NOTE: Cylinder block cannot be replaced as a single part because it is machined together with main bearing cap. EM-88 PBIC1384E CYLINDER BLOCK [CR] PISTON TO CYLINDER BORE CLEARANCE Inner Diameter of Cylinder Bore ● A Using a bore gauge (1), measure cylinder bore for wear, out-ofround and taper at 6 different points on each cylinder. (X and Y directions at A, B and C) (Y is in longitudinal direction of engine) EM C D PBIC1385E E Standard inner diameter: CR14DE : 73.000 - 73.030 mm (2.8740 - 2.8744 in) dia. Wear limit: 0.2 mm (0.008 in) Out-of-round (Difference between X and Y): 0.015 mm (0.0006 in) Taper limit (Difference between A and C): 0.01 mm (0.0004 in) F G H PBIC0613E ● ● ● If the measured value exceeds the limit, or if there are scratches and/or seizure on the cylinder inner wall, hone or rebore the inner wall. An oversize piston is provided. When using an oversize piston, rebore the cylinder so that the clearance of the piston-to-cylinder bore satisfies the standard. When using an oversize piston, use it for all cylinders with oversize piston rings. I J Oversize (OS) : 0.2 mm (0.008 in) Outer Diameter of piston ● K Measure piston skirt outer diameter using micrometer (1). Measurement point (Distance from the top) CR14DE : 32.3 mm (1.272 in) Standard CR14DE : 72.980 - 73.010 mm (2.7953 - 2.7957 in) dia. L M PBIC1386E Piston to Cylinder Bore Clearance ● Calculate by outer diameter of piston skirt and inner diameter of cylinder (direction X, position B). (Clearance) = (Inner diameter of cylinder) – (Outer diameter of piston skirt). Standard ● : 0.010 - 0.030 mm (0.0004 - 0.0012 in) If clearance exceeds the standard, replace piston and piston pin assembly. Refer to EM-83, "HOW TO SELECT PISTON" . EM-89 CYLINDER BLOCK [CR] Reboring Cylinder Bore 1. Cylinder bore size is determined by adding piston-to-cylinder bore clearance to piston diameter “A”. Rebored size calculation: D = A + B - C where, D: Bored diameter A: Piston diameter as measured B: Piston - to - cylinder bore clearance (standard value) C: Honing allowance 0.02 mm (0.0008 in) 2. 3. ● ● 4. 5. ● Install main bearing caps, and tighten to the specified torque. Otherwise, cylinder bores may be distorted in final assembly. Cut cylinder bores. When any cylinder needs boring, all other cylinders must also be bored. Do not cut too much out of cylinder bore at a time. Cut only 0.05 mm (0.0020 in) or so in diameter at a time. Hone cylinders to obtain specified piston-to-cylinder bore clearance. Measure finished cylinder bore for out-of-round and taper. Measurement should be done after cylinder bore cools down. OUTER DIAMETER OF CRANKSHAFT JOURNAL ● Using a micrometer (1), measure outer diameter of crankshaft journals. Standard ● : 44.954 - 44.970 mm (1.7698 - 1.7705 in) dia. If it is out of the standard, measure the main bearing oil clearance. Then use the undersize bearing. Refer to EM-92, "OIL CLEARANCE OF MAIN BEARING" . PBIC1387E OUTER DIAMETER OF CRANKSHAFT PIN ● Using a micrometer, measure outer diameter of crankshaft pin. Standard ● : 39.961 - 39.974 mm (1.5733 - 1.5738 in) dia. If it is out of the standard, measure the connecting rod bearing oil clearance. Then use the undersize bearing. Refer to EM-91, "OIL CLEARANCE OF CONNECTING ROD BEARING" . OUT-OF-ROUND AND TEPER OF CRANKSHAFT ● ● ● Using a micrometer, measure the dimensions at 4 different points shown in the figure on each journal and pin. Out-of-round (1) is indicated by the difference in dimensions between 1 and 2 at A and B. Taper (2) is indicated by the difference in dimension between A and B at 1 and 2. Limit: Out-of-round (X – Y) Taper (1 – 2) : 0.005 mm (0.0002 in) : 0.005 mm (0.0002 in) PBIC1388E ● ● If the measured value exceeds the limit, correct or replace the crankshaft. If corrected, measure the bearing oil clearance of the corrected journal or pin. Then select the main bearing or connecting rod bearing. Refer to EM-92, "OIL CLEARANCE OF MAIN BEARING" or EM-91, "OIL CLEARANCE OF CONNECTING ROD BEARING" . EM-90 CYLINDER BLOCK [CR] CRANKSHAFT RUNOUT ● ● ● Limit ● A Place a V-block on a precise flat table to support the journals on the both end of the crankshaft. Place a dial gauge (1) straight up on the No. 3 journal. Rotate crankshaft and read indication on the gauge. (Total indicator reading) EM : 0.05 mm (0.002 in) C If it exceeds the limit, replace the crankshaft. PBIC1389E OIL CLEARANCE OF CONNECTING ROD BEARING Method of Measurement ● ● E Install the connecting rod bearings to the connecting rod and the cap, and tighten the connecting rod nuts to the specified torque. Using a inside micrometer (1) measure the inner diameter of connecting rod bearing. Refer to EM-77, "ASSEMBLY" for the tightening procedure. (Oil clearance) = (Inner diameter of connecting rod bearing) – (Outer diameter of crankshaft pin) Standard Limit F G : 0.010 - 0.044 mm (0.0004 - 0.0017 in) : 0.064 mm (0.0025 in) When exceeding limit, use undersize bearing so that oil clearance remains within the standard value. Refer to EM-91, "Undersize Bearing Usage Guide" . D H PBIC1382E I Method of Using Plastigage ● ● ● ● Remove oil and dust on the crankshaft pin and the surfaces of each bearing completely. Cut a plastigage (1) slightly shorter than the bearing width, and place it in crankshaft axial direction, avoiding oil holes. Install the connecting rod bearings to the connecting rod cap, and tighten the connecting rod nuts to the specified torque. Refer to EM-77, "ASSEMBLY" for the tightening procedure. CAUTION: Never rotate crankshaft while Plastigage is in place. Remove the connecting rod cap and bearings, and using the PBIC1390E scale on the plastigage bag, measure the plastigage width. NOTE: The procedure when the measured value exceeds the limit is same as that described in the “Method of Measurement”. Undersize Bearing Usage Guide ● ● If specified oil clearance cannot be obtained by standard size connecting rod bearing, use undersize (US) bearing. When using undersize bearing, install it, measure bearing inner diameter, and grind crankshaft pin to obtain specified oil clearance. EM-91 J K L M CYLINDER BLOCK [CR] Bearing undersize table Unit: mm (in) Size Thickness STD (Reference) 1.504 - 1.508 (0.0529 - 0.0594) US 0.25 (0.0098) 1.627 - 1.635 (0.0641 - 0.0644) CAUTION: Keep fillet R when grinding crankshaft pin (1) in order to use undersize bearing (All crankshaft pin). PBIC1391E OIL CLEARANCE OF MAIN BEARING Method of Measurement ● Install the main bearings to the cylinder block and bearing cap. Measure the main bearing inner diameter with the bearing cap bolt tightened with main bearing cap to the specified torque. Refer to EM-77, "ASSEMBLY" for the tightening procedure. (Oil clearance) = (Inner diameter of main bearing) – (Outer diameter of crankshaft journal) Standard Limit ● : 0.018 - 0.034 mm (0.0007 - 0.0013 in) : 0.05 mm (0.002 in) If the measured value exceeds the limit, select main bearings (including the undersize) referring to the main bearing inner diameter and crankshaft journal outer diameter, so that the oil clearance satisfies the standard. Refer to EM-84, "HOW TO SELECT MAIN BEARING" . Method of Using Plastigage ● ● ● ● Remove oil and dust on the crankshaft journal and the surfaces of each bearing completely. Cut a plastigage (1) slightly shorter than the bearing width, and place it in crankshaft axial direction, avoiding oil holes. Tighten the main bearing bolts with main bearing cap to the specified torque. Refer to EM-77, "ASSEMBLY" for the tightening procedure. CAUTION: Never rotate crankshaft while Plastigage is in place. Remove the bearing cap and bearings, and using the scale on PBIC1392E the plastigage bag, measure the plastigage width. NOTE: The procedure when the measured value exceeds the limit is same as that described in the “Method of Measurement”. CRUSH HEIGHT OF MAIN BEARING OR CONNECTING ROD BEARING ● When the bearing cap is removed after being tightened to the specified torque with main bearings or connecting rod bearings (1) installed, the tip end of bearing must protrude. Refer to EM77, "ASSEMBLY" for the tightening procedure. Standard ● : There must be crush height (2). If the standard is not met, replace main bearings or connecting bearings. PBIC1393E EM-92 CYLINDER BLOCK [CR] FLYWHEEL RUNOUT ● A The runout of the clutch contact surface of the flywheel should be measured using a dial gauge (1). (Total indicator reading) Flywheel Limit EM : 0.15 mm (0.0059 in) C PBIC1394E D E F G H I J K L M EM-93 SERVICE DATA AND SPECIFICATIONS (SDS) [CR] SERVICE DATA AND SPECIFICATIONS (SDS) Standard and Limit PFP:00030 BBS002NT GENERAL SPECIFICATIONS Engine CR14DE Cylinder arrangement 4, in-line cm3 (cu in) Displacement Bore and stroke 1,386 (84.57) mm (in) 73.0 x 82.8 (2.874 x 3.260) Valve arrangement DOHC Firing order 1-3-4-2 Number of piston rings Compression 2 Oil 1 Number of main bearings 5 Compression ratio 9.9 Compression pressure kPa (bar, kg/cm2 , psi) / 350 rpm Standard 1,383 (13.83, 14.1, 201) Minimum 1,187 (11.87, 12.1, 172) Differential limit between cylinders 98 (0.98, 1.0, 14) Valve timing (Intake valve timing control - OFF) PBIC0187E Unit: degree CR14DE a b c d e f 216 224 − 11 55 4 32 INTAKE MANIFOLD AND EXHAUST MANIFOLD Unit: mm (in) Limit Surface distortion 0.3 (0.012) EM-94 SERVICE DATA AND SPECIFICATIONS (SDS) [CR] DRIVE BELTS Deflection [mm (in)] [When pressed by force of 98.1N (10 kg, 22lb)] Tension [N (kg, lb)] Location New Alternator and A/C compressor belt 603 - 691 (61.5 - 70.5, 135.6 - 155.3) 603 - 691 (61.5 - 70.5, 135.6 - 155.3) Alternator belt 446 - 534 (45.5 - 54.5, 100.3 - 120.0) Water pump belt At adjustment 495 - 583 (50.5 - 59.5, 111.3 - 131.1) 495 - 583 (50.5 - 59.5, 111.3 - 131.1) 348 - 436 (35.5 - 44.5, 78.2 - 98.0) Limit EM Measuring point New belt At adjustment Limit A 6.6 - 7.8 (0.260 0.307) 7.3 - 8.5 (0.287 0.335) 13.8 (0.543) C B 5.6 - 6.6 (0.220 0.260) 7.1 - 8.3 (0.280 0.327) 11.9 (0.469) D A 3.1 - 4.1 (0.122 0.161) 9.8 - 10.6 (0.386 0.417) 13.8 (0.543) E C 6.7 - 7.3 (0.264 0.287) 7.6 - 8.6 (0.299 0.339) 12.4 (0.448) D 4.7 - 5.6 (0.185 0.220) 7.0 - 7.7 (0.276 0.303) 8.6 (0.339) 196 (20, 44.1) 196 (20, 44.1) A 137 (14, 30.9) F G H I J PBIC1414E PBIC1415E SPARK PLUG Make K NGK Champion Standard type LFR5AP-11 REC10PYC4 Hot type LFR4AP-11 — Cold type LFR6AP-11 — Gap (nominal) L 1.1 mm (0.043 in) M CYLINDER HEAD Unit: mm (in) Limit Cylinder head distortion 0.1 (0.004) Height 121.2 (4.77) EM-95 SERVICE DATA AND SPECIFICATIONS (SDS) [CR] VALVE Valve Dimensions Unit: mm (in) SEM188A Standard Valve head diameter “D” Valve length “L” Valve stem diameter “d” Intake 27.4 - 27.6 (1.079 - 1.087) Exhaust 22.4 - 22.6 (0.882 - 0.890) Intake 97.85 (3.8524) Exhaust 97.92 (3.8551) Intake 5.465 - 5.480 (0.2152 - 0.2157) Exhaust 5.445 - 5.460 (0.2144 - 0.2150) Valve seat angle “α” 45°15′ - 45°45′ Valve margin “T” 1.05 - 1.35 (0.0413 - 0.0531) Valve Clearance Unit: mm (in) Hot Cold* (reference data) Intake 0.314 - 0.426 (0.012 - 0.017) 0.29 - 0.37 (0.011 - 0.015) Exhaust 0.338 - 0.462 (0.013 - 0.018) 0.32 - 0.40 (0.013 - 0.016) *: At a temperature of approximately 20°C (68°F) Valve Guide Unit: mm (in) Engine Models CR14DE Intake Outer diameter Valve guide Inner diameter (Finished size) Exhaust Standard Service Standard Service 9.522 - 9.534 (0.3749 - 0.3754) 9.723 - 9.734 (0.3828 - 0.3832) 9.522 - 9.534 (0.3749 - 0.3754) 9.723 - 9.734 (0.3828 - 0.3832) 5.500 - 5.518 (0.2165 - 0.2172) 5.500 - 5.518 (0.2165 - 0.2172) Cylinder head valve guide hole diameter 9.475 - 9.496 (0.3730 - 0.3739) 9.685 - 9.696 (0.3813 - 0.3817) 9.475 - 9.496 (0.3730 - 0.3739) 9.685 - 9.696 (0.3813 - 0.3817) Interference fit of valve guide 0.026 - 0.059 (0.0010 - 0.0023) 0.027 - 0.049 (0.0011 - 0.0019) 0.026 - 0.059 (0.0010 - 0.0023) 0.027 - 0.049 (0.0011 - 0.0019) Stem to guide clearance Valve deflection limit (Dial gauge reading) 0.020 - 0.053 (0.0008 - 0.0021) 0.040 - 0.073 (0.0016 - 0.0029) 0.2 (0.0079) 0.2 (0.0079) EM-96 SERVICE DATA AND SPECIFICATIONS (SDS) [CR] Valve Seat Unit: mm (in) A EM C D E F G MBIB1127E MBIB1128E Dia. CR14DE A 25.4 (1.00) B 27.0 - 27.2 (1.062 - 1.070) C 28.7 - 28.9 (1.129 - 1.137) D 29.000 - 29.016 (1.1417 - 1.1424) E 22.0 - 22.2 (0.866 - 0.874) F 23.7 - 23.9 (0.933 - 0.940) G 24.000 - 24.016 (0.9449 - 0.9455) H I J K Valve Spring Free height Pressure load mm (in) N (kg, lb) at height mm (in) Standard Out-of-square mm (in) L 53.3 (2.098) Installation 149 - 165 N (15.2 - 16.8, 33.5 - 37.1) at 32.82 (1.2921) Valve open 228 - 250 N (23.3 - 25.5, 51.3 - 56.2) at 24.73 (0.9736) Limit Less than 1.6 (0.063) Valve Lifter Unit: mm (in) Standard Valve lifter outer diameter 29.960 - 29.975 (1.1795 - 1.1801) Valve lifter hole inner diameter 30.000 - 30.021 (1.1811 - 1.1819) Clearance between valve lifter and valve lifter hole 0.025 - 0.061 (0.0010 - 0.0024) Available Valve Lifter Thickness mm (in) Identification Mark 3.000 (0.1181) 00 3.020 (0.1189) 02 3.040 (0.1197) 04 EM-97 M SERVICE DATA AND SPECIFICATIONS (SDS) [CR] Thickness mm (in) Identification Mark 3.060 (0.1205) 06 3.080 (0.1213) 08 3.100 (0.1220) 10 3.120 (0.1228) 12 3.140 (0.1236) 14 3.160 (0.1244) 16 3.180 (0.1252) 18 3.200 (0.1260) 20 3.220 (0.1268) 22 3.240 (0.1276) 24 3.260 (0.1283) 26 3.280 (0.1291) 28 3.300 (0.1299) 30 3.320 (0.1307) 32 3.340 (0.1315) 34 3.360 (0.1323) 36 3.380 (0.1323) 38 3.400 (0.1339) 40 3.420 (0.1346) 42 3.440 (0.1354) 44 3.460 (0.1362) 46 3.480 (0.1370) 48 3.500 (0.1378) 50 3.520 (0.1386) 52 3.540 (0.1394) 54 3.560 (0.1402) 56 3.580 (0.1409) 58 3.600 (0.1417) 60 3.620 (0.1425) 62 3.640 (0.1433) 64 3.660 (0.1441) 66 3.680 (0.1449) 68 PBIC1077E EM-98 SERVICE DATA AND SPECIFICATIONS (SDS) [CR] CAMSHAFT AND CAMSHAFT BEARING Unit: mm (in) A Standard Camshaft runout [TIR*] 0.04 (0.0016) EM C D E SEM671 CR14DE F Standard Intake 40.359 - 40.549 (1.5889 - 1.5964) Exhaust 39.743 - 39.933 (1.5647 - 1.5722) Cam height “A” G No. 1 journal 27.935 - 27.955 (1.0998 - 1.1006) No. 2 to No. 5 journals 23.450 - 23.470 (0.9232 - 0.9240) Outer diameter of camshaft journal No. 1 journal 28.000 - 28.021 (1.1024 - 1.1032) No. 2 to No. 5 journals 23.500 - 23.525 (0.9252 - 0.9262) No. 1 journal 0.045 - 0.086 (0.0018 - 0.0034) No. 2 to No. 5 journals 0.030 - 0.071 (0.0012 - 0.0028) Inner diameter of camshaft bracket Camshaft journal clearance Camshaft end play 0.070 - 0.143 (0.0028 - 0.0056) H I J *: Total indicator reading K CYLINDER BLOCK Unit: mm (in) L M PBIC0613E CR14DE Limit Standard Surface flatness Height “H” (nominal) Cylinder bore inner diameter — 0.1 (0.004) 189 (8.4232 - 8.4271) — Grade No. 1 73.000 - 73.010 (2.8740 - 2.8744) Grade No. 2 73.010 - 73.020 (2.8744 - 2.8748) Grade No. 3 73.020 - 73.030 (2.8748 - 2.8752) Out-of-round (Difference between X and Y) — EM-99 0.2 (0.008)* 0.015 (0.0006) SERVICE DATA AND SPECIFICATIONS (SDS) [CR] Taper (Difference between A and C) — 0.01 (0.0004) 0.05 (0.0020) 0.2 (0.008) Grade 0 49.000 - 49.004 (1.9291 - 1.9293) — Grade 1 49.004 - 49.008 (1.9293 - 1.9294) — Grade 2 49.008 - 49.012 (1.9294 - 1.9296) — Grade 3 49.012 - 49.016 (1.9296 - 1.9298) — Difference in inner diameter between cylinders Main bearing housing inner diameter *: Cylinder bore wear PISTON, PISTON RING AND PISTON PIN Available Piston Unit: mm (in) PBIC0188E CR14DE Standard Piston skirt diameter “A” Grade No. 1 72.980 - 72.990 (2.8732 - 2.8736) Grade No. 2 72.990 - 73.000 (2.8736 - 2.8740) Grade No. 3 73.000 - 73.010 (2.8740 - 2.8744) 0.2 (0.002) oversize (service) 73.180 - 73.210 (2.8811 - 2.8823) “H” dimension 32.3 (1.272) Piston pin hole inner diameter 18.008 - 18.012 (0.7090 - 0.7091) Piston to cylinder bore clearance 0.010 - 0.030 (0.0004 - 0.0012) Piston Ring Unit: mm (in) Side clearance End gap Standard Limit Top 0.040 - 0.080 (0.0016 - 0.0031) 0.110 (0.0043) 2nd 0.025 - 0.070 (0.0010 - 0.0028) 0.1 (0.0039) Oil ring 0.030 - 0.140 (0.0021 - 0.0055) — Top 0.18 - 0.33 (0.0071 - 0.0130) 0.57 (0.0224) 2nd 0.50 - 0.65 (0.0197 - 0.0256) 0.85 (0.0335) Oil (rail ring) 0.20 - 0.70 (0.0079 - 0.0276) 0.96 (0.0378) Piston Pin Unit: mm (in) Piston pin outer diameter Standard 17.996 - 18.000 (0.7085 - 0.7087) Piston pin to piston clearance Standard 0.008 - 0.016 (0.0003 - 0.0006) Piston pin to connecting rod bushing clearance Standard –0.018 - –0.038 (–0.0007 - –0.0015) EM-100 SERVICE DATA AND SPECIFICATIONS (SDS) [CR] CONNECTING ROD Unit: mm (in) A CR14DE Center distance 129.45 - 129.55 (5.096 - 5.100) EM Bend [per 100 (3.94)] Limit 0.15 (0.0059) Torsion [per 100 (3.94)] Limit 0.30 (0.0118) Connecting rod bushing inner diameter* (small end) Standard 17.962 -17.978 (0.7072 - 0.7078) Connecting rod big end inner diameter Standard 43.000 - 43.013 (1.6929 - 1.6934) Standard 0.050 - 0.420 (0.0020 - 0.0165) Side clearance Limit C D 0.5 (0.0197) *: After installing in connecting rod E CRANKSHAFT Unit: mm (in) Grade No. 0 44.966 - 44.970 (1.7703 - 1.7705) Grade No. 1 44.962 - 44.966 (1.7702 - 1.7703) Grade No. 2 44.958 - 44.962 (1.7700 - 1.7702) Grade No. 3 44.954 - 44.958 (1.7698 - 1.7700) Pin dia. “Dp” Standard 39.961 - 39.974 (1.5733 - 1.5738) Out-of-round (X − Y) Limit 0.005 (0.0002) Taper (A − B) Limit 0.005 (0.0002) Runout [TIR*] Limit Main journal dia. “Dm” G H 0.05 (0.0020) Standard Side clearance F I 0.060 - 0.260 (0.0024 - 0.0102) Limit 0.3 (0.012) J K L SEM645 M SEM715 *: Total indicator reading MAIN BEARING Standard size Unit: mm (in) Grade No. Thickness Identification color STD1 2.002 - 2.006 (0.0788 - 0.0790) Red STD2 2.004 - 2.008 (0.0789 - 0.0791) Green STD3 2.006 - 2.010 (0.0790 - 0.0791) Yellow STD4 2.008 - 2.012 (0.0791 - 0.0792) Blue STD5 2.010 - 2.014 (0.0791 - 0.0793) Pink STD6 2.012 - 2.016 (0.0792 - 0.0794) White STD7 2.014 - 2.018 (0.0793 - 0.0794) Blue/yellow EM-101 SERVICE DATA AND SPECIFICATIONS (SDS) [CR] Undersize Unit: mm (in) Grade Thickness US 0.25 (0.0098) 2.123 - 2.131 (0.836 - 0.839) Bearing Clearance Unit: mm (in) Standard Main bearing clearance 0.018 - 0.034 (0.0007 - 0.0013) Limit 0.05 (0.002) CONNECTING ROD BEARING Standard Size Unit: mm (in) Grade Thickness Standard 1.504 - 1.508 (0.0529 - 0.0594) Grade Thickness US 0.25 (0.0098) 1.627 - 1.635 (0.0641 - 0.0644) Undersize Unit: mm (in) Bearing Clearance Unit: mm (in) Standard Connecting rod bearing clearance 0.010 - 0.044 (0.0004 - 0.0017) Limit 0.064 (0.0025) MISCELLANEOUS COMPONENTS Unit: mm (in) Flywheel runout [TIR*] Camshaft sprocket runout [TIR*] Limit Limit 0.15 (0.0059) Intake 0.20 (0.0079) Exhaust 0.15 (0.0059) *: Total indicator reading EM-102 SERVICE DATA AND SPECIFICATIONS (SDS) [CR] Tightening Torque BBS002NU A *1: Parts to be tightened in particular orders 1)-: Order of tightening when tightening two or more steps separately. Unit: N·m (kg-m, ft-lb) Unit: N·m (kg-m, in-lb)*2 24.5 - 31.4 (2.5 - 3.2, 18 - 23) Idler pulley locknut (for water pump belt) *1 *1 *1 Idler pulley locknut (for alternator and A/C compressor belt) 24.5 - 31.4 (2.5 - 3.2, 18 - 23) Idler pulley bracket (for alternator and A/C compressor belt) 16.6 - 23.5 (1.7 - 2.4, 13 - 17) Manifold absolute pressure sensor 1.2 - 1.7 (0.12 - 0.17, 11 - 15)*2 Air cleaner case (upper) to (lower) 1) 2) *1 *1 *1 C 1.9 - 2.2 (0.20 - 0.22, 17 - 19)*2 5.4 - 7.3 (0.55 - 0.74, 48 - 64)*2 Electronic throttle control actuator 7.2 - 9.6 (0.73 - 0.99, 64 - 86)*2 EVAP canister purge volume control solenoid valve 4.3 - 5.8 (0.44 - 0.59, 38 - 51)*2 Intake manifold 6.9 - 9.4 (0.71 - 0.96, 61 - 84)*2 M6 × 15 mm (0.59 in) 6.9 - 9.5 (0.71 - 0.96, 61 - 84)*2 M6 × 12 mm (0.47 in) 8.4 - 10.8 (0.86 - 1.1, 75 - 95)*2 Fuel injector and fuel tube assembly 1) 2) Exhaust manifold 25.5 - 29.4 (2.6 - 2.9, 19 - 21) Exhaust manifold cover 6.3 - 8.3 (0.65 - 0.84, 56 - 73)*2 Heated oxygen sensor 1 40 - 50 (4.1 - 5.1, 30 - 36) Heated oxygen sensor harness bracket 6.9 - 9.5 (0.71 - 0.96, 61 - 84)*2 Three way catalyst (under exhaust manifold) 29.4 - 34.3 (3.0 - 3.4, 22 - 25) Three way catalyst support 33.3 - 46.1 (3.4 - 4.7, 25 - 34) Three way catalyst cover 6.3 - 8.3 (0.65 - 0.84, 56 - 73)*2 Ignition coil 3.8 - 4.4 (0.39 - 0.44, 34 - 38)* Spark plug 19.6 - 29.4 (2.0 - 2.9, 15 - 21) G M6 × 20 mm (0.79 in) 6.9 - 10.8 (0.71 - 1.1, 61 - 95)*2 Intake valve timing control solenoid valve 6.3 - 8.3 (0.65 - 0.84, 56 - 73)*2 Harness bracket 6.3 - 8.3 (0.65 - 0.84, 56 - 73)*2 *1 Oil pan (upper) 6.9 - 9.5 (0.71 - 0.96, 61 - 84)*2 *1 Oil pan (lower) 6.9 - 9.5 (0.71 - 0.96, 61 - 84)*2 Oil pan drain plug 29.4 - 39.2 (3.0 - 3.9, 22 - 28) Connecting bolt between oil pan (upper) and transaxle 16.6 - 23.5 (1.7 - 2.3, 13 - 17) Oil strainer 6.3 - 8.3 (0.65 - 0.84, 56 - 73)*2 Cylinder head front cover 6.9 - 9.5 (0.71 - 0.96, 61 - 84)*2 Chain tensioner 6.9 - 9.5 (0.71 - 0.96, 61 - 84)*2 Camshaft position sensor (PHASE) 7.1 - 10.8 (0.73 - 1.1, 63 - 95)*2 78.4 - 88.2 (8.0 - 8.9, 58 - 65) Exhaust 78.4 - 88.2 (8.0 - 8.9, 58 - 65) K 2 8.8 - 10.8 (0.90 - 1.1, 78 - 95)*2 Intake I J M6 × 45 mm (1.77 in) EM-103 F H 1.0 - 1.5 (0.10 - 0.15, 9- 13)*2 Camshaft sprocket E 11.8 - 13.8 (1.2 - 1.4, 9 - 10) 20.8 - 28.2 (2.1 - 2.9, 16 - 20) Clamp for fuel feed hose Rocker cover D 3.8 - 4.4 (0.40 - 0.44, 35 - 38)*2 Air cleaner case assembly Support bracket EM L M SERVICE DATA AND SPECIFICATIONS (SDS) [CR] *1 *1 *1 *1 Camshaft bracket 1) 2.0 (0.2, 18)*2 2) 5.9 (0.6, 52)*2 3) 9.0 - 11.8 (0.92 - 1.2, 80 - 104)*2 Chain tension guide 16.6 - 23.5 (1.7 - 2.3, 13 - 17) Chain slack guide 12.7 - 18.6 (1.3 - 1.8, 10 - 13) Crankshaft pulley 132.4 - 152.0 (14 - 15, 98 - 112) Front cover 6.3 - 8.3 (0.65 - 0.84, 56 - 73)*2 Cylinder head bolt 1) 61.7 - 71.7 (6.3 - 7.3, 46 - 52) 2) 0 (0.0, 0) 3) 22.5 - 32.5 (2.3 - 3.3, 17 - 23) 4) 90° - 95° (Angle tightening) Cylinder head auxiliary bolt 9.0 - 11.8 (0.92 - 1.2, 80 - 104)*2 Engine slinger 16.6 - 23.5 (1.7 - 2.3, 13 - 17) LH engine mount insulator 95 - 115 (9.7 - 11, 70 - 84) LH engine mount bracket (vehicle side) 43 - 54 (4.4 - 5.5, 32 - 39) LH engine mount bracket (transaxle side) 60 - 70 (6.2 - 7.1, 45 - 51) RH engine mount stay 40 - 50 (4.1 - 5.1, 30 - 36) RH engine mount insulator RH 60 - 70 (6.2 - 7.1, 45 - 51) RH engine mount bracket (upper) 40 - 50 (4.1 - 5.1, 30 - 36) RH engine mount bracket (lower) 40 - 50 (4.1 - 5.1, 30 - 36) Rear engine mount bracket 75 - 85 (7.7 - 8.7, 56 - 62) Rear torque rod 75 - 85 (7.7 - 8.7, 56 - 62) Connecting nut between LH engine mount insulator and LH engine mount bracket (transaxle side) 60 - 70 (6.2 - 7.1, 45 - 51) Connecting bolt between RH engine mount insulator and RH engine mount bracket (upper) 90 - 100 (9.2 - 10, 67 - 73) Main bearing cap Connecting rod cap 1) 24.5 - 30.3 (2.5 - 3.0, 18 - 22) 2) 95° - 100° (Angle tightening) 1) 13.7 - 15.7 (1.4 - 1.6, 10.1 - 11.5) 2) 45° - 50° (Angle tightening) Rear oil seal retainer 6.9 - 9.5 (0.71 - 0.96, 61 - 84)*2 Flywheel 83.4 - 93.2 (8.5 - 9.5, 62 - 68) Knock sensor 15.7 - 20.6 (1.6 - 2.1, 12 - 15) Crankshaft position sensor (POS) [Note: transaxle side mounting parts] 7.1 - 10.8 (0.73 - 1.1, 63 - 95)*2 EM-104 PRECAUTIONS [HR] PRECAUTIONS Precautions for Procedures without Cowl Top Cover [HR] PFP:00001 A BBS002NV When performing the procedure after removing cowl top cover, cover the lower end of windshield with urethane, etc. EM C D PIIB3706J Precautions for Draining Engine Coolant E BBS002NW Drain engine coolant when engine is cooled. Precautions for Disconnecting Fuel Piping ● ● ● Before starting work, make sure no fire or spark producing items are in the work area. Release fuel pressure before disassembly. After disconnecting pipes, plug openings to stop fuel leakage. Precautions for Removal and Disassembly ● ● ● ● ● BBS002NX G BBS002NY When instructed to use special service tools, use the specified tools. Always be careful to work safely, avoid forceful or uninstructed operations. Exercise maximum care to avoid damage to mating or sliding surfaces. Cover openings of engine system with tape or the equivalent, if necessary, to seal out foreign materials. Mark and arrange disassembly parts in an organized way for easy troubleshooting and re-assembly. When loosening nuts and bolts, as a basic rule, start with the one furthest outside, then the one diagonally opposite, and so on. If the order of loosening is specified, do exactly as specified. Precautions for Inspection, Repair and Replacement ● ● ● ● ● ● ● ● ● – BBS002O0 Use torque wrench to tighten bolts or nuts to specification. When tightening nuts and bolts, as a basic rule, equally tighten in several different steps starting with the ones in center, then ones on inside and outside diagonally in this order. If the order of tightening is specified, do exactly as specified. Replace with new gasket, packing, oil seal or O-ring. Thoroughly wash, clean, and air-blow each part. Carefully check the engine oil and engine coolant passages for any restriction and blockage. Avoid damaging the sliding or mating surfaces. Completely remove foreign materials such as cloth lint or dust. Before assembly, oil sliding surfaces well. Release air within route when refilling after draining coolant. Before starting engine, apply fuel pressure to fuel lines with turning ignition switch ON (with engine stopped). Then make sure there are no leaks at fuel line connections. After repairing, start engine and increase engine speed to check engine coolant, fuel, engine oil, and exhaust gas for leakage. Parts Requiring Angle Tightening BBS002O1 Use angle wrench (SST: KV10112100) for the final tightening of the following engine parts. Cylinder head bolts EM-105 H I J BBS002NZ Before repairing or replacing, thoroughly inspect parts. Inspect new replacement parts in the same way, and replace if necessary. Precautions for Assembly and Installation F K L M PRECAUTIONS [HR] – – – ● ● ● Main bearing cap bolts Connecting rod cap bolts Crankshaft pulley bolt (No angle wrench is required as the bolt flange is provided with notches for angle tightening) Do not use a torque value for final tightening. The torque value for these parts are for a preliminary step. Ensure thread and seat surfaces are clean and coated with engine oil. Precautions For Liquid Gasket BBS002O2 REMOVAL OF LIQUID GASKET ● ● ● After removing the mounting bolts and nuts, separate the mating surface using seal cutter (SST) and remove the old liquid gasket sealing. CAUTION: Be careful not to damage the mating surfaces. Tap seal cutter to insert it (1), and then slide it (2) by tapping on the side as shown in the figure. In areas where seal cutter is difficult to use, use plastic hammer to lightly tap the parts, to remove it. CAUTION: If for some unavoidable reason tool such as screwdriver is used, be careful not to damage the mating surfaces. PBIC0275E LIQUID GASKET APPLICATION PROCEDURE 1. 2. Using a scraper, remove the old liquid gasket adhering to the liquid gasket application surface and the mating surface. ● Remove the liquid gasket completely from the groove of the liquid gasket application surface, mounting bolts and bolt holes. Wipe the liquid gasket application surface and the mating surface with white gasoline (lighting and heating use) to remove adhering moisture, grease and foreign materials. PBIC0003E 3. 4. Attach liquid gasket tube to the tube presser (SST). Use Genuine Liquid Gasket or equivalent. Apply the liquid gasket without breaks to the specified location with the specified dimensions. ● If there is a groove for the liquid gasket application, apply the liquid gasket to the groove. PBIC2160E EM-106 PRECAUTIONS [HR] As for the bolt holes, normally apply the liquid gasket inside the holes. Occasionally, it should be applied outside the holes. Make sure to read the text of service manual. ● Within 5 minutes of liquid gasket application, install the mating component. ● If the liquid gasket protrudes, wipe it off immediately. ● Do not retighten mounting bolts or nut after the installation. ● Wait 30 minutes or more after installation before refilling engine oil and engine coolant. CAUTION: If there are specific instructions in this manual, observe them. ● A EM C SEM159F D E F G H I J K L M EM-107 PREPARATION [HR] PREPARATION Special Service Tools PFP:00002 BBS002O3 Tool number Tool name Description KV10111100 Seal cutter Removing oil pan (lower and upper) etc. S-NT046 KV10116200 Valve spring compressor 1. KV10115900 Attachment 2. KV10109220 Adapter Disassembling and assembling valve mechanism Part (1) is a component of KV10116200, but Part (2) is not so. PBIC1650E KV10112100 Angle wrench Tightening bolts for bearing cap, cylinder head, etc. in angle S-NT014 KV10117100 Heated oxygen sensor wrench Loosening or tightening heated oxygen sensor 1 For 22 mm (0.87 in) width hexagon nut NT379 KV10107902 Valve oil seal puller 1. KV10116100 Valve oil seal puller adapter Removing valve oil seal S-NT605 KV10115600 Valve oil seal drift Installing valve oil seal Use side A. a: 20 (0.79) dia. d: 8 (0.31) dia. b: 13 (0.51) dia. e: 10.7 (0.421) c: 10.3 (0.406) dia. f: 5 (0.20) Unit: mm (in) S-NT603 EM03470000 Piston ring compressor Installing piston assembly into cylinder bore S-NT044 EM-108 PREPARATION [HR] Tool number Tool name Description WS39930000 Tube presser A Pressing the tube of liquid gasket EM C S-NT052 KV11103000 Pulley puller Removing crankshaft pulley D E NT676 Quick connector release Removing fuel tube quick connectors in engine room (Available in SEC. 164 of PARTS CATALOG: Part No. 16441 6N210) F G PBIC0198E 1. Press stand: ST13030020 2. Center shaft: KV10114120 3. Drift: KV10109730 4. Spring: ST13030030 5. Center cap: KV10110310 Installing and removing piston pin H I J PBIC3873E KV11105210 Stopper plate Fixing flywheel K L ZZA0009D ST16610001 Pilot bushing puller Removing pilot converter (A/T models) M S-NT045 EM-109 PREPARATION [HR] Commercial Service Tools BBS002O4 Tool name Description Spark plug wrench Removing and installing spark plug PBIC3874E Valve seat cutter set Finishing valve seat dimensions S-NT048 Piston ring expander Removing and installing piston ring S-NT030 Valve guide drift Removing and installing valve guide PBIC4012E Valve guide reamer 1: Reaming valve guide inner hole 2: Reaming hole for oversize valve guide PBIC4013E Oxygen sensor thread cleaner Reconditioning the exhaust system threads before installing a new heated oxygen sensor (Use with anti-seize lubricant shown below.) a = 18 mm (0.71 in) dia. for zirconia heated oxygen sensor b = 12 mm (0.47 in) dia. for titania heated oxygen sensor AEM488 EM-110 PREPARATION [HR] Tool name Description Anti-seize lubricant (Permatex 133AR or equivalent meeting MIL specification MIL-A-907) Lubricating oxygen sensor thread cleaning tool when reconditioning exhaust system threads A EM C AEM489 Manual lift table caddy Removing and installing engine D E ZZA1210D F G H I J K L M EM-111 NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING [HR] NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING NVH Troubleshooting — Engine Noise PFP:00003 BBS002O5 PBIC3870E EM-112 NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING [HR] Use the Chart Below to Help You Find the Cause of the Symptom. BBS002O6 A 1. Locate the area where noise occurs. 2. Confirm the type of noise. 3. Specify the operating condition of engine. 4. Check specified noise source. If necessary, repair or replace these parts. EM C Operating condition of engine Location of noise Top of engine Rocker cover Cylinder head Type of noise When idling When racing A — A B Rattle C A — A B — Slap or rap Knock Front of engine When starting C Knock Front of engine Front cover After warmup Ticking or clicking Slap or knock Crankshaft pulley Cylinder block (Side of engine) Oil pan Before warmup Tapping or ticking A A A A A — B B A — — C — — B B B A B B B B B B While driving Source of noise Check item D — Tappet noise Valve clearance EM-166 C Camshaft bearing noise Camshaft journal oil clearance Camshaft runout EM-158 EM-158 — Piston pin noise Piston to piston pin oil clearance Connecting rod bushing oil clearance EM-206 EM-208 A Piston slap noise Piston to cylinder bore clearance Piston ring side clearance Piston ring end gap Connecting rod bend and torsion EM-210 EM-207 EM-207 EM-208 B Connecting rod bearing noise Connecting rod bushing oil clearance Connecting rod bearing oil clearance EM-208 EM-211 C Main bearing noise Main bearing oil clearance Crankshaft runout EM-212 EM-211 B Timing chain and chain tensioner noise Timing chain cracks and wear Timing chain tensioner operation EM-142 C Drive belt (Sticking or slipping) Drive belt deflection Squeaking or fizzing A Creaking A B A B A B Drive belt (Slipping) Idler pulley bearing operation Squall Creak A B — B A B Water pump noise Water pump operation A: Closely related B: Related B — C: Sometimes related B — —: Not related EM-113 Reference page E F G H I J K L M EM-114 CO-36 DRIVE BELTS [HR] DRIVE BELTS Checking Drive Belts ● ● ● ● PFP:02117 BBS002O7 Inspection should be done only when engine is cold or over 30 minutes after the engine is stopped. 1. : Alternator 2. : Water pump 3. : Crankshaft pulley 4. : A/C compressor (with A/C models) : Idler pulley (without A/C models) 5. : Idler pulley 6. : Drive belt PBIC3642E Visually check belts for wear, damage, and cracks on inside and edges. Turn crankshaft pulley two time clockwise, and make sure tension on all pulleys is equal before doing the test. When measuring deflection, apply 98 N (10 kg, 22 lb) at the ( ) marked point. Measure the belt tension and frequency with acoustic tension gauge (commercial service tool) at the ( ) marked point. CAUTION: ● When the tension and frequency are measured, the acoustic tension gauge should be used. ● When checking immediately after installation, first adjust it to the specified value. Then, after turning crankshaft two turns or more, re-adjust to the specified value to avoid variation in deflection between pulleys. ● Belt Deflection Deflection adjustment * Location Drive belt Unit: mm (in) Used belt New belt Limit After adjusted With A/C models 7.9 (0.31) 4.8 - 5.3 (0.19 - 0.21) 4.2 - 4.5 (0.17 - 0.18) Without A/C models 7.1 (0.28) 4.3 - 4.7 (0.17 - 0.19) 3.6 - 3.9 (0.14 - 0.15) Applied pushing force 98 N (10 kg, 22lb) *: When engine is cold. Tension Adjustment BBS002O8 Location Location of adjuster and tightening method Drive belt Adjusting bolt on idler pulley CAUTION: ● When belt is replaced with new one, adjust belt tension to the value for “New belt”, because new belt will not fully seat in the pulley groove. ● When tension of the belt being used exceeds “Limit”, adjust it to the value for “After adjusted”. ● When installing a belt, make sure it is correctly engaged with the pulley groove. ● Do not allow oil or engine coolant to get on the belt. ● Do not twist or bend the belt strongly. 1. Remove front fender protector (RH). Refer to EI-14, "FENDER PROTECTOR" . EM-114 DRIVE BELTS [HR] 2. 3. 4. Loosen the idler pulley lock nut (A) from the tightening position with the specified torque by 45 degrees. 1 : Alternator 2 : Water pump 3 : Crankshaft pulley 4 : A/C compressor (with A/C models) : Idler pulley (without A/C models) 5 : Idler pulley 6 : Drive belt A EM C PBIC3643E CAUTION: ● When the lock nut is loosened excessively, the idler pulley tilts and the correct tension adjustment cannot be performed. Do not loosen it excessively (more than 45 degrees). ● Put a matching mark on the lock nut (A), and check turning angle with a protractor. Do not visually check the tightening angle. Adjust the belt tension by turning the adjusting bolt (B). Refer to EM-114, "Checking Drive Belts" . CAUTION: ● When checking immediately after installation, first adjust it to the specified value. Then, after turning crankshaft two turns or more, re-adjust to the specified value to avoid variation in deflection between pulleys. ● When the tension adjustment is performed, the lock nut should be in the condition at step“ 2”. If the tension adjustment is performed when the lock nut is loosened more than the standard, the idler pulley tilts and the correct tension adjustment cannot be performed. Tighten the lock nut (A). D E F G H : 34.8 N·m (3.5 kg-m, 26 ft-lb) I Removal and Installation BBS002O9 REMOVAL 1. 2. J Remove front fender protector (RH). Refer to EI-14, "FENDER PROTECTOR" . Loosen the lock nut (A), and then adjust the belt tension by turning the adjusting bolt (B). 1 : Alternator 2 : Water pump 3 : Crankshaft pulley 4 : A/C compressor (with A/C models) : Idler pulley (without A/C models) 5 : Idler pulley 6 : Drive belt K L M PBIC3643E 3. Remove drive belt. INSTALLATION 1. Pull the idler pulley in the loosening direction, and then temporarily tighten the lock nut (A) to the following torque. 1 : Alternator 2 : Water pump 3 : Crankshaft pulley 4 : A/C compressor (with A/C models) : Idler pulley (without A/C models) 5 : Idler pulley 6 : Drive belt PBIC3643E : 4.4 N·m (0.45 kg-m, 39 in-lb) EM-115 DRIVE BELTS [HR] 2. 3. 4. NOTE: Do not move the lock nut from the tightened position. Go to step “2”. Install the drive belt to each pulley. CAUTION: ● Make sure that there is no oil, grease, or coolant, etc. in pulley grooves. ● Make sure that the belt is securely inside the groove on each pulley. Adjust drive belt tension by turning the adjusting bolt (B). Refer to EM-114, "Tension Adjustment" . CAUTION: ● Perform the belt tension adjustment with the lock nut temporarily tightened at the step “1” so as not to tilt the idler pulley. ● When checking immediately after installation, first adjust it to the specified value. Then, after turning crankshaft two turns or more, re-adjust to the specified value to avoid variation in deflection between pulleys. Tighten the lock nut (A). : 34.8 N·m (3.5 kg-m, 26 ft-lb) 5. Make sure that belt tension of each belt within the standard. Removal and Installation of Drive Belt Idler Pulley BBS002OA REMOVAL 1. 2. Remove drive belts. Refer to EM-115, "Removal and Installation" . Remove the lock nut, and then remove the plate (7), idler pulley (6), and washer (5). 1 3. : Alternator bracket Remove the center shaft (2) together with the spacer (3) with inserting the adjusting bolt (4). PBIC3644E EM-116 DRIVE BELTS [HR] INSTALLATION 1. 2. A Insert the center shaft (1) into the slide groove of the spacer (2). Fully screw in the adjusting bolt (3) in the belt loosening direction ( ). ● At that time, place the flange (a) of the adjusting bolt and the seat (b) of the center shaft on the spacer. Place each surface (c, d) of the spacer on the alternator bracket. Install the washer, idler pulley, and plate, and then temporarily tighten the lock nut. EM C : 4.4 N·m (0.45 kg-m, 39 in-lb) D E F G PBIC3885E 3. Install removed parts in the reverse order of removal. H I J K L M EM-117 AIR CLEANER AND AIR DUCT [HR] AIR CLEANER AND AIR DUCT Components PFP:16500 BBS002OB MBIB1370E 1. Air cleaner filter 2. Mass air flow sensor 3. O-ring 4. Holder 5. Air cleaner cover 6. Air duct 7. PCV hose 8. Clip 9. Air duct (Inlet) 10. Grommet 11. Air duct 12. Grommet 13. Air cleaner case A. To electric throttle control actuator B. To rocker cover Refer to GI-11, "Components" for symbol marks in the figure. Removal and Installation BBS002OC REMOVAL 1. 2. 3. 4. 5. 6. a. b. c. 7. Remove the air duct (inlet). Remove the air cleaner filter from the air cleaner case. Refer to EM-119, "Changing Air Cleaner Filter" . Remove the air duct [between air duct (inlet) and air cleaner case] from the air cleaner case. Remove the PCV hose. Remove the air duct (between air cleaner case and electric throttle control actuator). ● Add marks as necessary for easier installation. Remove air cleaner case with the following procedure. Remove battery. Refer to SC-5, "BATTERY" . Disconnect harness connector from mass air flow sensor. Remove the air cleaner case. Remove the mass air flow sensor from the air cleaner case, if necessary. CAUTION: ● Handle it carefully and avoid impacts. ● Do not touch sensor part. EM-118 AIR CLEANER AND AIR DUCT [HR] INSTALLATION A Note the following, and install in the reverse order of removal. ● Align marks. Attach each joint. Screw clamps firmly. Changing Air Cleaner Filter BBS002OD REMOVAL 1. 2. Push the tabs (A) of both ends of the air cleaner cover (1) into the inside (B). Pull up the air cleaner cover forward (C) and remove it. EM C D E PBIC3557J 3. 4. F Remove the air cleaner filter (1) and holder (2) assembly from the air cleaner case. Remove the air cleaner filter from the holder. G H I PBIC3558J INSPECTION AFTER REMOVAL It is necessary to clean air cleaner filter or replace it at the recommended intervals, more often under dusty driving conditions. Refer to MA-8, "PERIODIC MAINTENANCE" . ● Blow air into the back side of air cleaner filter until no any object sprays out. J K L M SMA384C INSTALLATION Note the following, and install in the reverse order of removal. ● Install the air cleaner cover (1) in the direction shown in the figure. 2 : Air cleaner filter 3 : Holder PBIC3559J EM-119 INTAKE MANIFOLD [HR] INTAKE MANIFOLD Components PFP:14003 BBS002OE PBIC3649E 1. EVAP hose 2. Vacuum tank 3. EVAP hose 4. O-ring 5. EVAP canister purge volume control solenoid valve 6. Electric throttle control actuator 7. Water hose 8. Water hose 9. Gasket 10. Intake manifold support (Rear) 11. Intake manifold 12. Intake manifold support (Front) 13. Intake manifold support (Center) 14. Cylinder head 15. Vacuum hose B. C. 16. Gasket A. To centralized under-floor piping To brake booster Refer to GI-11, "Components" for symbol marks in the figure. EM-120 To water outlet INTAKE MANIFOLD [HR] Removal and Installation BBS002OF A REMOVAL 1. Remove engine cover (1). 2 : Intake manifold 3 : Grommet EM C D E F G MBIB1371E 2. 3. 4. 5. 6. 7. 8. Remove the air duct (inlet) and the air duct (between air cleaner case and electric throttle control actuator). Refer to EM-118, "AIR CLEANER AND AIR DUCT" . Move the reservoir tank. Refer to CO-31, "RADIATOR" . Disconnect water hoses from electric throttle control actuator, attach blind plug to prevent engine coolant leakage. CAUTION: ● Perform this step when the engine is cold. ● Do not spill engine coolant on drive belts. Pull out oil level gauge. CAUTION: Cover the oil level gauge guide openings to avoid entry of foreign materials. Remove electric throttle control actuator. CAUTION: ● Handle it carefully and avoid impacts. ● Do not disassemble or adjust. Disconnect the harness connector and EVAP hose from the EVAP canister purge volume control solenoid valve. CAUTION: Handle it carefully and avoid impacts. Disconnect vacuum hose for brake booster from intake manifold. EM-121 H I J K L M INTAKE MANIFOLD [HR] 9. Remove intake manifold support front (1) and rear (2). PBIC3650E 10. Remove intake manifold. ● Loosen bolts in the reverse of the order shown in the figure. : Engine front PBIC3652E 11. Remove EVAP canister purge volume control solenoid valve from intake manifold, if necessary. CAUTION: Handle it carefully and avoid impacts. 12. Remove intake manifold support (center) from cylinder head if necessary. NOTE: The intake manifold support (center) functions as the guide when the intake manifold is installed. INSTALLATION Note the following, and install in the reverse order of removal. Intake Manifold 1. Install the gasket to the intake manifold. ● Align the protrusion (A) of gasket to the groove of intake manifold. PBIC3651E 2. Place the intake manifold into the installation position. CAUTION: Make sure that the oil level gauge guide is not disconnected from the fixing clip of water inlet due to interference with intake manifold. EM-122 INTAKE MANIFOLD [HR] 3. Tighten bolts in the numerical order shown in the figure. A : Engine front EM C PBIC3652E D 4. Install intake manifold support (front and rear). Electric Throttle Control Actuator ● ● ● Tighten bolts of electric throttle control actuator equally and diagonally in several steps. Perform “Throttle Valve Closed Position Learning” after repair when removing harness connector of the electric throttle control actuator. Refer to EC-857, "Throttle Valve Closed Position Learning" (with EUROOBD) or EC-1279, "Throttle Valve Closed Position Learning" (without EURO-OBD). Perform “Throttle Valve Closed Position Learning” and “Idle Air Volume Learning” after repair when replacing electric throttle control actuator. Refer to EC-858, "Idle Air Volume Learning" (with EURO-OBD) or EC-1279, "Idle Air Volume Learning" (without EURO-OBD). E F G H I J K L M EM-123 EXHAUST MANIFOLD [HR] EXHAUST MANIFOLD Components PFP:14004 BBS002OG MBIB9023E 1. Exhaust manifold cover 2. Exhaust manifold cover 3. Harness bracket 4. Heated oxygen sensor 1 5. Exhaust manifold stay 6. Exhaust manifold 7. Gasket 8. Stud bolt 9. Heat insulator 10. Seal bearing Engine front Refer to GI-11, "Components" for symbol marks in the figure. EM-124 EXHAUST MANIFOLD [HR] Removal and Installation BBS002OH A REMOVAL 1. 2. 3. 4. Remove exhaust front tube. Refer to EX-3, "EXHAUST SYSTEM" . Remove the harness bracket of heated oxygen sensor 1 from the cylinder head. Remove exhaust manifold cover. Remove the heated oxygen sensor 1. ● Using heated oxygen sensor wrench (SST: KV10117100) (A), remove heated oxygen sensor 1. CAUTION: Handle it carefully and avoid impacts. NOTE: The exhaust manifold can be removed and installed without removing the heated oxygen sensor 1 (Disassembly of harness connector is necessary) EM C D E PBIC3654E 5. 6. Remove exhaust manifold side mounting bolt of exhaust manifold stay. Remove exhaust manifold mounting bolts from underbody in the reverse order shown, and remove exhaust manifold. F G H I MBIB9021E ● J Loosen nuts in the reverse of the order shown in the figure. K : Engine front L M PBIC3774E 7. 8. Remove gasket. CAUTION: Cover engine openings to avoid entry of foreign materials. Remove exhaust manifold cover from back of exhaust manifold. EM-125 EXHAUST MANIFOLD [HR] INSPECTION AFTER REMOVAL Mounting Surface Distortion ● Using a straightedge (B) and feeler gauge (A), check distortion of exhaust manifold mounting surface. Limit ● : 0.3 mm (0.012 in) Replace exhaust manifold if outside the limit. PBIC3530J INSTALLATION Note the following, and install in the reverse order of removal. Exhaust Manifold 1. Tighten nuts in numerical order shown in the figure. : Engine front 2. Tighten to the specified torque again. PBIC3774E EM-126 OIL PAN AND OIL STRAINER [HR] OIL PAN AND OIL STRAINER Components PFP:11110 A BBS002OI EM C D E F G H I J MBIB1372E 1. Rear oil seal 4. Chain tensioner 5. Oil pump drive chain 6. Crankshaft sprocket 7. Oil pump sprocket 8. Oil pan drain plug 9. Washer 11. Oil filter stud bolt 12. Oil filter B. Refer to LU-19 C. 10. Oil pan (lower) 2. O-ring 3. K Oil pan (upper) L 13. Oil level sensor A. Refer to EM-142 Oil pan side M Refer to GI-11, "Components" for symbol marks in the figure. Removal and Installation BBS002OJ NOTE: The oil strainer and oil pump are included in the oil pan (upper). Individual disassembly is prohibited. REMOVAL NOTE: When removing oil pan (lower) only, steps “2” and “3” are not necessary. Perform step “5” after completing step “4”. 1. Remove engine undercover. 2. Remove engine and transaxle assembly from the vehicle, and then separate engine and transaxle. Refer to EM-184, "ENGINE ASSEMBLY" . 3. Install engine assembly to widely use engine stand. Refer to EM-189, "CYLINDER BLOCK" . 4. Drain engine oil. Refer to LU-16, "ENGINE OIL" . 5. Remove the oil pan (lower) with the following procedure. EM-127 OIL PAN AND OIL STRAINER [HR] a. Loosen bolts in the reverse of the order shown in the figure. : Engine front b. 6. 7. 8. a. Insert the seal cutter (SST: KV10111100) between oil pan (upper) and oil pan (lower). CAUTION: ● Be careful not to damage the mating surface. ● A more adhesive liquid gasket is applied compared to previous types when shipped, so it should not be forced off using a flat- bladed screwdriver, etc. MBIB1433E Remove front cover and timing chain. Refer to EM-142, "TIMING CHAIN" . Remove oil pump sprocket and crankshaft sprocket together with oil pump drive chain. Refer to EM-142, "TIMING CHAIN" . Remove oil pan (upper) with the following procedure. Loosen oil pan (upper) mounting bolts in the reverse of the order shown in the figure. : Engine front MBIB1374E b. Insert a flat-bladed offset screwdriver into the arrow ( ) in the figure and open up a crack between the oil pan (upper) cylinder block. : Engine front c. 9. Insert the seal cutter (SST: KV10111100) between remove the oil pan (upper) and cylinder block.Slide seal cutter by tapping on the side of tool with a hammer. CAUTION: ● Be careful not to damage the mating surface. MBIB1375E ● A more adhesive liquid gasket is applied compared to previous types when shipped, so it should not be forced off using a screwdriver, etc. outside the indicated location. ● Do not remove oil pump and oil strainer from oil pan (upper). Remove rear oil seal from crankshaft. INSTALLATION 1. a. b. Install the oil pan (upper) in the following procedure. Use scraper to remove old liquid gasket from mating surfaces. ● Also remove the old liquid gasket from mating surface of cylinder block. ● Remove old liquid gasket from the bolt holes and threads. CAUTION: Do not scratch or damage the mating surfaces when cleaning off old liquid gasket. Install O-ring to the cylinder block. EM-128 OIL PAN AND OIL STRAINER [HR] c. Apply a continuous bead of liquid gasket (C) with the tube presser (SST: WS39930000) to areas shown in the figure. Use Genuine Liquid Gasket or equivalent. A : 2 mm (0.07 in) protruded to outside B : 2 mm (0.07 in) protruded to rear oil seal mounting side A EM : Engine front : Oil pan out side C CAUTION: Attaching should be done within 5 minutes after coating. D E F G MBIB1434E d. Tighten bolts in the numerical order shown in the figure. H : Engine front CAUTION: Install avoiding misalignment of both oil pan gasket and Oring. ● The bolts are different according to the installation position. Refer to the numbers shown in the figure. M8 × 180 mm (7.09 in) M8 × 25 mm (0.98 in) M8 × 90 mm (3.54 in) 2. a. b. c. : No. 9, 10 : No. 3, 4, 7, 8 : No. 1, 2, 5, 6 I J MBIB1374E Install rear oil seal with the following procedure: CAUTION: ● The installation of rear oil seal should be completed within 5 minutes after installing oil pan (upper). ● Do not touch oil seal lip. Wipe off any liquid gasket protruding to the rear oil seal mounting part of oil pan (upper) and cylinder block using a spatula. Apply the liquid gasket lightly to entire outside area of new rear oil seal. Use Genuine Liquid Gasket or equivalent. Press-fit the rear oil seal using a drift with outer diameter 113 mm (4.45 in) and inner diameter 90 mm (3.54 in) (commercial service tool) (A). PBIC3660E EM-129 K L M OIL PAN AND OIL STRAINER [HR] ● d. 3. 4. 5. 6. a. b. Press-fit to the dimensions specified in the figure. 1. Rear oil seal A. Rear end surface of cylinder block CAUTION: ● Do not touch the grease applied to the oil seal lip. ● Be careful not to damage the rear oil seal mounting part of oil pan (upper) and cylinder block or the crankshaft. ● Press-fit straight make sure that oil seal does not curl PBIC3761E or tilt. After press-fitting the rear oil seal, completely wipe off any liquid gasket protruding to rear end surface side. Install crankshaft sprocket, oil pump sprocket, oil pump drive chain, and chain tensioner. Refer to EM-142, "TIMING CHAIN" . Install timing chain and related parts. Refer to EM-142, "TIMING CHAIN" . Install front cover and related parts. Refer to EM-142, "TIMING CHAIN" . Install oil pan (lower) with the following procedure. Use scraper to remove old liquid gasket from mating surfaces. ● Also remove the old liquid gasket from mating surface of oil pan (upper). ● Remove old liquid gasket from the bolt holes and threads. CAUTION: Do not scratch or damage the mating surfaces when cleaning off old liquid gasket. Apply a continuous bead of liquid gasket (A) with the tube presser (SST: WS39930000) to areas shown in the figure. : Engine out side Use Genuine Liquid Gasket or equivalent. CAUTION: Attaching should be done within 5 minutes after coating. MBIB1376E EM-130 OIL PAN AND OIL STRAINER [HR] c. Tighten bolts in the numerical order shown in the figure. A : Engine front EM C MBIB1373E D 7. 8. Install oil pan drain plug. ● For installation direction of washer. Refer to EM-127, "Components" . Install in the reverse order of removal. CAUTION: Pour engine oil at least 30 minutes after oil pan is installed. F INSPECTION AFTER INSTALLATION 1. 2. 3. 4. E Check engine oil level and adjust engine oil. Refer to LU-16, "ENGINE OIL" . Check for leakage of engine oil when engine is warmed. Stop engine and wait for 10 minutes. Check engine oil level again. Refer to LU-16, "ENGINE OIL" . G H I J K L M EM-131 IGNITION COIL [HR] IGNITION COIL Components PFP:22448 BBS002OK PBIC3662E 1. Ignition coil 2. Spark plug Removal and Installation BBS002OL REMOVAL 1. 2. 3. Remove intake manifold. Refer to EM-120, "INTAKE MANIFOLD" . Disconnect harness connector from the ignition coil. Remove ignition coil. CAUTION: ● Handle it carefully and avoid impacts. ● Do not disassemble. INSTALLATION Installation is the reverse order of removal. EM-132 SPARK PLUG (PLATINUM-TIPPED TYPE) [HR] SPARK PLUG (PLATINUM-TIPPED TYPE) Components PFP:22401 A BBS002OM EM C D E F G PBIC3662E 1. Ignition coil 2. Spark plug Removal and Installation BBS002ON H REMOVAL 1. 2. 3. Remove intake manifold. Refer to EM-120, "INTAKE MANIFOLD" . Remove ignition coil. Refer to EM-132, "IGNITION COIL" . Remove spark plug using spark plug wrench (commercial service tool). CAUTION: Do not drop or shock it. I J K L PBIC3871E INSPECTION AFTER REMOVAL M Use standard type spark plug for normal condition. Hot type spark plug is suitable when fouling occurs with standard type spark plug under conditions such as: ● Frequent engine starts ● Low ambient temperatures Cold type spark plug is suitable when spark plug knock occurs with standard type spark plug under conditions such as: ● Extended highway driving ● Frequent high engine revolution Make NGK Standard type PLZKAR6A-11 Hot type PLZKAR5A-11 Cold type PLZKAR7A-11 Gap (Nominal) : 1.1 mm (0.043 in) EM-133 SPARK PLUG (PLATINUM-TIPPED TYPE) [HR] CAUTION: ● Do not drop or shock spark plug. ● Do not use wire brush for cleaning. ● If plug tip is covered with carbon, spark plug cleaner may be used. Cleaner air pressure: Less than 588 kPa (5.88 bar, 6 kg/cm2 , 85 psi) Cleaning time: Less than 20 seconds SMA773C ● Checking and adjusting plug gap is not required between change intervals. SMA806CA INSTALLATION Installation is the reverse order of removal. EM-134 FUEL INJECTOR AND FUEL TUBE [HR] FUEL INJECTOR AND FUEL TUBE Components PFP:16600 A BBS002OO EM C D E F G H I PBIC3663E 1. Quick connector cap 2. Fuel feed hose 3. Fuel tube 4. Fuel tube protector 5. O-ring (Black) 6. Clip 7. Fuel injector 8. O-ring (Green) J K CAUTION: Do not remove or disassemble parts unless instructed as shown in the figure. Refer to GI-11, "Components" for symbol marks in the figure. L Removal and Installation BBS002OP WARNING: ● Put a “CAUTION: INFLAMMABLE” sign in the workshop. ● Be sure to work in a well ventilated area and furnish workshop with a CO2 fire extinguisher. ● Do not smoke while servicing fuel system. Keep open flames and sparks away from the work area. REMOVAL 1. 2. Release the fuel pressure. Refer to EC-860, "FUEL PRESSURE RELEASE" (with EURO-OBD) or EC1281, "FUEL PRESSURE RELEASE" (without EURO-OBD). Remove intake manifold. Refer to EM-120, "INTAKE MANIFOLD" . EM-135 M FUEL INJECTOR AND FUEL TUBE [HR] 3. Disconnect quick connector with the following procedure. Disconnect fuel feed hose from fuel tube. 1 : Quick connector cap NOTE: There is no fuel return path. PBIC3771E a. b. Remove quick connector cap (1) from quick connector connection. Disconnect fuel feed hose from hose clamp. PBIC3664E c. d. e. With the sleeve side of quick connector release facing quick connector, install quick connector release onto fuel tube. Insert quick connector release into quick connector until sleeve contacts and goes no further. Hold quick connector release on that position. CAUTION: Inserting quick connector release hard will not disconnect quick connector. Hold quick connector release where it contacts and goes no further. Draw and pull out quick connector straight from fuel tube. CAUTION: ● Pull quick connector holding “A” position in the figure. KBIA0702E ● Do not pull with lateral force applied. O-ring inside quick connector may be damaged. ● Prepare container and cloth beforehand as fuel will leak out. ● Avoid fire and sparks. ● Keep parts away from heat source. Especially, be careful when welding is performed around them. ● Do not expose parts to battery electrolyte or other acids. ● Do not bend or twist connection between quick connector and fuel feed hose during installation/removal. ● To keep clean the connecting portion and to avoid damage and foreign materials, cover them completely with plastic bags or something similar. PBIC2205E EM-136 FUEL INJECTOR AND FUEL TUBE [HR] 4. 5. Disconnect harness connector from fuel injector. Remove fuel tube protector. ● Loosen bolts in the reverse of the order shown in the figure. A EM : Engine front C D PBIC3665E 6. E Remove the fuel injector and fuel tube assembly. ● Loosen bolts in the reverse of the order shown in the figure : Engine front F CAUTION: ● When removing, be careful to avoid any interference with fuel injector. ● Use a shop cloth to absorb any fuel leaks from fuel tube. G H PBIC3666E 7. a. b. I Remove the fuel injector (3) from the fuel tube (1) with the following procedure. Open and remove the clip (2). Remove fuel injector from the fuel tube by pulling straight. CAUTION: ● Be careful about fuel leakage remaining in fuel tube. ● Be careful not to damage the nozzle of fuel injector. ● Do not subject it to impact by dropping or hitting. ● Do not disassemble. J K PBIC3667E L INSTALLATION 1. Install new the O-ring to the fuel injector, paying attention to the following. CAUTION: ● The upper and lower O-rings are different. Be careful not to confuse them. Fuel tube side Nozzle side ● ● ● ● ● ● : Black : Green Handle O-ring with bare hands. (Do not wear gloves.) Lubricate O-ring with engine oil. Do not clean O-ring with solvent. Make sure that the O-ring and its mating part are free of foreign material. Be careful not to scratch O-ring with tool or fingernails when installing it. Also be careful not to twist or stretch O-ring. If O-ring was stretched while it was being attached, do not insert it into fuel tube immediately. Insert O-ring straight into fuel tube. Do not decenter or twist it. EM-137 M FUEL INJECTOR AND FUEL TUBE [HR] 2. Install the fuel injector (4) onto the fuel tube (1) with the following procedure: 3 : O-ring (Black) 5 : O-ring (Green) a. b. c. Insert the clips (2) into the clip mounting grooves on the fuel injector. ● Insert clip cut-out (D) into fuel injector protrusion (F). CAUTION: ● Always replace clip with new one. ● Make sure that the clip does not interfere with the Oring. If interference occurs, replace the O-ring. Insert the fuel injector into the fuel tube with clip attached. ● Make sure that the axis is lined up when inserting. ● Insert clip cut-out (C) into fuel tube protrusion (B). ● Make sure that the flange (A) on the fuel tube fits securely in the clip flange fixing groove (E). Make sure that installation is complete by checking that fuel injector does not rotate or come off. PBIC3668E 3. Install fuel tube and fuel injector assembly onto cylinder head. ● Tighten bolts in the numerical order shown in the figure. : Engine front CAUTION: Be careful not to let tip of fuel injector nozzle come in contact with other parts. PBIC3665E 4. Install fuel tube protector. ● Tighten bolts in the numerical order shown in the figure. : Engine front PBIC3666E 5. 6. a. b. Connect harness connector to fuel injector. Connect fuel feed hose with the following procedure. Check for damage or foreign material on the fuel tube and quick connector. Apply new engine oil lightly to area around the top of fuel tube. EM-138 FUEL INJECTOR AND FUEL TUBE [HR] c. Align center to insert quick connector straightly into fuel tube. A ● Insert quick connector to fuel tube until the top spool on fuel tube is inserted completely and the 2nd level spool is positioned slightly below quick connector bottom end. CAUTION: EM ● Hold “A” position in the figure when inserting fuel tube into quick connector. ● Carefully align center to avoid inclined insertion to preC vent damage to O-ring inside quick connector. ● Insert until you hear a “click” sound and actually feel KBIA0272E the engagement. D ● To avoid misidentification of engagement with a similar sound, be sure to perform the next step. d. Before clamping fuel feed hose with hose clamp, pull quick connector hard by hand holding “A” position. E Make sure it is completely engaged (connected) so that it does not come out from fuel tube. e. Install quick connector cap (1) to quick connector connection. ● Install quick connector cap with the side arrow facing quick F connector side (fuel feed hose side). CAUTION: ● Make sure that the quick connector and fuel tube are G securely engaged with the quick connector cap mounting groove. ● Quick connector may not be connected correctly if H quick connector cap cannot be installed easily. Remove the quick connector cap, and then check the PBIC3664E connection of quick connector again. I f. Install fuel feed hose to hose clamp. 7. Install in the reverse order of removal. J INSPECTION AFTER INSTALLATION Check on Fuel Leaks 1. 2. Apply fuel pressure to fuel lines with turning ignition switch ON (with engine stopped). Then make sure there are no fuel leaks at connections. NOTE: Use mirrors for checking on invisible points. Start engine. With engine speed increased, make sure again there are no fuel leaks at connections. CAUTION: Do not touch engine immediately after stopped as engine becomes extremely hot. K L M EM-139 ROCKER COVER [HR] ROCKER COVER Components PFP:13264 BBS002OQ PBIC3669E 1. PCV hose 2. Oil filler cap 3. Rocker cover 4. Gasket 5. Bracket 6. Grommet 7. PCV valve 8. PCV hose A. To air duct Refer to GI-11, "Components" for symbol marks in the figure. Removal and Installation BBS002OR REMOVAL 1. 2. 3. 4. 5. 6. Remove intake manifold. Refer to EM-120, "INTAKE MANIFOLD" . Remove ignition coil. Refer to EM-132, "IGNITION COIL" . Remove engine mounting stay (RH). Refer to EM-184, "ENGINE ASSEMBLY" . NOTE: For supporting engine load, it is not necessary that only the engine mounting stay (RH) is removed. Remove fuel tube protector. Refer to EM-135, "FUEL INJECTOR AND FUEL TUBE" . Remove the PCV hose from rocker cover. Remove PCV valve if necessary. EM-140 ROCKER COVER [HR] 7. Loosen bolts in the reverse of the order shown in the figure. A : Engine front NOTE: 13 and 14 shown in the figure are used to tighten the fuel tube protector. EM C PBIC3670E D 8. 9. Remove gasket from rocker cover. Remove all traces of liquid gasket from cylinder head and front cover. E INSTALLATION 1. a. Install the rocker cover with the following procedure. Install the gasket to the rocker cover. ● Check for damage or foreign material. ● Make sure that it is securely inserted in the mounting groove of rocker cover. ● For the 2 bolt holes shown in the figure, push the gasket into the boss for the rocker cover bolt hole to prevent it from falling. F G H KBIA3331J b. I Apply liquid gasket to the position shown in the figure. 1 : Cylinder head 2 : Front cover J Use Genuine Liquid Gasket or equivalent. K L PBIC3671E c. d. Install the rocker cover to the cylinder head. CAUTION: Make sure the gasket is not dropped. Tighten bolts in two steps in numerical order as shown in the figure. M : Engine front NOTE: 13 and 14 shown in the figure tighten together with the fuel tube protector. Refer to EM-135, "Components" . PBIC3670E 2. Install in the reverse order of removal. EM-141 TIMING CHAIN [HR] TIMING CHAIN Components PFP:13028 BBS002OS PBIC3709E 1. Timing chain slack guide 2. Chain tensioner (For timing chain) 3. Camshaft sprocket (EXH) 4. Camshaft sprocket (INT) 5. Plug 6. Front oil seal 7. Crankshaft pulley 8. Crankshaft pulley bolt 9. Front cover 10. Crankshaft sprocket 11. Oil pump sprocket 12. Oil pump drive chain Chain tensioner (For oil pump drive 13. chain) 14. Timing chain A. Refer to EM-146 Refer to GI-11, "Components" for symbol marks in the figure. EM-142 15. Timing chain tension guide TIMING CHAIN [HR] Removal and Installation BBS002OT CAUTION: The rotation direction indicated in the text indicates all directions seen from the engine front direction. REMOVAL 1. 2. 3. 4. 5. 6. a. EM Remove front RH wheel. Refer to WT-5, "ROAD WHEEL AND TYRE ASSEMBLY" . Remove front fender protector (RH). Refer to EI-14, "FENDER PROTECTOR" . Drain engine oil. Refer to LU-16, "ENGINE OIL" . NOTE: Perform this step when engine is cold. Remove the following parts. ● Rocker cover: Refer to EM-140, "ROCKER COVER" . ● Drive belt: Refer to EM-114, "DRIVE BELTS" . ● Water pump pulley: Refer to CO-36, "WATER PUMP" . ● Ground cable (between engine mounting bracket (RH) and radiator core support) Support the bottom surface of engine using a transmission jack, and then remove the engine mounting bracket and insulator (RH). Refer to EM-184, "ENGINE ASSEMBLY" . Set No. 1 cylinder at TDC of its compression stroke with the following procedure: Rotate crankshaft pulley (2) clockwise and align TDC mark (without paint mark) (A) to timing indicator (1) on front cover. B A C D E F G : White paint mark (Not use for service) H I PBIC3673E b. Make sure the matching marks on each camshaft sprocket are positioned as shown in the figure. ● K 1 : Camshaft sprocket (EXH) 2 : Camshaft sprocket (INT) A : Matching mark (stamp) B : Matching mark (peripheral stamp line) L If not, rotate crankshaft pulley one more turn to align matching marks to the positions in the figure. M PBIC3872E 7. a. b. J Remove crankshaft pulley with the following procedure: Secure crankshaft pulley (1) using a pulley holder (commercial service tool) (A). Loosen and pull out crankshaft pulley bolts. CAUTION: Do not remove the mounting bolts as they will be used as a supporting point for the pulley puller (SST: KV11103000). PBIC3710E EM-143 TIMING CHAIN [HR] c. Attach a pulley puller (SST: KV11103000) (A) in the M 6 thread hole on crankshaft pulley, and remove crankshaft pulley. B : M6 bolt PBIC3711E 8. a. Remove front cover with the following procedure: Loosen bolts in the reverse of the order shown in the figure. KBIA3429J b. Cut liquid gasket by prying the position ( and then remove the front cover. ) shown in the figure, PBIC3712E 9. Remove front oil seal from front cover. ● Remove by lifting it up using a suitable tool. CAUTION: Be careful not to damage the front cover. EM-144 TIMING CHAIN [HR] 10. Remove chain tensioner (1) with the following procedure. A a. Fully push down the chain tensioner lever (A), and then push the plunger (C) into the inside of tensioner. ● The tab (B) is released by fully pushing the lever down. As a result, the plunger can be moved. EM b. Pull up the lever to align its hole position with the body hole position. C ● When the lever hole is aligned with the body hole position, the plunger is fixed. ● When the protrusion parts of the plunger ratchet and the tab PBIC3713E face each other, both hole positions are not aligned. At that D time, correctly engage them and align these hole positions by slightly moving the plunger. c. Insert the stopper pin (D) into the body hole through the lever hole, and then fix the lever at the upper position. E ● Figure shows the example that a hexagonal wrench for 2.5 mm (0.098 in) is used. d. Remove chain tensioner. 11. Remove the timing chain tension guide (2) and the timing chain F slack guide (1). G H PBIC3714E 12. Remove the timing chain (2). ● Pull the looseness of timing chain toward the camshaft sprocket (EXH) (1), and then remove the timing chain and start the removal from camshaft sprocket (EXH) side. CAUTION: Do not rotate crankshaft or camshaft while timing chain is removed. It causes interference between valve and piston. I J K L PBIC3715E 13. Remove the crankshaft sprocket and the oil pump drive related parts with the following procedure. a. Remove chain tensioner (1). ● Pull out from the shaft (B) and spring fixing holes (A). PBIC3716E EM-145 M TIMING CHAIN [HR] b. c. Hold the top of the oil pump shaft using the TORX socket (size: E8), and then loosen the oil pump sprocket nuts and remove them. Remove the crankshaft sprocket (1), the oil pump drive chain (2), and the oil pump sprocket (3) at the same time. PBIC3720E INSPECTION AFTER REMOVAL Timing Chain Check timing chain for cracks (A) and any excessive wear (B) at the roller links of timing chain. Replace timing chain if necessary. PBIC3169J INSTALLATION NOTE: The figure shows the relationship between the matching mark on each timing chain and that on the corresponding sprocket, with the components installed. 1. 1 : Timing chain 2 : Camshaft sprocket (EXH) 3 : Timing chain slack guide 4 : Chain tensioner 5 : Oil pump drive chain 6 : Oil pump sprocket 7 : Crankshaft sprocket 8 : Timing chain tension guide 9 : Camshaft sprocket (INT) A : Yellow link B : Matching mark (stamp) C : Orange link D : Matching mark (stamp) E : Crankshaft key (point straight up) F : Matching mark (peripheral stamp line) G : Yellow link Install the crankshaft sprocket and the oil pump drive related parts with the following procedure: EM-146 PBIC3718E TIMING CHAIN [HR] a. Install the crankshaft sprocket (1), the oil pump drive chain (2), and the oil pump sprocket (3) at the same time. A : Engine front Install the crankshaft sprocket so that its invalid gear area (A) is towards the back of the engine. ● Install the oil pump sprocket so that its hexagonal surface faces (B) the front of engine. NOTE: There is no matching mark in the oil pump drive related parts. ● EM C PBIC3719E D b. Hold the top of the oil pump shaft using the TORX socket (size: E8), and then tighten the oil pump sprocket nuts. 1 : Crankshaft sprocket 2 : Oil pump drive chain 3 : Oil pump sprocket E F G PBIC3720E c. Install chain tensioner (1). ● Insert the body into the shaft (B) while inserting the spring into the fixing hole (A) of cylinder block front surface. ● Make sure that the tension is applied to the oil pump drive chain after installing. H I J PBIC3716E 2. K Install timing chain with the following procedure. A : Yellow link B : Matching mark (stamp) C : Orange link D : Matching mark (stamp) E : Crankshaft key (point straight up) F : Matching mark (peripheral stamp line) G : Yellow link L M Install by aligning matching marks on each sprocket and timing chain. ● If these matching marks are not aligned, rotate the camshaft slightly to correct the position. CAUTION: ● For the following note, after the matching marks are aligned, keep them aligned by holding them with a hand. ● To avoid skipped teeth, do not rotate crankshaft and camshaft until front cover is installed. ● PBIC3721E EM-147 TIMING CHAIN [HR] 3. Install timing chain tension guide (2) and timing chain slack guide (1). PBIC3714E 4. Install chain tensioner (1). ● Fix the plunger at the most compressed position using a stopper pin (A), and then install it. ● Securely pull out the stopper pin after installing the chain tensioner. PBIC3722E 5. 6. 7. a. Check matching mark position of timing chain and each sprocket again. Install the front oil seal to the front cover. Refer to EM-171, "Removal and Installation of Front Oil Seal" Install front cover with the following procedure: Apply a continuous bead of liquid gasket with tube presser (SST: WS39930000) to front cover as shown in the figure. Use Genuine Liquid Gasket or equivalent. 1 : Cylinder head 2 : Cylinder block 3 : Oil pan (upper) A : Liquid gasket application area φ 3.0 - 4.0 mm (0.12 - 0.16 in) PBIC3724E EM-148 TIMING CHAIN [HR] b. Apply a continuous bead of liquid gasket with tube presser (SST: WS39930000) to front cover as shown in the figure. Use Genuine Liquid Gasket or equivalent. A A : Liquid gasket application area φ 3.0 - 4.0 mm (0.12 - 0.16 in) EM C D E F G PBIC3725E c. d. Tighten bolts in the numerical order shown in the figure. After all bolts are tightened, retighten them to specified torque in numerical order as shown in the figure. CAUTION: Be sure to wipe off any excessive liquid gasket leaking to surface. H I J K L M KBIA3429J 8. 9. a. b. Insert crankshaft pulley by aligning with crankshaft key. ● When inserting crankshaft pulley with a plastic hammer, tap on its center portion (not circumference). CAUTION: Install protecting front oil seal lip section from any damage. Tighten crankshaft pulley bolt with the following procedure: ● Secure crankshaft pulley with a pulley holder (commercial service tool), and tighten crankshaft pulley bolt. Apply new engine oil to thread and seat surfaces of crankshaft pulley bolt. Tighten crankshaft pulley bolt. EM-149 TIMING CHAIN [HR] : 35.0 N·m (3.6 kg-m, 26 ft-lb) c. d. Put a paint mark (B) on crankshaft pulley, mating with any one of six easy to recognize angle marks (A) on crankshaft bolt flange (1). Turn another 60 degrees clockwise (angle tightening). ● Check the tightening angle with movement of one angle mark. PBIC3726E 10. Make sure that crankshaft turns smoothly by rotating by hand clockwise. 11. Install in the reverse order of removal. INSPECTION AFTER INSTALLATION Inspection for Leaks The following are procedures for checking fluids leak, lubricates leak and exhaust gases leak. ● Before starting engine, check oil/fluid levels including engine coolant and engine oil. If less than required quantity, fill to the specified level. Refer to MA-24, "RECOMMENDED FLUIDS AND LUBRICANTS" . ● Use procedure below to check for fuel leakage. – Turn ignition switch “ON” (with engine stopped). With fuel pressure applied to fuel piping, check for fuel leakage at connection points. – Start engine. With engine speed increased, check again for fuel leakage at connection points. ● Run engine to check for unusual noise and vibration. NOTE: If hydraulic pressure inside timing chain tensioner drops after removal/installation, slack in the guide may generate a pounding noise during and just after engine start. However, this is normal. Noise will stop after hydraulic pressure rises. ● Warm up engine thoroughly to make sure there is no leakage of fuel, exhaust gases, or any oil/fluids including engine oil and engine coolant. ● Bleed air from lines and hoses of applicable lines, such as in cooling system. ● After cooling down engine, again check oil/fluid levels including engine oil and engine coolant. Refill to the specified level, if necessary. Summary of the inspection items: Item Before starting engine Engine running After engine stopped Engine coolant Level Leakage Level Engine oil Level Leakage Level Other oils and fluid* Level Leakage Level Leakage Leakage Leakage — Leakage — Fuel Exhaust gases * Transmission/transaxle fluid, power steering fluid, brake fluid, etc. EM-150 CAMSHAFT [HR] CAMSHAFT Components PFP:13001 A BBS002OU EM C D E F G H I J PBIC3672E 1. Camshaft bracket (No. 2 to 5) 2. Camshaft bracket (No. 1) 3. 4. Camshaft sprocket (INT) 5. Cylinder head 6. Oil filter (for intake valve timing control) 7. Washer 8. Plug 9. Intake valve timing control solenoid valve 10. O-ring 11. O-ring 12. Camshaft position sensor (PHASE) 13. Valve lifter 14. Camshaft (INT) 15. Camshaft (EXH) A. Refer to EM-161 Removal and Installation BBS002OV CAUTION: The rotation direction indicated in the text indicates all directions seen from the engine front direction. REMOVAL NOTE: This section describes the procedure for removal and installation of camshaft with front cover. If the front cover is removed first, change the following procedure. 1. L M Refer to GI-11, "Components" for symbol marks in the figure. ·Step 8 ·Step 9 ·Step 10 K Camshaft sprocket (EXH) : After camshaft sprocket is removed, remove the camshaft brackets (No. 2 to 5). : The camshaft (EXH) can be removed simultaneously with the camshaft (INT). : When the camshaft sprocket (INT) mounting bolt is removed, the lifting up of camshaft is not necessary. Support the bottom surface of engine using a transmission jack, and then remove the engine mounting bracket and insulator (RH). Refer to EM-184, "ENGINE ASSEMBLY" . EM-151 CAMSHAFT [HR] 2. 3. 4. a. Remove rocker cover. Refer to EM-140, "ROCKER COVER" . Remove camshaft position sensor (PHASE) from rear end of cylinder head. CAUTION: Handle it carefully and avoid impacts. Place cylinder No. 1 at TDC of its compression stroke with the following procedure. Rotate crankshaft pulley (2) clockwise and align TDC mark (without paint mark) (A) to timing indicator (1) on front cover. B : White paint mark (Not use for service) PBIC3673E b. Make sure that the matching marks on each the camshaft sprockets are in the position shown in the figure. 1. : Timing chain 2. : Camshaft sprocket (EXH) 3. : Camshaft sprocket (INT) A : Matching mark (Paint) B : Matching mark (Stamp) C : Matching mark (Peripheral stamp line) If not, rotate crankshaft pulley one more turn to align matching PBIC3674E marks to the positions in the figure. Paint matching marks (A) on the timing chain links Secure the plunger of chain tensioner in the fully compressed position with the following procedure. And then, loosen the timing chain tension. Remove the plug (2) from the front cover (1). ● c. 5. a. PBIC3675E b. Fully push down the lever (B) of chain tensioner (2) from the plug hole, and then insert the stopper pin (A) into the body side hole and secure the lever at the lowest position. C : Front cover has been omitted The tab is released by fully pushing the lever down. As a result, the plunger (1) can be moved. NOTE: Hexagonal wrench [2.5 mm (0.098 in)] is used for a stopper pin as an example. CAUTION: The stopper pin must use a shape that cannot fall in the front cover when dropping out. ● EM-152 PBIC3676E CAMSHAFT [HR] c. Turn the crankshaft pulley (2) counterclockwise with the camshaft (EXH) (1) fixing. Apply the tension to the timing chain, and then push the plunger of into the inside of chain tensioner. CAUTION: Hold the camshaft hexagonal part (A), and then secure the camshaft. A EM C PBIC3677E D d. Pull out the stopper pin (A) of chain tensioner (2) side from plug hole. Lift the lever (B) up to align its hole position with the hole of the body. E D : Front cover has been omitted When the lever hole (C) is aligned with the body hole position, the plunger (1) is fixed. ● When the protrusion parts of the plunger ratchet and the tab face each other, both hole positions are not aligned. At that time, correctly engage them and align these hole positions by slightly moving the plunger. Insert the stopper pin into the body hole through the lever hole, and then fix the lever at the upper position. Slightly rotate the crankshaft pulley (2) clockwise to loosen the timing chain on camshaft sprocket (EXH) (1) side. CAUTION: Hold the camshaft hexagonal part (A), and then secure the camshaft. ● e. f. F G PBIC3772E H I J K PBIC3773E 6. 7. Remove camshaft sprocket (EXH) (1). CAUTION: ● Hold the camshaft hexagonal part (A), and then secure the camshaft. ● Do not rotate crankshaft and camshaft separately, so as not to contact valve with piston in the following steps. NOTE: The timing chain with the front cover installed is not disengaged from the crankshaft sprocket and it is not dropped into the front cover. Therefore, the timing chain tension holding device is not PBIC3678E necessary. Turn the camshaft sprocket (INT) to the most advanced position. CAUTION: Installation and removal of the camshaft sprocket (INT) must be done in the most advanced position for the following reasons, so make sure that you follow the procedure exactly. EM-153 L M CAMSHAFT [HR] ● ● ● The sprocket (C) and vane (camshaft coupling) (B) are designed to spin and move within the range of a certain angle. With the engine stopped and the vane in the most retarded angle, it will not spin because it is locked to the sprocket side by the internal lock pin (A). If the camshaft sprocket mounting bolts are turned in the situation described above, the lock pin will become damaged and cause malfunctions because of the increased horizontal load (cutting force) on the lock pin. PBIC3679E Put the camshaft sprocket (INT) in the most advance position with the following procedure. Remove camshaft bracket (No. 1) (1). ● a. : Engine front ● Loosen the bolts in several steps, and then remove them. PBIC3680E b. Apply the following air pressure to the No. 1 journal oil hole (A) of camshaft (INT) (1) shown in the figure using an air gun. Pressure ● ● : 300 kPa (3.0 bar, 3.1 kg/cm2 , 44psi) or more Apply the air pressure into the oil hole on the second groove from the front of camshaft thrust (B). Proceed all the way through step “e” with the air pressure on. PBIC3681E Attach the rubber nozzle (B) narrowed to the top of the air gun (A) to prevent air leakage from the oil hole. Securely apply the air pressure to the oil hole. CAUTION: ● There are other oil holes in the side grooves. Do not use the incorrect oil holes. ● Be sure not to damage the oil path with the tip of the air gun. ● Wipe all the oil off the air gun to prevent oil from being blown all over along with the air, and the area around the PBIC3682E air gun should be wiped with a rag when applying air pressure. Eye protection should be worn as needed. NOTE: The air pressure is used to move the lock pin into the disengage position. Hold the camshaft sprocket (INT) with hands, and then apply the power counterclockwise/clockwise alternatively. ● Finally rotate the sprocket of the camshaft sprocket (INT) counterclockwise [the direction shown by the arrow ( )]. ● Perform the work while applying the air pressure to the oil hole. ● c. EM-154 CAMSHAFT [HR] ● ● If the lock pin is not released by hands, tap the camshaft sprocket (INT) lightly with a plastic hammer (A). If the camshaft sprocket (INT) is not rotated counterclockwise even if the above procedures are performed, check the air pressure and the oil hole position. A EM C PBIC3683E D d. While doing the above, once you hear a click (the sound of the internal lock pin disengaging) from inside the camshaft sprocket (INT), start turning the camshaft sprocket (INT) in the counterclockwise direction in the most advanced angle position. C : Lock pin engaged D : Most advanced angle E F Keep the air pressure on. ● If there is no click, as soon as the vane-side (camshaft side) starts moving independently of the sprocket, the lock pin has become disengaged. PBIC3684E ● Make sure that it is in the most advanced angle position by seeing if the stopper pin groove (A) and the stopper pin hole (B) are matched up as shown in the figure. Complete the applying procedure of air pressure and the holding procedure of camshaft (INT). Insert the stopper pin (A) into the stopper pin holes in the camshaft sprocket (INT) and lock in the most advanced angle position. CAUTION: No load is exerted on the stopper pin (spring reaction, etc.). Since it comes out easily, secure it with tape (B) to prevent it from coming out. NOTE: The stopper pin in the figure shows one example of a hexagonal wrench for 2.5 mm (0.098 in) [length of inserted section: PBIC3685E approximately15 mm (0.59 in)]. ● e. f. G H I J K L 8. Remove camshaft brackets (No. 2 to 5). ● Loosen bolts in several steps in the reverse of the order shown in the figure. A : EXH side B : INT side M : Engine front NOTE: The camshaft bracket (No. 1) has been already removed. PBIC3686E 9. Remove camshaft (EXH). EM-155 CAMSHAFT [HR] 10. Remove the camshaft (INT) (1) and the camshaft sprocket (INT) (2) with the following procedure. a. Lift up the camshaft sprocket (INT), and then set the thin tools (a box wrench, etc.) to the mounting bolt (A). b. Return the camshaft (INT) to the cylinder head journal quietly. PBIC3687E c. Keeping the camshaft hexagonal part (A) still with the wrench, loosen mounting the bolts for the camshaft sprocket (INT) (2). 1. Camshaft (INT) PBIC3688E d. Lift up the camshaft (INT) (1), and then disassemble the camshaft from the camshaft sprocket (INT) (2). PBIC3689E e. Remove camshaft (INT) rearward. CAUTION: Do not damage the signal plate of rear end. f. Remove camshaft sprocket (INT) (1). CAUTION: Do not drop stopper pin. PBIC3690E EM-156 CAMSHAFT [HR] CAUTION: ● Tape (C) the stopper pin (B) so it does not come out. ● Do not subject it to impact by dropping. ● Do not disassemble. [Do not loosen the three mounting bolts (A)]. NOTE: While removing the camshaft sprocket (INT), if you have taken out the stopper pin and the lock pin has been rejoined in the most retarded angle, do the following to restore it. A EM C PBIC3691E i. ii. iii. iv. 11. 12. 13. Install the camshaft (INT) and tighten the mounting bolts enough to prevent air from leaking out. CAUTION: The internal lock pin will get damaged, so keep the torque on the mounting bolts to the minimum required to prevent air from escaping. Apply the air pressure, disengage the lock pin, and turn the vane to the most advanced angle position. Insert the stopper pin. Remove camshaft sprocket (INT) from the camshaft. Remove valve lifter. ● Identify installation positions, and store them without mixing them up. Remove intake valve timing control solenoid valve (1). Remove the alternator and bracket, remove the plug (2), and then remove the oil filter. Refer to SC-51, "Removal and Installation (HR Engine Models)" . D E F G H I J PBIC3692E K INSPECTION AFTER REMOVAL Oil Filter ● ● ● L Make sure that there is no foreign material on the oil filter (1) and check it for clogging. Check the oil filter for damage. If there is some damage, replace the oil filter, the plug, and the washer as a set. M PBIC3693E EM-157 CAMSHAFT [HR] Camshaft Runout 1. 2. 3. Put V-block on a precise flat table, and support No. 2 and 5 journals of camshaft. CAUTION: Do not support No. 1 journal (on the side of camshaft sprocket) because it has a different diameter from the other four locations. Set a dial indicator vertically to No. 3 journal. Turn camshaft to one direction with hands, and measure the camshaft runout on the dial indicator. (Total indicator reading) Standard: PBIC2499E : 0.02 mm (0.0008 in) Limit: : 0.1 mm (0.0039 in) 4. If it exceeds the limit, replace camshaft. Camshaft Cam Height 1. Measure the camshaft cam height with a micrometer (A). Standard: Intake : 41.705 - 41.895 mm (1.6419 - 1.6494 in) Exhaust : 40.175 - 40.365 mm (1.5816 - 1.5891 in) Cam wear limit : 0.2 mm (0.0078 in) 2. If wear exceeds the limit, replace camshaft. PBIC3178J Camshaft Journal Oil Clearance CAMSHAFT JOURNAL DIAMETER Measure the outer diameter of camshaft journal with a micrometer (A). Standard: No. 1 No. 2, 3, 4, 5 : 27.935 - 27.955 mm (1.0998 - 1.1006 in) : 24.950 - 24.970 mm (0.9822 - 0.9830 in) PBIC3179J CAMSHAFT BRACKET INNER DIAMETER ● Tighten camshaft bracket bolts with the specified torque. Refer to EM-161, "INSTALLATION" for the tightening procedure. EM-158 CAMSHAFT [HR] ● Measure inner diameter (B) of camshaft bracket with a bore gauge (A). Standard: No. 1 No. 2, 3, 4, 5 A : 28.000 - 28.021 mm (1.1024 - 1.1032 in) : 25.000 - 25.021 mm (0.9842 - 0.9850 in) EM C PBIC3180J D CAMSHAFT JOURNAL OIL CLEARANCE (Oil clearance) = (Camshaft bracket inner diameter) – (Camshaft journal diameter) E ● Standard No. 1 No. 2, 3, 4, 5 Limit ● : 0.045 - 0.086 mm (0.0018 - 0.0034 in) : 0.030 - 0.071 mm (0.0011 - 0.0027 in) F : 0.15 mm (0.0059 in) G If it exceeds the limit, replace either or both camshaft and cylinder head. NOTE: Camshaft brackets cannot be replaced as single parts, because they are machined together with cylinder head. Replace whole cylinder head assembly. Camshaft End Play 1. 2. I Install camshaft in cylinder head. Refer to EM-176, "INSTALLATION" for tightening procedure. Install a dial indicator (A) in thrust direction on front end of camshaft. Measure the camshaft end play on the dial indicator when camshaft is moved forward/backward (in direction to axis). Standard Limit H J : 0.075 - 0.153 mm (0.0029 - 0.0060 in) : 0.2 mm (0.0078 in) K L PBIC3694E M ● – Measure the following parts if out of the standard. Dimension “A” for cylinder head No. 1 journal bearing Standard – Dimension “B” for camshaft thrust Standard ● : 4.000 - 4.030 mm (0.1574 - 0.1586 in) : 3.877 - 3.925 mm (0.1526 - 0.1545 in) Refer to the standards above, and then replace camshaft and/ or cylinder head. KBIA3345J Camshaft Sprocket Runout 1. Put V-block on precise flat table, and support No. 2 and 5 journals of camshaft. CAUTION: Do not support No. 1 journal (on the side of camshaft sprocket) because it has a different diameter from the other four locations. EM-159 CAMSHAFT [HR] 2. Measure the camshaft sprocket runout with a dial indicator. (Total indicator reading) Limit ● : 0.15 mm (0.0059 in) If it exceeds the limit, replace camshaft sprocket. KBIA1493J Valve Lifter Check if surface of valve lifter has any wear or cracks. ● If anything above is found, replace valve lifter. Refer to EM-217, "Available Valve Lifter" . KBIA0182E Valve Lifter Clearance VALVE LIFTER OUTER DIAMETER ● Measure the outer diameter of valve lifter with a micrometer (A). Standard : 29.977 - 29.987 mm (1.1801 - 1.1805 in) PBIC3185J VALVE LIFTER HOLE DIAMETER Measure the diameter of valve lifter hole of cylinder head with an inside micrometer (A). Standard : 30.000 - 30.021 mm (1.1811 - 1.1819 in) PBIC3184J VALVE LIFTER CLEARANCE ● (Valve lifter clearance) = (Valve lifter hole diameter) – (Valve lifter outer diameter) Standard ● : 0.013 - 0.044 mm (0.0005 - 0.0017 in) If out of the standard, referring to the each standard of valve lifter outer diameter and valve lifter hole diameter, replace either or both valve lifter and cylinder head. EM-160 CAMSHAFT [HR] INSTALLATION 1. A Install the oil filter (1). 2 ● : Washer The oil filter is assembled to the plug (3), and then install it to the cylinder head. EM C PBIC3695E 2. 3. 4. a. b. Install intake valve timing control solenoid valve. ● Insert it straightly into the cylinder head. ● Tighten bolts after placing it completely. D E Install valve lifter. ● If it is reused, install in its original positions. Put a matching mark for positioning the camshaft (INT) and the camshaft sprocket (INT) with the following procedure. NOTE: It prevents the knock pin from engaging with the incorrect pin hole after installing the camshaft (INT) and the camshaft sprocket (INT). Put the matching marks (A) on a line extending from the knock pin position of camshaft (INT) (1) front surface. ● Put the marks on the visible position with the camshaft sprocket installed. (The figure shows an example.) Put the matching marks on a line extending from the knock pin hole (B) position of camshaft sprocket (INT) (2). (The figure shows an example.) ● Put the marks on the visible position with it installed to the camshaft. F G H I J K PBIC3696E 5. Set the camshaft sprocket (INT) to between cylinder head and front cover. ● Set it with the knock pin hole (A) facing up. CAUTION: Make sure the stopper pin is inserted at the most advanced position beforehand. L M PBIC3697E EM-161 CAMSHAFT [HR] 6. Install camshaft. ● 1 : Camshaft (EXH) 2 : Camshaft (INT) A : Identification mark Distinction between camshaft (INT and EXH) is performed with the different shapes of rear end. PBIC3698E ● Install camshafts to the cylinder head so that knock pins (A) on front end are positioned as shown in the figure. 1 : Camshaft (EXH) 2 : Camshaft (INT) : Upper side NOTE: Though camshaft does not stop at the portion as shown in the figure, for the placement of cam nose, it is generally accepted camshaft is placed for the same direction of the figure. PBIC3699E 7. a. Install the camshaft sprocket (INT) to the camshaft (INT) with the following procedure. Refer to the matching mark (A) put according to step “4”. Securely align the knock pin and the pin hole, and then install them. PBIC3700E b. Lift up the front side of camshaft (INT) (1), and then temporarily tighten the bolt. 2 : Camshaft sprocket (INT) PBIC3689E 8. 9. Put a thick shop cloth (B) to the lower surface, and then set the tools to the bolt while lifting up the front side of camshaft (INT) (1). Tighten the mounting bolt. CAUTION: Hold the camshaft hexagonal part (A), and then secure the camshaft. PBIC3701E EM-162 CAMSHAFT [HR] 10. Return the camshaft (INT) to the cylinder head quietly. 11. Install timing chain (1) by aligning its matching mark (marked when timing chain is removed) (B) with matching mark (peripheral stamp line) (A) on camshaft sprocket (INT) (2). A EM C D PBIC3702E 12. Install camshaft brackets (No. 2 to 5) aligning the identification marks on upper surface as shown in the figure. A : EXH side B : INT side E F : Engine front ● Install so that identification mark can be correctly read when viewed from the INT side. G PBIC3703E H 13. Tighten mounting bolts of camshaft brackets in the following steps, in numerical order as shown in the figure. A : EXH side B : INT side I : Engine front a. J Tighten No. 9 to 11 in numerical order. : 2.0 N·m (0.2 kg-m, 1 ft-lb) b. K Tighten No. 1 to 8 in numerical order. PBIC3686E : 2.0 N·m (0.2 kg-m, 1 ft-lb) c. L Tighten all bolts in numerical order. : 5.9 N·m (0.6 kg-m, 4 ft-lb) d. M Tighten all bolts in numerical order. : 10.4 N·m (1.1 kg-m, 8 ft-lb) 14. Install the camshaft (EXH) to the camshaft sprocket (EXH) (2) while aligning the matching make (marked when timing chain is removed) (A) and the matching mark (stamp) (B) of camshaft sprocket (EXH). ● 1 : Timing chain 3 : Camshaft sprocket (INT) C : Matching mark (peripheral stamp line) If the positions of knock pin and pin groove are not aligned, move the camshaft (EXH) slightly to correct these positions. PBIC3674E EM-163 CAMSHAFT [HR] 15. Tighten the mounting bolt. 1 : Camshaft sprocket (EXH) CAUTION: Hold the camshaft hexagonal part (A), and then secure the camshaft. ● Make sure that the matching mark (marked when timing chain is removed) and each camshaft sprocket matching mark are in the correct location. ● PBIC3678E 16. Pull out the stopper pin (A), and then apply the tension to the timing chain by rotating the crankshaft pulley clockwise slightly. 1 : Plunger 2 : Chain tensioner B : Lever C : Lever hole D : Front cover has been omitted PBIC3772E 17. Install the plug (2) to the front cover (1). ● Apply liquid gasket to the threads, and tighten them. Use Genuine Liquid Gasket or equivalent. PBIC3675E 18. Return the camshaft sprocket (INT) in the most retarded position with the following procedure. a. Remove the stopper pin (A) from the camshaft sprocket (INT). B : Tape PBIC3685E EM-164 CAMSHAFT [HR] b. Turn the crankshaft pulley (1) slowly clockwise (A) and return the camshaft sprocket (INT) to the most retarded angle position. A EM C PBIC3704E D ● ● ● When first turning the crankshaft the camshaft sprocket (INT) will turn. Once it is turned more, and the vane (camshaft) also turns, then it has reached the most retarded angle position. B : Stopper pin hole C : Most advanced angle D : Lock pin engaged E F The most retarded angle position can be checked by seeing if the stopper pin groove (A) is shifted clockwise. After spinning the crankshaft slightly in the counterclockwise direction, you can make sure the lock pin has joined by seeing if the vane (camshaft) and the sprocket move together. G PBIC3705E 19. Install the camshaft position sensor (PHASE) to the rear end of cylinder head. ● Tighten bolts with it seated completely. 20. Check and adjust valve clearance. Refer to EM-166, "Valve Clearance" . 21. Install in the reverse order of removal. INSPECTION AFTER INSTALLATION Inspection for Leaks H I J The following are procedures for checking fluids leak, lubricates leak. ● Before starting engine, check oil/fluid levels including engine coolant and engine oil. If less than required quantity, fill to the specified level. Refer to MA-24, "RECOMMENDED FLUIDS AND LUBRICANTS" . ● Use procedure below to check for fuel leakage. – Turn ignition switch “ON” (with engine stopped). With fuel pressure applied to fuel piping, check for fuel leakage at connection points. – Start engine. With engine speed increased, check again for fuel leakage at connection points. ● Run engine to check for unusual noise and vibration. NOTE: If hydraulic pressure inside timing chain tensioner drops after removal/installation, slack in the guide may generate a pounding noise during and just after engine start. However, this is normal. Noise will stop after hydraulic pressure rises. ● Warm up engine thoroughly to make sure there is no leakage of fuel, or any oil/fluids including engine oil and engine coolant. ● Bleed air from lines and hoses of applicable lines, such as in cooling system. ● After cooling down engine, again check oil/fluid levels including engine oil and engine coolant. Refill to the specified level, if necessary. EM-165 K L M CAMSHAFT [HR] Summary of the inspection items: Item Before starting engine Engine running After engine stopped Engine coolant Level Leakage Level Engine oil Level Leakage Level Other oils and fluid* Level Leakage Level Leakage Leakage Leakage — Leakage — Fuel Exhaust gases * Transmission/transaxle fluid, power steering fluid, brake fluid, etc. Inspection of Camshaft Sprocket (INT) Oil Groove CAUTION: ● Perform this inspection only when DTC P0011 is detected in self-diagnostic results of CONSULT-II and it is directed according to inspection procedure of EC section. Refer to EC-830, "ON BOARD DIAGNOSTIC (OBD) SYSTEM" (with EURO-OBD) or EC-1264, "ON BOARD DIAGNOSTIC (OBD) SYSTEM" (without EURO-OBD). ● Check when engine is cold so as to prevent burns from the splashing engine oil. 1. Check engine oil level. Refer to LU-16, "ENGINE OIL" . 2. Perform the following procedure so as to prevent the engine from being unintentionally started while checking. a. Release the fuel pressure. Refer to EC-860, "FUEL PRESSURE RELEASE" (with EURO-OBD) or EC1281, "FUEL PRESSURE RELEASE" (Without EURO-OBD). b. Remove intake manifold. Refer to EM-120, "INTAKE MANIFOLD" . c. Disconnect ignition coil and injector harness connectors. 3. Remove intake valve timing control solenoid valve. Refer to EM-151, "CAMSHAFT" . 4. Crank engine, and then make sure that engine oil comes out from intake valve timing control solenoid valve hole (A). End crank after checking. 1 : Plug :Engine front 5. 6. 7. WARNING: Be careful not to touch rotating parts (drive belts, idler pulley, and crankshaft pulley, etc.). CAUTION: PBIC3706E ● Prevent splashing by using a shop cloth so as to prevent the worker from injury from engine oil and so as to prevent engine oil contamination. ● Prevent splashing by using a shop cloth so as to prevent engine oil from being splashed to engine and vehicle. Especially, be careful not to apply engine oil to rubber parts of drive belts, engine mounting insulator, etc. Wipe engine oil off immediately if it is splashed. Perform the following inspection if engine oil does not come out from intake valve timing control solenoid valve oil hole of the cylinder head. ● Remove oil filter, and then clean it. Refer to EM-157, "Oil Filter" . ● Clean oil groove between oil strainer and intake valve timing control solenoid valve. Refer to LU-15, "Lubrication Circuit" . Remove components between intake valve timing control solenoid valve and camshaft sprocket (INT), and then check each oil groove for clogging. ● Clean oil groove if necessary. Refer to LU-15, "Lubrication Circuit" . After inspection, install removed parts in the reverse order. Valve Clearance BBS002OW INSPECTION Perform inspection as follows after removal, installation or replacement of camshaft or valve-related parts, or if there is unusual engine conditions regarding valve clearance. EM-166 CAMSHAFT [HR] 1. 2. a. Remove rocker cover. Refer to EM-140, "ROCKER COVER" . Measure the valve clearance with the following procedure: Set No. 1 cylinder at TDC of its compression stroke. ● Rotate crankshaft pulley (2) clockwise and align TDC mark (without paint mark) (A) to timing indicator (1) on front cover. B A EM : White paint mark C D PBIC3673E ● ● At the same time, make sure that both intake and exhaust cam noses of No. 1 cylinder face outside as shown in the figure. If they do not face outside, rotate crankshaft pulley once more (360 degrees) and align as shown in the figure. E F G H KBIA0400J b. Use a feeler gauge, measure the clearance between valve lifter and camshaft. I J K SEM139D L Valve clearance: Unit: mm (in) Cold Hot * (reference data) Intake 0.26 - 0.34 (0.010 - 0.013) 0.304 - 0.416 (0.012 - 0.016) Exhaust 0.29 - 0.37 (0.011 - 0.014) 0.308 - 0.432 (0.012 - 0.017) M *:Approximately 80°C (176°F) ● By referring to the figure, measure the valve clearances at locations marked “×” as shown in the table below [locations indicated with black arrow ( ) in the figure] with a feeler gauge. A : No. 1 cylinder compression TDC : Engine front Measuring position Measurement position No. 1 CYL. EXH × INT × No. 2 CYL. No. 3 CYL. No. 4 CYL. × × PBIC3707E EM-167 CAMSHAFT [HR] c. Rotate crankshaft pulley (2) one revolution (360 degrees) and align TDC mark (without paint mark) (A) to timing indicator (1) on front cover. B : White paint mark PBIC3673E ● By referring to the figure, measure the valve clearance at locations marked “×” as shown in the table below [locations indicated with black arrow ( ) in the figure] with a feeler gauge. A : No. 4 cylinder compression TDC : Engine front Measuring position Measurement point 3. EXH INT No. 1 CYL. No. 2 CYL. No. 3 CYL. No. 4 CYL. × × × × PBIC3708E If out of standard, perform adjustment. Refer to EM-168, "ADJUSTMENT" . ADJUSTMENT ● 1. 2. 3. Perform adjustment depending on selected head thickness of valve lifter. Remove camshaft. Refer to EM-151, "REMOVAL" . Remove valve lifters at the locations that are out of the standard. Measure the center thickness of the removed valve lifters with a micrometer. KBIA0057E 4. Use the equation below to calculate valve lifter thickness for replacement. Valve lifter thickness calculation: t = t1 + (C1 – C2 ) t = Valve lifter thickness to be replaced = Removed valve lifter thickness t1 C1 = Measured valve clearance C2 = Standard valve clearance: Intake : 0.30 mm (0.012 in) Exhaust : 0.33 mm (0.013 in) EM-168 CAMSHAFT [HR] ● ● Thickness of new valve lifter can be identified by stamp mark on the reverse side (inside the cylinder). Stamp mark “300” indicates 3.00 mm (0.118 in) in thickness. A EM C KBIA0119E D NOTE: Available thickness of valve lifter: 26 sizes range 3.00 to 3.50 mm (0.118 to 0.137 in) in steps of 0.02 mm (0.0008 in) (when manufactured at factory). Refer to EM-217, "Available Valve Lifter" . 5. Install the selected valve lifter. 6. Install camshaft. Refer to EM-161, "INSTALLATION" . 7. Manually rotate crankshaft pulley a few rotations. 8. Make sure that valve clearances for cold engine are within specifications by referring to the specified values. Refer to EM-166, "INSPECTION" . 9. Install all removed parts in the reverse order of removal. Refer to EM-161, "INSTALLATION" . 10. Warm up the engine, and check for unusual noise and vibration. E F G H I J K L M EM-169 OIL SEAL [HR] OIL SEAL Removal and Installation of Valve Oil Seal PFP:12279 BBS002OX REMOVAL 1. 2. 3. 4. Remove camshafts. Refer to EM-151, "CAMSHAFT" . Remove valve lifters. Refer to EM-151, "CAMSHAFT" . Rotate crankshaft, and set piston whose valve oil seal is to be removed to TDC. This will prevent valve from dropping into cylinder. CAUTION: When rotating crankshaft, be careful to avoid scarring front cover with timing chain. Remove valve collet. ● Compress valve spring with the valve spring compressor, the attachment and the adapter (SST: KV10116200) (A). Remove valve collet with a magnet hand (B). CAUTION: When working, be careful not to damage valve lifter holes. PBIC3727E 5. 6. Remove valve spring retainer, valve spring and valve spring seat. Remove valve oil seal with the valve oil seal puller (SST: KV10107902) (A). PBIC3728E INSTALLATION 1. 2. Apply new engine oil to valve oil seal joint surface and seal lip. Press in valve oil seal to the height “H” shown in the figure with the valve oil seal drift (SST: KV10115600) (A). Height “H” : 13.2 - 13.8 mm (0.519 - 0.543 in) PBIC3211J 3. Install in the reverse order of removal after this step. EM-170 OIL SEAL [HR] Removal and Installation of Front Oil Seal BBS002OY A REMOVAL 1. 2. Remove the following parts. ● Front fender protector (RH); Refer to EI-14, "FENDER PROTECTOR" . ● Drive belt; Refer to EM-114, "DRIVE BELTS" . ● Crankshaft pulley; Refer to EM-142, "TIMING CHAIN" . Remove front oil seal with a suitable tool. CAUTION: Be careful not to damage front cover and crankshaft. EM C D INSTALLATION 1. 2. Apply new engine oil to new front oil seal joint surface and seal lip. Install front oil seal so that each seal lip is oriented as shown in the figure. A : Dust seal lip B : Oil seal lip E F : Engine outside : Engine inside G PBIC3485J ● Press-fit front oil seal (2) using a drift with outer diameter 50 mm (1.97 in) and inner diameter 44 mm(1.73 in) (commercial service tool) (A) so as to be the dimension specified in the figure. 1 I : Front cover J : Engine front CAUTION: ● Be careful not to damage front cover and crankshaft. ● Press-fit oil seal straight to avoid causing burrs or tilting. 3. H Install in the reverse order of removal after this step. K PBIC3729E L M EM-171 OIL SEAL [HR] Removal and Installation of Rear Oil Seal BBS002OZ REMOVAL 1. 2. 3. 4. Remove transaxle assembly. Refer to MT-7, "REMOVAL AND INSTALLATION" for M/T models, AT-356, "TRANSAXLE ASSEMBLY" for A/T models. Remove clutch cover and clutch disk. Refer to CL-11, "CLUTCH DISC, CLUTCH COVER AND FLYWHEEL" . Remove drive plate (A/T models) or flywheel (M/T models). Refer to EM-189, "CYLINDER BLOCK" . Remove rear oil seal with a suitable tool. CAUTION: Be careful not to damage crankshaft and cylinder block. INSTALLATION 1. 2. Apply the liquid gasket lightly to entire outside area of new rear oil seal. Use Genuine Liquid Gasket or equivalent. Install rear oil seal so that each seal lip is oriented as shown in the figure. A : Dust seal lip B : Oil seal lip : Engine outside : Engine inside PBIC3485J ● Press-fit rear oil seal with a drift outer diameter 113 mm (4.45 in) and inner diameter 90 mm (3.54 in) (commercial service tool) (A). CAUTION: ● Be careful not to damage crankshaft and cylinder block. ● Press-fit oil seal straight to avoid causing burrs or tilting. ● Do not touch grease applied onto oil seal lip. PBIC3660E ● Press in rear oil seal (1) to the position as shown in the figure. A : Rear end surface of cylinder block PBIC3761E 3. 4. After press-fitting rear oil seal, completely wipe off any liquid gasket protruding to rear end surface side. Install in the reverse order of removal after this step. EM-172 CYLINDER HEAD [HR] CYLINDER HEAD On-Vehicle Service PFP:11041 A BBS002P0 CHECKING COMPRESSION PRESSURE 1. 2. 3. Warm up engine thoroughly. Then, stop it. EM Release fuel pressure. Refer to EC-860, "FUEL PRESSURE RELEASE" (with EURO-OBD) or EC-1281, "FUEL PRESSURE RELEASE" (without EURO-OBD). Disconnect fuel pump fuse (1) to avoid fuel injection during meaC surement. : Vehicle front D E PBIA9861J 4. 5. 6. 7. Remove engine cover. Refer to EM-120, "INTAKE MANIFOLD" . Remove ignition coil and spark plug from each cylinder. Refer to EM-132, "IGNITION COIL" and EM-133, "SPARK PLUG (PLATINUM-TIPPED TYPE)" . Connect an engine tachometer (not required in use of CONSULT-II). Install a compression tester (B) with an adapter (commercial service tool) (A) onto spark plug hole. F G H I J PBIC3730E ● Use the adapter whose picking up end inserted to spark plug hole is smaller than 20 mm (0.79 in) in diameter. Otherwise, it may be caught by cylinder head during removal. K L M SBIA0533E 8. With accelerator pedal fully depressed, turn ignition switch to “START” for cranking. When the gauge pointer stabilizes, read the compression pressure and the engine rpm. Perform these steps to check each cylinder. Compression pressure: Unit: kPa (bar, kg/cm2 , psi) /rpm Standard Minimum 1,510 (15.1, 15.4, 219) / 200 1,265 (12.65, 12.9, 183) / 200 Differential limit between cylinders CAUTION: Always use fully a changed battery to obtain the specified engine speed. EM-173 981 (9.81, 10.0, 142) / 200 CYLINDER HEAD [HR] If the engine speed is out of the specified range, check battery liquid for proper gravity. Check engine speed again with normal battery gravity. ● If compression pressure is below minimum value, check valve clearances and parts associated with combustion chamber (Valve, valve seat, piston, piston ring, cylinder bore, cylinder head, cylinder head gasket). After the checking, measure the compression pressure again. ● If some cylinder has low compression pressure, pour small amount of engine oil into the spark plug hole of the cylinder to re-check it for compression. – If the added engine oil improves the compression, piston rings may be worn out or damaged. Check piston rings and replace if necessary. – If the compression pressure remains at low level despite the addition of engine oil, valves may be malfunctioning. Check valves for damage. Replace valve or valve seat accordingly. ● If two adjacent cylinders have respectively low compression pressure and their compression remains low even after the addition of engine oil, cylinder head gasket is leaking. In such a case, replace cylinder head gasket. 9. After inspection is completed, install removed parts. 10. Start the engine, and confirm that the engine runs smoothly. 11. Perform trouble diagnosis. If DTC appears, erase it. Refer to EC-863, "TROUBLE DIAGNOSIS" (with EURO-models) or EC-1284, "TROUBLE DIAGNOSIS" (without EURO-models). ● Components BBS002P1 PBIC3731E 1. Cylinder head assembly 4. Cylinder head gasket A. Refer to EM-176 2. Cylinder head bolt 3. Washer Refer to GI-11 for symbol marks in the figure. Removal and Installation BBS002P2 REMOVAL 1. 2. 3. Release fuel pressure. Refer to EC-860, "FUEL PRESSURE RELEASE" (with EURO-OBD) or EC-1281, "FUEL PRESSURE RELEASE" (without EURO-OBD). Drain engine coolant and engine oil. Refer to CO-28, "Changing Engine coolant" and LU-17, "Changing Engine Oil" . CAUTION: Perform this step when the engine is cold. Remove the following components and related parts. ● Exhaust manifold; Refer to EM-124, "EXHAUST MANIFOLD" . ● Intake manifold; Refer to EM-120, "INTAKE MANIFOLD" . EM-174 CYLINDER HEAD [HR] Fuel tube and fuel injector; Refer to EM-135, "FUEL INJECTOR AND FUEL TUBE" . Water outlet; Refer to CO-40, "WATER OUTLET" . ● Front fender protector (RH); Refer to EI-14, "FENDER PROTECTOR" . ● Drive belt; Refer to EM-114, "DRIVE BELTS" . ● Front cover; Refer to EM-142, "TIMING CHAIN" . ● Camshaft; Refer to EM-151, "CAMSHAFT" . Remove cylinder head loosening bolts in reverse order as shown in the figure with cylinder head wrench (commercial service tool). ● A ● 4. A : EXH side B : INT side EM C D : Engine front E PBIC3732E 5. Remove cylinder head gasket. INSPECTION AFTER REMOVAL Cylinder Head Bolts Outer Diameter ● G Cylinder head bolts are tightened by plastic zone tightening method. Whenever the size difference between “d1” and “d2” exceeds the limit, replace them with a new one. H Limit (“d1” – “d2”): 0.15 mm (0.0059 in) ● F I If reduction of outer diameter appears in a position other than “d2”, use it as “d2” point. J PBIC3717E K Cylinder Head Distortion NOTE: When performing this inspection, cylinder block distortion should be also checking. Refer to EM-209, "CYLINDER BLOCK DISTORTION" . 1. Wipe off engine oil and remove water scale (like deposit), gasket, sealant, carbon, etc. with a scraper. CAUTION: Use utmost care not to allow gasket debris to enter passages for engine oil or engine coolant. 2. At each of several locations on bottom surface of cylinder head, measure the distortion in six directions. Limit ● A : Straightedge B : Feeler gauge : 0.1 mm (0.004 in) If it exceeds the limit, replace cylinder head. PBIC3207J EM-175 L M CYLINDER HEAD [HR] INSTALLATION 1. 2. Install new cylinder head gasket. Tighten cylinder head bolts in numerical order as shown in the figure with the following procedure to install cylinder head. A : EXH side B : INT side : Engine front a. b. CAUTION: If cylinder head bolts are re-used, check their outer diameters before installation. Refer to EM-175, "Cylinder Head Bolts Outer Diameter" . Apply new engine oil to threads and seating surfaces of mounting bolts. Tighten all bolts. PBIC3732E : 66.7 N·m (6.8 kg-m, 49 ft-lb) c. Completely loosen. : 0 N·m (0 kg-m, 0 ft-lb) d. CAUTION: In this step, loosen bolts in reverse order of that indicated in the figure. Tighten all bolts. : 40.0 N·m (4.1 kg-m, 30 ft-lb) e. f. Turn all bolts 75 degrees clockwise (angle tightening). CAUTION: Check and confirm the tightening angle by using the angle wrench (SST: KV10112100) (A) or protractor. Avoid judgment by visual inspection without the tool. Turn all bolts 75 degrees clockwise again (angle tightening). PBIC3733E 3. Install in the reverse order of removal after this step. INSPECTION AFTER INSTALLATION Inspection for Leaks The following are procedures for checking fluids leak, lubricates leak and exhaust gases leak. ● Before starting engine, check oil/fluid levels including engine coolant and engine oil. If less than required quantity, fill to the specified level. Refer to MA-24, "RECOMMENDED FLUIDS AND LUBRICANTS" . ● Use procedure below to check for fuel leakage. – Turn ignition switch ON (with engine stopped). With fuel pressure applied to fuel piping, check for fuel leakage at connection points. – Start engine. With engine speed increased, check again for fuel leakage at connection points. ● Run engine to check for unusual noise and vibration. NOTE: If hydraulic pressure inside timing chain tensioner drops after removal/installation, slack in the guide may generate a pounding noise during and just after engine start. However, this is normal. Noise will stop after hydraulic pressure rises. ● Warm up engine thoroughly to make sure there is no leakage of fuel, exhaust gases, or any oil/fluids including engine oil and engine coolant. EM-176 CYLINDER HEAD [HR] Bleed air from lines and hoses of applicable lines, such as in cooling system. After cooling down engine, again check oil/fluid levels including engine oil and engine coolant. Refill to the specified level, if necessary. ● ● Summary of the inspection items: Item EM Before starting engine Engine running After engine stopped Engine coolant Level Leakage Level Engine oil Level Leakage Level Other oils and fluid* Level Leakage Level Leakage Leakage Leakage — Leakage — Fuel Exhaust gases A C D * Transmission/transaxle fluid, power steering fluid, brake fluid, etc. Components BBS002P3 E F G H I J K L M PBIC3734E 1. Spark plug 4. Valve spring 5. Valve spring seat 6. Valve oil seal 7. Valve guide (EXH) 8. Valve guide (INT) 9. Cylinder head 10. Valve seat (EXH) 2. Valve collet 11. Valve (EXH) 13. Valve (INT) A. Refer to EM-180 B. Refer to EM-181 Refer to GI-11, "Components" for symbol marks in the figure. EM-177 3. Valve spring retainer 12. Valve seat (INT) CYLINDER HEAD [HR] Disassembly and Assembly BBS002P4 DISASSEMBLY 1. 2. 3. Remove spark plug with a spark plug wrench (commercial service tool). Remove valve lifter. ● Identify installation positions, and store them without mixing them up. Remove valve collet. ● Compress valve spring with the valve spring compressor, the attachment and the adapter (SST: KV10116200) (A). Remove valve collet with a magnet hand (B). CAUTION: When working, be careful not to damage valve lifter holes. PBIC3727E 4. 5. 6. Remove valve spring retainer and valve spring. Push valve stem to combustion chamber side, and remove valve. ● Identify installation positions, and store them without mixing them up. Remove valve oil seal with the valve oil seal puller (SST: KV10107902) (A). PBIC3728E 7. 8. 9. Remove valve spring seat. When valve seat must be replaced, refer to EM-181, "VALVE SEAT REPLACEMENT" to removal. When valve guide must be replaced, refer to EM-180, "VALVE GUIDE REPLACEMENT" to removal. ASSEMBLY 1. 2. 3. Install valve guide if removed. Refer to EM-180, "VALVE GUIDE REPLACEMENT" . Install valve seat if removed. Refer to EM-181, "VALVE SEAT REPLACEMENT" . Install valve oil seal. ● Install with the valve oil seal drift (SST: KV10115600) (A) to match dimension in the figure. Height “H” : 13.2 - 13.8 mm (0.519 - 0.543 in) PBIC3211J 4. 5. 6. Install valve spring seat. Install valve. ● Install larger diameter to intake side. Install valve spring. EM-178 CYLINDER HEAD [HR] 7. 8. NOTE: It can be installed in either direction. Install valve spring retainer. Install valve collet. ● Compress valve spring with the valve spring compressor, the attachment and the adapter (SST: KV10116200) (A). Install valve collet with a magnet hand (B). CAUTION: When working, be careful not to damage valve lifter holes. ● Tap valve stem edge lightly with a plastic hammer after installation to check its installed condition. A EM C D PBIC3727E 9. Install valve lifter. 10. Install spark plug with a spark plug wrench (commercial service tool). Inspection After Disassembly F BBS002P5 VALVE DIMENSIONS ● ● E G Check dimensions of each valve. For dimensions, refer to EM-216, "Valve Dimensions" . If dimensions are out of the standard, replace valve. VALVE GUIDE CLEARANCE Valve Stem Diameter H Measure the diameter of valve stem with a micrometer. Standard Intake Exhaust I : 4.965 - 4.980 mm (0.1954 - 0.1960 in) : 4.955 - 4.970 mm (0.1950 - 0.1956 in) J K SEM938C L Valve Guide Inner Diameter Measure the inner diameter of valve guide with a bore gauge. Standard Intake and Exhaust : 5.000 - 5.018 mm (0.1968 - 0.1975 in) Valve Guide Clearance (Valve guide clearance) = (Valve guide inner diameter) – (Valve stem diameter). Valve guide clearance: Standard Intake : 0.020 - 0.053 mm (0.0008 - 0.0021 in) Exhaust : 0.030 - 0.063 mm (0.0012 - 0.0025 in) Limit Intake : 0.1 mm (0.004 in) Exhaust : 0.1 mm (0.004 in) ● If it exceeds the limit, replace valve guide and/or valve. When valve guide must be replaced, refer to EM180, "VALVE GUIDE REPLACEMENT" . EM-179 M CYLINDER HEAD [HR] VALVE GUIDE REPLACEMENT When valve guide is removed, replace with oversized [0.2 mm (0.008 in)] valve guide. 1. To remove valve guide, heat cylinder head to 110 to 130°C (230 to 266°F) by soaking in heated oil. SEM008A 2. Drive out valve guide with a press [under a 20 kN (2 ton, 2.2 US ton, 2.0 lmp ton) force] or hammer and valve guide drift (commercial service tool). CAUTION: Cylinder head contains heat, when working, wear protective equipment to avoid getting burned. SEM931C 3. Ream cylinder head valve guide hole with a valve guide reamer (commercial service tool). Valve guide hole diameter (for service parts): Intake and exhaust : 9.175 - 9.196 mm (0.3612 - 0.3620 in) SEM932C 4. Heat cylinder head to 110 to 130°C (230 to 266°F) by soaking in heated oil. SEM008A EM-180 CYLINDER HEAD [HR] 5. Using a valve guide drift (commercial service tool), press valve guide (1) from camshaft side to dimensions as shown in the figure. Projection “H”: A : 11.4 - 11.8 mm (0.448 - 0.464 in) EM CAUTION: Cylinder head (2) contains heat, when working, wear protective equipment to avoid getting burned. C PBIC3217J D 6. Apply reamer finish to valve guide with a valve guide reamer (commercial service tool). E Standard 5.000 - 5.018 mm (0.1968 - 0.1975 in) F G SEM932C VALVE SEAT CONTACT ● ● ● ● After confirming that the dimensions of valve guides and valves are within specifications, perform this procedure. Apply prussian blue (or white lead) onto contacting surface of valve seat to check the condition of the valve contact on the surface. Check if the contact area band is continuous all around the circumference. If not, grind to adjust valve fitting and check again. If the contacting surface still has NG conditions even after the re-check, replace valve seat. Refer to EM-181, "VALVE SEAT REPLACEMENT" . H I J K L SBIA0322E VALVE SEAT REPLACEMENT M When valve seat is removed, replace with oversized [0.5 mm (0.020 in)] valve seat. 1. Bore out old seat until it collapses. Boring should not continue beyond the bottom face of the seat recess in cylinder head. Set the machine depth stop to ensure this. Refer to EM-219, "Valve Seat" . CAUTION: Prevent to scratch cylinder head by excessive boring. 2. Ream cylinder head recess diameter for service valve seat. Oversize [0.5 mm (0.020 in)] Intake : 31.900 - 31.916 mm (1.2559 - 1.2565 in) Exhaust : 26.400 - 26.416 mm (1.0393 - 1.0399 in) ● Be sure to ream in circles concentric to the valve guide center. This will enable valve seat to fit correctly. SEM795A EM-181 CYLINDER HEAD [HR] 3. Heat cylinder head to 110 to 130°C (230 to 266°F) by soaking in heated oil. SEM008A 4. Provide valve seats cooled well with a dry ice. Press-fit valve seats into cylinder head. CAUTION: ● Avoid directly to touching cold valve seats. ● Cylinder head contains heat, when working, wear protective equipment to avoid getting burned. 5. Using a valve seat cutter set (commercial service tool) or a valve seat grinder, finish valve seat to the specified dimensions. For dimensions, refer to EM-219, "Valve Seat" . CAUTION: When using a valve seat cutter, firmly grip the cutter handle with both hands. Then, press on the contacting surface all around the circumference to cut in a single drive. Improper pressure on with the cutter or cutting many different times may result in stage valve seat. SEM934C 6. 7. Using compound, grind to adjust valve fitting. Check again for normal contact. Refer to EM-181, "VALVE SEAT CONTACT" . VALVE SPRING SQUARENESS ● Set a try square along the side of valve spring and rotate valve spring. Measure the maximum clearance between the top of valve spring and try square. Limit ● : 1.8 mm (0.070 in) If it exceeds the limit, replace valve spring. PBIC0080E VALVE SPRING DIMENSIONS AND VALVE SPRING PRESSURE LOAD ● Check valve spring pressure with valve spring seat installed at the specified spring height. SEM113 EM-182 CYLINDER HEAD [HR] Standard: Free height 42.26 mm (1.6637 in) Installation height 32.40 mm (1.2755 in) Installation load 136 - 154 N (13.9 - 15.7 kg, 31 - 35 lb) Height during valve open EM 23.96 mm (0.9433 in) Load with valve open ● A 262 - 296 N (26.7 - 30.2 kg, 59 - 67 lb) If the installation load or load with valve open is out of the standard, replace valve spring. C D E F G H I J K L M EM-183 ENGINE ASSEMBLY [HR] ENGINE ASSEMBLY Components PFP:10001 BBS002P6 MBIB1379E 1. Engine mounting insulator (LH) 2. Engine mounting bracket (LH) 3. Engine mounting insulator (RH) 4. Engine mounting stay (RH) 5. Engine mounting bracket (RH) 6. Rear engine mounting bracket 7. Rear torque rod 8. Washer 9. Engine mountin bracket (LH) A. Front mark Refer to GI-11, "Components" for symbol marks in the figure. Removal and Installation BBS002P7 WARNING: ● Situate the vehicle on a flat and solid surface. ● Place chocks at front and back of rear wheels. ● Attach proper slingers and bolts described in PARTS CATALOG if engine slingers are not equipped. CAUTION: ● Always be careful to work safely, avoid forceful or uninstructed operations. ● Do not start working until exhaust system and coolant are cool enough. EM-184 ENGINE ASSEMBLY [HR] If items or work required are not covered by the engine section, refer to the applicable sections. A Always use the support point specified for lifting. ● Use either 2-pole lift type or separate type lift as best you can. If board-on type is used for unavoidable reasons, support at the rear axle jacking point with a transmission jack or similar tool before starting work, in preparation for the backward shift of center of gravity. EM ● For supporting points for lifting and jacking point at rear axle, refer to GI-40, "Garage Jack, Safety Stand and 2-Pole Lift" . C REMOVAL ● ● Outline Remove the engine and the transaxle assembly from the vehicle downward. Separate the engine and the transaxle. D Preparation 1. 2. 3. 4. 5. When engine can be hoisted, remove hood assembly. Refer to BL-8, "Removal and Installation" . When engine can be hoisted, remove cowl top cover and cowl top extension assembly. Refer to EI-12, "COWL TOP" . Release fuel pressure. Refer to EC-860, "FUEL PRESSURE RELEASE" (with EURO-OBD) or EC-1281, "FUEL PRESSURE RELEASE" (without EURO-OBD). Drain engine coolant from radiator. Refer to CO-28, "Changing Engine coolant" . CAUTION: Perform this step when the engine is cold. Remove the following parts. ● Engine undercover ● Remove headlamp. Refer to LT-32, "Removal and Installation" or LT-51, "Removal and Installation" . ● Remove cowl top. Refer to EI-12, "COWL TOP" ● Front fender protector (RH and LH); Refer to EI-14, "FENDER PROTECTOR" . ● Front road wheels and tires; Refer toWT-5, "ROAD WHEEL AND TYRE ASSEMBLY" . ● Battery and battery tray; Refer to SC-5, "BATTERY" . ● Drive belt; Refer to EM-114, "DRIVE BELTS" . ● Air duct and air cleaner case assembly; Refer to EM-118, "AIR CLEANER AND AIR DUCT" . ● Radiator hose (upper and lower) A/T fluide cooler and cooling fan assembly; Refer to CO-31, "RADIATOR" . ● Exhaust front tube; Refer to EX-3, "EXHAUST SYSTEM" . 2. 3. 4. 5. Disconnect all connections of engine harness around the engine mounting insulator (LH), and then temporarily secure the engine harness into the engine side. CAUTION: Protect connectors using a resin bag to protect against foreign materials during the operation. Disconnect fuel feed hose at engine side. Refer to EM-135, "FUEL INJECTOR AND FUEL TUBE" . Disconnect heater hoses, and install plugs them to prevent engine coolant from draining. Refer to CO-40, "WATER OUTLET" . Disconnect control linkage from transaxle. Refer to MT-12, "CONTROL LINKAGE" . Remove ground cable at transaxle side. Engine Room RH 1. 2. 3. F G H I J K L Engine Room LH 1. E Remove ground cable between front cover and vehicle. Alternator and alternator bracket; Refer to SC-40, "Removal and Installation (HR Engine Models)" . Remove A/C compressor (with A/C models) with piping connected from the engine. Temporarily secure it on the vehicle side with a rope to avoid putting load on it. Refer to ATC-140, "Removal and Installation of Compressor" (with auto A/C models) or MTC-86, "Removal and Installation of Compressor" (with manual A/C models). EM-185 M ENGINE ASSEMBLY [HR] Vehicle Underbody 1. 2. 3. 4. Remove front wheel sensor (LH and RH) for ABS from steering knuckle. Refer to BRC-86, "WHEEL SENSORS" (with ESP models) or BRC-36, "WHEEL SENSORS" (without ESP models). Remove brake caliper assembly with piping connected from steering knuckle. Temporarily secure it on the vehicle side with a rope to avoid load on it. Refer to BR-21, "FRONT DISC BRAKE" . Remove drive shafts (LH and RH) from steering knuckle. Refer to FAX-10, "FRONT DRIVE SHAFT" . Remove rear torque rod (1). MBIB1377E PBIC3737E 5. Preparation for the separation work of transaxle is as follows: ● Remove transaxle joint bolts which pierce at oil pan (upper) lower rear side. Refer to MT-7, "REMOVAL AND INSTALLATION" or AT-356, "TRANSAXLE ASSEMBLY" . Removal 1. 2. When engine can be hoisted, remove the intake manifold to prevent the hanging chain from interfering. Refer to EM-120, "INTAKE MANIFOLD" . When engine can be hoisted, install engine slinger to cylinder head front left side (A) and rear right side (B) and support the engine position with a hoist. : Engine front Slinger bolts : 25.5 N·m (2.6 kg-m, 19 ft-lb) PBIC3738E 3. Lift with a hoist and secure the engine in appropriate position. EM-186 ENGINE ASSEMBLY [HR] 4. Use a manual lift table caddy (commercial service tool) (A) or equivalently rigid tool such as a transmission jack. Securely support bottom of the engine and the transaxle, and simultaneously adjust hoist tension. CAUTION: Put a piece of wood or something similar as the supporting surface, secure a completely stable condition. A EM C PBIC1454E D 5. 6. Remove engine mounting stay (RH) (1), engine mounting insulator (RH) (2) and engine mounting bracket (RH) (3). 4 : Engine mounting insulator (LH) A : Engine front side B : Transaxle side E F Remove engine mounting through bolt-securing nut (C). G MBIB1378E 7. Remove the engine and the transaxle assembly from the vehicle downward by carefully operating supporting tools. CAUTION: ● During the operation, make sure that no part interferes with the vehicle side. ● Before and during this lifting, always check if any harnesses are left connected. ● During the removal operation, always be careful to prevent the vehicle from falling off the lift due to changes in the center of gravity. ● If necessary, support the vehicle by setting jack or suitable tool at the rear. H I J Separation CAUTION: During operation, securely support the engine by placing a piece of wood under the engine oil pan and transaxle oil pan. Securely support the engine slingers with a hoist. 1. When the engine hoisting is not performed simultaneously, install engine slinger to cylinder head front left side and rear right side. Refer to EM-185, "REMOVAL" . 2. Remove starter motor. Refer to SC-51, "Removal and Installation (HR Engine Models)" . 3. Lift with a hoist and position above engine. 4. Separate the engine and the transaxle. Refer to MT-7, "REMOVAL AND INSTALLATION" or AT-356, "TRANSAXLE ASSEMBLY" . INSTALLATION Note the following, and install in the reverse order of removal. ● Do not allow engine oil to get on engine mounting insulator. Be careful not to damage engine mounting insulator. ● When installation directions are specified, install parts according to the direction marks on them referring to the figure of components. Refer to EM-184, "Components" . ● Make sure that each mounting insulator is seated properly, and tighten mounting nuts and bolts. EM-187 K L M ENGINE ASSEMBLY [HR] ● Tighten engine mounting insulator (RH) bolts in the numerical order shown in the figure. : Vehicle front MBIB1380E INSPECTION AFTER INSTALLATION Inspection for Leaks The following are procedures for checking fluids leak, lubricates leak and exhaust gases leak. ● Before starting engine, check oil/fluid levels including engine coolant and engine oil. If less than required quantity, fill to the specified level. Refer to MA-24, "RECOMMENDED FLUIDS AND LUBRICANTS" . ● Use procedure below to check for fuel leakage. – Turn ignition switch ON (with engine stopped). With fuel pressure applied to fuel piping, check for fuel leakage at connection points. – Start engine. With engine speed increased, check again for fuel leakage at connection points. ● Run engine to check for unusual noise and vibration. ● Warm up engine thoroughly to make sure there is no leakage of fuel, exhaust gases, or any oil/fluids including engine oil and engine coolant. ● Bleed air from lines and hoses of applicable lines, such as in cooling system. ● After cooling down engine, again check oil/fluid levels including engine oil and engine coolant. Refill to the specified level, if necessary. Summary of the inspection items: Before starting engine Engine running After engine stopped Engine coolant Item Level Leakage Level Engine oil Level Leakage Level Other oils and fluid* Level Leakage Level Leakage Leakage Leakage — Leakage — Fuel Exhaust gases * Transmission/transaxle fluid, power steering fluid, brake fluid, etc. EM-188 CYLINDER BLOCK [HR] CYLINDER BLOCK Components PFP:11010 A BBS002P8 EM C D E F G H I J K L M PBIC3770E EM-189 CYLINDER BLOCK [HR] 1. Crank shaft position sensor (POS) cover 2. Crankshaft position sensor (POS) 3. O-ring 4. Water drain plug 5. Cylinder block 6. Oil level gauge 7. Oil level gauge guide 8. O-ring 9. Knock sensor 10. Oil pressure switch 11. Top ring 12. Second ring 13. Oil ring 14. Piston pin 15. Piston 16. Connecting rod 17. Connecting rod bearing (upper) 18. Main bearing (upper) 19. Thrust bearing 20. Crankshaft key 21. Connecting rod bolt 22. Connecting rod cap 23. Connecting rod bearing (lower) 24. Main bearing (lower) 25. Crankshaft 26. Pilot converter (A/T models) 27. Signal plate 28. Rear oil seal 29. Drive plate (A/T models) 30. Reinforcement plate (A/T models) 31. Flywheel (M/T models) 32. Main bearing cap 33. Main bearing cap bolt A. B. Refer to EM-193 Refer to EM-193 Refer to GI-11 for symbol marks in the figure. Disassembly and Assembly BBS002P9 DISASSEMBLY NOTE: Explained here is how to disassemble with an engine stand supporting mating surface of transaxle. When using different type of engine stand, note with difference in steps and etc. 1. Remove the engine and the transaxle assembly from the vehicle, and separate the transaxle from the engine. Refer to EM-184, "ENGINE ASSEMBLY" . 2. Remove clutch cover and clutch disc. Refer to CL-11, "CLUTCH DISC, CLUTCH COVER AND FLYWHEEL" . 3. Remove flywheel (M/T models) or drive plate (A/T models). ● Secure flywheel or drive plate with a stopper plate (SST: KV11105210) (A), and remove mounting bolts. ● Using TORX socket (size E20), loosen mounting bolts. CAUTION: Be careful not to damage or scratch drive plate (A/T models) and contact surface for clutch disc of flywheel. MBIB1382E 4. Lift the engine with a hoist to install it onto widely use engine stand. CAUTION: ● Use the engine stand that has a load capacity [approximately 150 kg (331 lb) or more] large enough for supporting the engine weight. ● If the load capacity of stand is not adequate, remove the following parts beforehand to reduce the potential risk of overturning stand. – Intake manifolds; Refer to EM-120, "INTAKE MANIFOLD" . – Exhaust manifold; Refer to EM-124, "EXHAUST MANIFOLD" . – Rocker cover; Refer to EM-140, "ROCKER COVER" . EM-190 CYLINDER BLOCK [HR] NOTE: The figure shows an example of widely use engine stand that can support mating surface of transaxle with flywheel or drive plate removed. CAUTION: Before removing the hanging chains, make sure the engine stand is stable and there is no risk of overturning. A EM C PBIC0085E 5. 6. Drain engine oil. Refer to LU-16, "ENGINE OIL" . Drain engine coolant by removing water drain plug (1) from inside of the engine. D E : Engine front F G PBIC3742E Remove cylinder head. Refer to EM-174, "Removal and Installation" . Remove oil pan (upper and lower). Refer to EM-127, "OIL PAN AND OIL STRAINER" . Remove knock sensor. CAUTION: Carefully handle knock sensor avoiding shocks. 10. Remove cover, and then crankshaft position sensor (POS). 7. 8. 9. H I J : Engine front 1. Crank shaft position sensor (POS) 2. O ring 3. Cover A. Cylinder block LHD side K L CAUTION: ● Avoid impacts such as a dropping. ● Do not disassemble. ● Keep it away from metal particles. ● Do not place the sensor in a location where it is exposed to magnetism. M MBIB1383E 11. Remove pilot converter (1) using the pilot bushing puller (SST: ST16610001) (A) or suitable tool. (A/T models) NOTE: M/T models have no pilot bushing. PBIC3743E 12. Remove piston and connecting rod assembly with the following procedure: EM-191 CYLINDER BLOCK [HR] Before removing piston and connecting rod assembly, check the connecting rod side clearance. Refer to EM-206, "CONNECTING ROD SIDE CLEARANCE" . Position crankshaft pin corresponding to connecting rod to be removed onto the bottom dead center. Remove connecting rod cap. Using a hammer handle or similar tool, push piston and connecting rod assembly out to the cylinder head side. CAUTION: ● Be careful not to damage matching surface with connecting rod cap. ● Be careful not to damage the cylinder wall and crankshaft pin, resulting from an interference of the connecting rod big end. ● a. b. c. KBIA3365J 13. Remove connecting rod bearings. CAUTION: Identify installation positions, and store them without mixing them up. 14. Remove piston rings form piston. ● Before removing piston rings, check the piston ring side clearance. Refer to EM-207, "PISTON RING SIDE CLEARANCE" . ● Use a piston ring expander (commercial service tool). CAUTION: ● When removing piston rings, be careful not to damage the piston. ● Be careful not to damage piston rings by expanding them excessively. PBIC0087E 15. Remove piston from connecting rod. ● Use a piston pin press stand (SST) and a press to remove the piston pin. ● For the details of SST, refer to the following. Press stand Drift Center cap : ST13030020 : KV10109730 : KV10110310 CAUTION: Be careful not to damage the piston and connecting rod. NOTE: The joint between the connecting rod and the piston pin is a press fit. 16. Remove the main bearing cap in the following procedure. ● Measure crankshaft end play before loosening main bearing cap bolts. Refer to EM-206, "CRANKSHAFT END PLAY" . EM-192 KBIA3470J CYLINDER BLOCK [HR] a. Loosen and remove bolts in several steps in reverse of the numerical order shown in the figure. A : Engine front ● TORX socket (size: E14) can be used. EM C PBIC3744E D b. Remove the main bearing cap from the cylinder block while tapping lightly with a plastic hammer. 17. Remove crankshaft (2). CAUTION: ● Be careful not damage or deform signal plate (1) mounted on crankshaft. ● When setting crankshaft on a flat floor surface, use a block of wood to avoid interference between signal plate and the floor surface. ● Do not remove signal plate unless it is necessary to do so. NOTE: PBIC3745E When removing or installing signal plate, use TORX socket (size T40). 18. Pull rear oil seal out from rear end of crankshaft. 19. Remove main bearing (upper and lower) and thrust bearings from cylinder block and main bearing cap. CAUTION: Identify installation positions, and store them without mixing them up. 2. F G H I J ASSEMBLY 1. E Fully air-blow engine coolant and engine oil passages in cylinder block, cylinder bore and crankcase to remove any foreign material. CAUTION: Use a goggles to protect your eye. Install water drain plug (1) to cylinder block as shown in the figure. K L : Engine front M Use Genuine Liquid Gasket or equivalent. : 9.8 N·m (1.0 kg-m, 87 in-lb) PBIC3742E 3. a. Install main bearings and thrust bearings with the following procedure: Remove dust, dirt, and engine oil on the bearing mating surfaces of cylinder block. EM-193 CYLINDER BLOCK [HR] b. Install thrust bearings to the both sides of the No. 3 journal housing (B) on cylinder block. : Engine front ● Install thrust bearings with the oil groove (A) facing crankshaft arm (outside). PBIC3258J c. Install the main bearings (1) paying attention to the direction. ● Install the one with oil holes (A) onto cylinder block and the one without oil holes onto main bearing cap. ● Before installing main bearings, apply new engine oil to the bearing surface (inside). Do not apply engine oil to the back surface, but thoroughly clean it. ● Ensure the oil holes on cylinder block and those on the corresponding bearing are aligned. PBIC3746E ● Install the main bearing in the position shown in the figure. 1 : Cylinder block 2 : Main bearing (upper) 3 : Main bearing (lower) 4 : Main bearing cap : Engine front NOTE: Install the main bearing in the center position with the following dimension. For service operation, the center position can be checked visually. Journal position L1 [Unit: mm (in)] L2 [Unit: mm (in)] 4. a. c. No. 1 No. 2 No. 3 No. 4 No. 5 1.65–2.05 1.25–1.65 2.30–2.70 1.25–1.65 1.60–2.00 (0.064-0.080) (0.049-0.064) (0.090-0.106) (0.049-0.064) (0.062-0.078) 1.30–1.70 1.30–1.70 2.30–2.70 1.30–1.70 1.30–1.70 (0.051-0.066) (0.051-0.066) (0.090-0.106) (0.051-0.066) (0.051-0.066) CAUTION: Dimension L1 of journal No. 3 is the distance from the housing base end surface (bulk) (it is not the distance from the thrust bearing mounting end surface). Install signal plate to crankshaft if removed. Set the signal plate (1) with the flange facing toward the counterweight side (engine front side) to the crankshaft rear surface. A b. PBIC3747E : Dowel pin hole After positioning crankshaft and signal plate with positioning dowel pin, tighten bolt. NOTE: Dowel pin of crankshaft and signal plate is provided as a set for each. Remove dowel pin. PBIC3748E EM-194 CYLINDER BLOCK [HR] 5. 6. CAUTION: Be sure to remove dowel pin. Install crankshaft to cylinder block. ● While turning crankshaft by hand, make sure that it turns smoothly. CAUTION: Do not install rear oil seal yet. Install main bearing caps. ● Install the main bearing cap while referring to the front mark (B) and the journal number stamp (A). A EM C : Engine front D NOTE: Main bearing cap cannot be replaced as a single parts, because it is machined together with cylinder block. E PBIC3749E 7. Tighten main bearing cap bolts in numerical order shown in the figure with the following steps. F G : Engine front a. b. H Apply new engine oil to threads and seat surfaces of the mounting bolts. Tighten main bearing cap bolts. I : 32.4 N·m (3.3 kg-m, 24 ft-lb) PBIC3744E c. J Turn main bearing cap bolts 60 degrees clockwise (angle tightening) in numerical order shown in the figure. CAUTION: Check and confirm the tightening angle by using the angle wrench (SST: KV10112100) (A) or protractor. Avoid judgment by visual inspection without the tool. K L M PBIC3750E ● ● 8. a. After installing the mounting bolts, make sure that crankshaft can be rotated smoothly by hand. Check crankshaft end play. Refer to EM-206, "CRANKSHAFT END PLAY" . Install piston to connecting rod with the following procedure: Set so that the front mark (A) on the piston head and the cylinder number (C) are in the position shown in the figure. B : Oil hole D : Connecting rod big end grade NOTE: The symbols without notes are for management PBIC3766E EM-195 CYLINDER BLOCK [HR] b. Press-fit the piston pin using the piston pin press stand (SST). ● For the details of SST, refer to the following. Press stand Spring Drift Center shaft Center cap : ST13030020 : ST13030030 : KV10109730 : KV10114120 : KV10110310 CAUTION: Press-fit the piston so as not to damage it. NOTE: The joint between the connecting rod and the piston pin is a press fit. ● KBIA3470J Press-fit the piston pin (2) from piston surface“A” to the depth of 2.35 mm (0.092 in). 1 : Connecting rod : Press-fit direction ● After finishing work, make sure that the piston (3) moves freely. PBIC3751E 9. Using a piston ring expander (commercial service tool), install piston rings. CAUTION: ● Be careful not to damage piston. ● Be careful not to damage piston rings by expanding them excessively. ● Position each ring with the gap as shown in the figure referring to the piston front mark (B). ● A : Oil ring upper or lower rail gap (either of them) C : Second ring and oil ring spacer gap D : Top ring gap Install second ring with the stamped mark (E) facing upward. Stamped mark: Second ring :R PBIC3752E 10. Install connecting rod bearings to connecting rod and connecting rod cap. ● When installing connecting rod bearings, apply new engine oil to the bearing surface (inside). Do not apply engine oil to the back surface, but thoroughly clean it. ● Install the bearing in the center position. NOTE: There is no stopper tab. ● Make sure that the oil holes on connecting rod and connecting rod bearing are aligned. EM-196 CYLINDER BLOCK [HR] ● Install the connecting rod in the dimension shown in the figure. A EM C MBIB1429E 1 : Connecting rod 2 4 : Connecting rod cap : Connecting rod bearing (upper) 3 D : Connecting rod bearing (lower) : Engine front E NOTE: Install the connecting rod bearing in the center position with the dimension shown in the figure. For service operation, the center position can be checked visually. 11. Install piston and connecting rod assembly to crankshaft. ● Position crankshaft pin corresponding to connecting rod to be installed onto the bottom dead center. ● Apply new engine oil sufficiently to the cylinder bore, piston and crankshaft pin. ● Match the cylinder position with the cylinder number on connecting rod to install. ● Using the piston ring compressor (SST: EM03470000) (A) or suitable tool, install piston with the front mark on the piston head facing the front of the engine. CAUTION: ● Be careful not to damage matching surface with connecting rod cap. ● Be careful not to damage the cylinder wall and crankshaft pin, resulting from an interference of the connecting rod big end. F G H I J K PBIC3765E 12. Install connecting rod cap. ● Match the stamped cylinder number marks (C) on connecting rod with those on connecting rod cap to install. A : Front mark B : Oil hole D : Connecting rod big end grade L M PBIC3766E 13. Inspect outer diameter of connecting rod bolts. Refer to EM-214, "CONNECTING ROD BOLT OUTER DIAMETER" . 14. Tighten connecting rod bolt with the following procedure: a. Apply new engine oil to the threads and seats of connecting rod bolts. b. Tighten bolts in several steps. : 27.5 N·m (2.8 kg-m, 20 ft-lb) c. Completely loosen bolts. EM-197 CYLINDER BLOCK [HR] : 0 N·m (0 kg-m, 0 ft-lb) d. Tighten bolts in several steps. : 19.6 N·m (2.0 kg-m, 14 ft-lb) e. Then turn all bolts 60 degrees clockwise (angle tightening). CAUTION: Check and confirm the tightening angle by using the angle wrench (SST: KV10112100) (A) or protractor. Avoid judgement by visual inspection without the tool. PBIC3753E After tightening connecting rod bolt, make sure that crankshaft rotates smoothly. Check the connecting rod side clearance. Refer to EM-206, "CONNECTING ROD SIDE CLEARANCE" . 15. Install oil pan (upper). Refer to EM-128, "INSTALLATION" . NOTE: Install the rear oil seal after installing the oil pan (upper). 16. Install rear oil seal. Refer to EM-172, "INSTALLATION" . 17. Install flywheel (M/T models) or drive plate (A/T models). ● When installing flywheel (M/T models) or drive plate (A/T models) to crankshaft, make sure that align crankshaft side dowel pin with flywheel/drive-plate side dowel pin hole correctly. ● Install drive plate (1), reinforcement plate (2) and pilot converter (3) as shown in the figure (A/T models). ● ● A : Crankshaft rear end B : Rounded C : Chamfered CAUTION: Be careful about the installing direction (front/back). ● Using a drift of 33 mm (1.30 in) in diameter, press-fit pilot converter into the end of crankshaft until it stops (A/T models). ● Tighten bolts with the following procedure. – Using a stopper plate (SST: KV11105210), secure and tighten the crankshaft. – Tighten them diagonally in several steps. PBIC3259J 18. Install knock sensor (1). : Engine front Install connectors so that they are positioned towards the rear of the engine. CAUTION: ● Do not tighten mounting bolt while holding the connector. ● If any impact by dropping is applied to knock sensor, replace it with a new one. PBIC3754E NOTE: ● Make sure that there is no foreign material on the cylinder block mating surface and the back surface of knock sensor. ● Make sure that knock sensor does not interfere with other parts. 19. Install crankshaft position sensor (POS). ● EM-198 CYLINDER BLOCK [HR] ● Tighten bolts with it seated completely. 20. For the oil level gauge guide (1), fix the position (B) shown in the figure to the water inlet clip (A) after inserting to the cylinder block side. A EM C PBIC3755E D 21. Assemble in the reverse order of disassembly after this step. How to Select Piston and Bearing BBS002PA E DESCRIPTION Selection points Selection parts Between cylinder block and crankshaft Between crankshaft and connecting rod ● ● ● Main bearing Connecting rod bearing Selection items Selection methods Main bearing grade (bearing thickness) Determined by match of cylinder block bearing housing grade (inner diameter of housing) and crankshaft journal grade (outer diameter of journal) Connecting rod bearing grade (bearing thickness) Combining service grades for connecting rod big end diameter and crankshaft pin outer diameter determine connecting rod bearing selection. The identification grade stamped on each part is the grade for the dimension measured in new condition. This grade cannot apply to reused parts. For reused or repaired parts, measure the dimension accurately. Determine the grade by comparing the measurement with the values of each selection table. For details of the measurement method of each part, the reuse standards and the selection method of the selective fitting parts, refer to the text. HOW TO SELECT CONNECTING ROD BEARING When New Connecting Rod and Crankshaft Are Used 1. : Oil hole B : Cylinder number D : Front mark H I J K M PBIC3756E EM-199 G L Apply connecting rod big end diameter grade stamped (C) on connecting rod side face to the row in the “Connecting Rod Bearing Selection Table”. A F CYLINDER BLOCK [HR] 2. Apply crankshaft pin journal diameter grade stamped (B) on crankshaft front side to the column in the “Connecting Rod Bearing Selection Table”. A : Main journal diameter grade (No. 1 to 5 from left) B : Crankshaft pin journal diameter grade (No. 1 to 4 from left) PBIC3757E 3. 4. Read the symbol at the cross point of selected row and column in the “Connecting Rod Bearing Selection Table”. Apply the symbol obtained to the “Connecting Rod Bearing Grade Table” to select connecting rod bearing. When Crankshaft and Connecting Rod Are Reused 1. 2. 3. 4. Measure the dimensions of the connecting rod big end diameter and crankshaft pin journal diameter individually. Refer to EM-208, "CONNECTING ROD BIG END DIAMETER" and EM-211, "CRANKSHAFT PIN JOURNAL DIAMETER" . Apply the measured dimension to the “Connecting Rod Bearing Selection Table”. Read the symbol at the cross point of selected row and column in the “Connecting Rod Bearing Selection Table”. Apply the symbol obtained to the “Connecting Rod Bearing Grade Table” to select connecting rod bearing. EM-200 CYLINDER BLOCK [HR] Connecting Rod Bearing Selection Table A EM C D E F G H I J K L M MBIB9024E EM-201 CYLINDER BLOCK [HR] Connecting Rod Bearing Grade Table Unit: mm (in) Grade number Thickness Identification color 0 1.501 - 1.498 (0.0591 - 0.0590) Black 1 1.504 - 1.501 (0.0592 - 0.0591) Brown 2 1.507 - 1.504 (0.0593 - 0.0592) Green 3 1.510 - 1.507 (0.0594 - 0.0593) Yellow 4 1.513 - 1.510 (0.0596 - 0.0594) Blue UPR 1.501 - 1.498 (0.0591 - 0.0590) Black LWR 1.504 - 1.501 (0.0592 - 0.0590) Brown UPR 1.504 - 1.501 (0.0592 - 0.0590) Brown LWR 1.507 - 1.504 (0.0593 - 0.0592) Green UPR 1.507 - 1.504 (0.0593 - 0.0592) Green LWR 1.510 - 1.507 (0.0594 - 0.0593) Yellow UPR 1.510 - 1.507 (0.0594 - 0.0593) Yellow LWR 1.513 - 1.510 (0.0596 - 0.0594) Blue 01 12 Remarks Grade and color are the same for upper and lower bearings. Grade and color are different for upper and lower bearings. 23 34 Undersize Bearings Usage Guide When the specified connecting rod bearing oil clearance is not obtained with standard size connecting rod bearings, use undersize (US) bearings. ● When using undersize (US) bearing, measure the connecting rod bearing inner diameter with bearing installed, and grind the crankshaft pin so that the connecting rod bearing oil clearance satisfies the standard. CAUTION: In grinding crankshaft pin to use undersize bearings, keep the fillet R (A) [0.8 - 1.2 mm (0.031 - 0.047 in)]. ● PBIC3263J Bearing undersize table Unit: mm (in) Size Thickness US 0.25 (0.0098) 1.623 - 1.631 (0.0638 - 0.0642) HOW TO SELECT MAIN BEARING When New Cylinder Block and Crankshaft Are Used 1. “Main Bearing Selection Table” rows correspond to main bearing housing grade on left side of cylinder block. A : Basic stamp mark : Engine front ● If there is a corrected stamp mark (B) on cylinder block, use it as a correct reference. PBIC3760E EM-202 CYLINDER BLOCK [HR] 2. Apply main journal diameter grade stamped (A) on crankshaft front side to column in the “Main Bearing Selection Table”. A : Main journal diameter grade (No. 1 to 5 from left) B : Crankshaft pin journal diameter grade (No. 1 to 4 from left) A EM C PBIC3757E 3. 4. Read the symbol at the cross point of selected row and column in the “Main Bearing Selection Table”. Apply the symbol obtained to the “Main Bearing Grade Table” to select main bearing. NOTE: Service part is available as a set of both upper and lower. When Cylinder Block and Crankshaft Are Reused 1. 2. 3. 4. Measure the dimensions of the cylinder block main bearing housing inner diameter and crankshaft main journal diameter individually. Refer to EM-209, "MAIN BEARING HOUSING INNER DIAMETER" and EM211, "CRANKSHAFT MAIN JOURNAL DIAMETER" . Apply the measured dimension to the “Main Bearing Selection Table”. Read the symbol at the cross point of selected row and column in the “Main Bearing Selection Table”. Apply the symbol obtained to the “Main Bearing Grade Table” to select main bearing. D E F G H I J K L M EM-203 CYLINDER BLOCK [HR] Main Bearing Selection Table PBIC3759E EM-204 CYLINDER BLOCK [HR] Main Bearing Grade Table Unit: mm (in) Grade number Thickness Identification color 0 1.996 - 1.999 (0.0785 - 0.0787) Black 1 1.999 - 2.002 (0.0787 - 0.0788) Brown 2 2.002 - 2.005 (0.0788 - 0.0789) Green 3 2.005 - 2.008 (0.0789 - 0.0790) Yellow 4 2.008 - 2.011 (0.0790 - 0.0791) Blue 5 2.011 - 2.014 (0.0791 - 0.0792) Pink UPR 1.996 - 1.999 (0.0785 - 0.0787) Black LWR 1.999 - 2.002 (0.0787 - 0.0788) Brown UPR 1.999 - 2.002 (0.0787 - 0.0788) Brown LWR 2.002 - 2.005 (0.0788 - 0.0789) Green UPR 2.002 - 2.005 (0.0788 - 0.0789) Green LWR 2.005 - 2.008 (0.0789 - 0.0790) Yellow UPR 2.005 - 2.008 (0.0789 - 0.0790) Yellow LWR 2.008 - 2.011 (0.0790 - 0.0791) Blue UPR 2.008 - 2.011 (0.0790 - 0.0791) Blue LWR 2.011 - 2.014 (0.0791 - 0.0792) Pink 01 12 23 34 45 A Remarks EM Grade and color are the same for upper and lower bearings. C D E Grade and color are different for upper and lower bearings. F G H Use Undersize Bearing Usage Guide When the specified main bearing oil clearance is not obtained with standard size main bearings, use undersize (US) bearing. ● When using undersize (US) bearing, measure the main bearing inner diameter with bearing installed, and grind main journal so that the main bearing oil clearance satisfies the standard. CAUTION: In grinding crankshaft main journal to use undersize bearings, keep fillet R (A) [0.8 - 1.2 mm (0.031 - 0.047 in)]. ● I J K L PBIC3263J Bearing undersize table Unit: mm (in) Size Thickness US 0.25 (0.0098) 2.126 - 2.134 (0.0837 - 0.0840) EM-205 M CYLINDER BLOCK [HR] Inspection After Disassembly BBS002PB CRANKSHAFT END PLAY ● Measure the clearance between thrust bearings and crankshaft arm when crankshaft is moved fully forward or backward with a dial indicator (A). Standard Limit ● : 0.098 - 0.260 mm (0.0038 - 0.0102 in) : 0.35 mm (0.0137 in) If the measured value exceeds the limit, replace thrust bearings, and measure again. If it still exceeds the limit, replace crankshaft also. PBIC3762E CONNECTING ROD SIDE CLEARANCE ● Measure the side clearance between connecting rod and crankshaft arm with a feeler gauge (A). Standard ● : 0.200 - 0.352 mm (0.0079 - 0.0138 in) If the measured value exceeds the limit, replace connecting rod, and measure again. If it still exceeds the standard, replace crankshaft also. PBIC3763E PISTON TO PISTON PIN OIL CLEARANCE Piston Pin Hole Diameter Measure the inner diameter of piston pin hole with an inside micrometer. Standard: 19.006 - 19.012 mm (0.7482 - 0.7485 in) PBIC0116E Piston Pin Outer Diameter Measure the outer diameter of piston pin with a micrometer. Standard: 18.996 - 19.002 mm (0.7478 - 0.7481 in) PBIC0117E Piston to Piston Pin Oil Clearance (Piston to piston pin oil clearance) = (Piston pin hole diameter) – (Piston pin outer diameter) Standard: 0.008 - 0.012 mm (0.0003 - 0.0004 in) ● If oil clearance is out of the standard, replace piston and piston pin assembly. EM-206 CYLINDER BLOCK [HR] PISTON RING SIDE CLEARANCE ● ● A Measure the side clearance of piston ring and piston ring groove with a feeler gauge. Standard: Top ring 2nd ring Oil ring : 0.040 - 0.080 mm (0.0015 - 0.0031 in) : 0.030 - 0.070 mm (0.0012 - 0.0028 in) : 0.045 - 0.125 mm (0.0017 - 0.0049 in) Limit: Top ring 2nd ring : 0.11 mm (0.0043 in) : 0.10 mm (0.0039 in) EM C SEM024AA If the measured value exceeds the limit, replace piston ring, and measure again. If it still exceeds the limit, replace piston also. D E PISTON RING END GAP ● ● Make sure that cylinder bore inner diameter is within the specification. Refer to EM-210, "Cylinder Bore Inner Diameter" . Lubricate with new engine oil to piston and piston ring, and then insert piston ring until middle of cylinder with piston, and measure piston ring end gap with a feeler gauge. Standard: Top ring 2nd ring Oil ring (rail ring) F G : 0.20 - 0.30 mm (0.0078 - 0.0118 in) : 0.35 - 0.50 mm (0.0137 - 0.0196 in) : 0.20 - 0.60 mm (0.0079 - 0.0236 in) H SEM822B Limit: Top ring 2nd ring Oil ring (rail ring) ● : 0.50 mm (0.0196 in) : 0.66 mm (0.0259 in) : 0.92 mm (0.0362 in) If the measured value exceeds the limit, replace piston ring. I J K L M EM-207 CYLINDER BLOCK [HR] CONNECTING ROD BEND AND TORSION ● Check with a connecting rod aligner. Bend: Limit: 0.15 mm (0.0059 in) per 100 mm (3.94 in) length Torsion: Limit: 0.30 mm (0.0118 in) per 100 mm (3.94 in) length ● If it exceeds the limit, replace connecting rod assembly. PBIC2077E CONNECTING ROD BIG END DIAMETER ● ● Install connecting rod cap without connecting rod bearing installed, and tightening connecting rod bolts to the specified torque. Refer to EM-193, "ASSEMBLY" for the tightening procedure. Measure the inner diameter of connecting rod big end with an inside micrometer. Standard: 43.000 - 43.013 mm (1.6929 - 1.6934 in) ● If out of the standard, replace connecting rod assembly. PBIC1641E CONNECTING ROD BUSHING OIL CLEARANCE Connecting Rod Bushing Inner Diameter Measure the inner diameter of connecting rod bushing with an inside micrometer. Standard: 18.958 - 18.978 mm (0.7463 - 0.7471 in) PBIC0120E EM-208 CYLINDER BLOCK [HR] Piston Pin Outer Diameter A Measure the outer diameter of piston pin with a micrometer. Standard: 18.996 - 19.002 mm (0.7478 - 0.7481 in) EM C PBIC0117E D Connecting Rod Bushing Oil Clearance (Connecting rod bushing oil clearance) = (Connecting rod bushing inner diameter) – (Piston pin outer diameter) E Standard: –0.018 to –0.044 mm (–0.0007 to –0.0017 in) ● ● If the measured value is out of the standard, replace connecting rod assembly and/or piston and piston pin assembly. If replacing connecting rod assembly, refer to EM-211, "CONNECTING ROD BEARING OIL CLEARANCE" to select connecting rod bearing. F G CYLINDER BLOCK DISTORTION ● ● Using a scraper, remove gasket on the cylinder block surface, and also remove engine oil, scale, carbon, or other contamination. CAUTION: Be careful not to allow gasket flakes to enter engine oil or engine coolant passages. Measure the distortion on the cylinder block upper face at some different points in six directions with a straight edge and a feeler gauge. H I J Limit: 0.1 mm (0.004 in) ● If it exceeds the limit, replace cylinder block. K L PBIC0121E MAIN BEARING HOUSING INNER DIAMETER ● ● ● Install main bearing cap without main bearings installed, and tighten main bearing cap bolts to the specified torque. Refer to EM-193, "ASSEMBLY" for the tightening procedure. Measure the inner diameter of main bearing housing with a bore gauge. Measure the position shown in the figure [5 mm (0.196 in) rearward from main bearing housing front side end surface) in the 2 directions as shown in the figure. The smaller one is the measured value. 1 : Cylinder block 2 : Main bearing cap : Engine front Standard: 51.997 - 52.017 mm (2.0471 - 2.0479 in) ● If out of the standard, replace cylinder block and main bearing caps as an assembly. EM-209 PBIC3879E M CYLINDER BLOCK [HR] NOTE: These components cannot be replaced as a single unit, because they were processed together. PISTON TO CYLINDER BORE CLEARANCE Cylinder Bore Inner Diameter ● Using a bore gauge, measure the cylinder bore for wear, out-ofround and taper at six different points on each cylinder. (“X” and “Y” directions at “A”, “B” and “C”) (“Y” is in longitudinal direction of the engine) A : Unit: mm (in) NOTE: When determining cylinder bore grade, measure cylinder bore at “B” position. Standard inner diameter: 78.000 - 78.015 mm (3.0708 - 3.0714 in) Wear limit: 0.2 mm (0.008 in) Out-of-round (Difference between “X” and “Y”): 0.015 mm (0.0006 in) Taper limit (Difference between “A” and “C”): 0.010 mm (0.0004 in) ● PBIC3767E If the measured value exceeds the limit, or if there are scratches and/or seizure on the cylinder inner wall, replace cylinder block. NOTE: There is no service setting for oversized piston. Piston Skirt Diameter Measure the outer diameter of piston skirt with a micrometer. Measure point : Distance from the top 37.1 mm (1.460 in) Standard : 77.965 - 77.980 mm (3.0694 - 3.0700 in) PBIC0125E Piston to Cylinder Bore Clearance Calculate by piston skirt diameter and cylinder bore inner diameter (direction “X”, position “B”). (Clearance) = (Cylinder bore inner diameter) – (Piston skirt diameter) Standard : 0.020 - 0.050 mm (0.0007 - 0.0019 in) Limit : 0.09 mm (0.0035 in) ● If it exceeds the limit, replace piston and piston pin assembly and/or cylinder block. EM-210 CYLINDER BLOCK [HR] CRANKSHAFT MAIN JOURNAL DIAMETER ● A Measure the outer diameter of crankshaft main journals with a micrometer (A). Standard: 47.959 - 47.979 mm (1.8881 - 1.8888 in) dia. ● EM If out of the standard, measure the main bearing oil clearance. Then use undersize bearing. Refer to EM-212, "MAIN BEARING OIL CLEARANCE" . C PBIC3457J CRANKSHAFT PIN JOURNAL DIAMETER ● D E Measure the outer diameter of crankshaft pin journal with a micrometer. Standard: 39.953 - 39.971 mm (1.5729-1.5736 in) dia. ● If out of the standard, measure the connecting rod bearing oil clearance. Then use undersize bearing. Refer to EM-211, "CONNECTING ROD BEARING OIL CLEARANCE" . OUT-OF-ROUND AND TAPER OF CRANKSHAFT ● ● ● ● ● G Measure the dimensions at four different points as shown in the figure on each main journal and pin journal with a micrometer. Out-of-round is indicated by the difference in dimensions between “X” and “Y” at “A” and “B”. Taper is indicated by the difference in dimension between “A” and “B” at “X” and “Y”. Limit: Out-of-round (Difference between “X” and “Y”) : 0.003 mm (0.0001 in) Taper (Difference between “A” and “B”) : 0.004 mm (0.0001 in) F H I J PBIC2203E K If the measured value exceeds the limit, correct or replace crankshaft. If corrected, measure the bearing oil clearance of the corrected main journal and/or pin journal. Then select main bearing and/or connecting rod bearing. Refer to EM-212, "MAIN BEARING OIL CLEARANCE" and/or EM-211, "CONNECTING ROD BEARING OIL CLEARANCE" . L CRANKSHAFT RUNOUT ● ● ● Limit ● M Place a V-block on a precise flat table to support the journals on the both end of crankshaft. Place a dial indicator (A) straight up on the No. 3 journal. While rotating crankshaft, read the movement of the pointer on the dial indicator. (Total indicator reading) : 0.10 mm (0.0039 in) If it exceeds the limit, replace crankshaft. PBIC3458J CONNECTING ROD BEARING OIL CLEARANCE Method by Calculation ● Install connecting rod bearings to connecting rod and cap, and tighten connecting rod bolts to the specified torque. Refer to EM-193, "ASSEMBLY" for tightening procedure. EM-211 CYLINDER BLOCK [HR] ● Measure the inner diameter of connecting rod bearing with an inside micrometer. (Bearing oil clearance) = (Connecting rod bearing inner diameter) – (Crankshaft pin journal diameter) Standard Limit ● : 0.037 - 0.047 mm (0.0014 - 0.0018 in) : 0.10 mm (0.0039 in) If the clearance exceeds the limit, select proper connecting rod bearing according to connecting rod big end diameter and crankshaft pin journal diameter to obtain the specified bearing oil clearance. Refer to EM-199, "HOW TO SELECT CONNECTING ROD BEARING" . PBIC1642E Method of Using Plastigage ● ● ● ● Remove engine oil and dust on crankshaft pin and the surfaces of each bearing completely. Cut a plastigage slightly shorter than the bearing width, and place it in crankshaft axial direction, avoiding oil holes. Install connecting rod bearings to connecting rod and cap, and tighten connecting rod bolts to the specified torque. Refer to EM-193, "ASSEMBLY" for the tightening procedure. CAUTION: Do not rotate crankshaft. Remove connecting rod cap and bearing, and using the scale on the plastigage bag, measure the plastigage width. NOTE: The procedure when the measured value exceeds the limit is same as that described in the “Method by Calculation”. PBIC1149E MAIN BEARING OIL CLEARANCE Method by Calculation Install main bearings to cylinder block and main bearing cap, and tighten main bearing cap bolts to the specified torque. Refer to EM-193, "ASSEMBLY" for the tightening procedure. ● Measure the inner diameter of main bearing with a bore gauge. (Bearing oil clearance) = (Main bearing inner diameter) – (Crankshaft main journal diameter) ● Standard: : 0.024 - 0.034 mm (0.0009 - 0.0013 in) ● If the clearance exceeds the limit, select proper main bearing according to main bearing inner diameter and crankshaft main journal diameter to obtain the specified bearing oil clearance. Refer to EM-202, "HOW TO SELECT MAIN BEARING" . PBIC1644E Method of Using Plastigage ● ● ● Remove engine oil and dust on crankshaft main journal and the surfaces of each bearing completely. Cut a plastigage slightly shorter than the bearing width, and place it in crankshaft axial direction, avoiding oil holes. Install main bearings to cylinder block and main bearing cap, and tighten main bearing cap bolts to the specified torque. Refer to EM-193, "ASSEMBLY" for the tightening procedure. CAUTION: Do not rotate crankshaft. EM-212 CYLINDER BLOCK [HR] ● Remove main bearing cap and bearings, and using the scale on the plastigage bag, measure the plastigage width. NOTE: The procedure when the measured value exceeds the limit is same as that described in the “Method by Calculation”. A EM C PBIC1149E D MAIN BEARING CRUSH HEIGHT ● When main bearing cap is removed after being tightened to the specified torque with main bearings installed, the tip end of bearing must protrude. Refer toEM-193, "ASSEMBLY" for the tightening procedure. E Standard: There must be crush height. ● F If the standard is not met, replace main bearings. G SEM502G CONNECTING ROD BEARING CRUSH HEIGHT ● H When connecting rod bearing cap is removed after being tightened to the specified torque with connecting rod bearings installed, the tip end of bearing must protrude. Refer to EM-193, "ASSEMBLY" for the tightening procedure. I Standard: There must be crush height. ● J If the standard is not met, replace connecting rod bearings. K PBIC1646E MAIN BEARING CAP BOLT OUTER DIAMETER ● ● L Measure the outer diameters (“d1 ”, “d2” ) at two positions as shown in the figure. If reduction appears in a position other than “d2 ” , regard it as “d2” . M Limit (“d1 ” – “d2 ”): 0.2 mm (0.0078 in) ● If it exceeds the limit (a large difference in dimensions), replace main bearing cap bolt with a new one. PBIC3768E EM-213 CYLINDER BLOCK [HR] CONNECTING ROD BOLT OUTER DIAMETER ● ● Measure the outer diameter “d” at position as shown in the figure. If reduction appears in a position other than “d”, regard it as “d”. Limit: 7.75 mm (0.3051 in) ● When “d” falls below the limit (when it becomes thinner), replace connecting rod bolt with a new one. PBIC3769E FLYWHEEL DEFLECTION ● Measure the deflection of flywheel contact surface to clutch with a dial indicator. Standard ● : 0.25 mm (0.0098 in) or less. If measured value is out of the standard, replace flywheel. PBIC2646E EM-214 SERVICE DATA AND SPECIFICATIONS (SDS) [HR] SERVICE DATA AND SPECIFICATIONS (SDS) Standard and Limit PFP:00030 A BBS002PC GENERAL SPECIFICATIONS Engine type HR16DE Cylinder arrangement In-line 4 cm3 (cu in) Displacement Bore and stroke 1,598 (97.51) mm (in) C 78.0 x 83.6 (3.070 x 3.291) Valve arrangement DOHC Firing order 1-3-4-2 Number of piston rings EM Compression 2 Oil 1 Compression ratio D E 9.8 Compression pressure kPa (bar, kg/cm2 , psi) / 200 rpm Standard 1,510 (15.1, 15.4, 219) Minimum 1,265 (12.69, 12.9, 183) Differential limit between cylinders F 981 (9.81, 10.0, 142) DRIVE BELT G Belt Deflection: Deflection adjustment * Location Used belt Limit Drive belt Unit: mm (in) New belt After adjusted With A/C models 7.9 (0.31) 4.8 - 5.3 (0.19 - 0.21) 4.2 - 4.5 (0.17 - 0.18) Without A/C models 7.1 (0.28) 4.3 - 4.7 (0.17 - 0.19) 3.6 - 3.9 (0.14 - 0.15) Applied pushing force H I 98 N (10 kg, 22lb) *: When engine is cold. J EXHAUST MANIFOLD Unit: mm (in) Items K Limit Surface distortion 0.3 (0.012) SPARK PLUG (PLATINUM-TIPPED TYPE) L Unit: mm (in) Make NGK Standard type PLZKAR6A-11 Hot type PLZKAR5A-11 Cold type Spark plug gap M PLZKAR7A-11 Standard 1.1 (0.043) CYLINDER HEAD Unit: mm (in) Items Limit Head surface distortion 0.1 (0.004) EM-215 SERVICE DATA AND SPECIFICATIONS (SDS) [HR] VALVE Valve Timing Unit: degree Valve timing PBIC0187E ( a b c d e f 208 228 -11 (19) 59 (19) 4 24 ): Valve timing control “ON” Valve Dimensions Unit: mm (in) PBIC3878E Valve head diameter “D” Valve length “a” “b” “c” Intake 31.0 - 31.3 (1.220 - 1.232) Exhaust 25.3 - 25.6 (0.996 - 1.007) Intake 101.65 (4.0019) Exhaust 102.46 (4.0338) Intake 1.0 (0.0393) Exhaust 1.0 (0.0393) Intake 2.1 - 2.8 (0.0826 - 0.1102) Exhaust 2.3 - 3.0 (0.0905 - 0.1181) Intake “c′ ” “d ” 3.0 (0.1181) Exhaust – Intake 4.965 - 4.980 (0.1954 - 0.1960 in) Exhaust 4.955 - 4.970 (0.1950 - 0.1956 in) Intake Valve seat angle “α” 45°15′ - 45°45′ Exhaust Valve Clearance Unit: mm (in) Cold Hot * (reference data) Intake 0.26 - 0.34 (0.010 - 0.013) 0.304 - 0.416 (0.012 - 0.016) Exhaust 0.29 - 0.37 (0.011 - 0.014) 0.308 - 0.432 (0.012 - 0.017) *:Approximately 80°C (176°F) EM-216 SERVICE DATA AND SPECIFICATIONS (SDS) [HR] Available Valve Lifter Thickness mm (in) Identification mark A EM C D KBIA0119E 3.00 (0.1181) 300 3.02 (0.1188) 302 3.04 (0.1196) 304 3.06 (0.1204) 306 3.08 (0.1212) 308 3.10 (0.1220) 310 3.12 (0.1228) 312 3.14 (0.1236) 314 3.16 (0.1244) 316 3.18 (0.1251) 318 3.20 (0.1259) 320 3.22 (0.1267) 322 3.24 (0.1275) 324 3.26 (0.1283) 326 3.28 (0.1291) 328 3.30 (0.1299) 330 3.32 (0.1307) 332 3.34 (0.1314) 334 3.36 (0.1322) 336 3.38 (0.1330) 338 3.40 (0.1338) 340 3.42 (0.1346) 342 3.44 (0.1354) 344 3.46 (0.1362) 346 3.48 (0.1370) 348 3.50 (0.1377) 350 EM-217 E F G H I J K L M SERVICE DATA AND SPECIFICATIONS (SDS) [HR] Valve Spring Standard: Free height 42.26 mm (1.6637 in) Installation height 32.40 mm (1.2755 in) Installation load 136 - 154 N (13.9 - 15.7 kg, 31 - 35 lb) Height during valve open 23.96 mm (0.9433 in) Load with valve open 262 - 296 N (26.7 - 30.2 kg, 59 - 67 lb) Valve Lifter Unit: mm (in) Items Standard Valve lifter outer diameter 29.977 - 29.987 (1.1801 - 1.1805) Valve lifter hole diameter 30.000 - 30.021 (1.1811 - 1.1819) Valve lifter clearance 0.013 - 0.044 (0.0005 - 0.0017) Valve Guide Unit: mm (in) PBIC0184E Items Valve guide Outer diameter Standard part Service part 9.023 - 9.034 (0.3552 - 0.3556) 9.223 - 9.234 (0.3631 - 0.3635) Inner diameter (Finished size) Cylinder head valve guide hole diameter 5.000 - 5.018 (0.1968 - 0.1975) 8.975 - 8.996 (0.3533 - 0.3541) Interference fit of valve guide 0.027 - 0.059 (0.0011 - 0.0023) Items Valve guide clearance 9.175 - 9.196 (0.3612 - 0.3620) Standard Limit Intake 0.020 - 0.053 (0.0008 - 0.0021) 0.1 (0.004) Exhaust 0.030 - 0.063 (0.0012 - 0.0025) 0.1 (0.004) Projection length “H” 11.4 - 11.8 (0.448 - 0.464) EM-218 SERVICE DATA AND SPECIFICATIONS (SDS) [HR] Valve Seat Unit: mm (in) A EM C D PBIC2745E Items Cylinder head seat recess diameter “D” Valve seat outer diameter “d” Valve seat interference fit Diameter “d1”*1 Diameter “d2”*2 Angle “α1” Angle “α2” Angle “α3” Contacting width “W”*3 Height “h” Standard Oversize [0.5 (0.02)] (Service) Intake 31.400 - 31.416 (1.2362 - 1.2368) 31.900 - 31.916 (1.2559 - 1.2565) Exhaust 25.900 - 25.916 (1.0196 - 1.0203) 26.400 - 26.416 (1.0393 - 1.0399) Intake 31.497 - 31.513 (1.2400 - 1.2406) 31.997 - 32.013 (1.2597 - 1.2603) Exhaust 25.997 - 26.013 (1.0235 - 1.0241) 26.497 - 26.513 (1.0431 - 1.0438) Intake 0.081 - 0.113 (0.0032 - 0.0044) Exhaust 0.081 - 0.113 (0.0032 - 0.0044) Intake 29.0 (1.141) Exhaust 23.0 (0.905) Intake 30.6 - 30.8 (1.204 - 1.212) Exhaust 24.9 - 25.1 (0.980 - 0.988) Intake 60° Exhaust 60° Intake 89°45′ - 90°15′ Exhaust 89°45′ - 90°15′ Intake 120° Exhaust 120° J K Exhaust 1.25 - 1.55 (0.0492 - 0.0610) Intake 6.0 (0.236) 5.45 (0.214) Exhaust 6.0 (0.236) 5.43 (0.213) *1 : Diameter made by intersection point of conic angles α1 and α2 *2 : Diameter made by intersection point of conic angles α2 and α3 *3 : Machining data EM-219 G I 1.05 - 1.35 (0.0413 - 0.0531) 6.0 (0.236) F H Intake Depth “H” E L M SERVICE DATA AND SPECIFICATIONS (SDS) [HR] CAMSHAFT AND CAMSHAFT BEARING Unit: mm (in) Items Camshaft runout [TIR*] Standard Limit 0.02 (0.0008) 0.1 (0.0039) SEM671 Camshaft cam height “A” Camshaft journal outer diameter Camshaft bracket inner diameter Camshaft journal oil clearance Intake 41.705 - 41.895 (1.6419 - 1.6494) — Exhaust 40.175 - 40.365 (1.5816 - 1.5891) — No. 1 27.935 - 27.955 (1.0998 - 1.1006) — No. 2, 3, 4, 5 24.950 - 24.970 (0.9822 - 0.9830) — No. 1 28.000 - 28.021 (1.1024 - 1.1032) — No. 2, 3, 4, 5 25.000 - 25.021 (0.9842 - 0.9850) — No. 1 0.045 - 0.086 (0.0018 - 0.0034) — No. 2, 3, 4, 5 0.030 - 0.071 (0.0011 - 0.0027) — 0.075 - 0.153 (0.0029 - 0.0060) 0.2 (0.0078) — 0.15 (0.0059) Camshaft end play Camshaft sprocket runout [TIR*] *: Total indicator reading CYLINDER BLOCK Unit: mm (in) PBIC3924E Surface distortion Cylinder bore Limit Inner diameter 0.1 (0.004) Standard 78.000 - 78.015 (3.0708 - 3.0714) Wear limit 0.2 (0.008) Out-of-round (Difference between “X” and “Y”) Taper (Difference between “A” and “C”) 0.015 (0.0006) Limit 0.010 (0.0004) EM-220 SERVICE DATA AND SPECIFICATIONS (SDS) [HR] Grade No. A Grade No. B Grade No. C Grade No. D Grade No. E Grade No. F Grade No. G Grade No. H Grade No. J Grade No. K Grade No. L Grade No. M Grade No. N Grade No. P Grade No. R Grade No. S Grade No. T Grade No. U Grade No. V Grade No. W Cylinder block main bearing housing inner diameter grade Difference in inner diameter between cylinders 51.997 - 51.998 (2.0471 - 2.0472) 51.998 - 51.999 (2.0472 - 2.0472) 51.999 - 52.000 (2.0472 - 2.0472) 52.000 - 52.001 (2.0472 - 2.0472) 52.001 - 52.002 (2.0473 - 2.0473) 52.002 - 52.003 (2.0473 - 2.0473) 52.003 - 52.004 (2.0474 - 2.0474) 52.004 - 52.005 (2.0474 - 2.0474) 52.005 - 52.006 (2.0474 - 2.0474) 52.006 - 52.007 (2.0475 - 2.0475) 52.007 - 52.008 (2.0475 - 2.0475) 52.008 - 52.009 (2.0476 - 2.0476) 52.009 - 52.010 (2.0476 - 2.0476) 52.010 - 52.011 (2.0476 - 2.0476) 52.011 - 52.012 (2.0477 - 2.0477) 52.012 - 52.013 (2.0477 - 2.0477) 52.013 - 52.014 (2.0478 - 2.0478) 52.014 - 52.015 (2.0478 - 2.0478) 52.015 - 52.016 (2.0478 - 2.0478) 52.016 - 52.017 (2.0479 - 2.0479) Standard A EM C D E F Less than 0.03 (0.0012) PISTON, PISTON RING AND PISTON PIN Available Piston G Unit: mm (in) H I J PBIC0188E Piston skirt diameter “A” 77.965 - 77.980 (3.0694 - 3.0700) Piston height “H” dimension 37.1 (1.460) Piston pin hole diameter 19.006 - 19.012 (0.7482 - 0.7485) Piston to cylinder bore clearance Unit: mm (in) Side clearance End gap L 0.020 - 0.050 (0.0007 - 0.0019) Piston Ring Items K Standard Limit Top 0.040 - 0.080 (0.0015 - 0.0031) 0.11 (0.0043) 2nd 0.030 - 0.070 (0.0012 - 0.0028) 0.10 (0.0039) Oil (rail ring) 0.045 - 0.125 (0.0017 - 0.0049) — Top 0.20- 0.30 (0.0078 - 0.0118) 0.50 (0.0196) 2nd 0.35 - 0.50 (0.0137 - 0.0196) 0.66 (0.0259) Oil (rail ring) 0.20 - 0.60 (0.0079 - 0.0236) 0.92 (0.0362) Piston Pin Unit: mm (in) Piston pin outer diameter 18.996 - 19.002 (0.7478 - 0.7481) Piston to piston pin oil clearance Standard 0.008 - 0.012 (0.0003 - 0.0004) Connecting rod bushing oil clearance Standard –0.018 to –0.044 (–0.0007 to –0.0017) EM-221 M SERVICE DATA AND SPECIFICATIONS (SDS) [HR] CONNECTING ROD Unit: mm (in) Center distance 129.84 - 129.94 (5.1118 - 5.1157) Bend [per 100 (3.94)] Limit 0.15 (0.0059) Torsion [per 100 (3.94)] Limit 0.30 (0.0118) Connecting rod bushing inner diameter* 18.958 - 18.978 (0.7463 - 0.7471) Side clearance Standard Connecting rod big end diameter Grade No. A Grade No. B Grade No. C Grade No. D Grade No. E Grade No. F Grade No. G Grade No. H Grade No. J Grade No. K Grade No. L Grade No. M Grade No. N 0.200 - 0.352 (0.0079 - 0.0138) 43.000 - 43.001 (1.6929 - 1.6929) 43.001 - 43.002 (1.6929 - 1.6930) 43.002 - 43.003 (1.6930 - 1.6930) 43.003 - 43.004 (1 6930 - 1.6931) 43.004 - 43.005 (1.6931 - 1.6931) 43.005 - 43.006 (1.6931 - 1.6931) 43.006 - 43.007 (1.6931 - 1.6932) 43.007 - 43.008 (1.6932 - 1.6932) 43.008 - 43.009 (1.6932 - 1.6933) 43.009 - 43.010 (1.6933 - 1.6933) 43.010 - 43.011 (1.6933 - 1.6933) 43.011 - 43.012 (1.6933 - 1.6934) 43.012 - 43.013 (1.6934 - 1.6934) *: After installing in connecting rod CRANKSHAFT Unit: mm (in) SBIA0535E SEM645 Center distance “r” 41.68 - 41.76 (1.6409 - 1.6440) Out-of-round (Difference between “X” and “Y”) Limit 0.003 (0.0001) Taper (Difference between “A” and “B”) Limit 0.004 (0.0001) Runout [TIR*] Limit 0.10 (0.0039) Standard Crankshaft end play 0.098 - 0.260 (0.0038 - 0.0102) Limit 0.35 (0.0137) EM-222 SERVICE DATA AND SPECIFICATIONS (SDS) [HR] Crankshaft pin journal diameter grade. “DP” Crankshaft main journal diameter grade. “Dm” Grade No. A Grade No. B Grade No. C Grade No. D Grade No. E Grade No. F Grade No. G Grade No. H Grade No. J Grade No. K Grade No. L Grade No. M Grade No. N Grade No. P Grade No. R Grade No. S Grade No. T Grade No. U 39.971 - 39.970 (1.5737 - 1.5736) 39.970 - 39.969 (1.5736 - 1.5736) 39.969 - 39.968 (1.5736 - 1.5735) 39.968 - 39.967 (1.5735 - 1.5735) 39.967 - 39.966 (1.5735 - 1.5735) 39.966 - 39.965 (1.5736 - 1.5734) 39.965 - 39.964 (1.5735 - 1.5734) 39.964 - 39.963 (1.5734 - 1.5733) 39.963 - 39.962 (1.5734 - 1.5733) 39.962 - 39.961 (1.5733 - 1.5733) 39.961 - 39.960 (1.5733 - 1.5732) 39.960 - 39.959 (1.5732 - 1.5732) 39.959 - 39.958 (1.5732 - 1.5731) 39.958 - 39.957 (1.5731 - 1.5731) 39.957 - 39.956 (1.5731 - 1.5731) 39.956 - 39.955 (1.5731 - 1.5730) 39.955 - 39.954 (1.5730 - 1.5730) 39.954 - 39.953 (1.5730 - 1.5729) Grade No. A Grade No. B Grade No. C Grade No. D Grade No. E Grade No. F Grade No. G Grade No. H Grade No. J Grade No. K Grade No. L Grade No. M Grade No. N Grade No. P Grade No. R Grade No. S Grade No. T Grade No. U Grade No. V Grade No. W 47.979 - 47.978 (1.8889 - 1.8889) 47.978 - 47.977 (1.8889 - 1.8889) 47.977 - 47.976 (1.8889 - 1.8888) 47.976 - 47.975 (1.8888 - 1.8888) 47.975 - 47.974 (1.8888 - 1.8887) 47.974 - 47.973 (1.8887 - 1.8887) 47.973 - 47.972 (1.8887 - 1.8887) 47.972 - 47.971 (1.8887 - 1.8886) 47.971 - 47.970 (1.8886 - 1.8886) 47.970 - 47.969 (1.8886 - 1.8885) 47.969 - 47.968 (1.8885 - 1.8885) 47.968 - 47.967 (1.8885 - 1.8885) 47.967 - 47.966 (1.8885 - 1.8884) 47.966 - 47.965 (1.8884 - 1.8884) 47.995 - 47.964 (1.8884 - 1.8883) 47.994 - 47.963 (1.8883 - 1.8883) 47.963 - 47.962 (1.8883 - 1.8883) 47.962 - 47.961 (1.8883 - 1.8882) 47.961 - 47.960 (1.8882 - 1.8882) 47.960 - 47.959 (1.8882 - 1.8881) A EM C D E F G H I J K *: Total indicator reading L M EM-223 SERVICE DATA AND SPECIFICATIONS (SDS) [HR] MAIN BEARING Unit: mm (in) SEM685D Grade number Thickness Identification color 0 1.996 - 1.999 (0.0785 - 0.0787) Black 1 1.999 - 2.002 (0.0787 - 0.0788) Brown 2 2.002 - 2.005 (0.0788 - 0.0789) Green 3 2.005 - 2.008 (0.0789 - 0.0790) Yellow 4 2.008 - 2.011 (0.0790 - 0.0791) Blue 5 01 12 23 34 45 2.011 - 2.014 (0.0791 - 0.0792) Pink UPR 1.996 - 1.999 (0.0785 - 0.0787) Black LWR 1.999 - 2.002 (0.0787 - 0.0788) Brown UPR 1.999 - 2.002 (0.0787 - 0.0788) Brown LWR 2.002 - 2.005 (0.0788 - 0.0789) Green UPR 2.002 - 2.005 (0.0788 - 0.0789) Green LWR 2.005 - 2.008 (0.0789 - 0.0790) Yellow UPR 2.005 - 2.008 (0.0789 - 0.0790) Yellow LWR 2.008 - 2.011 (0.0790 - 0.0791) Blue UPR 2.008 - 2.011 (0.0790 - 0.0791) Blue LWR 2.011 - 2.014 (0.0791 - 0.0792) Pink Remarks Grade and color are the same for upper and lower bearings. Grade and color are different for upper and lower bearings. Undersize Unit: mm (in) Item Thickness Main journal diameter US 0.25 (0.0098) 2.126 - 2.134 (0.0837 - 0.0840) Grind so that bearing clearance is the specified value. Standard 0.024 - 0.034 (0.0009 - 0.0013) Bearing Oil Clearance Unit: mm (in) Main bearing oil clearance EM-224 SERVICE DATA AND SPECIFICATIONS (SDS) [HR] CONNECTING ROD BEARING Unit: mm (in) Grade number Thickness Identification color 0 1.501 - 1.498 (0.0591 - 0.0590) Black 1 1.504 - 1.501 (0.0592 - 0.0591) Brown 2 1.507 - 1.504 (0.0593 - 0.0592) Green 3 1.510 - 1.507 (0.0594 - 0.0593) Yellow 4 1.513 - 1.510 (0.0596 - 0.0594) Blue UPR 1.501 - 1.498 (0.0591 - 0.0590) Black LWR 1.504 - 1.501 (0.0592 - 0.0590) Brown UPR 1.504 - 1.501 (0.0592 - 0.0590) Brown LWR 1.507 - 1.504 (0.0593 - 0.0592) Green UPR 1.507 - 1.504 (0.0593 - 0.0592) Green LWR 1.510 - 1.507 (0.0594 - 0.0593) Yellow UPR 1.510 - 1.507 (0.0594 - 0.0593) Yellow LWR 1.513 - 1.510 (0.0596 - 0.0594) Blue 01 12 A Remarks EM Grade and color are the same for upper and lower bearings. C D Grade and color are different for upper and lower bearings. E 23 34 F G Undersize Unit: mm (in) Item Thickness Crankshaft pin journal diameter US 0.25 (0.0098) 1.623 - 1.635 (0.0639 - 0.0644) Grind so that bearing clearance is the specified value. H Bearing Oil Clearance Unit: mm (in) Connecting rod bearing oil clearance Standard I 0.029 - 0.039 (0.0011 - 0.0015) Limit 0.10 (0.0039) J K L M EM-225 APPLICATION NOTICE [K9K] APPLICATION NOTICE How to Check Vehicle Type [K9K] PFP:00000 BBS005AQ Confirm K9K engine type with Model written on identification plate (refer to GI-45, "IDENTIFICATION INFORMATION" ), then refer to service information in EM section. Vehicle type Engine type xTKxxxxE11xxE 50kW xTKxxxxE11xxA 63kW EM-226 PRECAUTIONS [K9K] PRECAUTIONS Precautions for Drain Coolant PFP:00001 A BBS002PE Drain coolant when engine is cooled. Precautions for Disconnecting Fuel Piping ● ● ● Before starting work, make sure no fire or spark producing items are in the work area. Release fuel pressure before disassembly. After disconnecting pipes, plug openings to stop fuel leakage. Precautions for Removal and Disassembly ● ● ● ● ● EM BBS002PF C BBS002PG When instructed to use special service tools, use the specified tools. Always be careful to work safely, avoid forceful or uninstructed operations. Exercise maximum care to avoid damage to mating or sliding surfaces. Cover openings of engine system with tape or the equivalent, if necessary, to seal out foreign materials. Mark and arrange disassembly parts in an organized way for easy troubleshooting and re-assembly. When loosening nuts and bolts, as a basic rule, start with the one furthest outside, then the one diagonally opposite, and so on. If the order of loosening is specified, do exactly as specified. Precautions for Inspection, Repair and Replacement ● ● ● ● ● ● ● ● – – – – ● ● ● BBS002PI Use torque wrench to tighten bolts or nuts to specified value. When tightening nuts and bolts, as a basic rule, equally tighten in several different steps starting with the ones in center, then ones on inside and outside diagonally in this order. If the order of tightening is specified, do exactly same as specified. Replace with new gasket, packing, oil seal or O-ring. Thoroughly wash, clean, and air-blow each part. Carefully check oil or coolant passages for any restriction and blockage. Avoid damaging sliding or mating surfaces. Completely remove foreign materials such as cloth lint or dust. Before assemble, spread the oil on sliding surfaces well. Release air within route when refilling after draining coolant. Before starting engine, apply fuel pressure to fuel lines with turning ignition switch ON (with engine stopped). Then make sure that there are no leaks at fuel line connections. After repairing, start engine and increase engine speed to check coolant, fuel, oil, and exhaust systems for leakage. F G H I J K L M Parts Requiring Angular Tightening ● E BBS002PH Before repairing or replacing, thoroughly inspect parts. Inspect new replacement parts in the same way, and replace if necessary. Precautions for Assembly and Installation D BBS002PJ Use an angle wrench for the final tightening of the following engine parts. Cylinder head bolts Lower cylinder block bolts Connecting rod cap bolts Crankshaft pulley bolt (No angle wrench is required as the bolt flange is provided with notches for angular tightening) Do not use a torque value for final tightening. The torque value for these parts are for a preliminary step. Ensure thread and seat surfaces are clean and coated with engine oil. EM-227 PRECAUTIONS [K9K] Precautions For Liquid Gasket BBS002PK REMOVAL OF LIQUID GASKET ● ● After removing the mounting bolts and nuts, separate the mating surface using a seal cutter and remove the liquid gasket. CAUTION: Be careful not to damage the mating surfaces. In areas where the cutter is difficult to use, use a plastic hammer to lightly tap the liquid gasket applied area. CAUTION: If for some unavoidable reason a tool such as a flat-bladed screwdriver is used, be careful not to damage the mating surfaces. PBIC0275E LIQUID GASKET APPLICATION PROCEDURE 1. 2. 3. Using a scraper, remove the old liquid gasket adhering to the gasket application surface and the mating surface. ● Remove the liquid gasket completely from the groove of the gasket application surface, mounting bolts and bolt holes. Wipe the gasket application surface and the mating surface with white gasoline (lighting and heating use) to remove adhering moisture, grease and foreign materials. Attach the liquid gasket to the tube presser. Use Genuine Liquid Gasket or equivalent. PBIC0003E 4. Apply the liquid gasket without breaks to the specified location with the specified dimensions. ● If there is a groove for the liquid gasket application, apply the gasket to the groove. EMA0622D As for the bolt holes, normally apply the gasket inside the holes. If specified, it should be applied outside the holes. Make sure to read the instruction in this manual. ● Within five minutes of gasket application, install the mating component. ● If the liquid gasket protrudes, wipe it off immediately. ● Do not retighten after the installation. ● After 30 minutes or more have passed from the installation, fill the engine oil and coolant. CAUTION: If there are instructions in this manual, observe them. ● EM-228 SEM159F PRECAUTIONS [K9K] Precautions for Diesel Equipment BBS0058A A CLEANLINESS CLEANLINESS INSTRUCTIONS WHICH MUST BE FOLLOWED WHEN WORKING ON THE HIGH PRESSURE DIRECT INJECTION SYSTEM Risks relating to contamination EM The system is very sensitive to contamination. The risks caused by the introduction of contamination are: ● Damage or destruction of the high pressure injection system and the engine, C ● Seizing or leaking of a component. All After-Sales operations must be performed under very clean conditions. This means that no impurities (particles a few microns in size) get into the system during dismantling or into the circuits via the fuel unions. D The cleanliness principle must be applied from the filter to the injectors. WHAT ARE THE SOURCES OF CONTAMINATION? Contamination is caused by: E ● Metal or plastic chips, ● Paint, ● Fibres: F – Boxes, – Brushes, – Paper, G – Clothing, – Cloths, ● Foreign bodies such as hair, H ● Ambient air, ● Etc. I IMPORTANT: It is not possible to clean the engine using a high pressure washer because of the risk of damaging connections. In addition, moisture may collect in the connectors and create electrical connection malfunctions. INSTRUCTIONS TO BE FOLLOWED BEFORE ANY WORK IS CARRIED OUT ON THE INJECTION SYS- J TEM ● Ensure that you have the plugs for the unions to be opened (bag of plugs sold at the Parts Stores - Nissan part No.: 16830 BN700, Renault part No.: 77 01 206 804). Plugs are to be used once only. After use, they K must be thrown away (once used they are soiled and cleaning is not sufficient to make them reusable). Unused plugs must be thrown away. ● Ensure that you have hermetically resealable plastic bags for storing removed parts. Stored parts will therefore be less subject to the risk of impurities. The bags must be used only once, and after use they L must be thrown away. ● Lint-free towelettes to be used for injection pump related service purpose. The use of a normal cloth or paper for cleaning purposes is forbidden. These are not lint-free and may contaminate the fuel circuit of M the system. Each lint-free cloth should only be used once. INSTRUCTIONS TO BE FOLLOWED BEFORE OPENING THE FUEL CIRCUIT ● For each operation, use new thinner (used thinner contains impurities). Pour it into a clean receptacle. ● For each operation, use a clean brush which is in good condition (the brush must not shed its bristles). ● Use a brush and thinners to clean the connections to be opened. ● Blow compressed air over the cleaned parts (tools, cleaned the same way as the parts, connections and injection system zone). Check that no bristles remain adhered. ● Wash your hands before and during the operation if necessary. ● When wearing leather protective gloves, cover these with latex gloves. INSTRUCTIONS TO BE FOLLOWED DURING THE OPERATION ● As soon as the circuit is open, all openings must be plugged to prevent impurities from entering the system. The plugs to be used are available from the Parts Stores - Nissan part No.: 16830 BN700, Renault part No.: 77 01 206 804. They must not, under any circumstances, be reused. ● Close the hermetically sealed bag, even if it has to be reopened shortly afterwards. Ambient air carries contamination. EM-229 PRECAUTIONS [K9K] All components of the injection system that are removed must be stored in a hermetically sealed plastic bag once the plugs have been inserted. ● The use of a brush, thinner, bellows, sponge or normal cloth is strictly forbidden once the circuit has been opened. These items are likely to allow impurities to enter the system. ● A new component replacing an old one must not be removed from its packaging until it is to be fitted to the vehicle. Instructions for Fitting the Plugs Nissan part number: 16830 BN700 (Renault part number: 77 01 206 804) ● MBIB0321E CAUTION: ● The engine must not run with: – Diesel containing more than 10% diester – Petrol, even in very small amounts. EM-230 PRECAUTIONS [K9K] ● ● The system can inject the diesel into the engine at a pressure of up to 140,000 kPa (1,400 bar, 1,428 kg/cm2 , 20,300 psi). Before carrying out any work, check that the injector rail is no longer A pressurized and that the fuel temperature is not too high. You must respect the cleaning and safety advice specified in this document for any work on the high pressure injection system. EM SPECIAL FEATURES CAUTION: ● The engine must not operate with: – Diesel engine fuel containing more than 10% diester, – Petrol, even in tiny quantities. ● The system can inject the diesel into the engine at a pressure up to 1400 bars. Before carrying out any work, check that the injector rail is not under pressure and that the fuel temperature is not too high. ● You must respect the cleaning and safety advice specified in this document for any work on the high pressure injection system. ● Removal of the interior of the pump and injectors is prohibited. Only the flow actuator, the fuel temperature sensor and the venturi can be replaced. ● For safety reasons, it is strictly forbidden to slacken a high pressure pipe union when the engine is running. ● It is not possible to remove the pressure sensor from the fuel rail because this may cause circuit contamination malfunctions. If the pressure sensor fails, the pressure sensor, the rail and the five high pressure pipes must be replaced. ● It is strictly forbidden to remove any injection pump pulley marked number 070 575. If the pump is being replaced, the pulley must be replaced. ● It is forbidden to repair the wiring connecting the knock sensor (accelerometer) and the CKP sensor (engine speed sensor). If the wiring should fail, it has to be replaced with new wiring. ● Applying 12 volts directly to any component in the system is prohibited. ● Ultrasonic carbon removal and cleaning are prohibited. ● Never start the engine without the battery being connected correctly. ● It is essential to replace all the disconnected air inlet plastic pipes. There is a 16 digit code on the injectors called individual injector correction. This code is specific to each injector, and takes into account differences in manufacture and specifies the flow injected by each of them. When an injector is replaced, it is necessary to program the code of the new injector into the ECM. Refer to EC-1625, "Injector Adjustment Value Registration" . INSTRUCTIONS FOR HIGH PRESSURE PIPES CAUTION: All the high pressure pipe removed must be systematically replaced along with the clips. TIGHTENING THE HIGH PRESSURE PIPES NOTE: fit the pump/rail pipe before the rail/injector pipes. Rail-pump pipe ● Undo the rail, ● Grease the threads of the high pressure pipe nuts, ● Insert the high pressure pipe olive into the taper of the high pressure pump outlet, ● Insert the high pressure pipe olive into the taper of the high pressure rail inlet. ● Move the nut into position by hand, on the rail side then the pump side, ● Tighten the rail, ● Tighten the high pressure pipe nuts on the rail side then on the pump side. Rail/injector pipes ● Undo the rail, ● Grease the threads of the high pressure pipe nuts, ● Insert the high pressure pipe olive into the taper of the high pressure injector inlet, EM-231 C D E F G H I J K L M PRECAUTIONS [K9K] Insert the high pressure pipe olive into the taper of the high pressure rail outlet, Move the nuts into position by hand, on the injector side then the rail side, ● Tighten the rail, ● Ensure that the new clip, supplied with the new high pressure pipe, is fitted, ● Tighten the nuts of the high pressure pipes on the injector side first and then on the fuel rail side. NOTE: Before fitting a new high pressure pipe, move back the nuts on the pipe then lightly lubricate the nut threads with the oil from the sachet provided in the parts kit. CHECKING SEALING AFTER REPAIR CAUTION: After any operation, check that there are no diesel leaks. ● Reprime the circuit using the priming pump. ● Start the engine and allow to warm up at idle speed, visually inspecting for any fuel leaks. ● Apply tracing fluid around the high pressure connections of the pipe that has been replaced. ● Once the engine coolant temperature is above 50°C and provided there are no malfunctions present, carry out a road test, taking the engine speed up to 4000 rpm at least once to check that there are no leaks. ● Perform a visual inspection after the road test to make sure that there are no high pressure leaks. ● Clean off the tracing fluid. REPLACING THE INJECTORS NOTE: Individual injector correction is a factory calibration carried out on each injector to adjust the flow of each one precisely, taking into account differences in manufacture. The correction values are written on a label affixed to each injector then entered in the ECM which can then control each injector by taking account of their differences in manufacture. The system can be programmed “WORK SUPPORT” mode with CONSULT-II. The correction values (16 digit code) must be replaced after replacing an injector. Refer to EC-1625, "Injector Adjustment Value Registration" . ● Entering each injector's individual correction value, when replacing the ECM. Refer to EC-1626, "Replacing ECM" . ● ● EM-232 PREPARATION [K9K] PREPARATION Special Service Tools PFP:00002 A BBS002PR NISSAN tool number (RENAULT tool No.) Tool name Description KV113B0020 (Emb. 880) Sliding hammer EM Inertia extractor C D MBIB0358E KV113B0030 (Mot. 11) Crankshaft bearing remover Crankshaft bearing extractor E F MBIB0359E KV113B0040 (Mot. 251-01) Dial gauge stand set Gauge stand used with KV113B0050 (Mot. 252-01) G H I MBIB0360E KV113B0050 (Mot. 252-01) Dial gauge stand set Thrust plate for measuring the protrusion of cylinder liners used with KV113B0040 (Mot. 251-01). J K MBIB0361E KV113B0060 (Mot. 582-01) Ring gear stopper Flywheel immobilizing tool. L M MBIB0363E KV113B0070 (Mot. 792-03) Engine sub-attachment Engine mounting plate for engine stand MBIB0367E KV113B0080 (Mot. 799-01) Camshaft pulley holder Tool for locking sprockets for toothed timing belt MBIB0368E EM-233 PREPARATION [K9K] NISSAN tool number (RENAULT tool No.) Tool name Description KV113B0090 (Mot. 1335) Valve seal remover Tool for removing valve stem seals MBIB0370E KV113B0100 (Mot. 1378) Engine sub-attachment X and Y engine pins MBIB0371E KV113B0110 (Mot. 1430) TDC set pin Set of TDC pins KV113B0120 (Mot. 1485-01) Oil jet remover Tool for removing the piston bottom oil jets MBIB0372E KV113B0130 (Mot. 1489) TDC set pin TDC setting pin MBIB0373E KV113B0140 (Mot. 1492) Bearing assembling set Tool for installing connecting rod bearing MBIB0374E KV113B0150 (Mot. 1492-03) Bearing assembling adapter Adaptation kit for installing the detachable cap connecting rod bearing MBIB0375E KV113B0160 (Mot. 1493-01) Bearing insert Tool for installing main bearing MBIB0376E EM-234 PREPARATION [K9K] NISSAN tool number (RENAULT tool No.) Tool name Description KV113B0170 (Mot. 1494) Oil jet remover plate Tool for removing oil jets KV113B0180 (Mot. 1511-01) Valve seal drift Tool for installing valve stem seals A EM C D MBIB0378E KV113E0010 (Mot. 1566) Fuel spill tube spanner Spanner for installing and removing high pressure pipes E F MBIB0379E KV113B0190 (Mot. 1567) Clip pliers Pliers for exhaust gas recycling pipe clips KV113B0200 (Mot. 1573) Cylinder head stand Cylinder head support G H I MBIB0380E KV113B0210 (Mot. 1585) Front oil seal drift J Tool for installing crankshaft seals, flywheel end K L MBIB0381E KV113B0220 (Mot. 1586) Front oil seal drift set Tool for installing crankshaft seals, timing end KV113B0230 (Mot. 1632) Camshaft seal insert Tool for installing inlet camshaft seals KV113B0240 (Rou. 15-01) Shaft protector Internal shaft protector 16 mm (0.63 in) dia. EM03470000 ( — ) Piston ring compressor Installing piston assembly into cylinder bore M NT044 EM-235 PREPARATION [K9K] NISSAN tool number (RENAULT tool No.) Tool name KV10111100 ( — Seal cutter Description Removing oil pan ) NT046 WS39930000 ( — Tube presser Pressing the tube of liquid gasket ) NT052 KV10112100 ( — ) Angle wrench Tightening bolts for bearing cap, cylinder head, etc. in angle NT014 Commercial Service Tools BBS002PS (RENAULT tool No.) Tool name Description Manual lift table caddy Removing and installing engine ZZA1210D Piston ring expander Removing and installing piston ring NT030 (Mot. 588) Liner retaining strap MBIB0364E EM-236 PREPARATION [K9K] (RENAULT tool No.) Tool name (664000) Cylinder head test container Description A Tool for testing the cylinder head, including: a tray and the various kits suited for each model of cylinder head (plug, sealing plate, blanking plate). EM C MBIB0383E Torx socket Standard 1/2" (12.7 mm) square drive 8/12 / 14 female torx socket. (Mot. 1505) (Mot. 1715) Belt tension setting tool Tool for belt tension checking with frequency D E F MBIB1423E Glow plug wrench Articulated wrench for removing and installing the glow plugs G H MBIB0387E Main bearing wrench Wrench for removing main bearings I J MBIB0388E (Mot. 1638) Belt tension gauge Setting drive belt tension K L MBIB0382E Engine support bar M Using with engine support chain A: Approx. 12.5 mm (0.492in) MBIB0961E Engine support chain Using with engine support bar MBIB0962E EM-237 IDENTIFICATION INFORMATION [K9K] IDENTIFICATION INFORMATION Engine Identification PFP:00010 BBS002PT Identification is by means of an engraved plate on the cylinder block which carries: ● A: engine type ● B: engine type approval letter ● D: code ● E: engine suffix ● F: engine serial number ● G: engine assembly plant Engine Compression ratio Bore and stroke mm (in) K9K 18.25/1 76 x 80.5 (2.992 x 3.169) Displacement cm3 (cu in) 1,461 (89.15) MBIB0322E EM-238 NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING [K9K] NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING NVH Troubleshooting —Engine Noise PFP:00003 A BBS002PU EM C D E F G H I J K L M MBIB0554E EM-239 NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING [K9K] Use the Chart Below to Help You Find the Cause of the Symptom. BBS002PV 1. Locate the area where noise occurs. 2. Confirm the type of noise. 3. Specify the operating condition of engine. 4. Check specified noise source. If necessary, repair or replace these parts. Operating condition of engine Location of noise Type of noise Before warmup After warmup When starting When idling When racing While driving Source of noise Check item Reference page Top of engine Rocker cover Cylinder head Ticking or clicking C A — A B — Tappet noise Valve clearance EM-324 Crankshaft pulley Cylinder block (Side of engine) Oil pan Slap or rap A — — B B A Piston slap noise Piston ring end gap EM-327 Front of engine Timing belt cover Tapping or ticking B Timing belt tensioner noise Timing belt tensioner operation EM-272 Drive belts deflection EM-242 Water pump operation CO-54 Front of engine A A — B B Squeaking or fizzing A B — B — C Drive belts (Sticking or slipping) Squall Creak A B — B A B Water pump noise A: Closely related B: Related C: Sometimes related —: Not related EM-240 ENGINE ROOM COVER [K9K] ENGINE ROOM COVER Removal and Installation PFP:14049 A BBS002PW EM C D E F G H I MBIB1412E 1. Engine room cover 2. Engine room cover bracket J REMOVAL Remove engine room cover from engine room cover bracket. CAUTION: Do not damage or scratch cover when installing or removing. ● INSTALLATION ● K L Install in the reverse order of removal. NOTE: Press engine room cover until hearing the “click”. EM-241 M DRIVE BELTS [K9K] DRIVE BELTS Checking Drive Belts PFP:02117 BBS002PX WARNING: Be sure to perform when the engine is stopped. 1. Inspect belts for cracks, fraying, wear and oil. If necessary, replace. 2. Tighten auto-tensioner lock nut (models with A/C compressor) or idler pulley lock nut (models without A/C compressor) by hand and measure deflection or tension without looseness. MBIB0664E 3. When measuring deflection, apply 98 N (10 kg, 22 lb) at the marked point as shown (models without A/C compressor). MBIB1066E Tension Adjustment BBS002PY MODELS WITH A/C COMPRESSOR Belt tensioning is not necessary, as it is automatically adjusted by auto-tensioner. MODELS WITHOUT A/C COMPRESSOR ● ● Tighten the accessories belt using tool (Mot. 1638) by tightening the nut (both tension wheel mounting bolts are loosened). Check the belt tension using tools (Mot. 1715) and (Mot. 1505) . MBIB1422E EM-242 DRIVE BELTS [K9K] Belt tightening method for adjustment Adjusting bolt on idler pulley A The tension value is 234±10 Hz. NOTE: EM The engine must be turned through two revolutions in order to position the belt correctly. CAUTION: ● When checking belt tension immediately after installation, first adjust it to the specified value. Then, after turning the crankshaft two turns or more, re-adjust to the specified value to avoid vari- C ation in deflection between pulleys. ● When installing belt, make sure that it is correctly engaged with pulley groove. ● Keep oil and water away from belt. D ● Do not twist or bend belt excessively. ● Removal and Installation BBS002PZ CAUTION: ● Replace any belt that has been removed with a new one. ● Auto-tensioner and idle pulley must be replaced with a new one when the belt is replaced. ● Do not run the engine without the drive belts to avoid damaging the crankshaft pulley. E F REMOVAL 1. 2. 3. 4. 5. ● G Remove engine undercover. Remove RH front wheel. Remove right side splash cover. Remove RH head light assembly. Remove drive belt. Turn clockwise adjusting bolt. H I J K MBIB0353E 6. If necessary, remove auto-tensioner (models with A/C compressor) or idler pulley (models without A/C compressor). INSTALLATION 1. Install auto-tensioner mounting bolt (models with A/C compressor) or idler pulley mounting bolt (models without A/C compressor). Auto-tensioner mounting bolt (models with A/C compressor) Idler pulley mounting bolt (models without A/C compressor) : 40 N·m (4.1 kg-m, 30 ft-lb) : 30 N·m (3.1 kg-m, 22 ft-lb) EM-243 L M DRIVE BELTS [K9K] ● The right figure is for example of models with A/C compressor. Align the notch and tighten mounting bolt. MBIB0558E 2. Install the drive belt. CAUTION: ● Make sure belt is correctly engaged with the pulley groove. ● Check for oil and coolant on belt and each pulley groove. NOTE: The drive belt has five teeth as opposed to the pulleys which have six. It is therefore essential to ensure that tooth (O) remains free when installing the belt. MBIB0516E 3. 4. Adjust belt tension (models without A/C compressor). Refer to EM-242, "Tension Adjustment" . Make sure that tension of each belt is within the standard. EM-244 AIR CLEANER AND AIR DUCT [K9K] AIR CLEANER AND AIR DUCT Removal and Installation PFP:16500 A BBS002Q1 EM C D E F G H I MBIB9017E 1. Air duct (suction) 2. Blow-by hose 3. Air cleaner case 6. Air mass flow sensor 4. Air cleaner filter 5. Air duct (inlet) 7. O-ring 8. Grommet J K : To turbocharger REMOVAL 1. 2. 3. 4. 5. 6. 7. 8. Disconnect battery ground cable. Disconnect battery positive cable. Remove engine room cover. Refer to EM-241, "ENGINE ROOM COVER" . Disconnect blow-by hose. Remove air duct (suction) mounting clip and remove air duct (suction). Remove battery. Remove air duct (inlet) by loosing clamp clip. Remove air cleaner case by sliding the air cleaner case frontward. CAUTION: Slide the air cleaner case carefully so as not to damage it on the air cleaner case and harness bracket. INSTALLATION ● Install in the reverse order of removal. EM-245 L M AIR CLEANER AND AIR DUCT [K9K] Changing Air Cleaner Filter BBS002Q2 REMOVAL 1. Open air cleaner case. MBIB1035E 2. Remove air cleaner filter. MBIB9018E INSTALLATION Install in the reverse order of removal. EM-246 CHARGE AIR COOLER [K9K] CHARGE AIR COOLER Removal and Installation (For 50kW) PFP:14461 A BBS002Q4 EM C D E F G H I J K L M MBIB9033E 1. Hose clamp 2. Inlet pipe assembly 3. Air inlet hose 4. Air inlet tube 5. Charge air cooler 6. Alternator 7. Spacer 8. Cylinder head 9. Radiator upper core 10. Inlet pipe bracket : Paint mark : Mark REMOVAL 1. 2. 3. Remove air inlet hose and tube between inlet pipe assembly and charge air cooler. Remove engine undercover. Remove bumper undercover. Refer to EI-4, "FRONT BUMPER" . EM-247 CHARGE AIR COOLER [K9K] 4. Liberate the clamp [A] securing charge air cooler (1) to radiator (2) and pull to release charge air cooler from the radiator lower core(3). MBIB9031E 5. 6. Remove charge air cooler from underbody as shown. Remove grommet (4) from the radiator lower core. Arrow: vehicle front direction CAUTION: ● Avoid interference between the charge air cooler and radiator. ● When removing charge air cooler, close opening on turbo charger and intake manifold with shop cloth or other suitable material. MBIB9020E INSPECTION AFTER REMOVAL 1. 2. Check that the charge air cooler is not full of oil. In that case, clean it with cleaning agent and then let it dry. Check air passages of charge air cooler core and fins for clogging, leaks or deformation. Clean or replace charge air cooler in necessary. ● Be careful not to deform core fins. ● For cleaning procedure of charge air cooler core, refer to CO-53, "Checking Radiator" . INSTALLATION Install in the reverse order of removal paying attention to the following points: ● Apply a neutral detergent (fluid) to the joint between hoses and pipes (oil is not permissible). ● Pay attention to identification mark and direction. ● When installing air inlet hoses and tubes. Refer to EM-247, "Removal and Installation (For 50kW)" . EM-248 CHARGE AIR COOLER [K9K] Removal and Installation (For 65kW) BBS002Q5 A EM C D E F G H I J K L M MBIB9016E 1. Hose clamp 2. Inlet pipe assembly 3. Air inlet hose 4. Air inlet tube 5. Charge air cooler 6. Alternator 7. Spacer 8. Cylinder head 9. Radiator upper core : Paint mark : Mark REMOVAL 1. 2. 3. Remove air inlet hose and tube between inlet pipe assembly and charge air cooler. Remove engine undercover. Remove bumper undercover. Refer to EI-4, "FRONT BUMPER" . EM-249 CHARGE AIR COOLER [K9K] 4. Liberate the clamp [A] securing charge air cooler (1) to radiator (2) and pull to release charge air cooler from the radiator lower core(3). MBIB9031E 5. 6. Remove charge air cooler from underbody as shown. Remove grommet (4) from the radiator lower core. Arrow: vehicle front direction CAUTION: ● Avoid interference between the charge air cooler and radiator. ● When removing charge air cooler, close opening on turbo charger and intake manifold with shop cloth or other suitable material. MBIB9020E INSPECTION AFTER REMOVAL 1. 2. Check that the charge air cooler is not full of oil. In that case, clean it with cleaning agent and then let it dry. Check air passages of charge air cooler core and fins for clogging, leaks or deformation. Clean or replace charge air cooler in necessary. ● Be careful not to deform core fins. ● For cleaning procedure of charge air cooler core, refer to CO-53, "Checking Radiator" . INSTALLATION Install in the reverse order of removal paying attention to the following points: ● Apply a neutral detergent (fluid) to the joint between hoses and pipes (oil is not permissible). ● Pay attention to identification mark and direction. ● When installing air inlet hoses and tubes. Refer to EM-249, "Removal and Installation (For 65kW)" . EM-250 EGR UNIT [K9K] EGR UNIT Removal and Installation PFP:14710 A BBS002Q7 EM C D E F G H I MBIB1414E 1. Air inlet tube 2. EGR solenoid valve 3. Air duct and blow-by unit assembly 4. Water port 5. EGR unit housing 6. EGR tube REMOVAL 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. K Remove battery ground cable. Remove engine room cover. Refer to EM-241, "ENGINE ROOM COVER" . Remove air cleaner case and air duct (inlet). Refer to EM-245, "AIR CLEANER AND AIR DUCT" . Remove wiper assembly. Remove bulk head cover. Disconnect EGR solenoid valve connector. Remove mounting bolts. Drain engine coolant and water hose. Loosen turbocharger inlet tube. Remove front engine slinger. Refer to EM-280, "REMOVAL" . Remove air inlet tube. L M MBIB1415E EM-251 J EGR UNIT [K9K] 12. Remove air duct and blow-by unit assembly. 13. Remove EGR tube mounting bolts. 14. Remove EGR unit housing and EGR tube. MBIB1427E INSTALLATION ● Install in the reverse order of removal. EM-252 EXHAUST MANIFOLD, TURBOCHARGER, CATALYST [K9K] EXHAUST MANIFOLD, TURBOCHARGER, CATALYST Removal and Installation PFP:14004 A BBS002QA EM C D E F G H I MBIB1416E 1. Catalyst 2. Bracket 3. Turbocharger assembly 4. Hose 5. Exhaust manifold 6. EGR unit 7. Gasket K REMOVAL 1. 2. 3. 4. 5. 6. 7. J Remove battery ground cable. Remove engine undercover. Remove air cleaner case and air duct (inlet). Refer to EM-245, "AIR CLEANER AND AIR DUCT" . Remove wiper assembly. Remove bulk head cover. Remove EGR unit assembly. Refer to EM-251, "EGR UNIT" . Remove turbocharger assembly as follows: EM-253 L M EXHAUST MANIFOLD, TURBOCHARGER, CATALYST [K9K] a. b. c. Remove catalyst mounting bolts and brackets. Remove exhaust front tube. Refer to EX-3, "Removal and Installation" . CAUTION: Temporarily fix on vehicle side with rope or so to avoid putting stress on exhaust center tube. Remove catalyst. MBIB1428E 8. 9. Each wiring and piping (disconnect/move). Loosen exhaust manifold mounting nuts in the reverse order as shown. MBIB1417E 10. Rotate the exhaust manifold and turbocharger assembly so that the rear side (EGR tube mounting side) faces upward. And then pull out the assembly from between the engine and the air conditioning piping. CAUTION: Be careful not to deform each turbocharger piping when pulling out the assembly. INSTALLATION 1. Tighten the mounting nuts in numerical order as shown. MBIB1417E 2. Install in reverse order of removal after this step. INSPECTION AFTER INSTALLATION Start engine and raise engine speed to check no exhaust emission leaks. EM-254 EXHAUST MANIFOLD, TURBOCHARGER, CATALYST [K9K] Disassembly and Assembly BBS002QB A EM C D E F MBIB1418E 1. Washer 2. 4. Turbocharger 7. Turbocharger oil outlet pipe Oil tube 3. O-ring 5. Exhaust manifold 6. Gasket 8. Gasket G H DISASSEMBLY ● After applying penetrative lubricant to the mounting nuts, check for the penetration of the lubricant, and then loosen the nuts to remove. CAUTION: Do not disassemble or adjust the turbocharger body. I J INSPECTION AFTER DISASSEMBLY Turbocharger K L M MBIB1419E CAUTION: When the compressor wheel turbine wheel or rotor shaft is damaged, remove all the fragments and foreign matter left in the following passages in order to prevent a secondary failure: Suction side Exhaust side : Between turbocharger and air cleaner : Between turbocharger and catalyst EM-255 EXHAUST MANIFOLD, TURBOCHARGER, CATALYST [K9K] ASSEMBLY Install in the reverse order of removal. NOTE: Apply LOCTITE FRENETANCH or equivalent to the threads of the turbocharger oil inlet pipe union to the cylinder head. ● EM-256 OIL PAN [K9K] OIL PAN Removal and Installation PFP:11110 A BBS002QC EM C D E F G H I MBIB0571E 1. Baffle plate 2. Gasket 3. Oil pan 4. O-ring 5. Drain plug 6. Oil level gauge 7. Crankshaft position sensor (POS) J K CAUTION: To avoid the danger of being scalded, never drain the engine oil when the engine is hot. REMOVAL 1. 2. 3. 4. L Remove engine undercover. Remove RH front wheel. Remove right side splash cover. Remove center bearing bracket as shown. M MBIB1037E EM-257 OIL PAN [K9K] 5. Remove A/C compressor bracket mounting bolt as shown. MBIB1038E 6. 7. 8. 9. Remove bolts (3) from the catalyst bracket. Refer to EM-253, "EXHAUST MANIFOLD, TURBOCHARGER, CATALYST" . Remove oil level gauge guide. Drain engine oil. Refer to LU-24, "Changing Engine Oil" . CAUTION: Perform when engine is cold. Remove oil pan and transaxle joint bolts. MBIB1039E 10. Support the engine bottom of the oil pan with a transmission jack etc. MBIB0575E 11. Remove oil pan bolt reverse order as shown. MBIB1257E EM-258 OIL PAN [K9K] ● Insert seal cutter (special service tool) between upper oil pan and cylinder block. Slide tool by tapping on the side of the tool with a hammer. CAUTION: Exercise care not to damage mating surface. A EM C SEM365EA D 12. Remove oil pan and baffle plate. INSPECTION AFTER REMOVAL E Clean oil pump assembly if any object attached. INSTALLATION ● 1. Install in the reverse order of removal paying attention to the following. Apply liquid gasket as shown. ● Use Genuine Liquid Gasket or equivalent. F G H I MBIB0593E J K L MBIB0594E 2. 3. 4. Install baffle plate. Install oil pan bolts in numerical order as shown. ● Tighten the bolts in the numerical order shown in the figure to a torque of 8 N·m (0.8 kg-m, 71 in-lb). ● Tighten the mounting bolts of oil pan on the clutch housing without locking. ● Tighten the bolts in the numerical order shown in the figure to a torque of 15 N·m (1.5 kg-m, 11 ft-lb). ● Tighten the mounting bolts of oil pan on the clutch housing to a torque of 44 N·m (4.5 kg-m, 32 ft-lb). At least 30 minutes after oil pan is installed, pour engine oil. INSPECTION AFTER INSTALLATION ● ● Inspection the engine oil level. Refer to LU-23, "ENGINE OIL" . Start the engine, and make sure there is no leak of engine oil. Refer to LU-23, "ENGINE OIL" . EM-259 MBIB1257E M GLOW PLUG [K9K] GLOW PLUG Removal and Installation PFP:22401 BBS002QD MBIB0576E 1. Glow plug REMOVAL CAUTION: Remove glow plug only if necessary. If carbon adheres, it may be stuck and broken. 1. Disconnect battery ground cable. 2. Remove engine room cover. Refer to EM-241, "ENGINE ROOM COVER" . 3. Disconnect harness connector from glow plug. 4. Remove glow plug. CAUTION: ● When removing or installing, do not use such tools as an air impact wrench. ● Handle it carefully without giving any impact, even after removal. [As a guide, if it drops from height of 10 cm (3.94 in) or higher, always replace it.] INSTALLATION 1. 2. 3. Remove adhered carbon from glow plug installation hole with a reamer. Install glow plug. Install remaining parts in reverse order of removal. EM-260 VACUUM PUMP [K9K] VACUUM PUMP Removal and Installation PFP:41920 A BBS002QF EM C D E F MBIB1420E 1. Vacuum pump 2. Gasket 3. Vacuum hose G INSPECTION BEFORE REMOVAL 1. 2. Disconnect vacuum hose, and connect a vacuum gauge via 3-way connector. ● Disconnect point where vacuum from vacuum pump can be measured directly and install 3-way connector. Start engine and measure generated vacuum at idle speed. Standard J Remove engine room cover. Refer to EM-241, "ENGINE ROOM COVER" . Remove battery. Remove air duct (suction). Refer to EM-245, "AIR CLEANER AND AIR DUCT" . Remove EGR inlet tube. Refer to EM-251, "EGR UNIT" . Disconnect vacuum hose from vacuum pump side. Remove vacuum pump. INSTALLATION ● I : – 86.6 to – 101.3 kPa (– 866 to – 1,013 mbar, – 650 to – 760 mmHg, – 25.59 to – 29.92 inHg) REMOVAL 1. 2. 3. 4. 5. 6. H K L M Install in the reverse order of removal. EM-261 HIGH PRESSURE PIPES [K9K] HIGH PRESSURE PIPES Removal and Installation PFP:16680 BBS0058E MBIB9025E 1. High pressure pipe 2. Dipstick guide 3. High pressure pipes protection cover REMOVAL CAUTION: ● Be sure to read “Precautions for Diesel Equipment”. Refer to EM-229, "Precautions for Diesel Equipment" . ● Wait until the fuel temperature drops before carrying out any work. ● Order the special high pressure injection circuit plug kit. NOTE: It is possible to replace a single high pressure pipe. 1. Disconnect the battery. 2. Remove charge air cooler hose and pipes. Refer to EM-247, "Removal and Installation (For 50kW)" and EM-249, "Removal and Installation (For 65kW)" . 3. Remove engine cover. Refer to EM-241, "ENGINE ROOM COVER" . 4. Remove the dipstick guide and plug the hole. 5. Remove high pressure pipes protection cover. 6. Remove the neck located on the fuel rail, 7. Remove the clips connecting the high pressure pipes. EM-262 HIGH PRESSURE PIPES [K9K] 8. Undo the mounting nut of the rail a few turns. A EM C MBIB9026E D CAUTION: ● When undoing the high pressure pipes, it is essential to maintain the central union of the injector (2). ● Do not damage the injector's leak return duct (1). E F G MBIB9027E H NOTE: Undo the nut on the pump side or the injector side, then the nut located on the rail side. Undo the nuts for each pipe in turn. Move the nut along the pipe keeping the olive in contact with the taper. 9. Remove all the high pressure pipes. 10. Plug all the holes in the injection circuit. 11. Remove the rail. I J K MBIB9026E L INSTALLATION CAUTION: All the high pressure pipes removed must be systematically replaced. 1. Finger tightens the nuts. 2. Before fitting the new high pressure pipes, lightly lubricate the nut threads with the oil from the sachet provided in the new parts kit. NOTE: Fit the pump/rail pipe before the rail/injector pipes. 3. Fit the pump-rail high pressure pipe as follow: ● Remove the protective plugs from the high pressure pump outlet, the high pressure rail inlet and the pipe. ● Insert the high pressure pipe olive into the taper of the high pressure pump outlet, ● Insert the high pressure pipe olive into the taper of the high pressure rail inlet. ● Finger tighten the nuts of the high pressure pipe starting with the one located on the rail side. 4. Fit the rail-injector high pressure pipe as follow: EM-263 M HIGH PRESSURE PIPES [K9K] 5. 6. 7. CAUTION: When tightening the high pressure pipes, it is essential to maintain the central union of the injector (2). ● Remove the protective plugs from the high pressure rail outlet, the injector high pressure inlet and the pipe. ● Insert the high pressure pipe olive into the taper of the high pressure injector inlet, ● Insert the high pressure pipe olive into the taper of the high pressure rail outlet. ● Finger tighten the nuts of the high pressure pipe starting with the one located on the injector side. Fit the remaining high pressure pipes as you did previously. NOTE: The order in which the pipes are installed is not important. Fit a new clips supplied with the new pipes onto the high pressure pipes: ● Insert the first half of the clip using adjustable pliers ● Insert the second half of the clip using adjustable pliers. CAUTION: Pay attention to the direction of installation of the second clip. The tabs located in the centre of the clip will only fit together in one position. Tighten the rail nuts to the torque. MBIB9027E : 28 N·m (2.9 kg-m, 21 ft-lb) CAUTION: ● Do not touch the pipes with the wrench when torque tightening. ● Follow the order and tightening torque of the high pressure pipes. 8. MBIB9028E Using the recommended tools, tighten the nuts on the rail pump high pressure pipe: ● Tighten the nut on the rail side to the torque : 38 N·m (3.9 kg-m, 28 ft-lb) ● Tighten the nut on the pump side to a torque of : 38 N·m (3.9 kg-m, 28 ft-lb) MBIB9037E 9. Using the recommended tools, tighten the nuts on the rail - injector high pressure pipes: Tool number: KV113E0010 (Mot.1566) ● Tighten the nut on the injector side to a torque of : 38 N·m (3.9 kg-m, 28 ft-lb) ● T tighten the nut on the rail side to a torque of : 38 N·m (3.9 kg-m, 28 ft-lb) MBIB9029E EM-264 HIGH PRESSURE PIPES [K9K] CAUTION: ● When undoing the high pressure pipes, it is essential to maintain the central union of the injector (2). ● Do not damage the injector's leak return duct (1). NOTE: Tighten one pipe fully before moving on to the next pipe. 10. Tighten the rail nut to the torque. Refer to EM-267, "INJECTOR RAIL" . 11. Refit in the reverse order to removal for the other refitting operations. 12. Test the sealing of the high pressure after it has been repaired (refer to EM-231, "SPECIAL FEATURES" ). A EM C MBIB9027E D E F G H I J K L M EM-265 FUEL INJECTOR [K9K] FUEL INJECTOR Removal and Installation PFP:16600 BBS0058B REMOVAL CAUTION: ● Be sure to read “Precautions for Diesel Equipment”. Refer to EM-229, "Precautions for Diesel Equipment" . ● Wait until the fuel temperature drops before carrying out any work. ● Order the special high pressure injection circuit plug kit. ● It is forbidden to open an injector. If you open an injector by mistake, you will have to change it. This is because of the manufacturing and installation tolerances and because there is a risk of contaminating the inside of the injector. ● The rod filter of the injector must not be removed. NOTE: It is possible to replace a single high pressure pipe. 1. Disconnect fuel return pipe. Refer to EM-268, "HIGH PRESSURE PUMP" . 2. Remove high pressure pipe of the injector. Refer to EM-262, "HIGH PRESSURE PIPES" . 3. Disconnect the diesel return pipe on the injector. 4. Plug all the holes of the injection circuit. 5. Disconnect the injector electrical connector (1). 6. Unscrew the injector bracket (2). 7. Remove the injector. 8. Pull off the flame shield washer. MBIB9030E INSTALLATION NOTE: Read the 16 digit code on the new injector before refitting it and programming the code into he ECM using the CONSULT-II (see section “Special features, Replacing injectors”). The codes unique to each injector, it specifies the flow. CAUTION: All the high pressure pipes removed must be systematically replaced. 1. Clean the injector sockets and the injector bodies, as well as their brackets using a lint-free cloth (use the wipes recommended for this purpose, dipped in clean solvent. 2. Dry off using a different new wipe. 3. Replace the flame shield washer with a new one. 4. Position the injector. 5. Tighten its mounting clamp to the torque. : 28 N·m (2.9 kg-m, 21 ft-lb) 6. Reinstall high pressures pipes. Refer to EM-262, "HIGH PRESSURE PIPES" . EM-266 MBIB9027E INJECTOR RAIL [K9K] INJECTOR RAIL Removal and Installation PFP:00018 A BBS0058C REMOVAL CAUTION: EM ● Be sure to read “Precautions for Diesel Equipment”. Refer to EM-229, "Precautions for Diesel Equipment" . ● Wait until the fuel temperature drops before carrying out any work. C ● Order the special high pressure injection circuit plug kit. 1. Disconnect the battery. 2. Remove charge air cooler hose and pipes. Refer to EM-247, "Removal and Installation (For 50kW)" and D EM-249, "Removal and Installation (For 65kW)" . 3. Remove engine cover. Refer to EM-241, "ENGINE ROOM COVER" . 4. Remove the neck located on the fuel rail. E 5. Remove the dipstick guide and plug the hole. 6. Remove fuel pipes cover. Refer to EM-262, "HIGH PRESSURE PIPES" . F 7. Disconnect the pressure sensor connector from the rail. 8. Remove all high pressure pipes connecting injectors to the rail. Refer to EM-262, "HIGH PRESSURE PIPES" . G 9. Remove all high pressure pipes connecting high pressure pump to the rail. Refer to EM-262, "HIGH PRESSURE PIPES" . 10. Plug all the holes of the injection circuit. H 11. Remove injector rail mounting nuts and remove the injector rail. I MBIB9026E INSTALLATION 1. 2. Refit in the reverse order to removal for the other refitting operations. Test the sealing of the high pressure after it has been repaired (refer to EM-231, "SPECIAL FEATURES" ). J K L M EM-267 HIGH PRESSURE PUMP [K9K] HIGH PRESSURE PUMP Removal and Installation PFP:17082 BBS0058D MBIB9035E 1. Flow actuator 2. Fuel temperature sensor 3. Injector connector 4. Fuel supply 5. Fuel return pipe 6. Fuel return pipe (injector) 7. Fuel rail neck 8. Pressure sensor REMOVAL CAUTION: ● Be sure to read “Precautions for Diesel Equipment”. Refer to EM-229, "Precautions for Diesel Equipment" . ● Wait until the fuel temperature drops before carrying out any work. ● Order the special high pressure injection circuit plug kit. ● It is strictly forbidden to remove any injection pump pulley marked number 070 575 (see diagram). If the pump is being replaced, the pulley must be replaced. 1. Disconnect the battery. 2. Remove charge air cooler hose and pipes. Refer to EM-247, "Removal and Installation (For 50kW)" and EM-249, "Removal and Installation (For 65kW)" . 3. Remove engine cover. Refer to EM-241, "ENGINE ROOM COVER" . 4. Remove the timing belt. Refer to EM-272, "TIMING BELT" . MBIB9036E 5. Remove the neck located on the fuel rail, 6. Remove the dipstick guide and plug the hole. EM-268 HIGH PRESSURE PUMP [K9K] 7. 8. Remove fuel pipes cover. Refer to EM-262, "HIGH PRESSURE PIPES" . A Carefully disconnect: ● The connectors from the flow actuator, ● The connectors from the fuel temperature sensor, EM ● The injector connectors, ● The pre-heater (glow) ● On the pump, the fuel supply and return pipes. C ● The return pipe connecting the injectors with the pump. 9. Remove the high pressure pipe connecting the pump to the rail. Refer to EM-262, "HIGH PRESSURE PIPES" . D 10. Plug all the holes of the injection circuit. 11. Remove the three mounting bolts from the injection pump then remove it. E INSTALLATION 1. 2. 3. 4. 5. Fit the pump then position the mounting bolts without tightening them. Before fitting the new high pressure pipe, lightly lubricate the nut threads with the oil from the sachet provided in the new parts kit. Refit the high pressure pipe, to do this: ● remove the protective plugs, ● insert the high pressure pipe olive into the taper of the high pressure pump outlet, ● insert the high pressure pipe olive into the taper of the high pressure rail inlet. Finger tighten the nuts of the high pressure pipe starting with the one located on the rail side. Tighten the mounting bolts on the high pressure pump to the torque. : 21 N·m (2.1 kg-m, 15 ft-lb) 6. 7. 8. F G H I Tighten the high pressure pipes to the torque. Refer to EM-262, "HIGH PRESSURE PIPES" . Refit in the reverse order to removal for the other refitting operations. Test the sealing of the high pressure after it has been repaired (refer to EM-231, "SPECIAL FEATURES" ). J K L M EM-269 ROCKER COVER [K9K] ROCKER COVER Removal and Installation PFP:13264 BBS002QG MLIA0009E 1. Oil filler cap 4. Gasket 2. Oil catcher 3. Rocker cover REMOVAL 1. 2. 3. 4. 5. 6. Remove engine room cover. Refer to EM-241, "ENGINE ROOM COVER" . Remove air duct (suction). Refer to EM-245, "AIR CLEANER AND AIR DUCT" . Remove inlet pipe assembly and air inlet hose, and inlet pipe bracket. Refer to EM-247, "Removal and Installation (For 50kW)" or EM-249, "Removal and Installation (For 65kW)" . Remove rear engine slinger. Unclip timing belt upper cover. Remove rocker cover. ● Loosen holding bolts in the reverse order as shown in the figure and remove. MBIB0580E EM-270 ROCKER COVER [K9K] INSTALLATION 1. A Apply liquid gasket on locations shown in the figure. ● Use Genuine Liquid gasket or equivalent. EM C D E F G MBIB0581E 2. H Tighten holding bolts in the numerical order as shown in the figure. : 10 N·m (1.02 kg-m, 7.4 ft-lb) 3. I Install in the reverse order of removal after this steps. J K MBIB0580E L M EM-271 TIMING BELT [K9K] TIMING BELT Removal and Installation PFP:13028 BBS002QH MBIB1258E 1. Timing belt inner cover 4. Timing belt tensioner 5. Timing belt upper cover 6. Camshaft position sensor 7. Timing belt lower cover 8. Cylinder head suspended bracket 9. Crankshaft pulley 10. Crankshaft sprocket 2. Timing belt 11. Rear oil seal 3. Camshaft sprocket 12. Rear oil seal retainer 13. Gasket CAUTION: ● Apply new engine oil to parts marked in illustration before installation. ● Replace any belt that has been removed. ● Never turn the engine in the direction opposite to that of normal operation. ● When replacing the timing belt, be sure to replace the timing belt tensioner. ● Do not run the engine without the drive belts to avoid damaging the crankshaft pulley. REMOVAL 1. 2. 3. 4. 5. Remove the following parts. ● Battery ground cable ● Undercover ● RH front wheel ● RH head light assembly Remove right side splash cover. Remove engine room cover. Refer to EM-241, "ENGINE ROOM COVER" . Remove drive belt. Refer to EM-242, "DRIVE BELTS" . Install engine slingers. Refer to EM-280, "REMOVAL" . EM-272 TIMING BELT [K9K] 6. Set the engine support bar (commercial service tool) or suitable tool, and secure the engine in position. A EM C MBIB1046E D 7. 8. Remove RH engine torque rod. Remove RH engine mounting. E F G MBIB1041E H 9. Remove RH engine mounting support bracket, RH engine mounting insulator and reservoir tank. 10. Remove upper timing cover, camshaft position sensor and cylinder head suspended mounting bracket. I J K MLIA0003E L 11. Remove timing belt lower cover. 12. Remove the TDC pin bolt. M MBIB0392E EM-273 TIMING BELT [K9K] 13. Rotate the crankshaft clockwise, until the position (A) of the came shaft pulley becomes opposite of the position (B) on the cylinder head. MBIB0393E 14. Screw in the TDC pin (special service tool). MBIB0394E 15. Turn the engine clockwise (timing side) until the crankshaft touches the TDC pin (special service tool). MBIB0395E 16. The pin (special service tool) must engage in the camshaft pulley and cylinder head holes. MBIB0396E 17. Remove crankshaft pulley: CAUTION: Do not remove fixing bolts. Keep loosened fixing bolts in place to protect removed crankshaft pulley from dropping. MBIB0591E EM-274 TIMING BELT [K9K] 18. Slacken the timing belt by loosening the bolt of tensioner, then remove timing belt. A EM C MBIB0592E D INSTALLATION ● Install in the reverse order of removal paying attention to the following. E Timing Belt Refer to EM-316, "TIMING ADJUSTMENT" . F G H I J K L M EM-275 CYLINDER HEAD [K9K] CYLINDER HEAD Removal and Installation PFP:11041 BBS002QI MBIB0596E 1. Front engine slinger 4. Camshaft sprocket 7. Valve rotator 2. Camshaft bracket 3. Camshaft 5. Cylinder head suspended bracket 6. Shim 8. Valve spring retainer 9. Valve spring 10. Valve cotter 11. Exhaust valve 12. Intake valve 13. Rear engine slinger 14. Cap 15. Cylinder head gasket 16. Cylinder head CAUTION: Apply new engine oil to parts marked in illustration before installation. REMOVAL 1. 2. 3. 4. 5. 6. 7. 8. Remove the following parts. ● Battery ground cable ● Undercover ● RH front wheel ● RH head light assembly Remove right side splash cover. Remove engine room cover. Refer to EM-241, "ENGINE ROOM COVER" . Drain engine coolant. Refer to CO-49, "DRAINING ENGINE COOLANT" . CAUTION: Perform when engine is cold. Remove air cleaner case and air duct (suction). Refer to EM-245, "AIR CLEANER AND AIR DUCT" . Remove radiator upper hose. Refer to CO-51, "RADIATOR" . Disconnect fuel feed tube and return tube from fuel injection pump. Refer to EM-268, "HIGH PRESSURE PUMP" . Remove oil level gauge guide. EM-276 CYLINDER HEAD [K9K] 9. Remove harnesses and connectors. A 10. Remove heater hoses. 11. Remove turbocharger assembly. Refer to EM-253, "EXHAUST MANIFOLD, TURBOCHARGER, CATALYST" . EM 12. Remove drive belt. Refer to EM-242, "DRIVE BELTS" . 13. Remove rocker cover. Refer to EM-270, "ROCKER COVER" . 14. Support underneath of engine by setting a manual lift table caddy (commercial service tool) or equivalent C tool. CAUTION: Put a piece of wood or something similar as supporting surface, secure a completely stable condiD tion. 15. Remove timing belt. Refer to EM-272, "TIMING BELT" . 16. Remove engine support bar. E CAUTION: During the removal operation, always be careful to prevent engine moves downward from the vehicle. F 17. Remove cylinder head bolt in the reverse order as shown. G H MBIB0323E I 18. Remove cylinder head assembly. J INSTALLATION ● Install in the reverse order of removal paying attention to the following. Cylinder Head Bolts K NOTE: Use a syringe to remove any oil which may have entered the cylinder head mounting bolt holes to achieve correct tightening of the bolts. CAUTION: All bolts must always be changed after removal. Do not oil the new bolts. ● Tighten all the bolts in the numerical order as shown. L : 25 N·m (2.6 kg-m, 18 ft-lb) ● Check that all the bolts are correctly tightened to 25 N·m (2.6 kgm, 18 ft-lb), then angle tightening of 245 to 265 degrees. CAUTION: ● Use an angle wrench (special service tool) to check tightening angle. ● Do not retighten the cylinder head bolts after preforming this procedure. MBIB0323E Disassembly and Assembly BBS002QJ DISASSEMBLY ● Refer to EM-288, "DISASSEMBLY OF THE CYLINDER HEAD" . INSPECTION AFTER DISASSEMBLY ● Refer to EM-291, "Inspection" . EM-277 M CYLINDER HEAD [K9K] ● ● Refer to EM-292, "Valve Clearance" . Refer to EM-321, "Cylinder Head" . ASSEMBLY ● Refer toEM-301, "Assembly" . EM-278 ENGINE ASSEMBLY [K9K] ENGINE ASSEMBLY Removal and Installation PFP:10001 A BBS002QL EM C D E F G H I MBIB9019E 1. Transaxle mounting insulator 2. Transaxle mounting upper bracket 3. Transaxle mounting stay 4. Engine torque rod 5. Engine mounting insulator 6. Engine mounting stay 7. Engine mounting bracket 8. Transaxle mounting lower bracket 9. Transaxle torque rod WARNING: ● Situate vehicle on a flat and solid surface. ● Place chocks at front and back of rear wheels. ● For engines not equipped with engine slingers, attach proper slingers and bolts described in PARTS CATALOG. CAUTION: ● Always be careful to work safely, avoid forceful or uninstructed operations. ● Do not start working until exhaust system and coolant are cool enough. ● If items or work required are not covered by the engine main body section, refer to the applicable sections. ● Always use the support point specified for lifting. ● Use either 2-pole lift type or separate type lift as best you can. If board-on type is used for unavoidable reasons, support at the rear axle jacking point with transmission jack or similar tool before starting work, in preparation for the backward shift of center of gravity. ● For supporting points for lifting and jacking point at rear axle, refer to GI-40, "LIFTING POINT" . EM-279 J K L M ENGINE ASSEMBLY [K9K] REMOVAL Description of work Remove engine and transaxle assembly from vehicle down ward. Separate engine and transaxle. Preparation 1. Remove the following parts. ● Battery ground cable ● Undercover ● Right side splash cover ● LH/RH front wheel ● RH head light assembly Engine room 2. Drain engine coolant. Refer to LU-24, "Changing Engine Oil" . CAUTION: Perform when engine is cold. 3. Remove engine room cover. Refer to EM-241, "ENGINE ROOM COVER" . 4. Remove air cleaner case and air duct (suction). Refer to EM-245, "AIR CLEANER AND AIR DUCT" . 5. Remove radiator upper hose. Refer to CO-51, "RADIATOR" . 6. Remove reservoir tank and hoses. Refer to CO-51, "RADIATOR" . 7. Remove fuel feed and return tubes. Refer to EM-268, "HIGH PRESSURE PUMP" . 8. Remove vacuum hose. Refer to EM-261, "VACUUM PUMP" . 9. Remove turbocharger air duct. Refer to EM-253, "EXHAUST MANIFOLD, TURBOCHARGER, CATALYST" . 10. Disconnect heater hoses. 11. Disconnect engine room harness from the engine side and set it aside for easier work. 12. Disconnect transaxle side harness and clutch hose. 13. Disconnect drain hose transaxle side. 14. Disconnect shift cable and select cable. Refer to MT-12, "CONTROL LINKAGE" . 15. Loosen wire bracket. 16. Disconnect all the body-side vacuum hoses and air hoses at engine side. 17. Disconnect fuel feed and return hoses, and plug it to prevent fuel from draining. Vehicle underbody 18. Remove drive shaft lock pin and lock nut. Refer to FAX-10, "FRONT DRIVE SHAFT" . 19. Remove ABS sensor from brake caliper. 20. Remove strut lower bolts. 21. Remove drive shaft assembly RH and LH. 22. Remove drive belt. Refer to EM-242, "DRIVE BELTS" . 23. Remove A/C compressor with piping connected from engine (with A/C compressor models). Temporarily secure it on body with a rope to avoid putting load on it. 24. Remove exhaust front tube. Refer to EX-3, "Removal and Installation" . 25. Remove engine rear mounting bracket. MBIB1044E Removal EM-280 ENGINE ASSEMBLY [K9K] 26. Install engine slingers (1) into front right of cylinder head and engine slinger (2) into rear left of cylinder head. A Slinger bolts: : 21 N·m (2.14 kg-m, 15.5 ft-lb) EM C MBIB9022E 27. Set the engine support bar (commercial service tool) or suitable tool, and secure the engine in position. ● Use a manual lift table caddy (commercial service tool) or equivalently rigid tool such as a jack or trestle. Securely support bottom of engine and transaxle. CAUTION: Put a piece of wood or something similar as the supporting surface, secure a completely stable condition. 28. Remove RH and LH engine mounting bolts. 29. Remove engine and transaxle assembly from vehicle downward by carefully operating supporting tools. CAUTION: MBIB1045E ● During the operation, make sure that no part interferes with body side. ● Before and during this lifting, always check if any harnesses are left connected. ● During the removal operation, always be careful to prevent vehicle from falling off the lift due to changes in the center of gravity. ● If necessary, support vehicle by setting a jack or equivalent tool at the rear. Separation Work CAUTION: During the operation, secure support the engine by placing a piece of wood under the engine oil pan, transaxle oil pan and suspended the engine slinger by baby crane (movable hoist) etc. 30. Remove starter motor. 31. Separate engine and transaxle. D E F G H I J K INSTALLATION L Install in the reverse order of removal. ● Do not allow oil to get on mounting insulator. Be careful not to damage mounting insulator. ● When installation directions are specified, install parts according to the direction marks on them referring to components illustration. ● Make sure that each mounting insulator is seated properly, and tighten mounting bolts and nuts. M INSPECTION AFTER INSTALLATION ● ● ● ● ● Before starting engine check the levels of coolant, lubrications and working oils. If less than required quantity, fill to the specified level. Before starting engine, bleed air from fuel piping. Refer to FL-28, "Bleeding Fuel Filter" . Run engine to check for unusual noise and vibration. Warm up engine thoroughly to make sure there is no leakage of coolant, lubricants, working oil, fuel and exhaust gas. Bleed air from passages in pipes and tubes of applicable lines. EM-281 OVERHAUL [K9K] OVERHAUL Tightening Torques PFP:00000 BBS002QM UPPER ENGINE Unit: N·m (kg-m, in-lb)*2 Unit: N·m (kg-m, ft-lb) Tightening torque Cylinder head : *1 Camshaft bearing : 10 (1.0, 7) Vacuum pump : 21 (2.1, 15) Cylinder head coolant outlet unit : 10 (1.0, 7) Exhaust manifold : 26 (2.7, 19) Glow plug : 15 (1.5, 11) Rocker cover : 10 (1.0, 7) Turbocharger-manifold mounting : 26 (2.7, 19) Turbocharger oil return pipe : 9 (0.9, 80)*2 Turbocharger oil delivery pipe : 23 (2.3, 17) Timing tensioner : 25 (2.6, 18) TDC cap : 20 (2.0, 15) Cylinder head suspended mounting bracket : 21 (2.1, 15) *1: Refer to tightening procedure in the text. BOTTOM ENGINE Unit: N·m (kg-m, in-lb)*2 Unit: N·m (kg-m, ft-lb) Tightening torque Oil cooler connector bolt : 45 (4.6, 33) Oil filter bracket : 45 (4.6, 33) Main bearing cap : 27 (2.8, 20) + 47°±5° (Angle tightening) Connecting rod : 20 (2.0, 15) + 45°±6° (Angle tightening) Knock sensor : 20 (2.0, 15) Oil level sensor : 25 (2.6, 18) Oil pump : 25 (2.6, 18) Oil pan : *1 Water pump : 11 (1.1, 8) Flywheel : 50 - 55 (5.1 - 5.6, 37 - 40) Crankshaft pulley : 20 (2.0, 15) + 130°±15° (Angle tightening) Water pump inlet pipe : 20 (2.0, 15) Alternator bracket : 44 (4.5, 32) Alternator : 25 (2.6, 18) A/C compressor : 21 (2.1, 15) *1: Refer to tightening procedure in the text. EM-282 OVERHAUL [K9K] Standard Replacement BBS002QN A PREPARING USED ENGINE The engine should be cleaned and drained (oil and water). Leave on the used engine or include in the return box: ● Oil filter ● Oil pressure switch ● Water pump ● Fuel injection pump ● Rail ● Injectors ● Glow plugs ● Oil level gauge ● Vacuum pump ● Flywheel Remember to remove: ● All coolant pipes ● Exhaust manifold ● Alternator ● Power steering pump ● A/C compressor ● Alternator bracket ● Oil level sensor ● Cylinder head coolant outlet unit The used engine should be secured to the base under the same conditions as the overhauled engine: ● Plastic plugs and covers fitted ● Cardboard cover over the assembly EM C D E F G H I J K L M EM-283 OVERHAUL [K9K] Disassembly BBS002QO REMOVING THE UPPER ENGINE 1. Remove the upper timing cover by unclipping the two tabs (A). MLIA0004E 2. Remove the lower timing cover by unclipping the three tabs (B) and pulling out the plastic bolt (C). MBIB0390E EM-284 OVERHAUL [K9K] 3. Remove the cylinder head suspended mounting bracket. A EM C D E F G MBIB0391E 4. Remove the TDC pin cap. H I J MBIB0392E POSITIONING THE BELT AT THE TIMING POINT 1. Position the hole (A) of the camshaft pulley almost opposite the hole (B) of the cylinder head. K L M MBIB0393E 2. Screw in the Tool KV113B0130 (Mot. 1489). MBIB0394E EM-285 OVERHAUL [K9K] 3. Turn the engine clockwise (timing side) until the crankshaft touches the Tool KV113B0130 (Mot. 1489). MBIB0395E 4. 5. The Tool KV113B110 (Mot. 1430) must engage in the camshaft pulley and cylinder head holes. Remove Tool KV113B0130 (Mot. 1489). MBIB0396E 6. Install the Tool KV113B0060 (Mot. 582-01). MBIB0397E 7. Remove the crankshaft pulley. MBIB0398E EM-286 OVERHAUL [K9K] 8. Slacken the timing belt by loosening the bolt of the tensioner, then remove the timing belt. A EM C D E F G MBIB0399E 9. Remove the timing belt tensioner and inner timing cover. H I J MBIB0400E 10. Remove air cleaner case. Refer to EM-245, "AIR CLEANER AND AIR DUCT" . 11. Remove the clamp, oil vapor rebreathing pipe and turbocharger oil supply pipe on the cylinder head side. K L M MBIB0402E EM-287 OVERHAUL [K9K] 12. Remove the turbocharger oil supply pipe on the turbocharger side, nuts (A) and the torx bolt of the turbocharger flange, bolts (B) of the catalytic converter bracket, and turbocharger oil return pipe (C). MBIB0403E 13. Unclip the fuel return pipe from the cylinder head cover at the fuel spill tube, then remove the rocker cover. MBIB0404E 14. Remove the oil level gauge guide and cylinder head. MBIB0405E DISASSEMBLY OF THE CYLINDER HEAD 1. Place the cylinder head on Tool KV113B0200 (Mot. 1573). CAUTION: Pay strict attention to the rules regarding cleanliness. Refer to EM-227, "PRECAUTIONS" . MBIB0406E 2. Remove fuel injection pump and related parts. Refer to EM-262, "Removal and Installation" , EM-268, "Removal and Installation" . EM-288 OVERHAUL [K9K] 3. Remove the injectors (by marking them in relation to their cylinder), glow plugs using Tool KV113E0010 (Mot. 1566), and rear engine slinger. A EM C MBIB0410E D 4. Remove the vacuum pump and water outlet. E F G MBIB0411E 5. Remove the front engine slinger, EGR unit, air inlet pipe and exhaust manifold. H I J MBIB0412E 6. K Remove the camshaft pulley using Tool KV113B0080 (Mot. 79901). L M MBIB0413E 7. Remove the camshaft brackets. MBIB0414E EM-289 OVERHAUL [K9K] 8. Remove the tappets, noting their position. MBIB0415E 9. Compress the valve springs using the valve lifter. Remove the keys, upper cups and springs. MBIB0416E NOTE: Before removing the valves and the valve stem seals, it is vital to measure position “H” of one of the old seals in relation to the cylinder head using Tool KV113B0180 (Mot. 151101) or suitable tool. MBIB0417E 10. Install the push rod (A) of Tool KV113B0180 (Mot. 1511-01) on the valve stem seal. NOTE: The inner diameter of the push rod must be identical to that of the valve. In addition, the bottom of the push rod must come into contact with the metal upper section of the valve stem seal. MBIB0418E EM-290 OVERHAUL [K9K] 11. Install the guide tube (B) over the push rod until the guide tube comes into contact with the cylinder head, locking the push rod with the knurled wheel. 12. Remove the guide tube assembly plus push rod, being careful not to loosen the knurled wheel. 13. Remove the valves and valve guide seals using the Tool KV113B0090 (Mot. 1335). A EM C MBIB0419E D Cleaning ● ● ● ● ● ● ● BBS002QP It is very important not to scratch the gasket faces of any aluminium components. Use suitable tool to dissolve any part of the seal which remains stuck to the metal surface. Apply the dissolving product to the part to be cleaned, wait approximately 10 minutes, then remove it using a wooden spatula. Wear gloves while carrying out this operation. Do not allow this dissolving product to drip on to the paintwork. Great care should be taken when performing this operation, to prevent foreign objects from entering the pipes taking oil under pressure to the camshafts (pipes in both the cylinder head and its cover) and the oil return pipes. Failure to follow these instructions could lead to the blocking of the oilways, resulting in rapid and serious damage to the engine. Inspection ● J K CAMSHAFT END PLAY NOTE: Set the dial gauge to the cylinder head and inspect following dimensions: 1. 2. H : 0.05 mm (0.0020 in) Test the cylinder head to detect possible cracks using the cylinder head test tools (comprising a tray and a kit suited to the cylinder head, plug, sealing plate and blanking plate). The approval number of the cylinder head test container (commercial service tool) is 664000. Outer diameter Height G I Inspect mating surface bow using a ruler and a set of shims. Maximum bow F BBS002QQ GASKET FACE ● E L : 18 mm (0.71 in) : 15 mm (0.59 in) M Install the camshaft. Install the camshaft brackets (positioning them correctly with bracket 1 on the flywheel end), then tighten the bolts to a torque of 10 N·m (1.0 kg-m, 7 ft-lb). Check the end play, which must be between 0.08 mm (0.0031 in) and 0.178 mm (0.0070 in). Remove the camshaft brackets and the camshaft. MBIB0420E EM-291 OVERHAUL [K9K] Valve Clearance BBS002QR CHECKING AND ADJUSTING THE VALVE CLEARANCE 1. 2. 3. Install the tappet. Install the camshaft. Install the camshaft brackets. : 10 N·m (1.0 kg-m, 7 ft-lb) 4. Place the valves of the cylinder concerned at the “end of exhaust - beginning of inlet” position and check the clearance (X). NOTE: Dimension (Y) corresponds to the tappet thickness sizes (there are 25 sizes at the service parts). 1 3 4 2 5. MBIB0333E 4 2 1 3 Compare the values recorded with the values specified, then replace the tappets which are not within tolerance. Clearance, under cold condition: Intake : 0.125 - 0.25 mm (0.0049 - 0.0098 in) Exhaust : 0.325 - 0.45 mm (0.0128 - 0.0177 in) 6. 7. 8. Remove the camshaft brackets. Remove the camshaft. Remove the tappet not within tolerance. Determining dimension Y. Set up the following assembly using KV113B0050 (Mot. 252-01) and dial gauge, then calibrate the gauge. MBIB0334E 9. 10. 11. 12. 13. Raise the gauge extension (without modifying the position of the magnetic support/gauge assembly), then slide in the tappet to be measured. ● Note dimension (Y) and repeat the operation for the tappets where the valve clearance is not within tolerance. ● Refer to the Replacement Parts Catalogue for the vehicle concerned to select the various thicknesses of the tappet(s). Check the valve clearance again. Remove the camshaft brackets. Remove the camshaft. Remove the tappet(s) not within tolerance. EM-292 MBIB0335E OVERHAUL [K9K] 14. Grease the underside of the tappets and the camshaft brackets. 15. Degrease the gasket faces (of the cylinder head and brackets 1 and 6). They should be clean, dry and free from grease (in particular, remove finger marks). 16. Lay four beads of Loctite with a width of 1 mm (0.04 in) on brackets 1 and 6 of the cylinder head. 17. Install the camshaft. 18. Install the camshaft brackets (these are numbered from 1 to 6 and bearing (1) should be positioned on the flywheel end). : 10 N·m (1.0 kg-m, 7 ft-lb) A EM C MBIB0427E D Assembly BBS002QS ASSEMBLY OF THE CYLINDER HEAD 1. E Install new valves and grind them gently into their respective seats. Clean all the parts thoroughly, mark them for identification purposes, then carry out the refitting operation. Lubricate the inside of the valve guide. ● It is imperative to fit the valve stem seals using Tool KV113B0180 (Mot. 1511-01) or suitable tool. NOTE: Do not lubricate the valve stem seals before fitting them. F G MBIB0421E H New Valve Stem Seals 1. 2. Place the valve in the cylinder head. Place the barrel of Tool KV113B0180 (Mot. 1511-01) over the valve stem (the inner diameter of the barrel must be identical to the diameter of the valve stem). I J K L MBIB0422E 3. 4. Keep the valve pressed against its seat. Place the valve stem seal (not lubricated) over the tool barrel. M MBIB0423E EM-293 OVERHAUL [K9K] 5. Push the valve stem seal past the tool barrel, then withdraw the barrel. MBIB0424E 6. 7. 8. Place the guide tube plus push rod assembly on the valve stem seal. Push the valve stem seal down by tapping the top of the sleeve with the palm of your hand until the guide tube touches the cylinder head. Repeat these operations for all the valves. MBIB0425E 9. Install the valve springs and upper cups using valve spring compressor. 10. Install the keys using tweezers. MBIB0416E EM-294 OVERHAUL [K9K] 11. Check the valve protrusion using KV113B0040 (Mot. 251-01) and KV113B0050 (Mot. 252-01) as shown. Valve protrusion A : −0.07 to 0.07 mm (−0.0028 to 0.0028 in) EM C MBIB0426E D Camshaft Seal ● 1. This engine can be fitted with two different types of seals. Old and new seals are easily recognized. The old rubber seal is installed with a spring (A) and has a “V”shaped sealing lip (B). E F G MBIB0428E 2. H The new rubber seal has a flat sealing lip (C) and a protector (D) which also assists in installing the seal to the engine. I J K MBIB0429E 3. 4. Screw the shouldered rod of Tool KV113B0230 (Mot. 1632) onto the stud of the camshaft. Install the old seal on the camshaft. L M MBIB0430E EM-295 OVERHAUL [K9K] 5. For the new seal, put the protector with the seal on the camshaft, taking care not to touch the seal. MBIB0431E 6. Install the cover (E) and the collar nut (F) of Tool KV113B0230 (Mot. 1632). MBIB0432E 7. Screw the collar nut until the cover touches the cylinder head. MBIB0433E 8. 9. Remove the nut, the cover, the protector and the shouldered rod. Install the camshaft pulley. Tighten the new nut to a torque of 30 N·m (3.1 kg-m, 22 ft-lb) plus an angle tightening of 84°. MBIB0434E EM-296 OVERHAUL [K9K] 10. Install the vacuum pump with a new gasket. Tighten the bolts to a torque of 21 N·m (2.1 kg-m, 15 ft-lb). 11. Install water outlet unit with a new gasket. Tighten the bolts to a torque of 26 N·m (2.7 kg-m, 19 ft-lb). A EM C MBIB0411E D 12. Install the exhaust manifold with new gasket. Tighten the bolts to a torque of 26 N·m (2.7 kg-m, 19 ft-lb) in the numerical order as shown. 13. Install the EGR unit with new clips. Tighten the mounting bolts of the valve to a torque of 21 N·m (2.1 kg-m, 15 ft-lb), then tighten the clips of the pipe using Tool KV113B0190 (Mot. 1567). 14. Install the air inlet pipe with a new seal. 15. Install the front engine slinger. E F G MBIB0435E 16. Clean the injector sockets and the injector bodies, as well as their brackets using a lint-free cloth (use the wipes recommended for this purpose) dipped in clean solvent. Dry off using a different new wipe. Replace the compression washer with a new washer. 17. Install the injectors (using the marks made during removal). Tighten the mounting flanges to a torque of 28 N·m (2.9 kg-m, 21 ft-lb). 18. Install the glow plugs. Tighten them to a torque of 15 N·m (1.5 kg-m, 11 ft-lb). 19. Install the rear engine slinger. 20. Install fuel injection pump and related parts. Refer to EM-268, "HIGH PRESSURE PUMP" . Disassembly of The Bottom Engine H I J K MBIB0410E BBS002QT L REMOVAL 1. Install the Tool KV113B0060 (Mot. 582-01). M MBIB0397E EM-297 OVERHAUL [K9K] 2. 3. Remove the clutch housing. Remove the flywheel. MBIB0439E 4. Remove the oil pan bolt in reverse order as shown. MBIB1257E 5. Remove the baffle plate. MBIB0441E 6. 7. Remove the oil level sensor. Remove the oil pump. MBIB0442E 8. 9. Remove the rear oil seal retainer. Remove the water pump. MBIB0443E EM-298 OVERHAUL [K9K] 10. Remove the oil pump chain. 11. Remove the oil pump drive sprocket. A EM C MBIB0444E WARNING: Do not use a sharp point to mark the bearing caps in relation to their connecting rods to avoid starting a crack in the rod. Use a permanent marker pen. 12. Remove the big end cap bolts and the connecting rod/piston assemblies. NOTE: It is essential to mark the position of the main bearing cap, as the category may be different for each bearing. 13. Remove the main bearing caps. 14. Remove the crankshaft. D E F G MBIB0341E H 15. Remove the oil pressure switch, the knock sensor and oil filter bracket connecting bolt. I J K MBIB0445E 16. Remove the oil cooler connecting bolt. L M MBIB0446E EM-299 OVERHAUL [K9K] REPLACEMENT OF THE OIL JETS Removal 1. To remove the oil jets (A), they must be drilled with a 7 mm (0.28 in) diameter drill. This is necessary in order to remove the spring stop (B) and the spring (C). MBIB0447E NOTE: Do not remove the ball (D) to prevent from entering the cooling circuit. MBIB0448E 2. Remove the using a suitable brush. MBIB0449E 3. Screw Tool KV113B0120 (Mot. 1485-01) in the drilled out jets using a 6 mm (0.24 in) Allen key which must slide into the tool. MBIB0450E EM-300 OVERHAUL [K9K] 4. Screw Tool KV113B0020 (Emb. 880) onto KV113B0120 (Mot. 1485-01) and remove the oil jet. A EM C MBIB0451E D Assembly BBS002QU INSTALLATION OF OIL JETS ● The oil jets must be installed using Tool KV113B0170 (Mot. 1494). E Installation of The Oil Jets For No. 1 and No. 3 Cylinders 1. 2. 3. 4. Install plate (A) of Tool KV113B0170 (Mot. 1494) onto the cylinder block (as shown in the figure) without tightening the two bolts (C). Position the guide rod (B) in the plate (A) and the end of the guide rod in the hole of the oil jet to center the plate (A). Tighten the two bolts (C). Remove the guide rod. F G H MBIB0452E I 5. Install the push rod instead of the guide rod, then insert the oil jet into the push rod. NOTE: Check that the oil jet is correctly oriented with the end of the jet (D) directed towards the center of the cylinder. J K L MBIB0453E 6. M With a hammer, tap the push rod until the shoulder (E) of the push rod comes into contact with the plate (A). MBIB0454E EM-301 OVERHAUL [K9K] Installation of The Oil Jets For No. 1 and No. 4 Cylinders 1. 2. 3. 4. Fit plate (A) of Tool KV113B0170 (Mot. 1494) onto the cylinder block (as shown in the figure) without tightening the two bolts (C). Position the guide rod (B) in the plate (A) and the end of the guide rod in the hole of the oil jet to center the plate (A). Tighten the two bolts (C). Remove the guide rod. MBIB0455E 5. Position the push rod instead of the guide rod, then insert the oil jet into the push rod. NOTE: Check that the oil jet is correctly oriented with the end of the jet (D) directed towards the center of the cylinder. MBIB0453E 6. With a hammer, tap the push rod until the shoulder (E) of the push rod comes into contact with the plate (A). MBIB0456E Orientation Of The Oil Jets (See Diagram Below) A Orientation of the oil jets of No. 2 and No. 4 cylinders B Orientation of the oil jets of No. 1 and No. 3 cylinders 1. Clean the cylinder block and crankshaft by passing a wire through the lubrication channels. MBIB0457E METHOD FOR INSTALLING THE OIL COOLER AND OIL FILTER 1. 2. Install oil cooler. Refer to LU-27, "OIL COOLER" . Install oil filter. Refer to LU-25, "OIL FILTER" . Removing The Piston Pins BBS002QV NOTE: It is imperative to mark the connecting rod to match it to its piston, because the piston height classes in the same engine may be different (see Technical Specifications section). To remove the piston pin, remove the snap ring using a screwdriver, then release the pin. EM-302 OVERHAUL [K9K] CONNECTING ROD BEARING 1. A The connecting rod bearing are installed using Tool KV113B0140 (Mot. 1492) and Tool KV113B0150 (Mot. 1492-03). EM C MBIB0461E D E F G MBIB0352E H ON THE CONNECTING ROD BODY 1. Slide the connecting rod bearing support (A) of Tool KV113B0150 [Mot. 1492-03 (positioning the engraved mark (B) as shown in the figure)] into the groove (C) of the base of Tool KV113B0140 (Mot. 1492). I J K MBIB0462E L 2. Install the guide (D) of Tool KV113B0150 (Mot. 1492-03) onto the base (as shown in the figure). M MBIB0463E EM-303 OVERHAUL [K9K] 3. Lay the body of the connecting rod on the base of the tool (as shown in the diagram). Check that the lower part (E) of the small end is touching the centering pin and push the guide (G) in the direction of the arrow. MBIB0464E 4. Lay the connecting rod bearing [with a width of 20.625 mm (0.8120 in)] (F) on the connecting rod bearing support, then push it in the direction of the arrow (as shown in the figure). MBIB0465E 5. 6. Bring the connecting rod support up against the base of the connecting rod body. Remove the connecting rod body support and repeat the operation for the remaining connecting rod bodies. MBIB0466E ON THE CONNECTING ROD CAP 1. 2. Position the connecting rod bearing support either on the engraved mark (C) if the width of the connecting rod bearing is equal to 20.625 mm (0.8120 in). Position the connecting rod bearing support either on the engraved mark (D) if the width of the connecting rod bearing is equal to 17.625 mm (0.6939 in). MBIB0467E EM-304 OVERHAUL [K9K] 3. Install the connecting rod cap as shown in the figure. A EM C MBIB0468E D 4. Push the guide (in the direction of the arrow) until the connecting rod cap is in contact with the pins (I) on the base of the tool. E F G MBIB0469E 5. Install the connecting rod bearing (H) on the bearing support, then push it in the direction of the arrow (as shown in the figure). H I J MBIB0470E 6. 7. Bring the connecting rod bearing support up against the base of the connecting rod cap. Remove the connecting rod bearing support and repeat the operation for the remaining connecting rod caps. K L M MBIB0471E EM-305 OVERHAUL [K9K] INSTALLATION OF MAIN BEARING 1. Position the grooved main bearing on the cylinder block. MBIB0348E 2. Install the smooth bearing cap on the bearings. MBIB0349E ON THE CYLINDER BLOCK 1. Position tool KV113B0160 (Mot. 1493-01) on the cylinder block. MBIB0472E 2. Install the bearing cap in Tool KV113B0160 (Mot. 1493-01), then press at (A) until the bearing cap is touching at (B) with KV113B0160 (Mot. 1493-01). MBIB0473E EM-306 OVERHAUL [K9K] ON THE BEARING CAPS 1. A Position Tool KV113B0160 (Mot. 1493-01) on the bearing cap. EM C MBIB0474E 2. Install the main bearing in Tool KV113B0160 (Mot. 1493-01), then press at (A) until the main bearing is touching at (B) with Tool KV113B0160 (Mot. 1493-01). D E F G MBIB0475E 3. 4. 5. 6. H Oil the main bearing. Install the crankshaft. Install the lateral shims on bearing No. 3, putting the grooves on the crankshaft side. Install the main bearing caps on bearing cap No. 1 (these are numbered from 1 - 5 and these numbers should be positioned opposite the water pump). Then tighten the bolts to a torque of 27 N·m (2.8 kg-m, 20 ft-lb) plus an angle tightening of 47°±5°. I J K MBIB0476E 7. 8. Check the lateral clearance of the crankshaft which should be without wear on lateral shims: 0.045 - 0.252 mm (0.0018 0.0099 in) Check the lateral clearance of the crankshaft which should be with wear on the lateral shims: 0.045 - 0.852 mm (0.0018 0.0335 in) L M MBIB0477E EM-307 OVERHAUL [K9K] INSTALLATION OF NO. 1 BEARING 1. 2. Degrease the gasket faces (of the cylinder block and bearing No. 1). They should be clean, dry and free from grease (in particular, remove finger marks). Lay two beads of liquid sealant with a width of 1 mm (0.04 in) on bearing No. 1 of the cylinder block. Tighten the bolts of bearing cap No. 1 to a torque of 27 N·m (2.8 kg-m, 20 ft-lb) plus an angle tightening of 47°±5°. MBIB0478E CONNECTING RODS / PISTON ASSEMBLY ● 1. 2. The pistons have a mark engraved on their heads indicating the engine rear side. Oil the piston pin. Check that the piston pins rotate correctly in the new piston and in the matching connecting rod. Direction Of Installation Of The Connecting Rod In Relation To The Piston ● Point the mark (A) engraved on the top of the piston upwards and the flat (B) of the big end downwards as shown in the figure. MBIB0342E DIRECTION FOR INSTALLATION THE SNAP RINGS ON THE PISTON ● Position the opening (C) of the snap rings opposite the removal and fitting channel (D). MBIB0343E INSTALLATION OF THE SNAP RINGS 1. 2. Rings set to their original adjustment must be free within their channels. Ensure the snap rings are fitted the correct way, with the word TOP pointing upwards. EM-308 OVERHAUL [K9K] Orientation Of The Piston Rings In The Piston 1. A Ensure the break in each piston ring is correctly oriented as shown in the figure. EM C MBIB0339E 2. 3. 4. 5. 6. 7. Apply new engine oil to the pistons. Install the connecting rod/piston assemblies into the cylinder block using the ring, being careful to fit them the right way round (mark towards the flywheel). Install the connecting rods onto the oiled crankshaft pins of the crankshaft. Install the connecting rod caps, ensuring they are correctly matched. Tighten the big end cap bolts to a torque of 20 N·m (2.0 kg-m, 15 ft-lb), plus an angle tightening of 45°±6°. Inspect that the big ends have the correct lateral clearance of 0.205 to 0.467 mm (0.0081 to 0.0184 in). D E F G MBIB0479E H CHECKING PISTON PROTRUSION 1. 2. 3. 4. 5. Clean the piston head. Turn the crankshaft one turn in its operating direction to bring piston No. 1 close to TDC. Install Tool KV113B0050 (Mot. 252-01) on the piston. Install Tool KV113B0040 (Mot. 251-01) equipped with a gauge on support plate KV113B0050 (Mot. 252-01), and find TDC. NOTE: All measurements must be carried out along the longitudinal axis of the engine, in order to eliminate any errors due to tilting of the piston. WARNING: The gauge follower must not be in the valve clearance. I J K MBIB0480E M Inspect the piston protrusion which must be 0.099 to 0.285 mm (0.0039 to 0.0112 in). MBIB0325E EM-309 L OVERHAUL [K9K] INSTALLATION OF REAR OIL SEAL RETAINER AND OIL PUMP 1. 2. 3. Tighten the knock sensor to a torque of 20 N·m (2.0 kg-m, 15 ftlb). Tighten the oil pressure switch to a torque of 22 N·m (2.2 kg-m, 16 ft-lb). Install the oil pump sprocket and chain to a torque of 25 N·m (2.6 kg-m, 18 ft-lb). MBIB0442E NOTE: The gasket faces (cylinder block, rear oil seal retainer and water pump) must be clean, dry and free from grease (in particular, remove finger marks). The rear oil seal retainer should be applied with liquid gasket. The bead (A) must be 1.5 to 2 mm (0.059 to 0.079 in) wide and be applied in accordance with the figure. ● Use Genuine Liquid Gasket or equivalent. MBIB0481E 4. 5. 6. 7. Install the rear oil seal retainer. ● Tighten bolts 1 and 6 to a torque of 8 N·m (0.8 kg-m, 71 in-lb). ● Tighten bolts 2, 3, 4 and 5 to a torque of 12 N·m (1.2 kg-m, 9 ft-lb). ● Tighten bolts 1 and 6 to a torque of 12 N·m (1.2 kg-m, 9 ft-lb). Put a new gasket to water pump face and install the water pump. Put a drop of locking sealant on the bolts, then tighten them to a torque of 11 N·m (1.1 kg-m, 8 ft-lb) in the numerical order. ● Use Genuine thread locking sealant or equivalent. MBIB0482E NOTE: The gasket faces (cylinder block and rear oil seal retainer) must be clean, dry and free from grease (in particular, remove finger marks). Apply four beads (B) of liquid gasket, with a diameter of 5 mm (0.20 in). Apply two drops (C) of liquid gasket, with a diameter of 7 mm (0.28 in) at the intersection of the rear oil seal retainer and the cylinder block. ● Use Genuine Liquid Gasket or equivalent. MBIB0483E EM-310 OVERHAUL [K9K] A EM C MBIB0484E D 8. When installing the oil pan, ensure that the tabs (D) of the baffle plate are correctly positioned in the slots (E). 9. When installing the oil pan, ensure that the cylinder block and the oil pan are correctly aligned on the flywheel side, to prevent the clutch housing from being damaged when installing the transaxle. 10. Install the baffle plate. E F G MBIB0485E 11. Install the oil pan and tighten the bolts as follows: ● Tighten the bolts in the numerical order shown in the figure to a torque of 8 N·m (0.8 kg-m, 71 in-lb). ● Tighten the mounting bolts of oil pan on the clutch housing without locking. ● Tighten the bolts in the numerical order shown in the figure to a torque of 15 N·m (1.5 kg-m, 11 ft-lb). ● Tighten the mounting bolts of oil pan on the clutch housing to a torque of 44 N·m (4.5 kg-m, 32 ft-lb). H I J MBIB1257E K INSTALLATION OF THE CRANKSHAFT SEAL GASKETS 1. 2. Crankshaft elastomer seal, timing side. Screw the threaded rod (A) of Tool KV113B0220 (Mot. 1586) into the crankshaft. L M MBIB0487E 3. Position the spacer (B) of Tool KV113B0220 (Mot. 1586) on the crankshaft. MBIB0488E EM-311 OVERHAUL [K9K] 4. Install the protector complete with the seal onto the spacer, taking care not to touch the seal. MBIB0489E 5. Install the cover (A) and the nut (B) (putting the threaded part (C) of the nut on the side away from the engine) of Tool KV113B0220 (Mot. 1586). MBIB0490E 6. Tighten the nut until the cover touches the spacer. MBIB0491E MBIB0492E EM-312 OVERHAUL [K9K] 7. Remove the nut, the cover, the protector and the threaded rod. A EM C MBIB0493E D 8. 9. Crankshaft elastomer seal, flywheel side. Install Tool KV113B0210 (Mot. 1585) on the crankshaft, securing it with bolts (F). E F G MBIB0494E 10. Put the protector complete with the seal on Tool KV113B0210 (Mot. 1585), being careful not to touch the seal. H I J MBIB0495E 11. Install the cover (G) and nut (H) (putting the threaded part (I) of the nut on the side away from the engine) of Tool KV113B0210 (Mot. 1585). K L M MBIB0496E 12. Tighten the nut until the cover touches the cylinder block. MBIB0497E EM-313 OVERHAUL [K9K] MBIB0498E 13. Remove the nut, the cover, the protector and the threaded rod. MBIB0499E 14. Install Tool KV113B0060 (Mot. 582-01) and tighten the new bolts to a torque of 50 to 55 N·m (5.1 to 5.6 kg-m, 37 to 40 ft-lb). MBIB0500E 15. Install the clutch housing, tightening the bolts to a torque of 8 N·m (0.8 kg-m, 71 in-lb). 16. Remove Tool KV113B0060 (Mot. 582-01). MBIB0501E EM-314 OVERHAUL [K9K] INSTALLATION OF THE CYLINDER HEAD 1. 2. 3. 4. 5. Position the pistons at mid-stroke. Install the cylinder head gasket using the centering dowels of the cylinder block. Tighten the cylinder head, Refer to EM-293, "ASSEMBLY OF THE CYLINDER HEAD" . NOTE: The gasket faces (cylinder head and rocker cover) must be clean, dry and free from grease (in particular, remove finger marks). Lay four beads (A) of liquid gasket, with a diameter of 2 mm (0.08 in). ● Use Genuine Liquid Gasket or equivalent. A EM C MBIB0502E D E Install the rocker cover, tightening the bolts to a torque of 10 N·m (1.0 kg-m, 7 ft-lb) in the numerical order as shown. F G H MBIB0503E 6. 7. 8. 9. Put new seals on the pipe ends and install the turbocharger oil return pipe. Install the turbocharger, tightening the nuts and the torx bolt to a torque of 26 N·m (2.7 kg-m, 19 ft-lb). Install the catalytic converter bracket. Install the turbocharger oil supply pipe. I J K MBIB0504E 10. Tighten the bolts of the turbocharger oil return pipe to a torque of 9 N·m (0.9 kg-m, 80 in-lb). 11. Tighten the nut and the bolt of the turbocharger oil supply pipe to a torque of 23 N·m (2.3 kg-m, 17 ft-lb). 12. Install the oil vapor rebreathing pipe. 13. Install the new turbocharger air ducts. M MBIB0505E EM-315 L OVERHAUL [K9K] 14. Install the inner timing cover. 15. Install the timing tensioner. MBIB0400E TIMING ADJUSTMENT CAUTION: It is essential to degrease the end of the crankshaft, the bore of the crankshaft sprocket and the bearing faces of the accessories pulley to prevent any slip between the timing and the crankshaft which would risk destroying the engine. Ensure that the peg (A) of the tension wheel is correctly positioned in the groove (B). 1. Insert Tool KV113B0110 (Mot. 1430) in the camshaft pulley and cylinder head holes. 2. Check that the mark on the high pressure pump pulley (C) is opposite the bolt head (D). 3. Check that the crankshaft is touching Tool KV113B0130 (Mot. 1489) (the crankshaft groove (E) must be facing upwards). MBIB0507E MBIB0395E EM-316 OVERHAUL [K9K] 4. Install the timing belt, aligning the marks on the belt with those on the camshaft and fuel injection pump sprockets (19 teeth spaces on the belt between the marks on the camshaft and pump sprockets). A EM C MBIB0508E D 5. Using a 6 mm (0.24 in) Allen key, move the movable index (F) of the tension wheel into the position shown below, by turning the key counterclockwise. E F G MBIB0509E 6. Tighten the tension wheel bolt to a torque of 25 N·m (2.6 kg-m, 18 ft-lb). 7. Install the crankshaft pulley, tightening the M12 bolt to a torque of 60 N·m (6.1 kg-m, 44 ft-lb), then angle tighten to 100°±10°, or M14 bolt to a torque of 120 N·m (12 kg-m, 89 ft-lb), then angle tighten to 95°±15°. 8. Remove Tool KV113B0130 (Mot. 1489) and Tool KV113B0110 (Mot. 1430). 9. Turn the crankshaft two full turns in a clockwise direction (timing side). Just before the hole (G) of the camshaft pulley is opposite the cylinder head hole (H), insert tool KV113B0130 (Mot. 1489) into the cylinder block. 10. Then turn the crankshaft slowly and without jolting it until it is resting on the pin. H I J MBIB0583E L 11. Check that Tool KV113B0110 (Mot. 1430) is correctly inserted in the holes of the camshaft pulley and cylinder head and that there are 19 teeth spaces between the marks on the camshaft (I) and the fuel pump (J) sprockets. 12. Remove Tool KV113B0130 (Mot. 1489) and Tool KV113B0110 (Mot. 1430). M MBIB0510E EM-317 K OVERHAUL [K9K] 13. Undo the tension wheel bolt by a maximum of one turn while holding it using a 6 mm (0.24 in) Allen key, then gradually bring the movable index (K) (by turning the key clockwise) to the center of the timing window (L) and tighten the nut to a torque of 25 N·m (2.6 kg-m, 18 ft-lb). 14. Install the cap of the TDC bolt, apply liquid gasket to the thread and tighten to a torque of 20 N·m (2.0 kg-m, 15 ft-lb). MBIB0511E 15. Install the cylinder head suspended bracket. Tighten the bolts to a torque of 21 N·m (2.1 kg-m, 15 ft-lb). MBIB0512E 16. Install the lower timing cover by positioning the tab (M) into the hole (N) on the inner timing cover. MBIB0513E EM-318 OVERHAUL [K9K] A EM C MBIB0514E D 17. Install the upper timing cover. 18. Remove the engine from the Tool KV113B0070 (Mot. 792-03). E F G H I J MBIB0515E K 19. Install the water pipe. Tighten the bolt to a torque of 22 N·m (2.2 kg-m, 16 ft-lb). 20. Install the two water hoses. L M MBIB0356E 21. Install the alternator bracket. Tighten the bolts to a torque of 44 N·m (4.5 kg-m, 32 ft-lb). MBIB0355E EM-319 OVERHAUL [K9K] 22. Install the alternator. Tighten the bolts to a torque of 21 N·m (2.1 kg-m, 15 ft-lb). 23. Install the A/C compressor. Tighten the bolts to a torque of 21 N·m (2.1 kg-m, 15 ft-lb). 24. Install the power steering pump or the washer which replaces the pulley (if the engine has one). Tighten the bolts to a torque of 21 N·m (2.1 kg-m, 15 ft-lb). MBIB0354E 25. Install the drive belt. NOTE: The accessories belt has five teeth as opposed to the pulleys which have six. It is therefore essential to ensure that tooth “O” remains free when installing the belt. MBIB0516E Models With A/C Compressor NOTE: The engine must be turned through two revolutions in order to position the belt correctly. MBIB0353E Models Without A/C Compressor 1. 2. The belt is tensioned using tool belt tension gauge (commercial service tool) (with the two mounting bolts of the tensioner undone). The tension value is 233±5 Hz. NOTE: The engine must be turned through two revolutions in order to position the belt correctly. MBIB1066E EM-320 BASIC INSPECTION [K9K] BASIC INSPECTION Cylinder Head PFP:00013 A BBS002QW CYLINDER HEAD TIGHTENING PROCEDURE NOTE: Use a syringe to remove any oil which may have entered the cylinder head mounting bolt holes to achieve correct tightening of the bolts. 1. All bolts must always be changed after removal. Do not oil the new bolts. 2. Tighten all the bolts in the numerical order as shown. EM C : 25 N·m (2.6 kg-m, 18 ft-lb) D 3. Check that all the bolts are correctly tightened to 25 N·m (2.6 kgm, 18 ft-lb) then angle tightening of 245 to 265 degrees. Do not retighten the cylinder head bolts after performing this procedure. E MBIB0323E THICKNESS OF THE CYLINDER HEAD GASKET ● F The thickness of the cylinder head gasket is measured at (A): Thickness : 0.75 - 0.81 mm (0.0295 - 0.0319 in) G H I MBIB0324E INSPECTION OF THE PISTON PROTRUSION Clean the piston heads in order to eliminate any traces of deposits. 2. Turn the crankshaft one turn in its operating direction to bring piston No. 1 close to TDC. 3. Install Tool KV113B0040 (Mot. 251-01) equipped with a gauge on its base plate KV113B0050 (Mot. 252-01), and find TDC of the piston. NOTE: All measurements must be carried out along the longitudinal axis of the engine, in order to eliminate any errors due to tilting of the piston. WARNING: The gauge follower must not be in the valve clearance. Measure the piston protrusion. The protrusion must be: 0.099 - 0.285 mm (0.0039 - 0.0112 in). J 1. K L MBIB0325E Height of the cylinder head: H = 127 mm (5.00 in) Gasket face bow: Cylinder head Cylinder block : 0.05 mm (0.0020 in) : 0.03 mm (0.0012 in) NO REGRINDING IS AUTHORIZED Test the cylinder head to detect possible cracks using the cylinder head test container (comprising a tray and a kit suited to the cylinder head, plug, sealing plate and blanking plate). EM-321 MBIB0326E M BASIC INSPECTION [K9K] VALVE Valve Dimensions Stem diameter: Intake : 5.969 - 5.985 mm (0.2350 - 0.2356 in) Exhaust : 5.955 - 5.971 mm (0.2344 - 0.2351 in) Face angle: Intake and : 90° exhaust Head diameter: Intake : 33.38 - 33.62 mm (1.3142 - 1.3236 in) Exhaust : 28.88 - 29.12 mm (1.1370 - 1.1465 in) Valve length: Intake : 100.73 - 101.17 mm (3.9657 - 3.9831 in) Exhaust : 100.53 - 100.97 mm (3.9579 - 3.9752 in) Max. valve lift: Intake : 8.015 mm (0.3156 in) Exhaust : 8.595 mm (0.3384 in) Protrusion of valves in relation to the cylinder head gasket face: Intake and : −0.7 to 0.7 mm (−0.028 to 0.028 in) exhaust VALVE SEAT Seat angle (α): Intake : 89°30′ and exhaust Contacting width (X): Intake : 1.8 mm (0.071 in) and exhaust Seat outer diameter (D): Intake : 34.444 - 34.460 mm (1.3561 - 1.3567 in) Exhaust : 30.034 - 30.050 mm (1.1824 - 1.1831 in) Diameter of the housing in the cylinder head: Intake : 34.444 - 34.474 mm (1.3561 - 1.3572 in) Exhaust : 29.955 - 29.985 mm (1.1793 - 1.1805 in) VALVE GUIDE Length: Intake and : 40.35 - 40.65 mm (1.5886 - 1.6004 in) exhaust Guide outer diameter: Standard : 11.044 - 11.062 mm (0.4348 - 0.4355 in) Guide inner diameter: Intake and exhaust Not : 5.50 - 5.62 mm (0.2165 - 0.2213 in) machined Machined* : 6.000 - 6.018 mm (0.2362 - 0.2369 in) EM-322 MBIB0327E BASIC INSPECTION [K9K] * This dimension is measured with the guide fitted in the cylinder head. Diameter of the housing in the cylinder head: Standard : 10.9925 - 11.0075 mm (0.4328 - 0.4334 in) A The intake and exhaust guides have valve stem seals which must be changed each time the valves are EM removed. It is imperative to fit the valve stem seals using Tool KV113B0180 (Mot. 1511-01) or suitable tool. C NOTE: Do not lubricate the valve stem seals before fitting them. D E MBIB0328E F G H I MBIB0329E J Angle of the intake and exhaust guides (in degrees) Intake and exhaust : α = 90 K L M MBIB0330E Position of the intake and exhaust valve guides Intake : A = 14 mm (0.55 in) Exhaust : A = 14.2 mm (0.559 in) MBIB0331E EM-323 BASIC INSPECTION [K9K] VALVE SPRING The valve springs are tapered (ensure the correct direction of fitting). Free height: Length under a load of 230 N (23.5 kg, 51.7 lb) 500 N (51.0 kg, 112.4 lb) Joined spires: Wire diameter: Inner diameter: Bottom Top Outer diameter: Bottom Top : 43.31 mm (1.7051 in) : 33.80 mm (1.3307 in) : 24.80 mm (0.9764 in) : 23.40 mm (0.9213 in) : 3.45 mm (0.1358 in) : 18.78 - 18.82 mm (0.7394 - 0.7409 in) : 13.90 - 14.30 mm (0.5472 - 0.5630 in) MBIB0332E : 25.50 - 25.90 mm (1.0039 - 1.0197 in) : 20.8 - 21.2 mm (0.819 - 0.835 in) WARNING: This engine does not have any valve spring lower washers. PISTON Piston outer diameter Diameter of the housing in the cylinder head : 34.965 - 34.985 mm (1.3766 - 1.3774 in) : 35.00 - 35.04 mm (1.3780 - 1.3795 in) INSPECTION OF VALVE CLEARANCE 1. Place the valves of the cylinder concerned at the “end of exhaust - beginning of intake” position and inspect the clearance (X). NOTE: Dimension (Y) corresponds to the tappet thickness sizes (there are 25 sizes at the service parts). 1 3 4 2 2. 4 2 1 3 Compare the values recorded with the values specified, then replace the tappets which are not within tolerance. MBIB0333E Clearance, when the engine is cold: Intake : 0.125 - 0.25 mm (0.0049 - 0.0098 in) Exhaust : 0.325 - 0.45 mm (0.0128 - 0.0177 in) 3. 4. The camshaft must be removed to replace the tappets. Determining dimension “Y”. Set up the following assembly using Tool KV113B0050 (Mot. 252-01) and dial gauge, then calibrate the gauge. MBIB0334E EM-324 BASIC INSPECTION [K9K] 5. Raise the gauge extension (without modifying the position of the magnetic support/gauge assembly), then slide in the tappet to be measured. Note dimension (Y) and repeat the operation for the tappets where the valve clearance is not within tolerance. Refer to the Replacement Parts Catalogue for the vehicle concerned to select the various thicknesses of the tappet(s). The service parts supplies 25 sizes of single-piece tappets. A EM C MBIB0335E D CAMSHAFT End play Number of bearings Diameter of the camshaft bearings On the camshaft: Bearings 1, 2, 3, 4, 5 Bearing 6 On the cylinder head: Bearings 1, 2, 3, 4, 5 Bearing 6 Timing diagram Intake opening retard * Intake closing retard Exhaust opening advance Exhaust closing advance ** : 0.08 - 0.178 mm (0.0031 - 0.0070 in) :6 E F : 24.979 - 24.999 mm (0.9834 - 0.9842 in) : 27.979 - 27.999 mm (1.1015 - 1.1023 in) G : 25.04 - 25.06 mm (0.9858 - 0.9866 in) : 28.04 - 28.06 mm (1.1039 - 1.1047 in) H : −9 : 20 : 27 : −7 I J * As the intake opening retard is negative, the valve is opened after TDC. ** As the exhaust closing advance is negative, the valve is closed before TDC. K 1 Cylinder block TDC fixed mark 2 Flywheel TDC moving mark 3 Flywheel BDC moving mark 4 Intake Opening Retard 5 Exhaust Closing Advance 6 Intake Closing Retard 7 Exhaust Opening Advance 8 Direction of engine rotation (flywheel end). L M EM-325 MBIB0336E BASIC INSPECTION [K9K] Piston ● ● BBS002QX Install the piston pin in the connecting rod and in the piston. The piston pin is retained by circlips. PISTON MARKING 1 Direction of fitting of the piston mark towards the flywheel 2 Height between the piston pin and the top of the piston (see table below). 3 Used by the supplier only 4 Used by the supplier only 5 Used by the supplier only 6 Piston axis of symmetry 7 Piston pin hole axis 8 Offset between the hole axis (7) and the piston's axis of symmetry (6) is 0.3 mm (0.012 in) MBIB0337E TABLE OF PISTON PIN HEIGHT Unit: mm (in) * Mark on piston Piston pin height K 41.667 (1.6404) L 41.709 (1.6421) M 41.751 (1.6437) N 41.793 (1.6454) P 41.835 (1.6470) The tolerance on the piston pin heights is ±0.02 mm (±0.0008). * The different piston pin heights are exclusively reserved for the engine assembly plant. The service parts will only supply piston classes (height) L, M, N. NOTE: ● If the engine is installed with a K class piston, an L class piston must be installed as a replacement. ● If the engine is installed with a P class piston, an N class piston must be installed as a replacement. MEASURING THE PISTON DIAMETER The piston diameter must be measured at height A = 56 mm (2.20 in). Piston diameter Piston pin: Length Outer diameter Inner diameter : 75.933 - 75.947 mm (2.9895 2.9900 in) : 59.7 - 60.3 mm (2.350 - 2.374 in) : 24.8 - 25.2 mm (0.976 - 0.992 in) : 13.55 - 13.95 mm (0.5335 0.5492 in) EM-326 MBIB0338E BASIC INSPECTION [K9K] PISTON RING Thickness: Top ring 2nd ring Oil ring A : 1.97 - 1.99 mm (0.0776 - 0.0783 in) : 1.97 - 1.99 mm (0.0776 - 0.0783 in) : 2.47 - 2.49 mm (0.0972 - 0.0980 in) EM The piston rings are supplied ready adjusted. C MBIB0339E D PISTON RING END GAP Top ring 2nd ring Oil ring E : 0.20 - 0.35 mm (0.0079 - 0.0138 in) : 0.70 - 0.90 mm (0.0276 - 0.0354 in) : 0.25 - 0.50 mm (0.0098 - 0.0197 in) Connecting Rod F BBS002QY The connecting rod is of the detachable cap type. WARNING: ● The bolts must be coated with engine oil under the heads and on the threads when the connecting rods are installed in the engine. ● The big end caps are positioned on the connecting rod by irregularities on the parting line. ● The occurrence of impacts or a foreign body between the body - cap mating surfaces will lead to rapid rupture of the connecting rod. G H I MBIB0340E Lateral big end play Diametrical big end play Center distance between the big end and small end Diameter of the big end Diameter of the small end (without ring) (with ring) : 0.205 - 0.467 mm (0.0081 0.0184 in) : 0.035 - 0.045 mm (0.0014 0.0018 in) : 133.75 mm (5.2657 in) : 47.610 - 47.628 mm (1.8744 - 1.8751 in) J K L M : 27.24 - 27.26 mm (1.0724 1.0732 in) : 25.013 - 25.025 mm (0.9848 - 0.9852 in) NOTE: The connecting rod small end rings cannot be replaced. EM-327 BASIC INSPECTION [K9K] The maximum weight difference for the connecting rod, piston and piston pin assemblies for the same engine must be 0.245 N (25 g, 0.88 oz). WARNING: ● To avoid initiating a crack in the connecting rod, do not use a sharp point to mark the big end caps in relation to their connecting rod. ● Use a permanent marker pen. MBIB0341E DIRECTION OF INSTALLATION OF THE CONNECTING ROD IN RELATION TO THE PISTON ● Point the mark (A) engraved on the top of the piston upwards and the machined flat (B) of the big end downwards as shown in the figure. MBIB0342E DIRECTION FOR INSTALLATION THE SNAP RINGS ON THE PISTON ● Position the opening (C) of the snap rings opposite of the removal and installation channel (D). MBIB0343E Crankshaft Number of main journals Crankshaft side clearance: Without wear on side shims With wear on side shims Crankshaft diametrical clearance: Journals Crankshaft pins Journal diameter: Crankshaft pin diameter: ● ● BBS002QZ :5 : 0.045 - 0.252 mm (0.0018 - 0.0099 in) : 0.045 - 0.852 mm (0.0018 - 0.0335 in) : 0.027 - 0.054 mm (0.0011 - 0.0021 in) : 0.035 - 0.045 mm (0.0014 - 0.0018 in) : 47.99 - 48.01 mm (1.8894 - 1.8902 in) : 43.96 - 43.98 mm (1.7307 - 1.7315 in) The lateral shims are located on bearing No. 3. No rectifications are allowed. EM-328 BASIC INSPECTION [K9K] WORKING OUT THE CLASS OF MAIN BEARING (ORIGINAL FITMENT) Marking (A) On The Crankshaft A Detail of the marking (A): Number of journals EM 1* 2 3 4 5 B B C C B Classes of journal diameters A = D1 B = D2 C = D3 C D * Flywheel end. MBIB0344E Table Of Journal Diameter Classes E Unit: mm (in) Journal class mark on the crankshaft Journal diameter A = D1 47.990 - 47.996 (1.8894 - 1.8896) B = D2 47.997 - 48.003 (1.8896 - 1.8899) C = D3 48.004 - 48.010 (1.8899 - 1.8902) Cylinder Block F G BBS002R0 The diameters of the bearings (A) of the cylinder block are marked by a hole on the block (B) located above the oil filter. H I J MBIB0345E K L M MBIB0346E TABLE OF CYLINDER BLOCK MAIN BEARING HOUSING INNER DIAMETERS Hole position (B) Class reference Cylinder block main bearing housing inner diameter X = 33 mm (1.30 in) 1 or blue 51.936 - 51.942 mm (2.0447 - 2.0450 in) Y = 43 mm (1.69 in) 2 or red 51.942 - 51.949 mm (2.0450 - 2.0452 in) NOTE: The marking zone includes: EM-329 BASIC INSPECTION [K9K] ● X - Y gives the diameter class of bearings A or B. MATCHING THE MAIN BEARING Journal diameter class D1 D2 D3 1* C1 1.949 - 1.955 mm (0.0767 - 0.0770 in) yellow C2 1.946 - 1.952 mm (0.0766 - 0.0769 in) blue C3 1.943 - 1.949 mm (0.0765 - 0.0767 in) black 2* C4 1.953 - 1.959 mm (0.0769 - 0.0771 in) red C1 1.949 - 1.955 mm (0.0767 - 0.0770 in) yellow C2 1.946 - 1.952 mm (0.0766 - 0.0769 in) blue Bearing thickness and class * Cylinder block main bearing diameter class. NOTE: The service parts will only supply class C2 (blue). Main Bearing and Cap BBS002R1 MAIN BEARING ● 1. The engine is installed with main bearing without a locator notch. The main bearings are installed on the cylinder block and on the bearings using Tool KV113B0160 (Mot. 1493-01). MBIB0347E 2. For direction of installation on the cylinder block, install grooved main bearing on all the bearings. MBIB0348E 3. For direction of installation on the bearing caps, install nongrooved main bearing. MBIB0349E EM-330 BASIC INSPECTION [K9K] CONNECTING ROD BEARING ● A The engine is installed with connecting rod bearing without a locator notch. NOTE: The upper and lower connecting rod bearing are not the same width. EM Connecting rod bearing width: Upper bearing : 20.625 mm (0.8120 in) Lower bearing : 17.625 mm (0.6939 in) C MBIB0350E ● The connecting rod bearing are installed using Tool KV113B0140 (Mot. 1492) and Tool KV113B0150 (Mot. 1492-03). D E F G MBIB0351E H I J K MBIB0352E Preparing the engine to be on the stand BBS002R2 Before the engine is mounted on the Tool KV113B0070 (Mot. 792-03), the engine's electrical harness must be removed and the engine oil drained. 1. Remove the drive belt. MBIB0353E EM-331 L M BASIC INSPECTION [K9K] 2. Remove the alternator. MBIB0354E 3. 4. Remove the air conditioning compressor or idler pulley. Remove the multifunction support. MBIB0355E 5. Remove the coolant inlet pipe on the water pump. MBIB0356E 6. Place the rods (A ), (X ), (Y ) or Tool KV113B0100 (Mot. 1378) on the cylinder block so that they fit into the holes (20, 32, 33 ) on the plate of Tool KV113B0070 (Mot. 792-03). MBIB0357E Parts To Be Replaced After Removal ● ● ● ● ● ● ● ● All gaskets Flywheel bolts Crankshaft bearing bolts Camshaft pulley bolt Crankshaft pulley bolts Big end cap bolts Injector holder copper washers Fuel injection tubes EM-332 BBS002R3 BASIC INSPECTION [K9K] ● ● ● ● ● Pipe plugs Belts Timing belt tension wheel Oil jets Turbocharger plastic pipes A EM Installation of Thread Inserts BBS002R4 Threaded holes on all engine component parts can be repaired by using thread inserts. C D E F G H I J K L M EM-333 BASIC INSPECTION [K9K] EM-334 EXHAUST SYSTEM B ENGINE SECTION EX EXHAUST SYSTEM A EX C D CONTENTS PREPARATION ........................................................... 2 Special Service Tool ................................................. 2 EXHAUST SYSTEM ................................................... 3 Checking Exhaust System ....................................... 3 Removal and Installation .......................................... 3 CR ENGINE .......................................................... 3 HR ENGINE .......................................................... 4 K9K ENGINE ......................................................... 5 REMOVAL ............................................................. 5 INSTALLATION (CR, HR ENGINE) ....................... 6 INSTALLATION (K9K ENGINE) ............................ 7 Inspection After Installation ...................................... 7 SERVICE DATA AND SPECIFICATIONS (SDS) ........ 8 Tightening Torque ..................................................... 8 CR ENGINE .......................................................... 8 HR ENGINE .......................................................... 8 K9K ENGINE ......................................................... 8 E F G H I J K L M EX-1 PREPARATION PREPARATION Special Service Tool PFP:00002 BBS003Z4 Tool number Tool name Description KV10117200 Heated oxygen sensor wrench Loosening or tightening heated oxygen sensors a: 22 mm (0.87 in) S-NT636 EX-2 EXHAUST SYSTEM EXHAUST SYSTEM Checking Exhaust System PFP:20100 A BBS003Z5 Check exhaust pipes, muffler and mounting for improper attachment, leaks, cracks, damage or deterioration. EX C D SMA211A E Removal and Installation BBS003Z6 CAUTION: ● Be sure to use genuine exhaust system parts or equivalents which are specially designed for heat resistance, corrosion resistance and shape. ● Perform the operation with the exhaust system fully cooled down because the system is still hot just after the engine stops. ● Be careful not to cut your hand on the insulator edge. F G CR ENGINE H I J K L M MBIB9012E 1. Main muffler 2. Mounting rubber 3. Clamp 4. Mounting rubber 5. Center muffler 6. Mounting bracket 7. Heated oxygen sensor 2 8. Seal bearing 9. Spring 10. Exhaust front tube 11. Seal bearing EX-3 12. Spring EXHAUST SYSTEM HR ENGINE MBIB9013E 1. Main muffler 2. Mounting rubber 3. Clamp 4. Center muffler 5. Mounting rubber 6. Spring 7. Seal bearing 8. Heated oxygen sensor 2 9. Exhaust front tube 10. Seal bearing 11. Stud bolt 12. Spring EX-4 EXHAUST SYSTEM K9K ENGINE A EX C D E F G H MBIB9014E 1. Main muffler 2. Mounting rubber 3. Clamp 4. Mounting rubber 5. Exhaust center tube 6. Exhaust front tube 7. Bolt 8. Spring 9. Seal bearing I J REMOVAL ● K Disconnect each joint and mounting. Heated Oxygen Sensor 2 (CR, HR Engine) ● 1. 2. When removing heated oxygen sensor 2 on vehicle, perform following procedure. Disconnect harness connector. Use a heated oxygen sensor wrench (special service tool) for removal of heated oxygen sensor 2. CAUTION: ● Do not apply impact while handling. L M PBIC1511E EX-5 EXHAUST SYSTEM Exhaust Front Tube (CR, HR Engine) 1. 2. 3. 4. Disconnect center muffler connecting points. Remove the ground cable on vehicle. Remove mount bracket mounting nuts on suspension member. Disconnect three way catalyst connecting points to remove exhaust front tube. PBIC1512E INSTALLATION (CR, HR ENGINE) Install in the reverse order of removal paying attention to the following. ● Remove all deposits, such as old gasket, from the sealing surfaces of each connection. Connect firmly without any leaks. ● When installing exhaust pipe assembly, temporarily tighten nuts on the exhaust manifold side mounting bolts and vehicle side mounting nuts. After making sure there is no unusual tension on each part, tighten nuts and bolts to the specified torque. ● Be careful not to twist or apply excess tension in any direction when installing mounting rubbers. ● Because thickness is different between center muffler rear side mounting rubber and main muffler side mounting rubbers, install thick mount rubber at main muffler side. ● Install seal bearing unit in the following procedures. ● When installing heated oxygen sensor 2, use heated oxygen sensor wrench (special service tool: KV10117200). CAUTION: ● Do not apply impact while handing. ● Do not use heated oxygen sensor 2 after being dropped on a solid concrete floor, from a height of 0.5 m (1.6 ft) or higher. Replace it with a new one. ● Do not tighten heated oxygen sensor 2 to a torque larger than specified. Excess tightening may result in damage of heated oxygen sensor 2, causing MI to turn ON. ● when using heated oxygen sensor wrench (special service tool: KV10117200), tighten to the middle of specified torque because length of tool may induce slight indication increase. Do not tighten to the maximum specified torque. Three Way Catalyst to Exhaust Front Tube 1. 2. Securely insert seal bearing into three way catalyst side in the direction shown in figure. CAUTION: Be careful not to damage seal bearing surface when installing. With spring large diameter side facing to exhaust front tube flange, tighten mounting bolt. ● Be careful that mounting bolt does not interfere with flanged area, and tighten it. PBIC1513E EX-6 EXHAUST SYSTEM Exhaust Front Tube to Center Muffler 1. 2. A Securely insert seal bearing into exhaust front tube side in the direction shown in figure. CAUTION: Be careful not to damage seal bearing surface when installing. With spring large diameter side facing to center muffler flange, tighten mounting bolt. ● Be careful that mounting bolt does not interfere with flanged area, and tighten it. EX C PBIC1514E D INSTALLATION (K9K ENGINE) Install in the reverse order of removal. CAUTION: ● Always replace exhaust gaskets with new ones when reassembling. ● If the insulator is badly deformed, repair or replace it. If deposits such as mud pile up on the insulator, remove them. ● When installing the insulator avoid large gaps or interference between the insulator and each exhaust pipe. ● Remove deposits from the sealing surface of each connection. Connect them securely to avoid gas leakage. ● Temporarily tighten mounting nuts on the exhaust manifold side and mounting bolts on the vehicle side. Check each part for unusual interference, and then tighten them to the specified torque. ● When installing each mounting rubber, avoid twisting or unusual extension in up/down and right/ left directions. ● Inspection After Installation ● ● E F G H I BBS003Z7 With the engine running, check exhaust tube joints for gas leakage and unusual noises. Check to ensure that mounting brackets and mounting insulators are installed properly and free from undue stress. Improper installation could result in excessive noise and vibration. J K L M EX-7 SERVICE DATA AND SPECIFICATIONS (SDS) SERVICE DATA AND SPECIFICATIONS (SDS) Tightening Torque PFP:00030 BBS003Z8 CR ENGINE Unit: N·m (kg-m, ft-lb) Unit: N·m (kg-m, in-lb)* Exhaust system connecting parts Three way catalyst to Exhaust front tube 43.1 - 54.9 (4.4 - 5.6, 32 - 40) Exhaust front tube to Center muffler 43.1 - 54.9 (4.4 - 5.6, 32 - 40) Center muffler to Main muffler 30.4 - 39.2 (3.1 - 3.9, 23 - 28) Heated oxygen sensor 2 40 - 60 (4.1 - 6.1, 30 - 44) Exhaust front tube mounting bracket 16.4 - 20.7 (1.7 - 2.1, 12 - 15) Ground cable 2.9 - 4.9 (0.3 - 0.49, 26 - 43)* HR ENGINE Unit: N·m (kg-m, ft-lb) Unit: N·m (kg-m, in-lb)* Exhaust system connecting parts Three way catalyst to Exhaust front tube 49.0 (5.0, 36) Exhaust front tube to Center muffler 49.0 (5.0, 36) Center muffler to Main muffler 34.8 (3.5, 26) Heated oxygen sensor 2 50 (5.1, 37) Ground cable 3.9 (0.4, 35)* K9K ENGINE Unit: N·m (kg-m, ft-lb) Exhaust system connecting parts Catalyst to Exhaust front tube 17.9 - 24.2 (1.9 - 2.4, 14 - 17) Exhaust front tube to Exhaust center tube 30.4 - 39.2 (3.1 - 3.9, 23 - 28) Exhaust center tube to Main muffler 30.4 - 39.2 (3.1 - 3.9, 23 - 28) EX-8 FRONT AXLE D DRIVELINE/AXLE SECTION FAX FRONT AXLE A B C FAX CONTENTS PRECAUTIONS .......................................................... 2 Cautions ................................................................... 2 Precautions for Brake System .................................. 2 PREPARATION ........................................................... 3 Special Service Tools ............................................... 3 NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING ................................................ 5 NVH Troubleshooting Chart ..................................... 5 FRONT WHEEL HUB AND KNUCKLE ...................... 6 On-Vehicle Inspection .............................................. 6 FRONT WHEEL BEARING ................................... 6 Removal and Installation .......................................... 6 REMOVAL ............................................................. 6 INSTALLATION ..................................................... 7 Disassembly and Assembly ..................................... 7 DISASSEMBLY ..................................................... 7 INSPECTION AFTER DISASSEMBLY ................. 8 ASSEMBLY ........................................................... 8 INSPECTION AFTER ASSEMBLY ....................... 9 FRONT DRIVE SHAFT ............................................. 10 On-Vehicle Inspection and Service ........................ 10 DRIVE SHAFT BOOT ......................................... 10 Removal and Installation ........................................ 13 REMOVAL ........................................................... 14 INSPECTION AFTER REMOVAL ....................... 14 INSTALLATION ................................................... 15 Disassembly and Assembly .................................... 16 INSPECTION BEFORE DISASSEMBLY ............. 16 DISASSEMBLY (CR AND HR16 ENGINE MODELS) .................................................................... 16 DISASSEMBLY (K9K ENGINE MODELS) .......... 18 INSPECTION AFTER DISASSEMBLY (CR AND HR16 ENGINE MODELS) ................................... 20 INSPECTION AFTER DISASSEMBLY (K9K ENGINE MODELS) ............................................. 20 ASSEMBLY (CR AND HR16 ENGINE MODELS)... 21 ASSEMBLY (K9K ENGINE MODELS) ................ 23 SERVICE DATA AND SPECIFICATIONS (SDS) ...... 27 Wheel Bearing ........................................................ 27 Drive shaft .............................................................. 27 Dynamic Damper .................................................... 27 Tightening Torque ................................................... 27 E F G H I J K L M FAX-1 PRECAUTIONS PRECAUTIONS Cautions PFP:00001 BDS0006R Observe the following precautions when disassembling and servicing drive shaft. ● The joint of drive shaft cannot be disassembled. Do not attempt to disassemble it. ● Perform work in a location which is as dust-free and dirt-free as possible. ● Before disassembling and servicing, clean the outside of parts. ● The disassembly and service location must be clean. Care must be taken to prevent parts from becoming dirty and to prevent the entry of foreign objects. ● Disassembled parts must be carefully reassembled in the correct order. If work is interrupted, a clean cover must be placed over parts. ● Paper shop cloths must be used. Fabric shop cloths must not be used because of the danger of lint adhering to parts. ● Disassembled parts (except for rubber parts) should be cleaned with kerosene which shall be removed by blowing with air or wiping with paper shop cloths. Precautions for Brake System ● ● ● ● BDS0006S When installing rubber parts, final tightening must be carried out under unladen condition* with tyres on ground. *: Fuel, radiator coolant and engine oil full. Spare tyre, jack, hand tools and mats in designated positions. Use flare nut wrench when removing or installing brake tubes. After installing removed suspension parts, check wheel alignment and adjust if necessary. Always tighten brake lines to the specified torque when installing. SBR820BA FAX-2 PREPARATION PREPARATION Special Service Tools PFP:00002 A BDS0006T Description Application B Hub lock nut wrench KV40104000 a: 85 mm (3.35 in) dia. b: 65 mm (2.56 in) dia. ● Removing and installing hub lock nuts ● Removing and installing drive shaft C FAX ZZA0802D E Protector KV38107900 a: 32 mm (1.26 in) dia. Installing drive shaft F ZZA0835D G Drift ST35271000 a: 72 mm (2.83 in) dia. b: 63 mm (2.48 in) dia. Installing wheel bearing H ZZA0837D I Drift ST33710000 a: 30 mm (1.18 in) dia. b: 23 mm (0.91 in) dia. ● Removing wheel hub ● Removing inner race (outside) of wheel bearing J ZZA1233D K Bearing replacer ST30031000 Removing inner race (outside) of wheel bearing M ZZA0700D Drift ST35321000 a: 49 mm (1.93 in) dia. b: 41 mm (1.61 in) dia. ST30621000 a: 79 mm (3.11 in) dia. b: 59 mm (2.32 in) dia. ● Removing wheel bearing ● Installing wheel hub ZZA1051D Drift ST27863000 a: 74 mm (2.91 in) dia. b: 62 mm (2.44 in) dia. Installing wheel bearing ZZA0936D FAX-3 L PREPARATION Description Application Boot band crimping tool KV40107300 Installing boot band ZZA1229D Flare nut torque wrench GG94310000 a: 10 mm (0.39 in) Removing and installing brake lines NT406 FAX-4 NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING NVH Troubleshooting Chart PFP:00003 A BDS0006U NVH in PS section. STEERING NVH in WT section. ROAD WHEEL NVH in WT section. E TYRES Refer to FAX-6, "FRONT WHEEL HUB AND KNUCKLE" FAX Parts interference FRONT AXLE C Noise × × × × × Shake × × × × × Vibration × × × Shimmy × × × × × Judder × × × × Poor quality ride or handling × × × ×: Applicable FAX-5 F G H × Wheel bearing damage Possible cause and SUSPECTED PARTS Symptom B Improper installation, looseness Reference page — Refer to FAX-6, "FRONT WHEEL HUB AND KNUCKLE" Use the chart below to help you find the cause of the symptom. If necessary, repair or replace these parts. × I J K × L M FRONT WHEEL HUB AND KNUCKLE FRONT WHEEL HUB AND KNUCKLE On-Vehicle Inspection PFP:40202 BDS0006V Inspect to check that there is no excessive play, cracking, wear, or other damage to front axle. ● Turn front wheels (left/right) and check the play. ● Check that no nails or other foreign objects are embedded. ● Retighten all axle nuts and bolts to the specified torque. SMA525A FRONT WHEEL BEARING With the vehicle raised, inspect the following: ● Move wheel hub in the axial direction by hand. Check if there is no looseness of front wheel bearings. Axial end play ● : 0.05 mm (0.0020 in) Rotate wheel hub and Make sure there is no unusual noise or other non-standard condition. If there are any non-standard conditions, replace the wheel bearing. Removal and Installation BDS0006W MDIA0032E 1. Steering knuckle 2. Sensor housing 3. Wheel bearing 4. Snap rings 5. Wheel hub 6. Front drive shaft REMOVAL 1. 2. 3. 4. 5. 6. Lift up the vehicle and remove tyre from the vehicle. Disconnect ABS wheel sensor harness connector. Refer to BRC-36, "WHEEL SENSORS" . Disconnect brake hose from strut. Refer to BR-11, "BRAKE PIPING AND HOSE" . Remove brake caliper from steering knuckle. Hang it in a place where it does not interfere with work. Refer to BR-23, "Removal and Installation of Brake Caliper Assembly" . CAUTION: Avoid depressing the brake pedal with the brake caliper removed. Remove disc rotor from wheel hub. Refer to BR-21, "FRONT DISC BRAKE" . Pull out ABS wheel sensor from steering knuckle. Refer to BRC-36, "WHEEL SENSORS" . FAX-6 FRONT WHEEL HUB AND KNUCKLE CAUTION: Do not pull on ABS wheel sensor harness. A 7. Use wheel hub lock nut wrench (SST) to remove lock nut from drive shaft. 8. Remove tie-rod from steering knuckle. If tie-rod is not easily B removed, use ball joint remover (commercial service tool). CAUTION: To prevent damage to threads and to prevent ball joint C remover (commercial service tool) from sudden coming off, temporarily tighten lock nuts. 9. Remove steering knuckle from strut. FAX CAUTION: MDIA0033E Do not place drive shaft joint at an extreme angle (22° or more). Also, hold steering knuckle tightly and do not overextend slide joint. E 10. Remove drive shaft from steering knuckle. CAUTION: When removing drive shaft, do not place drive shaft joint at an extreme angle (22° or more). Also F be careful not to overextend slide joint. ● Do not lift drive shaft with axle attached by grasping countershaft only. ● Do not allow drive shaft, with transaxle inserted, to hang down without support for countershaft, G wheel joints, and other parts. 11. Remove transverse link ball joint mounting bolt and nut. Then, remove transverse link from steering knuckle. H INSTALLATION For tightening torque and other details, FAX-6, "FRONT WHEEL BEARING" , BRC-36, "WHEEL SENSORS" , FSU-5, "FRONT SUSPENSION ASSEMBLY" and tighten in the reverse order of removal. Disassembly and Assembly I BDS0006X DISASSEMBLY 1. J Press the wheel bearing out with a drift (SST) to remove. K L SDIA0758J 2. Insert a screwdriver into cutout of snap ring and remove it from steering knuckle. CAUTION: Be careful not to scratch the steering knuckle. MDIA0034E FAX-7 M FRONT WHEEL HUB AND KNUCKLE 3. Use a puller (commercial service tool), drift (SST), and bearing replacer (SST) to remove inner race of outer wheel bearing from wheel hub. SDIA0759J 4. Press the wheel bearing and sensor housing out of the steering knuckle with a drift (SST). SDIA0760J INSPECTION AFTER DISASSEMBLY Wheel Hub ● Check wheel hub for cracks (with magnetic exploration or dye testing). Replace if necessary. Steering Knuckle ● Check steering knuckle for deformation, cracks, and other damage. Replace if any non-standard conditions are found. Snap Rings ● Check snap ring for wear or cracks. Replace if necessary. ASSEMBLY 1. Temporarily put sensor housing on steering knuckle. CAUTION: Protrusion of sensor housing ABS sensor mounting should fit in cutout of steering knuckle (as shown in figure). MDIA0035E FAX-8 FRONT WHEEL HUB AND KNUCKLE 2. Press-fit a wheel bearing into the steering knuckle with a drift (SST) from steering knuckle outer side. CAUTION: ● Be sure that wheel bearing is completely press-fit until sensor housing contacts the body tightly. ● Be sure that protrusion of ABS sensor mounting does not roll onto steering knuckle. ● Be sure to mount so that sensor rotor (rubber side) side comes to steering knuckle inner side. ● Do not press and weigh on wheel bearing inner lace and sealing part. NOTE: Final press-loading guideline [49,000 N (5,000 kg, 11,015 lb)] A B C MDIA0037E FAX E 3. Install snap ring onto steering knuckle. 4. Press-fit a wheel bearing into the steering knuckle with a drift (SST) from steering knuckle outer side. NOTE: Final press-loading guideline [49,000 N (5,000 kg, 11,015 lb)] CAUTION: Drift (special tool) which touches wheel bearing inner lace shall not touch sensor housing. F G H MDIA0037E I INSPECTION AFTER ASSEMBLY 1. 2. Apply a load of 34,300 to 49,000 N (3,500 to 5,000 kg, 7,710 - 11,015 lb). In this condition, rotate in forward and reverse directions 10 times each to insure a good fit. Set a spring balance on strut mounting hole (upper). Measure rotating torque at an rpm of 8 - 12 rpm. Rotating torque Spring balance measurement K : 0.30 - 1.43 N·m (0.03 - 0.14 kg-m) : 6.0 - 28.6 N (0.61 - 2.92 kg) L NOTE: In case the above loading is not possible ● Assemble drive shaft and tighten wheel hub lock nuts to specified torque. Then rotate in forward and reverse direction 10 times each to insure a good fit. ● At a rotating speed of 8 - 12 rpm, place a spring balance on hub bolt to measure torque. Rotating torque Spring balance measurement J : 0.23 N·m (0.02 kg-m) or less : 15.9 N (1.62 kg) or less FAX-9 M SDIA0762J FRONT DRIVE SHAFT FRONT DRIVE SHAFT On-Vehicle Inspection and Service PFP:39100 BDS0006Y DRIVE SHAFT BOOT Replacement CAUTION: When noise or vibration occur from drive shaft, replace entire drive shaft assembly. 1. Lift up the vehicle and remove the wheel from the vehicle. 2. Disconnect ABS wheel sensor harness connector. BRC-36, "WHEEL SENSORS" . 3. Disconnect brake hose from strut. Refer to BR-11, "BRAKE PIPING AND HOSE" . 4. Remove the ABS wheel sensor from the steering knuckle. Refer to BRC-36, "WHEEL SENSORS" . CAUTION: Do not pull on ABS wheel sensor harness. 5. Remove brake caliper assembly from brake rotor and hand cylinder body with a wire. Refer to BR-22, "Removal and Installation of Brake Pad" . 6. Use a hub lock nut wrench (SST), remove lock nuts. 7. Remove steering knuckle and strut installation bolt. CAUTION: Do not place drive shaft joint at an extreme angle (22° or more). Also, hold steering knuckle tightly and do not overextend slide joint. 8. Using a puller (commercial service tool), remove the drive shaft from the steering knuckle. CAUTION: When removing drive shaft, do not place drive shaft joint at MDIA0038E an extreme angle (22° or more). Also be careful not to overextend slide joint. ● Do not lift drive shaft with axle attached by grasping barshaft only. ● Do not allow the wheel-side joint and/or barshaft to hang from the transmission without support. 9. Remove boot bands and remove boot from the joint subassembly. 10. Screw drive shaft puller (commercial service tool) into joint subassembly screw part in depth of 30 mm (1.18in) or more. Fix drive shaft by one hand and pull out joint subassembly with sliding hammer (commercial service tool) from shaft. CAUTION: ● For K9K engines: before separating joint subassembly put matching marks on drive shaft and joint subassembly. ● Align sliding hammer and drive shaft and remove them by pulling firmly and uniformly. ● When joint subassembly is not able to be pulled out, try after removing drive shaft from the vehicle. 11. Remove boot from shaft. FAX-10 SDIA0881J FRONT DRIVE SHAFT 12. Remove circlip from the shaft. A B C MDIA0039E FAX 13. While rotating ball cage, remove old grease on joint subassembly with paper towels. CAUTION: Visually check joint subassembly for compression scar, cracks, fractures. Also check the grease for contamination by road debris and metal fragments. If any non-standard condition is detected, replace entire joint subassembly. 14. Inject Genuine Nissan Grease (see parts catalog) into the joint subassembly serration hole until the grease begins to ooze from the ball groove and serration hole. MDIA0040E After injecting the grease, wipe off the old grease that has oozed out with towel. 15. Cover drive shaft splines with tape so as not to damage boot during installation. Install new boot and boot bands to the shaft. NOTE: Install small band first. CAUTION: Do not reuse the boot bands and boot. 16. Remove the tape wrapped around the serration on the shaft. 17. Mount circlip on circlip groove at the shaft edge. Do not over extend the circlip. Align the shaft edge and joint subassembly center axle. Then, assemble on the circlip groove, holding circlip with screwdriver tip. Drive joint inserter (commercial service tool) is recommended as an assisting tool when mounting circlip. For K9K engines: install joint subassembly securely, ensuring marks which were made during disassembly are properly aligned. CAUTION: Do not reuse the circlip. E F G H I J K L M MDIA0041E 18. Press joint subassembly into shaft with plastic hammer. CAUTION: Confirm that joint subassembly is correctly engaged while rotating. 19. Working from the big end of the boot, add enough Genuine Nissan Grease (refer to the part catalog) to the boot to equal the quantity mentioned below. Grease quantity : For CR and HR16 engines: 45 - 55 g (1.59 1.94 oz) For K9K engines: 40 - 50 g (1.41 - 1.76 oz) FAX-11 MDIA0042E FRONT DRIVE SHAFT 20. Remove grease from the boot and joint mating surfaces. 21. Mount boot firmly on the groove shown in the figure (with * mark) and confirm the length of the boot (L) is same as shown below. Hold the boot band at the opposite side to the clip to prevent misalignment. Fit the small boot band as shown in the figure. Insert a screwdriver or fitting tool from the large-diameter side. Bleed air out of the inside boot (to adjust pressure outside and inside of boot) to prevent deformation of boot. Boot mounting length :Wheel side Transaxle side : AC1700i: 88.0 mm (3.46 in) AC2000i: 91.0 mm (3.58 in) AC2300i: 94.0 mm (3.70 in) : GI1700i: 89.4 mm (3.52 in) GI2000i: 90.45 mm (3.56 in) GI2300i: 91.5 mm (3.60 in) MDIA0043E CAUTION: If boot mounting length is outside the standard, it may cause breakage in the boot. ● Be careful not to damage the inside of the boot with the tip of a screwdriver. ● 22. Hold the boot band at the opposite side to the clip to prevent misalignment. As shown in the figure, secure the big end of the boot with new boot band. SDIA0876J 23. Confirm that the mounting position of the boot band does not deviate around the circumference of the joint. When it deviates, mount a new boot band again. CAUTION: When fixing boot band, fix so that the M gap on the drawing becomes as follows. Large-diameter side Small-diameter side : 5 mm (0.20 in) : 5 mm (0.20 in) YAX006 24. Confirm that the driveshaft is still engaged in the differential. 25. Insert the drive shaft to the steering knuckle, and tighten the lock nut. 26. Install bolts securing steering knuckle to the strut. For tightening torque, refer to FSU-5, "FRONT SUSPENSION ASSEMBLY" . 27. Fix the brake hose onto the strut with the lock plate. 28. Install tie-rod to steering knuckle. For tightening torque, refer to FSU-5, "FRONT SUSPENSION ASSEMBLY" . 29. Install ABS wheel sensor. Refer to BRC-36, "WHEEL SENSORS" . FAX-12 FRONT DRIVE SHAFT 30. Using a hub lock nut wrench (SST), tighten lock nut to the specified torque. Tightening torque A : 280 N·m (29 kg-m, 207 ft-lb) 31. Mount the wheel and lower lift. B C MDIA0044E FAX Removal and Installation BDS0006Z FOR CR AND HR16 ENGINES: E F G H I J MDIB9062E 1. Damper (RH side) 2. Damper (LH side) K FOR K9K ENGINES: L M MDIB9022E FAX-13 FRONT DRIVE SHAFT REMOVAL 1. 2. 3. 4. 5. 6. 7. 8. Lift up the vehicle and remove the wheel from the vehicle. Remove lock plate from strut. Disconnect brake hose from strut. Refer to BR-11, "BRAKE PIPING AND HOSE" . Remove the ABS wheel sensor from the steering knuckle. Refer to BRC-36, "WHEEL SENSORS" . CAUTION: Do not pull on ABS wheel sensor harness. Use a hub lock nut wrench (SST), remove lock nuts. Remove tie-rod from steering knuckle. If tie-rod is not easily removed, use ball joint remover (commercial service tool). CAUTION: To prevent damage to threads and to prevent ball joint remover (commercial service tool) from sudden coming off, temporarily fix lock nuts. Remove steering knuckle and strut installation bolt. CAUTION: Do not place drive shaft joint at an extreme angle (22° or MDIA0038E more). Also, hold steering knuckle tightly and do not overextend slide joint. Using a puller (commercial service tool), remove the drive shaft from the steering knuckle. CAUTION: When removing drive shaft, do not place drive shaft joint at an extreme angle (22° or more). Also be careful not to overextend slide joint. ● Do not lift drive shaft with axle attached by grasping barshaft only. ● Do not allow the wheel-side joint and/or barshaft to hang from the transmission without support. Remove driveshaft from transaxle with a wheel wrench or equivalent, as shown in figure. CAUTION: When removing drive shaft from vehicle, be careful to avoid interfering with brake hose, ABS wheel sensor harness, and other parts. Take care not to damage the dust shield. ● Confirm that the circlip is attached to the driveshaft. MAA0384D INSPECTION AFTER REMOVAL ● ● ● Move joint in up/down, left/right, and axial directions. Check for motion that is not smooth and for significant looseness. Listen for air or grease leakage from the boot. Check the boot for cracks, damage, and leakage of grease. Check the boot band for damage. SDIA1029J FAX-14 FRONT DRIVE SHAFT INSTALLATION 1. 2. 3. Protector SST (special service tool) No. 4. 5. A In order to prevent damage to differential side oil seal, first fit a protector (SST) onto oil seal before inserting drive shaft. Align the driveshaft splines with the splines in the transmission. Holding the barshaft and wheel-side joint, apply a shock force to drive the slide joint stem into the differential. CAUTION: Make sure the circlip is fully engaged. B C : KV38107900 MDIA0046E For vehicles equipped with support bearing, fix drive shaft with support bearing retainer. WARNING: Before tightening the support bearing retainer bolts, ensure that the driveshaft support bearing is fully inserted into the support bracket. Also ensure that rubber o-ring is fitted between the support bearing and the support bracket. Tighten support bearing retainer bolts in numerical order as shown in the figure. Tightening torque: 21 N·m (2.1 kg-m, 15 ft-lb) 6. FAX E F G Retighten support bearing retainer bolts in numerical order as shown in the figure. H Tightening torque: 21 N·m (2.1 kg-m, 15 ft-lb) NOTE: The second tightening operation should be performed with a manual torque wrench. MDIB9043E 7. Insert the drive shaft to the steering knuckle, and tighten the lock nut. 8. Install bolts securing steering knuckle to the strut. For tightening torque, refer to FSU-5, "FRONT SUSPENSION ASSEMBLY" . 9. Fix the brake hose onto the strut with the lock plate. 10. Install tie-rod to steering knuckle. For tightening torque, refer to FSU-5, "FRONT SUSPENSION ASSEMBLY" . 11. Install ABS wheel sensor. Refer to BRC-36, "WHEEL SENSORS" . 12. Using a hub lock nut wrench (SST), tighten lock nut to the specified torque. Tightening torque : 280 N·m (29 kg·m, 207 ft-lb) J K L M 13. Mount tyre and lower lift. MDIA0044E FAX-15 I FRONT DRIVE SHAFT Disassembly and Assembly BDS00070 INSPECTION BEFORE DISASSEMBLY ● ● Move joint in up/down, left/right, and axial directions. Check for motion that is not smooth and for significant looseness. Check the boot for cracks, damage, and leakage of grease. DISASSEMBLY (CR AND HR16 ENGINE MODELS) MDIA0047E 1. Boot 2. Circlip 3. Joint subassembly (fixed joint) 4. Boot band 5. Dynamic damper (right side only) 6. Band 7. Shaft 8. Boot band 9. Spider assembly 10. Boot 11. Snap rings 12. Housing (slide joint) 13. Circlip Transaxle Side 1. 2. 3. 4. 5. Remove the boot bands. Fix shaft in a vice. Remove housing. CAUTION: When securing in a vice, use aluminum plates, copper plates or something similar to protect the shaft. Do not clamp onto the damper. Put mating marks onto the shaft and spider assembly. CAUTION: Use paint or similar substance for alignment marks. Do not scratch the surface. Remove the snap ring, and remove the spider assembly from the shaft. Use a bar to apply the load directly to the body of the spider assembly. Do not apply load to the rollers. Remove boot from shaft. MDIA0048E Wheel Side 1. 2. Using a vice, secure the shaft. CAUTION: When securing in a vice, use aluminum plates, copper plates or something similar to protect the shaft. Do not clamp onto the damper. Remove boot bands and remove boot from the joint subassembly. FAX-16 FRONT DRIVE SHAFT 3. 4. 5. 6. Screw the drive shaft puller (commercial service tool) 30 mm (1.18 in) or more over the thread on joint subassembly, and pull the joint subassembly out of the shaft. CAUTION: ● Align sliding hammer and drive shaft and remove them by pulling firmly and uniformly. ● If joint subassembly cannot be removed after five or more unsuccessful attempts, replace entire drive shaft assembly. Remove boot from shaft. Remove circlip from the shaft. A B C MDIA0049E FAX While rotating ball cage, remove old grease on joint subassembly with paper towels. CAUTION: Visually check joint subassembly for compression scar, cracks, fractures. Also check the grease for contamination by road debris and metal fragments. If any non-standard condition is detected, replace entire joint subassembly. E F G MDIA0040E H Dynamic Damper ● Make the damper's position by applying paint to the barshaft. Remove band. Then, remove dynamic damper from shaft. I J K L M FAX-17 FRONT DRIVE SHAFT DISASSEMBLY (K9K ENGINE MODELS) MDIB9044E 1. Joint assembly 2. Boot 3. Boot band 4. Circular clip 5. Drive shaft 6. Dynamic damper band 7. Dynamic damper 8. Boot 9. Boot band 10. Spider assembly 11. Snap ring 12. Slide joint housing 13. Circular clip 14. Slide joint housing with extension shaft 15. Dust shield 16. Support bearing 17. Support bearing retainer 18. Bracket 19. Snap ring 20. Dust shield 21. Dust shield 22. O-ring Transaxle Side 1. 2. 3. 4. Remove the boot bands. Put matching marks on slide joint housing and drive shaft before separating joint assembly. Put matching marks on spider assembly and drive shaft. Remove slide joint housing. SFA963 FAX-18 FRONT DRIVE SHAFT 5. 6. Pry off snap ring, then remove spider assembly. CAUTION: Do not disassemble spider assembly. Draw out boot. CAUTION: Cover drive shaft serration with tape to prevent damage to the boot. A B C SFA612 FAX Wheel Side CAUTION: The joint on the wheel side cannot be disassembled. 1. Before separating joint assembly, put matching marks on drive shaft and joint assembly. 2. Separate joint assembly with a suitable tool. CAUTION: Be careful not to damage threads on drive shaft. 3. Remove boot bands. 4. Draw out boot. E F G H SFA092A Dynamic Damper I Remove bands. Then, remove dynamic damper from drive shaft. Support Bearing 1. Remove dust shield. J K L YAX002 2. Remove dust shield. Then, remove snap ring. YAX003 FAX-19 M FRONT DRIVE SHAFT 3. 4. Press support bearing assembly off of drive shaft. Remove dust shield. YAX004 INSPECTION AFTER DISASSEMBLY (CR AND HR16 ENGINE MODELS) Shaft ● If the shaft has runout, cracks, or damage, replace the shaft. Joint Subassembly (Fixed Joint) ● ● Check the joint for rough rotation and abnormal axial looseness. Check if there is any compression scar, cracks, or fractures. CAUTION: If there are any non-standard conditions of joint assembly component parts, replace the joint assembly. Also check the grease for contamination by road debris and metal fragments. Joint Assembly (Sliding Joint) ● ● ● If there is scratching or wear of housing roller contact surface or spider roller contact surface, replace joint assembly. If there is circumferential looseness or rough rotation of spider roller, replace joint assembly. If there are any non-standard conditions of joint assembly component parts, replace the joint assembly. Housing (Slide Joint) ● ● ● Check the ball rolling surface for damage and abnormal wear. Check the shaft thread for damage. Check the boot mount for deformation. Dynamic Damper ● Check for cracks, wear, and damage. Replace if necessary. INSPECTION AFTER DISASSEMBLY (K9K ENGINE MODELS) Thoroughly clean all parts in cleaning solvent, and dry with compressed air. Check parts for evidence of deformation or other damage. Drive Shaft Replace drive shaft if it is twisted or cracked. Boot Check boot for fatigue, cracks or wear. Replace boot with new boot bands. Joint Assembly (Transaxle side) ● ● ● ● Check spider assembly for needle bearing and washer damage. Replace if necessary. Check roller surfaces for scratches, wear or other damage. Replace if necessary. Check serration for deformation. Replace if necessary. Check slide joint housing for any damage. Replace if necessary. Joint Assembly (Wheel side) Replace joint assembly if it is deformed or damaged. Support Bearing Make sure wheel bearing rolls freely and is free from noise, cracks, pitting or wear. FAX-20 FRONT DRIVE SHAFT Support Bearing Bracket A Check support bearing bracket for cracks with a magnetic exploration or dyeing test. Dynamic Damper Check dynamic damper for cracks, wear, and damage. Replace if necessary. B ASSEMBLY (CR AND HR16 ENGINE MODELS) Wheel Side For mounting, perform steps 13 to 22 of On-Vehicle Inspection and Service, FAX-10, "On-Vehicle Inspection and Service" . Dynamic Damper (Right Drive Shaft) ● FAX When dynamic damper has been removed, secure with bands as shown in figure so that measurements from fixed-joint side are as listed below. CAUTION: Do not reuse dynamic damper bands. Dimension A Dimension B C E : RH (1) – 434 - 440 mm (17.09 - 17.32 in) LH (2) – 235 - 241 mm (9.25 - 9.49 in) : 70 mm (2.76 in) F G MDIB9063E H I J MDIB9064E K Transaxle Side 1. Cover drive shaft serration with tape so as not to damage boot during installation. Install new boot and boot bands to the shaft. CAUTION: Do not reuse the boot bands and boot. L M MDIA0051E 2. Remove the tape wrapped around the serration on the shaft. FAX-21 FRONT DRIVE SHAFT 3. 4. 5. Align mating marks painted when spider assembly was removed. Install spider assembly with serrated mounting surface facing drive shaft. Secure the spider assembly with a snap ring. CAUTION: Do not reuse the snap ring. Apply all of the Genuine Nissan Grease into the joint housing. Grease quantity: 95 - 105 g 6. Assemble the sliding joint housing onto spider assembly. 7. Install boot securely into grooves (indicated by * marks) shown in figure. CAUTION: If grease adheres to the boot mounting surface (with * mark) on the joint, the boot may come off. Remove all grease from the surface. MDIA0052E MDIB9023E 8. Secure big end of boot with new boot band as shown in the figure. Plunge the joint fully to envelope the spider assembly with grease. Pull the joint back to the indicated length. Insert a screwdriver or similar tool into the small-diameter side of the boot. Bleed air out of the inside boot (to adjust pressure outside and inside of boot) to prevent deformation of boot. Boot mounting length : GI1700i: 89.4 mm (3.52 in) GI2000i: 90.45 mm (3.56 in) CAUTION: If boot mounting length is outside the standard, it may cause breakage in the boot. ● Be careful not to damage the inside of the boot with the tip of the screwdriver. Secure the small end of boot with new boot band as shown in figure. CAUTION: Rotate housing and check if boot installation position does not change. If position changes, reinstall boot bands. ● 9. MDIA0043E MDIA0054E FAX-22 FRONT DRIVE SHAFT ASSEMBLY (K9K ENGINE MODELS) ● ● After drive shaft has been assembled, ensure that it moves smoothly over its entire range without binding. Use NISSAN GENUINE GREASE or equivalent after every overhaul. B Wheel Side 1. A Install boot and new small boot band on drive shaft. CAUTION: Cover drive shaft serration with tape so as not to damage boot during installation. C FAX E SFA800 2. F Set joint assembly onto drive shaft by lightly tapping it. Install joint assembly securely, ensuring marks which were made during disassembly are properly aligned. G H I SFA942A 3. Pack drive shaft with specified amount of grease. J Specified amount of grease : 40 - 50 g (1.41 - 1.76 oz) 4. Make sure that boot is properly installed on the drive shaft groove. Set boot so that it does not swell and deform when its length is “L1 ”. Length “L1 ” K L : AC2000i: 91.0 mm (3.58 in) AC2300i: 94.0 mm (3.70 in) SFA592B 5. Secure the big and small ends of the boot with new boot bands. SDIA0876J FAX-23 M FRONT DRIVE SHAFT 6. Rotate joint part and confirm that mounting position of boot does not deviate. When it deviates, mount a new boot band again. CAUTION: When fixing boot band, fix so that the M gap on the drawing becomes as follows. M gap Large diameter side: 5 mm (0.20 in) Small diameter side: 5 mm (0.20 in) YAX006 Dynamic Damper 1. 2. Use new damper bands when installing. Install dynamic damper from stationary-joint side while holding it securely. Dimension A Dimension B : 50kW: 207 - 213 mm (8.15 - 8.39 in) 63kW: 235 - 241 mm (9.25 - 9.49 in) : 70 mm (2.76 in) MDIA0077E Transaxle Side 1. 2. 3. 4. Install boot and new small boot band on drive shaft. CAUTION: Cover drive shaft serration with tape so as not to damage boot during installation. Install spider assembly as a unit, making sure the marks which were made during disassembly are properly aligned. Install new snap ring. Pack drive shaft with specified amount of grease. Specified amount of grease : 113 - 123 g (3.98 - 4.34 oz) MDIA0051E 5. 6. Install slide joint housing. Make sure that boot is properly installed on the drive shaft. Set boot so that it does not swell and deform when its length is “L2 ”. Length “L2 ” : GI2000i: 90.45 mm (3.56 in) GI2300i: 91.5 mm (3.60 in) MDIA0078E FAX-24 FRONT DRIVE SHAFT 7. Lock new larger boot band securely with a suitable tool. A B C SFA395 FAX 8. Secure the smaller end of the boot with new boot band. E F G SDIA0876J 9. Rotate joint part of smaller end boot band and confirm that mounting position of boot does not deviate. When it deviates, mount a new boot band again. CAUTION: When fixing boot band, fix so that the M gap on the drawing becomes as follows. H I M gap Small diameter side: 5 mm (0.20 in) J YAX006 K Support Bearing ● ● Install new dust shield on drive shaft. Press drive shaft into bearing. L M YAX007 FAX-25 FRONT DRIVE SHAFT ● ● Install new snap ring. Install new dust shields. YAX008 FAX-26 SERVICE DATA AND SPECIFICATIONS (SDS) SERVICE DATA AND SPECIFICATIONS (SDS) Wheel Bearing PFP:00030 A BDS00071 Drive type 2WD Axial end play B 0.05 mm (0.0020 in) Rotating torque 0.30 - 1.43 N·m (0.03 - 0.14 kg-m) Spring balance measurement 6.0 - 28.6 N (0.61 - 2.92 kg) C FAX Spring balance mounting position (Strut mounting hole upper side) E SDIA0833J Drive shaft BDS00072 Engine Joint type Amount of grease g (oz) Boot length mm (in) CR HR16 K9K 50 kW K9K 63 kW Wheel side AC1700i AC2000i AC2000i AC2300i Transaxle side GI1700i GI2000i GI2000i GI2300i Wheel side 45 - 55 (1.59 - 1.94) 45 - 55 (1.59 - 1.94) 40 - 50 (1.41 - 1.76) 40 - 50 (1.41 - 1.76) Transaxle side 95 - 105 (3.35 - 3.70) 95 - 105 (3.35 - 3.70) 113 - 123 (3.99 - 4.34) 113 - 123 (3.99 - 4.34) 88 (3.46) 91 (3.58) 91 (3.58) 94 (3.70) 89.4 (3.52) 90.45 (3.56) 90.45 (3.56) 91.5 (3.60) Wheel side Transaxle side Dynamic Damper Engine F G H I BDS00073 Type Drive type Specification Dimension A mm (in) Dimension B mm (in) Illustration CR/HR16 AC1700i/ GI1700i AC2000i/ GI2000i 2WD RH 434 - 440 (17.09 - 17.32) 70 (2.76) (1) CR/HR16 AC1700i/ GI1700i AC2000i/ GI2000i 2WD LH 235 - 241 (9.25 - 9.49) 70 (2.76) (2) K9K 50kW AC2000i/ GI2000i 2WD RH, LH 207 - 213 (8.15 - 8.39) 70 (2.76) (1) K9K 63kW AC2300i/ GI2300i 2WD RH, LH 235 - 241 (9.25 - 9.49) 70 (2.76) (1) J K L M MDIB9063E MDIB9064E Tightening Torque BDS00074 Unit: N·m (kg-m, ft-lb) Hub lock nut 280 N·m (29 kg-m, 207 ft-lb) FAX-27 SERVICE DATA AND SPECIFICATIONS (SDS) FAX-28 FUEL SYSTEM B ENGINE SECTION FL FUEL SYSTEM A FL C D E CONTENTS CR PREPARATION ........................................................... 2 Special Service Tools ............................................... 2 FUEL SYSTEM ........................................................... 3 Checking Fuel Lines ................................................. 3 General Precautions ................................................ 3 FUEL LEVEL SENSOR UNIT, FUEL FILTER AND FUEL PUMP ASSEMBLY ........................................... 4 Removal and Installation .......................................... 4 REMOVAL ............................................................. 4 INSTALLATION ..................................................... 6 INSPECTION AFTER INSTALLATION ................. 7 FUEL TANK ................................................................ 8 Removal and Installation .......................................... 8 REMOVAL ............................................................. 8 INSTALLATION ................................................... 10 INSPECTION AFTER INSTALLATION ................11 SERVICE DATA AND SPECIFICATIONS (SDS) ...... 12 Standard and Limit ................................................. 12 Tightening Torque ................................................... 12 HR PREPARATION ......................................................... 13 Special Service Tools ............................................. 13 FUEL SYSTEM ......................................................... 14 Checking Fuel Lines ............................................... 14 General Precautions .............................................. 14 FUEL LEVEL SENSOR UNIT, FUEL FILTER AND FUEL PUMP ASSEMBLY ......................................... 15 Removal and Installation ........................................ 15 REMOVAL ........................................................... 15 INSTALLATION ................................................... 17 INSPECTION AFTER INSTALLATION ............... 18 FUEL TANK .............................................................. 19 Removal and Installation ........................................ 19 REMOVAL ........................................................... 19 INSTALLATION ................................................... 21 INSPECTION AFTER INSTALLATION ................ 22 SERVICE DATA AND SPECIFICATIONS (SDS) ...... 23 Standard and Limit .................................................. 23 Tightening Torque ................................................... 23 K9K PREPARATION ......................................................... 24 Special Service Tool ............................................... 24 FUEL SYSTEM ......................................................... 25 Checking Fuel Lines ............................................... 25 FUEL FILTER ............................................................ 26 Removal and Installation ........................................ 26 Water Draining from Fuel Filter .............................. 26 DRAINING WATER (RHD) .................................. 26 DRAINING WATER (LHD) ................................... 27 FUEL FILTER CHECK ......................................... 27 Changing Fuel Filter ............................................... 27 REMOVAL (RHD) ................................................ 27 REMOVAL (LHD) ................................................. 27 INSTALLATION ................................................... 27 Bleeding Fuel Filter ................................................. 28 FUEL LEVEL SENSOR UNIT ................................... 29 Removal and Installation ........................................ 29 REMOVAL ........................................................... 29 INSTALLATION ................................................... 30 FUEL TANK .............................................................. 31 Removal and Installation ........................................ 31 REMOVAL ........................................................... 31 INSTALLATION ................................................... 32 INSPECTION AFTER INSTALLATION ................ 33 SERVICE DATA AND SPECIFICATIONS (SDS) ...... 34 Standard and Limit .................................................. 34 Tightening Torque ................................................... 34 FL-1 F G H I J K L M PREPARATION [CR] PREPARATION Special Service Tools [CR] PFP:00002 BBS003YH Tool number (RENAULT tool number) Tool name Description KV993G0010 (Mot. 1397) Lock ring wrench Removing and Installing lock ring PBIC1627E FL-2 FUEL SYSTEM [CR] FUEL SYSTEM Checking Fuel Lines PFP:17503 A BBS003YI Inspect fuel lines, fuel filler cap and tank for improper attachment, leaks, cracks, damage, loose connections, chafing or deterioration. If necessary, repair or replace faulty parts. FL C D SMA803A E General Precautions BBS003YJ WARNING: when replacing fuel line parts, be sure to observe the following. ● Put a “CAUTION: IN FLAMMABLE” sign in workshop. ● Be sure to work in a well-ventilated area and furnish workshop with a CO2 fire extinguisher. ● Do not smoke while servicing fuel system, keep open flames and spark away from work area. CAUTION: ● Use gasoline required by the regulation for octane number. Refer to GI-5, "Precautions for Fuel" ● Before removing fuel line parts, carry out the following procedures. – Put drained fuel in an explosion-proof container and put the lid on securely, keep the container in safe area. – Release fuel pressure from fuel line. Refer to EC-71, "FUEL PRESSURE RELEASE" (with EUROOBD), refer to EC-488, "FUEL PRESSURE RELEASE" (without EURO-OBD). – Disconnect battery negtive cable. ● Always replace O-ring and clamps with new ones. ● Do not tighten hose clamps excessively to avoid damaging hoses. ● Do not kink or twist tubes when they are being installed. ● Perform work on level place. ● Do not tighten hose clamps excessively to avoid damaging hoses. Tighten high-pressure rubber hose clamp so that clamp end is 3 mm (0.12 in) from hose end. Tightening torque specifications are the same for all rubber hose clamps. Ensure that screw does not contact adjacent parts. ● After installing tubes, run engine and check for fuel leaks at connections. ● For servicing “Evaporative Emission System” parts, refer to EC-40, "EVAPORATIVE EMISSION SYSTEM" (with EUROOBD), EC-469, "EVAPORATIVE EMISSION SYSTEM" (withMMA104A out EURO-OBD). FL-3 F G H I J K L M FUEL LEVEL SENSOR UNIT, FUEL FILTER AND FUEL PUMP ASSEMBLY [CR] FUEL LEVEL SENSOR UNIT, FUEL FILTER AND FUEL PUMP ASSEMBLY Removal and Installation PFP:17042 BBS003YK MBIB1354E 1. Lock ring 2. Fuel filter and fuel pump assembly 4. O-ring 5. Fuel tank 3. Fuel level sensor unit REMOVAL WARNING: Read “General Precautions” before working on the fuel system. Refer to FL-3, "General Precautions" . 1. Check fuel level. If gauge indicates more than the level shown in figure (full or almost full), drain fuel from fuel tank until gauge indicates the level in figure or below. When fuel pump malfunctions, insert hose with outer diameter of 25 mm (0.98 in) or less from fuel filler port. Drain fuel in fuel filler tube. Disconnect connections of fuel filler tube and fuel filler hose to drain fuel from fuel filler hose. ● As guide, fuel amount becomes the level shown in figure or below when approximately 7 liter (1-1/2 lmp gal) of fuel are drained from full. PBIC1495E NOTE: Adjusting fuel level is to prevent fuel from spilling, when fuel level sensor unit, fuel filter and fuel pump assembly are removed. 2. Release fuel pressure. Refer to EC-71, "Fuel Pressure Check" (with EURO-OBD), EC-488, "Fuel Pressure Check" (without EURO-OBD). a. Refer to steps 5 to 7. Remove harness connectors from fuel level sensor unit, fuel filter and fuel pump assembly. b. Start the engine. After stopping the engine, crank it two or three times to consume the fuel in the fuel line. 3. Open fuel filler lid. 4. Open the filler cap and release the pressure inside the fuel tank. 5. Remove rear seat. Refer to SE-12, "REAR SEAT" . 6. Remove inspection hole cover. ● Using a screwdriver, remove it by turning clips clockwise by 90°. FL-4 FUEL LEVEL SENSOR UNIT, FUEL FILTER AND FUEL PUMP ASSEMBLY [CR] 7. Remove harness connector and fuel feed hose from sender unit. NOTE: ● Connections of harness connector and fuel feed hose are called sender unit. A FL C PBIC1496E D ● – – ● Remove quick connector in the following procedures. Pinch quick connector square-parts with your fingers, and pull out the quick connector by hand. If quick connector and tube on sender unit are stuck, push and pull several times until they move, and pull out. CAUTION: ● The tube can be removed when the tabs are completely depressed. Do not twist it more than necessary. ● Do not use any tools to remove the quick connector. ● Keep the resin tube away from heat. Be especially careful when welding near the tube. ● Prevent acid liquid such as battery electrolyte etc. from getting on the resin tube. ● Do not bend or twist the tube during installation and removal. To keep clean the connecting portion and to avoid damage and foreign materials, cover them completely with plastic bags or something similar. CAUTION: Do not insert plug, preventing damage on O-ring in quick connector. E F G PBIC1497E H I J K PBIC0713E 8. 9. Using lock ring wrench [SST: KV993G0010], remove lock ring. CAUTION: Rotate SST while pressing fuel level sensor unit, fuel filter and fuel pump assembly as spring reaction force is applied from fuel tank inside to upward. Remove fuel level sensor unit, fuel filter and fuel pump assembly. CAUTION: ● Be careful not to bend the float arm when removing. ● Handle them carefully without subjecting them to impacts such as dropping. PBIC1498E FL-5 L M FUEL LEVEL SENSOR UNIT, FUEL FILTER AND FUEL PUMP ASSEMBLY [CR] 10. Install lock ring temporally by hand tightening until it stops with maximum force. ● Direct arrow mark on lock ring to vehicle rear. Then turn clockwise to tighten lock ring. CAUTION: Do not remove lock ring until fuel level sensor unit, fuel filter and fuel pump assembly is installed. 11. Remove fuel level sensor unit in the following procedures. a. Remove harness connector (brown). ● Hold connector with your fingers, because there is no tab for releasing stopper. Pull it out straight downward. b. Insert a screwdriver into the gap between fuel level sensor unit left side and mounting part. Pry the screwdriver in the direction shown by arrow. CAUTION: Be careful not to damage anything. c. When fixing tab comes off, slide fuel level sensor unit in the direction indicated by arrow to remove. CAUTION: ● Do not reuse removed fuel level sensor unit. ● Do not disassemble fuel filter and fuel tank pump assembly. PBIC1573E PBIC1500E INSTALLATION Install in the reverse order of removal which being careful of the following. Installation of Fuel Level Sensor Unit Install it in the following procedures. 1. Check fuel gauge mounting part of fuel filter and fuel pump assembly side for damage. 2. Slide fuel level sensor unit along with mounting groove. Insert new fuel level sensor unit until it contacts the face. ● After inserting, apply force to the reverse direction (removal direction). Make sure fuel level sensor unit does not come off. 3. Connect harness connector. ● Insert harness connector securely until it contacts the face. Installation of Fuel Level Sensor Unit, Fuel Filter and Fuel Pump Assembly Install it in the following procedures. 1. Remove lock ring. 2. Install O-ring to fuel tank without any twist. PBIC1501E FL-6 FUEL LEVEL SENSOR UNIT, FUEL FILTER AND FUEL PUMP ASSEMBLY [CR] 3. Install fuel level sensor unit, fuel filter and fuel pump assembly, aligning the sender unit rear side protrusion with the fuel tank opening rear side cutout. CAUTION: ● Do not allow O-ring to drop. ● Maintain closely jointed status by pressing fuel level sensor unit, fuel filter and fuel pump assembly at an opening of the tank until the end of step 5, in order to prevent the fallout of O-ring (To maintain the O-ring installed status of view A in the figure at step 2). A FL C PBIC1502E D 4. 5. Direct arrow mark on lock ring to vehicle rear. Then turn lock ring clockwise by hand until it steps with maximum force. CAUTION: Install lock ring horizontally. Tighten lock ring to the specification with lock ring wrench [SST: KV993G0010]. E F G PBIC1573E Fuel Feed Hose Installation ● 1. 2. 3. H Connect quick connector in the following procedures. Check connections for damage or foreign material. Align the mating side connection part with the center of shaft on the sender unit, and insert quick connector straight until it clicks. After connecting, pull out quick connector by hand. Make sure connections are secure. I J K PBIC1503E INSPECTION AFTER INSTALLATION ● 1. 2. Check for fuel leak in the following procedures. Turn the ignition switch to ON (do not start engine), and with fuel pressure applied in the fuel line, check to make sure there are no fuel leaks from the connection. Start the engine, and at increased speed, check again to see if there any fuel leaks from the connection. FL-7 L M FUEL TANK [CR] FUEL TANK Removal and Installation PFP:17202 BBS003YL MBIB9039E 1. Fuel tank 2. Vent hose 4. Fuel filler cap 5. 7. Vent hose 8. 10. Mounting band 3. EVAP tube Grommet 6. Fuel filler tube Clamp 9. Fuel filler hose 11. EVAP hose 12. Evap canister mounting screw 13. Evap canister 14. Evap canister hose* 15. Evap canister hose** 16. Evap air inlet hose 17. Evap air inlet hose *: To fuel tank **: To EVAP canister purge volume control solenoid valve : Air inlet REMOVAL WARNING: Be sure to read “General Precautions” when working on fuel system. Refer to FL-3, "General Precautions" . 1. Remove RH rear wheel. 2. Perform steps 1 to 7 of FL-4, "REMOVAL" in “FUEL LEVEL SENSOR UNIT, FUEL FILTER AND FUEL PUMP ASSEMBLY”. CAUTION: If fuel tank bottom face is not level, and remaining fuel level is high, tank position becomes unstable, causing a danger. Drain fuel further than that in step 1 of the referenced procedure until tank can be held by hand even if the balance is lost. 3. Remove center muffler and main muffler. Refer to EX-3, "EXHAUST SYSTEM" . 4. Remove vehicle side insulator on upper center muffler and main muffler. 5. Move parking brake cable from the lower face of fuel tank. Then remove clips for parking brake cable. FL-8 FUEL TANK [CR] 6. 7. Disconnect fuel filler hose on fuel tank side. CAUTION: Do not remove fuel filler hose at fuel filler tube side, preventing to interfere with suspension due to dislocation when installing. When removing at fuel filler tube side necessarily, put mating marks, and remove. Remove vent hose at RH rear wheelwell side. A FL C PBIC1505E D 8. Remove EVAP hose at front side of fuel tank. E F G PBIC1507E ● – – ● Remove quick connector in the following procedures. Pinch quick connector square-parts with your fingers, and pull out the quick connector by hand. If quick connector and tube on vehicle are stuck, push and pull several times until they move, and pull out. CAUTION: ● The tube can be removed when the tabs are completely depressed. Do not twist it more than necessary. ● Do not use any tools to remove the quick connector. ● Keep the resin tube away from heat. Be especially careful when welding near the tube. ● Prevent acid liquid such as battery electrolyte etc. from getting on the resin tube. ● Do not bend or twist the tube during installation and removal. To keep clean the connecting portion and to avoid damage and foreign materials, cover them completely with plastic bags or something similar. CAUTION: Do not insert plug, preventing damage on O-ring in quick connector. H I J K PBIC1509E L M PBIC0713E FL-9 FUEL TANK [CR] 9. If necessary, remove mounting screw and quick connectors and slide the EVAP canister rearward to remove it from the fuel tank. NOTE: For servicing “Evaporative Emission System” parts, refer to EC41, "EVAPORATIVE EMISSION LINE DRAWING" (with EUROOBD), EC-470, "EVAPORATIVE EMISSION LINE DRAWING" (without EURO-OBD). MBIB9040E 10. Support center of fuel tank with suitable transmission jack. CAUTION: Securely support the fuel tank with a piece of wood. 11. Remove RH/LH mounting band. 12. Lower suitable transmission jack carefully to remove fuel tank while holding it by hand. Perform the following works at the same time. ● Pull out vent hose from through hole of vehicle. ● Avoid interference with tank by pulling parking brake cable by hand. PBIC1508E CAUTION: Tank may be in an unstable condition because of the shape of fuel tank bottom. Do not rely on jack too much. Be sure to hold tank securely. INSTALLATION Install in the reverse order of removal which being careful of the following. Installation of Fuel Tank Mounting Band ● Install it by referring to the identification stamp mark “R” and “L” on the end. Installation of fuel Filler Hose ● Install fuel filler hose to fuel tank, paying attention to install mark. Marking faces downward. MBIB9043E ● ● ● ● Install fuel filler hose (2) to fuel filler tube (1), paying attention to install mark. Marking faces rightward. Insert filler hose into mating side part by 35 mm (1.38 in), and secure it with clamp. When installing clamp, do not allow clamp to contact the bulge (bump) part of the tube. Tighten the clamp of filler hose so that the remaining length becomes 5 - 9 mm (0.20 - 0.35 in) [or tightening torque: 1.3 - 3.7 N·m (0.13 - 0.38 kg-m, 12 - 32 in-lb]. MBIB9041E FL-10 FUEL TANK [CR] Installation of EVAP Hose ● 1. 2. 3. A Connect quick connector in the following procedures. Check connections for damage or foreign material. Align the mating side connection part with the center of shaft, and insert connector straight until it clicks. After connecting, pull out quick connector by hand. Make sure connections are secure. FL C PBIC1509E D INSPECTION AFTER INSTALLATION ● 1. 2. Check for fuel leak in the following procedures. Turn the ignition switch to ON (do not start engine), and with fuel pressure applied in the fuel line, check to make sure there are no fuel leaks from the connection. Start the engine, and at increased speed, check again to see if there any fuel leaks from the connection. E F G H I J K L M FL-11 SERVICE DATA AND SPECIFICATIONS (SDS) [CR] SERVICE DATA AND SPECIFICATIONS (SDS) Standard and Limit Fuel tank capacity PFP:00030 BBS003YM Approx. 46 (10-1/8 Imp gal) Tightening Torque BBS003YN Fuel tank mounting band Unit: N·m (kg-m, ft-lb) 21.0 - 29.0 (2.1 - 3.0, 15 - 21) Fuel filler tube 15.8 - 24.2 (1.7 - 2.4, 12 - 17) Lock ring 65.0 - 75.0 (6. - 7.7, 48 - 55) FL-12 PREPARATION [HR] PREPARATION Special Service Tools [HR] PFP:00002 A BBS003YO Tool number (RENAULT tool number) Tool name Description KV993G0010 (Mot. 1397) Lock ring wrench FL Removing and Installing lock ring C D PBIC1627E E F G H I J K L M FL-13 FUEL SYSTEM [HR] FUEL SYSTEM Checking Fuel Lines PFP:17503 BBS003YP Inspect fuel lines, fuel filler cap and fuel tank for improper attachment, leaks, cracks, damage, loose connections, chafing or deterioration. If necessary, repair or replace damaged parts. SMA803A General Precautions BBS003YQ WARNING: When replacing fuel line parts, be sure to observe the following. ● Put a “CAUTION: INFLAMMABLE” sign in the workshop. ● Be sure to work in a well ventilated area and furnish workshop with a CO2 fire extinguisher. ● Do not smoke while servicing fuel system. Keep open flames and sparks away from the work area. ● Put drained fuel in an explosion-proof container and put the lid on securely. Keep the container in safe area. CAUTION: ● Use gasoline required by the regulations for octane number. Refer to GI-5, "Precautions for Fuel" . ● Before removing fuel line parts, perform the following procedures: – Release fuel pressure from the fuel lines. Refer to EC-860, "FUEL PRESSURE RELEASE" (with EURO-OBD) or EC-1281, "FUEL PRESSURE RELEASE" (without EURO-OBD). – Disconnect the battery cable from the negative cable. ● Always replace O-rings and clamps with new ones. ● Do not kink or twist tubes when they are being installed. ● Perform work on level place. ● Do not tighten hose clamps excessively to avoid damaging hoses. ● After connecting fuel tube quick connectors, make sure quick connectors are secure. Ensure that connector and resin tube do not contact any adjacent parts. ● After installing tubes, make sure there is no fuel leakage at connections in the following steps. – Apply fuel pressure to fuel lines with turning ignition switch ON (with engine stopped). Then check for fuel leaks at connections. – Start engine and rev it up and check for fuel leaks at connections. ● Use only a genuine NISSAN fuel filler cap as a replacement. If an incorrect fuel filler cap is used, the “MIL” may come on. ● For servicing “Evaporative Emission System” parts, refer to EC-823, "EVAPORATIVE EMISSION SYSTEM" (with EURO-OBD) or EC-1257, "EVAPORATIVE EMISSION SYSTEM" (without EUROOBD). FL-14 FUEL LEVEL SENSOR UNIT, FUEL FILTER AND FUEL PUMP ASSEMBLY [HR] FUEL LEVEL SENSOR UNIT, FUEL FILTER AND FUEL PUMP ASSEMBLY Removal and Installation PFP:17042 A BBS003YR FL C D E F MBIB1354E 1. Lock ring 2. Fuel filter and fuel pump assembly 4. O-ring 5. Fuel tank 3. G Fuel level sensor unit H REMOVAL WARNING: Read “General Precautions” before working on the fuel system. Refer to FL-14, "General Precautions" . 1. Check fuel level. If gauge indicates more than the level shown in figure (full or almost full), drain fuel from fuel tank until gauge indicates the level in figure or below. When fuel pump malfunctions, insert hose with outer diameter of 25 mm (0.98 in) or less from fuel filler port. Drain fuel in fuel filler tube. Disconnect connections of fuel filler tube and fuel filler hose to drain fuel from fuel filler hose. ● As guide, fuel amount becomes the level shown in figure or below when approximately 7 liter (1-1/2 lmp gal) of fuel are drained from full. PBIC1495E NOTE: Adjusting fuel level is to prevent fuel from spilling, when fuel level sensor unit, fuel filter and fuel pump assembly are removed. 2. Release fuel pressure. Refer to EC-860, "FUEL PRESSURE RELEASE" (with EURO-OBD), EC-1281, "FUEL PRESSURE RELEASE" (without EURO-OBD). a. Refer to steps 5 to 7. Remove harness connectors from fuel level sensor unit, fuel filter and fuel pump assembly. b. Start the engine. After stopping the engine, crank it two or three times to consume the fuel in the fuel line. 3. Open fuel filler lid. 4. Open the filler cap and release the pressure inside the fuel tank. 5. Remove rear seat. Refer to SE-12, "REAR SEAT" . 6. Remove inspection hole cover. ● Using a screwdriver, remove it by turning clips clockwise by 90°. FL-15 I J K L M FUEL LEVEL SENSOR UNIT, FUEL FILTER AND FUEL PUMP ASSEMBLY [HR] 7. Remove harness connector and fuel feed hose from sender unit. NOTE: ● Connections of harness connector and fuel feed hose are called sender unit. PBIC1496E ● – – ● Remove quick connector in the following procedures. Pinch quick connector square-parts with your fingers, and pull out the quick connector by hand. If quick connector and tube on sender unit are stuck, push and pull several times until they move, and pull out. CAUTION: ● The tube can be removed when the tabs are completely depressed. Do not twist it more than necessary. ● Do not use any tools to remove the quick connector. ● Keep the resin tube away from heat. Be especially careful when welding near the tube. ● Prevent acid liquid such as battery electrolyte etc. from getting on the resin tube. ● Do not bend or twist the tube during installation and removal. To keep clean the connecting portion and to avoid damage and foreign materials, cover them completely with plastic bags or something similar. CAUTION: Do not insert plug, preventing damage on O-ring in quick connector. PBIC1497E PBIC0713E 8. 9. Using lock ring wrench [SST: KV993G0010], remove lock ring. CAUTION: Rotate SST while pressing fuel level sensor unit, fuel filter and fuel pump assembly as spring reaction force is applied from fuel tank inside to upward. Remove fuel level sensor unit, fuel filter and fuel pump assembly. CAUTION: ● Be careful not to bend the float arm when removing. ● Handle them carefully without subjecting them to impacts such as dropping. PBIC1498E FL-16 FUEL LEVEL SENSOR UNIT, FUEL FILTER AND FUEL PUMP ASSEMBLY [HR] 10. Install lock ring temporally by hand tightening until it stops with maximum force. ● Direct arrow mark on lock ring to vehicle rear. Then turn clockwise to tighten lock ring. CAUTION: Do not remove lock ring until fuel level sensor unit, fuel filter and fuel pump assembly is installed. 11. Remove fuel level sensor unit in the following procedures. a. Remove harness connector (brown). ● Hold connector with your fingers, because there is no tab for releasing stopper. Pull it out straight downward. b. Insert a screwdriver into the gap between fuel level sensor unit left side and mounting part. Pry the screwdriver in the direction shown by arrow. CAUTION: Be careful not to damage anything. c. When fixing tab comes off, slide fuel level sensor unit in the direction indicated by arrow to remove. CAUTION: ● Do not reuse removed fuel level sensor unit. ● Do not disassemble fuel filter and fuel tank pump assembly. A FL C PBIC1573E D E F G PBIC1500E INSTALLATION H Install in the reverse order of removal which being careful of the following. Installation of Fuel Level Sensor Unit Install it in the following procedures. 1. Check fuel gauge mounting part of fuel filter and fuel pump assembly side for damage. 2. Slide fuel level sensor unit along with mounting groove. Insert new fuel level sensor unit until it contacts the face. ● After inserting, apply force to the reverse direction (removal direction). Make sure fuel level sensor unit does not come off. 3. Connect harness connector. ● Insert harness connector securely until it contacts the face. I J K L Installation of Fuel Level Sensor Unit, Fuel Filter and Fuel Pump Assembly Install it in the following procedures. 1. Remove lock ring. 2. Install O-ring to fuel tank without any twist. M PBIC1501E FL-17 FUEL LEVEL SENSOR UNIT, FUEL FILTER AND FUEL PUMP ASSEMBLY [HR] 3. Install fuel level sensor unit, fuel filter and fuel pump assembly, aligning the sender unit rear side protrusion with the fuel tank opening rear side cutout. CAUTION: ● Do not allow O-ring to drop. ● Maintain closely jointed status by pressing fuel level sensor unit, fuel filter and fuel pump assembly at an opening of the tank until the end of step 5, in order to prevent the fallout of O-ring (To maintain the O-ring installed status of view A in the figure at step 2). PBIC1502E 4. 5. Direct arrow mark on lock ring to vehicle rear. Then turn lock ring clockwise by hand until it steps with maximum force. CAUTION: Install lock ring horizontally. Tighten lock ring to the specification with lock ring wrench [SST: KV993G0010]. PBIC1573E Fuel Feed Hose Installation ● 1. 2. 3. Connect quick connector in the following procedures. Check connections for damage or foreign material. Align the mating side connection part with the center of shaft on the sender unit, and insert quick connector straight until it clicks. After connecting, pull out quick connector by hand. Make sure connections are secure. PBIC1503E INSPECTION AFTER INSTALLATION ● 1. 2. Check for fuel leak in the following procedures. Turn the ignition switch to ON (do not start engine), and with fuel pressure applied in the fuel line, check to make sure there are no fuel leaks from the connection. Start the engine, and at increased speed, check again to see if there any fuel leaks from the connection. FL-18 FUEL TANK [HR] FUEL TANK Removal and Installation PFP:17202 A BBS003YS FL C D E F G H I MBIB9039E 1. Fuel tank 2. Vent hose 3. EVAP tube 4. Fuel filler cap 5. Grommet 6. Fuel filler tube 7. Vent hose 8. Clamp 9. Fuel filler hose 10. Mounting band 11. EVAP hose 12. Evap canister mounting screw 13. Evap canister 14. Evap canister hose* 15. Evap canister hose** 16. Evap air inlet hose 17. Evap air inlet hose J K L *: To fuel tank **: To EVAP canister purge volume control solenoid valve : Air inlet M REMOVAL WARNING: Be sure to read “General Precautions” when working on fuel system. Refer to FL-14, "General Precautions" . 1. Remove RH rear wheel. 2. Perform steps 1 to 7 of FL-15, "REMOVAL" in “FUEL LEVEL SENSOR UNIT, FUEL FILTER AND FUEL PUMP ASSEMBLY”. CAUTION: If fuel tank bottom face is not level, and remaining fuel level is high, tank position becomes unstable, causing a danger. Drain fuel further than that in step 1 of the referenced procedure until tank can be held by hand even if the balance is lost. 3. Remove center muffler and main muffler. Refer to EX-3, "EXHAUST SYSTEM" . 4. Remove vehicle side insulator on upper center muffler and main muffler. 5. Move parking brake cable from the lower face of fuel tank. Then remove clips for parking brake cable. FL-19 FUEL TANK [HR] 6. 7. Disconnect fuel filler hose on fuel tank side. CAUTION: Do not remove fuel filler hose at fuel filler tube side, preventing to interfere with suspension due to dislocation when installing. When removing at fuel filler tube side necessarily, put mating marks, and remove. Remove vent hose at RH rear wheelwell side. PBIC1505E 8. Remove EVAP hose at front side of fuel tank. PBIC1507E ● – – ● Remove quick connector in the following procedures. Pinch quick connector square-parts with your fingers, and pull out the quick connector by hand. If quick connector and tube on vehicle are stuck, push and pull several times until they move, and pull out. CAUTION: ● The tube can be removed when the tabs are completely depressed. Do not twist it more than necessary. ● Do not use any tools to remove the quick connector. ● Keep the resin tube away from heat. Be especially careful when welding near the tube. ● Prevent acid liquid such as battery electrolyte etc. from getting on the resin tube. ● Do not bend or twist the tube during installation and removal. To keep clean the connecting portion and to avoid damage and foreign materials, cover them completely with plastic bags or something similar. CAUTION: Do not insert plug, preventing damage on O-ring in quick connector. PBIC1509E PBIC0713E FL-20 FUEL TANK [HR] 9. If necessary, remove mounting screw and quick connectors and slide the EVAP canister rearward to remove it from the fuel tank. NOTE: For servicing “Evaporative Emission System” parts, refer to EC824, "EVAPORATIVE EMISSION LINE DRAWING" (with EURO-OBD), EC-1258, "EVAPORATIVE EMISSION LINE DRAWING" (without EURO-OBD). A FL C MBIB9040E D 10. Support center of fuel tank with suitable transmission jack. CAUTION: Securely support the fuel tank with a piece of wood. 11. Remove RH/LH mounting band. 12. Lower suitable transmission jack carefully to remove fuel tank while holding it by hand. Perform the following works at the same time. ● Pull out vent hose from through hole of vehicle. ● Avoid interference with tank by pulling parking brake cable by hand. PBIC1508E CAUTION: Tank may be in an unstable condition because of the shape of fuel tank bottom. Do not rely on jack too much. Be sure to hold tank securely. INSTALLATION E F G H I Install in the reverse order of removal which being careful of the following. Installation of Fuel Tank Mounting Band ● Install it by referring to the identification stamp mark “R” and “L” on the end. J Installation of fuel Filler Hose ● Install fuel filler hose to fuel tank, paying attention to install mark. Marking faces downward. K L M MBIB9043E ● ● ● ● Install fuel filler hose (2) to fuel filler tube (1), paying attention to install mark. Marking faces rightward. Insert filler hose into mating side part by 35 mm (1.38 in), and secure it with clamp. When installing clamp, do not allow clamp to contact the bulge (bump) part of the tube. Tighten the clamp of filler hose so that the remaining length becomes 5 - 9 mm (0.20 - 0.35 in) [or tightening torque: 1.3 - 3.7 N·m (0.13 - 0.38 kg-m, 12 - 32 in-lb]. MBIB9041E FL-21 FUEL TANK [HR] Installation of EVAP Hose ● 1. 2. 3. Connect quick connector in the following procedures. Check connections for damage or foreign material. Align the mating side connection part with the center of shaft, and insert connector straight until it clicks. After connecting, pull out quick connector by hand. Make sure connections are secure. PBIC1509E INSPECTION AFTER INSTALLATION ● 1. 2. Check for fuel leak in the following procedures. Turn the ignition switch to ON (do not start engine), and with fuel pressure applied in the fuel line, check to make sure there are no fuel leaks from the connection. Start the engine, and at increased speed, check again to see if there any fuel leaks from the connection. FL-22 SERVICE DATA AND SPECIFICATIONS (SDS) [HR] SERVICE DATA AND SPECIFICATIONS (SDS) Standard and Limit Fuel tank capacity PFP:00030 A BBS003YT Approx. 46 (10-1/8 Imp gal) FL Tightening Torque BBS003YU Fuel tank mounting band Unit: N·m (kg-m, ft-lb) 21.0 - 29.0 (2.1 - 3.0, 15 - 21) Fuel filler tube 15.8 - 24.2 (1.7 - 2.4, 12 - 17) Lock ring 65.0 - 75.0 (6.6 - 7.7, 48 - 55) C D E F G H I J K L M FL-23 PREPARATION [K9K] PREPARATION Special Service Tool [K9K] PFP:00002 BBS003YV Tool number (RENAULT tool number) Tool name Description KV993G0010 (Mot. 1397) Lock ring wrench Removing and Installing lock ring PBIC1627E FL-24 FUEL SYSTEM [K9K] FUEL SYSTEM Checking Fuel Lines PFP:17503 A BBS003YW Inspect fuel lines and tank for improper attachment, leaks, cracks, damage, chafing and deterioration.If necessary, repair or replace. FL C D SMA803A E F G H I J K L M FL-25 FUEL FILTER [K9K] FUEL FILTER Removal and Installation PFP:16400 BBS003YX MBIB1064E MBIB1065E Water Draining from Fuel Filter BBS003YY DRAINING WATER (RHD) CAUTION: Before carrying out any work, wait for the fuel temperature is dropped. Open drain valve at the bottom of fuel filter. MBIB0530E FL-26 FUEL FILTER [K9K] DRAINING WATER (LHD) A Refer to EM-227, "PRECAUTIONS" , EC-1625, "WATER DRAINING" . 1. Remove right fender protector. Refer to EI-14, "FENDER PROTECTOR" . 2. Remove foam insulator. 3. Open drain valve at the bottom of fuel filter. CAUTION: Put a shop cloth under the drain valve, to avoid the water and fuel spill on ABS actuator. FL C FUEL FILTER CHECK Check fuel filter for fuel leakage, damage and other abnormal signs. Changing Fuel Filter BBS003YZ D REMOVAL (RHD) 1. Remove quick connectors in the following procedures. ● Pinch quick connector square-parts with your fingers, and pull out the quick connector by hand. ● If quick connector and tube on vehicle are stuck, push and pull several times until they move, and pull out. E F G MBIB1048E 2. Remove fuel filter from fuel filter bracket. CAUTION: Do not spill the fuel during removal. If the fuel is spill, immediately wipe it off. Be especially careful to prevent the fuel from adhering to the insulators of the engine mounts. H I J K MBIB1049E REMOVAL (LHD) 1. 2. 3. Remove priming bulb from priming bulb bracket. Remove fuel filter from fuel filter bracket. Remove quick connectors as above. CAUTION: Put a shop cloth under the drain valve, to avoid the water and fuel spill on ABS actuator. Be especially careful to prevent any damage. INSTALLATION Install in the reverse order of removal, paying attention to the following points: ● To install fuel filter connectors, respect paint marks on fuel filter as shown. ● After installation, operate the priming bulb vertically, if it is possible, to perform air bleeding. Refer to FL-28, "Bleeding Fuel Filter" . CAUTION: Do not bend or twist the tube during installation and removal. MBIA0095E FL-27 L M FUEL FILTER [K9K] Bleeding Fuel Filter 1. 2. BBS003Z0 Prime the circuit using the priming bulb. Perform engine cranking with repeating several times until engine starting. MBIB9045E 3. 4. If the engine does not start, use a flat bladed screwdriver to lift up the button on the fuel return pipe and perform engine cranking. When the bleeding is completed, push the button, and check absence of leakage. : Bleeding position : Normal position MBIB9038E FL-28 FUEL LEVEL SENSOR UNIT [K9K] FUEL LEVEL SENSOR UNIT Removal and Installation PFP:17042 A BBS003Z1 FL C D E F MBIB9042E 1. Rock ring 4. Float arm 2. O-ring 3. G Fuel level sensor unit H : Always replace after every disassembly REMOVAL 1. 2. 3. 4. 5. 6. I Disconnect battery ground cable. Open fuel filler lid and filler cap to release the pressure inside the fuel tank. Remove rear seat cushion. Refer to SE-12, "REAR SEAT" . Remove inspection hole cover under the rear seat. Disconnect electrical connector. Disconnect the quick connectors. J K L M MBIB1051E ● Hold the connector while pushing in tabs, and pull out the tube. MBIB1052E FL-29 FUEL LEVEL SENSOR UNIT [K9K] JFE628A CAUTION: ● The tube can be removed when the tabs are completely depressed. Do not twist it more than necessary. ● Do not use any tools to remove the quick connector. ● Keep the resin tube away from heat. Be especially careful when welding near the tube. ● Prevent acid liquid such as battery electrolyte etc. from getting on the resin tube. ● Do not bend or twist the tube during installation and removal. ● Only when the tube is replaced, remove the remaining retainer. ● When the tube is replaced, also replace the retainer with a new one. Retainer color: Red (Feed hose side) White (Return hose side) 7. 8. Using lock ring wrench [SST: KV993G0010], remove lock ring. CAUTION: Rotate SST while pressing fuel level sensor unit as spring reaction force is applied from fuel tank inside to up ward. Remove fuel level sensor unit. CAUTION: ● Be careful not to bend the float arm when removing. ● Handle them carefully without subjecting them to impacts such as dropping. MBIB1231E INSTALLATION Install in the reverse order of removal. FL-30 FUEL TANK [K9K] FUEL TANK Removal and Installation PFP:17202 A BBS003Z2 FL C D E F G H I MBIB9044E 1. Fuel tank 2. Vent hose 4. Fuel filler cap 5. Grommet 6. Fuel filler tube 7. Vent hose 8. Clamp 9. Fuel filler hose 10. Mounting band 3. J EVAP tube K 11. EVAP hose REMOVAL 1. 2. 3. 4. 5. 6. Remove RH rear wheel. Perform steps 1 to 7 of FL-29, "REMOVAL" in “FUEL LEVEL SENSOR UNIT”. CAUTION: If fuel tank bottom face is not level, and remaining fuel level is high, tank position becomes unstable, causing a danger. Drain fuel further than that in step 1 of the referenced procedure until tank can be held by hand even if the balance is lost. Remove center muffler and main muffler. Refer to EX-3, "EXHAUST SYSTEM" . Remove vehicle side insulator on upper center muffler and main muffler. Move parking brake cable from the lower face of fuel tank. Then remove clips for parking brake cable. Disconnect fuel filler hose on fuel tank side. CAUTION: Do not remove fuel filler hose at fuel filler tube side, preventing to interfere with suspension due to dislocation when installing. When removing at fuel filler tube side necessarily, put mating marks, and remove. PBIC1505E FL-31 L M FUEL TANK [K9K] 7. 8. Remove vent hose at RH rear wheelwell side. Remove EVAP hose at front side of fuel tank. PBIC1507E ● – – ● Remove quick connector in the following procedures. Pinch quick connector square-parts with your fingers, and pull out the quick connector by hand. If quick connector and tube on vehicle are stuck, push and pull several times until they move, and pull out. CAUTION: ● The tube can be removed when the tabs are completely depressed. Do not twist it more than necessary. ● Do not use any tools to remove the quick connector. ● Keep the resin tube away from heat. Be especially careful when welding near the tube. ● Prevent acid liquid such as battery electrolyte etc. from getting on the resin tube. ● Do not bend or twist the tube during installation and removal. To keep clean the connecting portion and to avoid damage and foreign materials, cover them completely with plastic bags or something similar. CAUTION: Do not insert plug, preventing damage on O-ring in quick connector. PBIC1509E PBIC0713E 9. Support center of fuel tank with suitable transmission jack. CAUTION: Securely support the fuel tank with a piece of wood. 10. Remove RH/LH mounting band. 11. Lower suitable transmission jack carefully to remove fuel tank while holding it by hand. Perform the following works at the same time. ● Pull out vent hose from through hole of vehicle. ● Avoid interference with tank by pulling parking brake cable by hand. PBIC1508E CAUTION: Tank may be in an unstable condition because of the shape of fuel tank bottom. Do not rely on jack too much. Be sure to hold tank securely. INSTALLATION Install in the reverse order of removal which being careful of the following. FL-32 FUEL TANK [K9K] Installation of Fuel Tank Mounting Band ● A Install it by referring to the identification stamp mark “R” and “L” on the end. Installation of fuel Filler Hose ● ● ● Insert filler hose into mating side part by 35 mm (1.38 in), and secure it with clamp. FL When installing clamp, do not allow clamp to contact the bulge (bump) part of the tube. Tighten the clamp of filler hose so that the remaining length becomes 5 - 9 mm (0.20 - 0.35 in) [or tightening torque: 1.3 - 3.7 N·m (0.13 - 0.38 kg-m, 12 - 32 in-lb]. C Installation of EVAP Hose ● 1. 2. 3. Connect quick connector in the following procedures. Check connections for damage or foreign material. Align the mating side connection part with the center of shaft, and insert connector straight until it clicks. After connecting, pull out quick connector by hand. Make sure connections are secure. D E F PBIC1509E G Installation of Vent Hose ● ● Push vent hose into through hole of vehicle. Insert vent hose into vent rubber hose, and secure it with clamp. H INSPECTION AFTER INSTALLATION Make sure there is no fuel leakage at connections in the following procedure. ● Start engine, rev it up and make sure there is no fuel leakage at connections. I J K L M FL-33 SERVICE DATA AND SPECIFICATIONS (SDS) [K9K] SERVICE DATA AND SPECIFICATIONS (SDS) Standard and Limit Fuel tank capacity PFP:00030 BBS0058F Approx. 46 (10-1/8 Imp gal) Tightening Torque BBS0058G Unit: N·m (kg-m, ft-lb) Fuel tank mounting band 25.0 (2.6, 18) Fuel filler tube 15.8 - 24.2 (1.7 - 2.4, 12 - 17) Lock ring 65.0 - 75.0 (6.6 - 7.7, 48 - 55) FL-34 FRONT SUSPENSION E SUSPENSION SECTION FSU FRONT SUSPENSION A B C D CONTENTS PRECAUTIONS .......................................................... 2 PrecautionsforProcedureswithoutCowlTopCover..... 2 Precautions for Brake System .................................. 2 Cautions ................................................................... 2 PREPARATION ........................................................... 3 Special Service Tools ............................................... 3 NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING ................................................ 4 NVH Troubleshooting Chart ..................................... 4 FRONT SUSPENSION ASSEMBLY ........................... 5 Components ............................................................. 5 On-Vehicle Inspection and Service .......................... 6 LOOSENESS, BACKLASH, AND DAMAGE OF MOUNTING PARTS AND CONNECTIONS .......... 6 Wheel Alignment ...................................................... 6 DESCRIPTION ...................................................... 6 PRELIMINARY INSPECTION ............................... 6 INSPECTION OF CAMBER, CASTER, AND KINGPIN INCLINATION ANGLES ........................ 6 STEERING ANGLE INSPECTION ........................ 7 COIL SPRING AND SHOCK ABSORBER ................. 8 Removal and Installation .......................................... 8 REMOVAL ............................................................. 8 INSTALLATION ..................................................... 8 Disassembly and Assembly ...................................... 8 DISASSEMBLY ..................................................... 8 INSPECTION AFTER DISASSEMBLY .................. 9 ASSEMBLY ........................................................... 9 TRANSVERSE LINK ................................................. 10 Removal and Installation ........................................ 10 REMOVAL ........................................................... 10 INSPECTION AFTER REMOVAL ....................... 10 INSTALLATION ................................................... 10 STABILIZER BAR ..................................................... 11 Removal and Installation ........................................ 11 REMOVAL ........................................................... 11 INSPECTION AFTER REMOVAL ....................... 12 INSTALLATION ................................................... 12 FRONT SUSPENSION MEMBER ............................. 13 Removal and Installation ........................................ 13 REMOVAL ........................................................... 13 INSPECTION AFTER REMOVAL ....................... 13 INSTALLATION ................................................... 14 SERVICE DATA AND SPECIFICATIONS (SDS) ...... 15 Wheel Alignment .................................................... 15 Ball Joint ................................................................. 15 Tightening Torque ................................................... 15 FSU-1 FSU F G H I J K L M PRECAUTIONS PRECAUTIONS Precautions for Procedures without Cowl Top Cover PFP:00001 BES0002E When performing the procedure after removing cowl top cover, cover the lower end of windshield with urethane, etc. PIIB3706J Precautions for Brake System ● ● ● ● ● BES0002F Recommended fluid is brake fluid “Nissan Genuine Brake Fluid or DOT 3 or DOT4 (US FMVSS No.116)”. Never reuse drained brake fluid. Be careful not to splash brake fluid on painted areas; it may cause paint damage. If brake fluid is splashed on painted areas, wash it away with water immediately. Use flare nut wrench when removing flare nuts, and use a flare nut torque wrench when tighten flare nuts. Always tighten brake lines to the specified torque when installing. Cautions ● ● ● ● SBR820BA BES0002G When installing rubber bushings, final tightening must be carried out under unladen conditions with tyres on flat, level ground. Oil will shorten the life of rubber bushings. Be sure to wipe off any spilled oil. “Unladen condition” means that fuel, coolant and lubricant are full and ready for drive. However, spare tyre, jack, and hand tools should be unloaded. After installing the removed suspension parts, always check wheel alignment and adjust if necessary. Replace the caulking nut with a new one. Install a new nut without wiping the oil off before tightening. FSU-2 PREPARATION PREPARATION Special Service Tools PFP:00002 A BES0002H Description Application B CCK gauge attachment KV991040S1 1 KV99104020 Adapter A 2 KV99104030 Adapter B 3 KV99104040 Adapter C 4 KV99104050 Adapter D 5 KV99104060 Plate 6 KV99104070 Guide bolt 7 KV99104080 Spring 8 KV99104090 Center plate C Measuring wheel alignment D ZZA1167D FSU Strut attachment ST35652000 Disassembling and assembling strut F ZZA0807D G GG94310000 Flare nut torque wrench a: 10 mm (0.39 in) H Removing and installing brake lines NT406 I J K L M FSU-3 Symptom × × Judder × × × Poor quality ride or handling × × × ×: Applicable FSU-4 × NVH in PS section. × STEERING × NVH in BR section. Shimmy BRAKES × NVH in FAX section. × DRIVE SHAFT × NVH in WT section. × ROAD WEEL Vibration NVH in WT section. × TYRES × NVH in RAX and RSU section. × REAR AXLE AND REAR SUSPENSION × Refer to FSU-11, "STABILIZER BAR" Shake Stabilizer bar fatigue × Refer to FSU-6, "Wheel Alignment" × Incorrect wheel alignment — × Refer to FSU-5, "FRONT SUSPENSION ASSEMBLY" — Parts interference × Suspension looseness — Bushing or mounting deterioration Noise Spring fatigue Refer to FSU-8, "COIL SPRING AND SHOCK ABSORBER" FRONT SUSPENSION Shock absorber deformation, damage or deflection Possible cause and SUSPECTED PARTS Refer to FSU-5, "FRONT SUSPENSION ASSEMBLY" Reference page Improper installation, looseness NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING NVH Troubleshooting Chart × × × × × PFP:00003 BES0002I Use the chart below to help you find the cause of the symptom. If necessary, repair or replace these parts. × × × × × × × × × × × × × × × × × × × × × × × × × × × × × × × × FRONT SUSPENSION ASSEMBLY FRONT SUSPENSION ASSEMBLY Components PFP:54010 A BES0002J B C D FSU F G H I J K L M MEIB9026E FSU-5 FRONT SUSPENSION ASSEMBLY 1. Strut mounting insulator 2. Strut mounting bearing 3. Coil spring 4. Bound bumper 5. Strut 6. Knuckle 7. Clamp 8. Bushing 9. Connecting rod 10. Transverse link 11. Stabilizer 12. Rear upper link (A/T models only) 13. Upper link 14. Suspension member 15. Suspension member stay On-Vehicle Inspection and Service BES0002K LOOSENESS, BACKLASH, AND DAMAGE OF MOUNTING PARTS AND CONNECTIONS Lift the vehicle, and inspect as follows: ● Check mounting point of each component for looseness, backlash, and damage. ● Check end play of the lower ball joint. 1. Attach a dial gauge so that the contact rests on the brake caliper. 2. Set front wheels in a straight-ahead position. Do not depress brake pedal. 3. Measure axial end play by placing an iron pry bar or something similar between transverse link and steering knuckle. Standard Axial end play 4. : 0 mm (0 in) CAUTION: Be careful not to damage ball joint boot. If axial end play is outside the standard, remove transverse link and check lower ball joint. Wheel Alignment BES0002L DESCRIPTION ● Measure wheel alignment under unladen conditions. “Unladen conditions” means that fuel, coolant, and lubricant are full. However, spare tyre, jack, and hand tools should be unloaded. PRELIMINARY INSPECTION 1. 2. 3. 4. 5. 6. 7. 8. Check the tyres for improper air pressure and wear. Check road wheels for runout. Check wheel bearing axial end play. Check lower ball joint axial end play. Check strut operation. Check each mounting point of axle and suspension for looseness and deformation. Check each link and arm for cracks, deformation, and other damage. Check the vehicle posture. INSPECTION OF CAMBER, CASTER, AND KINGPIN INCLINATION ANGLES ● ● 1. 2. Camber, caster, and kingpin inclination angles cannot be adjusted. Before inspection, mount front wheels onto turning radius gauge. Mount rear wheels onto a stand that has same height so the vehicle will remain horizontal. Measure camber, caster and kingpin inclination of both right and left wheels with a suitable alignment gauge. Camber: Caster: -0°48′ - 0°42′ (-0.80° - 0.70°) 3°45′ - 5°15′ (3.75° - 5.25°) Kingpin offset: 9°00′ - 10°30′ (9.00° - 10.50°) If camber, caster or kingpin inclination is not within specification, inspect front suspension parts. Replace dam-aged or worn out parts. FSU-6 SRA096A FRONT SUSPENSION ASSEMBLY Toe-in A Measure toe-in using the following procedure. WARNING: ● Always perform the following procedure on a flat surface. ● Make sure that no person is in front of the vehicle before pushing it. 1. Bounce front of vehicle up and down to stabilize the posture. 2. Push the vehicle straight ahead about 5 m (16 ft). 3. Put a mark on base line of tread (rear side) of both tyres at the same height as hub center. These are measuring points. B C AFA050 4. 5. Measure distance “A” (rear side). Push the vehicle slowly ahead to rotate the wheels 180degrees (1/2 turn). If the wheels have rotated more than 180 degrees (1/2 turn), try the above procedure again from the beginning. Never push vehicle backward. 6. Measure distance “B” (front side). FSU F G Total toe-in: In 2 - 0 mm (0.08 - 0 in) SFA234AC STEERING ANGLE INSPECTION 1. 2. D Set wheels in straight-ahead position. Move vehicle to set front wheels on turning radius gauge. Turn steering wheel fully to right and left, and measure steering angle. Refer to PS-13, "SERVICE DATA AND SPECIFICATIONS (SDS)" . H I J K L M FSU-7 COIL SPRING AND SHOCK ABSORBER COIL SPRING AND SHOCK ABSORBER Removal and Installation PFP:54302 BES0002M REMOVAL 1. 2. 3. 4. 5. 6. 7. Raise vehicle and remove tyre. Remove cowl top cover. Refer to EI-12, "COWL TOP" . Remove electrical wires of ABS wheel sensor from strut. Refer to BRC-36, "WHEEL SENSORS" . Remove brake hose lock plate. Refer to BR-11, "BRAKE PIPING AND HOSE" . Remove stabilizer connecting rod. Remove nuts and bolts securing steering knuckle to strut. Remove upper bolts of the strut and remove strut from the vehicle. MEIA0013E INSTALLATION ● ● Refer to FSU-5, "FRONT SUSPENSION ASSEMBLY" for tightening torque. Tighten in the reverse order of removal. Make sure the identification letters on strut mounting insulator face toward vehicle front. Then install strut. MEIA0014E Disassembly and Assembly BES0002N DISASSEMBLY 1. 2. 3. 4. 5. Install strut attachment (SST) to strut and fix it in a vise. CAUTION: When installing strut attachment (SST), wrap a shop cloth around strut to protect it from damage. Slightly loosen piston rod lock nut. CAUTION: Do not remove piston rod lock nut completely. If it is removed completely, coil spring jumps out and may cause serious damage or injury. Compress coil spring using a spring compressor (commercial MEIA0015E service tool). CAUTION: Start compressing the coil spring after making sure that the spring compressor is completely attached to the coil spring. After making sure coil spring is free between strut mounting bearing and lower seats at the end of Step 3, remove piston rod lock nut. Remove small parts on strut. ● Remove strut mounting insulator and strut mounting bearing. Remove coil spring from strut. FSU-8 COIL SPRING AND SHOCK ABSORBER 6. 7. Remove bound bumper. Gradually release spring compressor (commercial service tool), and remove coil spring. A INSPECTION AFTER DISASSEMBLY Strut Inspection ● ● ● B Check the strut for deformation, cracks, and damage, and replace if necessary. Check piston rod for damage, uneven wear, and distortion, and replace if necessary. Check connections and packing for oil leakage, and replace if necessary. C Insulator and Rubber Parts Inspection Check strut mounting insulator for cracks and rubber parts for wear. Replace them if necessary. D Coil Spring Inspection Check coil spring for cracks, wear, and damage. Replace if necessary. FSU ASSEMBLY 1. 2. 3. 4. 5. 6. Compress coil spring using a spring compressor (commercial service tool), and install it onto the strut. CAUTION: ● Face the small diameter side (there is identification mark in 1.25 rotations) of coil spring downward. Align lower end to spring seat as shown in the figure. ● Start compressing the coil spring after making sure that the spring compressor is completely attached to the coil spring. Connect bound bumper to strut piston rod. Install small parts to the strut. ● Attach strut mounting insulator, strut mounting bearing. Position piston rod lock nut. CAUTION: Do not reuse piston rod lock nut. Be sure the identification letters on strut mounting insulator are positioned as shown. Be sure coil spring is properly set in strut mounting bearing. Gradually release spring compressor (commercial service tool). Tighten piston rod lock nut to the specified torque. Tightening torque F G H MEIA0016E I J K : 67.5 N·m (6.9 kg-m, 50 ft-lb) L MEIA0014E 7. Remove strut attachment (SST). MEIA0015E FSU-9 M TRANSVERSE LINK TRANSVERSE LINK Removal and Installation PFP:54500 BES0002O REMOVAL 1. 2. 3. a. b. Raise vehicle and remove tyre. Remove nuts and bolts of transverse link ball joint, and remove transverse link from steering knuckle. Remove transverse link nuts and bolts, and remove transverse link from suspension member. NOTE: When removing LH transverse link (A/T models), lower the suspension member in order to remove bolts to avoid contacting and releasing the mounting bolts on vehicle front. Remove suspension member. Refer to FSU-13, "FRONT SUSPENSION MEMBER" . Set jack under suspension member. Loosen RH upper link mounting bolt, LH upper link mounting MEIA0017E bolt (suspension member side), suspension member mounting bolts (left/right). Lower the suspension member in order to remove transverse link mounting bolts. INSPECTION AFTER REMOVAL Visual Inspection Check transverse link and bushing for deformation, cracks, and other damage, and replace entire transverse link assembly if necessary. Ball Joint Inspection ● Manually move ball stud to confirm it moves smoothly with no binding. Oscillating Torque Inspection CAUTION: Before measuring, move the ball joint at least ten times by hand to check for smooth movement. ● Hook the spring scale at the cutout on ball stud, and make sure the spring scale measurement value is within the standard when ball stud begins moving. Tensile force Spring balance measurement ● : 0.5 - 4.9 N·m (0.05 - 0.5 kg-m, 5 - 43 in-lb) : 15.4 - 150.8 N (1.6 - 15.4 kg, 3.5 33.9 lb) If value is outside the standard, replace transverse link. MEIA0018E Axial End Play Inspection ● Move the tip of the ball joint in the axial direction to check for looseness. Axial end play ● : 0 mm (0 in) If any looseness is noted, replace transverse link assembly as a single unit. INSTALLATION ● ● ● Refer to FSU-5, "FRONT SUSPENSION ASSEMBLY" for tightening torque. Tighten in the reverse order of removal. Fully tighten transverse link mounting nuts and bolts under unladen condition with tyres on level ground. After installation, check wheel alignment. Refer to FSU-6, "Wheel Alignment" . FSU-10 STABILIZER BAR STABILIZER BAR Removal and Installation PFP:54611 A BES0002P REMOVAL 1. 2. 3. 4. Raise vehicle and remove tyre. Remove the attachment nut on the stabilizer connecting rod and remove the stabilizer connecting rod. Remove tie-rod from steering knuckle. If it is difficult to remove tie-rod, remove it with a ball joint remover (commercial service tool). CAUTION: To prevent damage to threads and to prevent ball joint remover (commercial service tool) from coming off, temporarily tighten lock nuts. Remove exhaust tube mount (models with CR engine). Refer to EX-3, "Removal and Installation" . B C D FSU F G MEIA0019E 5. 6. 7. 8. Remove transaxle rear torque rod (1) (A/T models) or (2) (M/T models). Refer to MT-7, "REMOVAL AND INSTALLATION" (with JH3 transaxle) or MT-37, "REMOVAL AND INSTALLATION" (with JR5 transaxle) for M/T models, AT-356, "Removal and Installation" for A/T models. Remove rear side bolt of suspension member stay. Set jack under suspension member. Remove bolts of suspension member and suspension member stay. H I J K L M MEIB9028E 9. Lower suspension member in order to remove stabilizer mounting bolts. Refer to FSU-13, "FRONT SUSPENSION MEMBER" . CAUTION: Be careful not to lower it too far. (Do not overload the links.) SEIA0161J FSU-11 STABILIZER BAR 10. Remove stabilizer bolt and remove clamp and bushing. 11. Remove stabilizer from the vehicle. MEIA0023E MEIA0021E INSPECTION AFTER REMOVAL Check stabilizer, connecting rod, bushing and clamp for deformation, cracks and damage. Replace if necessary. INSTALLATION ● Refer to FSU-5, "FRONT SUSPENSION ASSEMBLY" for tightening torque. Tighten in the reverse order of removal. CAUTION: When installing suspension member stay, tighten bolts in numerical order as shown in the figure. MEIB9029E ● Because the stabilizer uses the pillow ball type connecting rod, position the ball joint with the case on the pillow ball head parallel to the stabilizer. MEIA0022E FSU-12 FRONT SUSPENSION MEMBER FRONT SUSPENSION MEMBER Removal and Installation PFP:54401 A BES0002Q REMOVAL 1. 2. 3. 4. Raise vehicle and remove tyre. Remove stabilizer connecting rod. Remove nuts and bolts of transverse link ball joint, and remove transverse link from steering knuckle. Remove steering gear mounting nuts and bolts. Separate steering gear from suspension member. B C D FSU SEIA0168J 5. Remove transaxle rear torque rod (1) (A/T models) or (2) (M/T models). Refer to MT-7, "REMOVAL AND INSTALLATION" (with JH3 transaxle) or MT-37, "REMOVAL AND INSTALLATION" (with JR5 transaxle) for M/T models, AT-356, "Removal and Installation" for A/T models. F G H I J K L M MEIB9028E 6. 7. 8. 9. Remove exhaust tube mount (models with CR engine). Refer to EX-3, "Removal and Installation" . Remove body side bolt of upper link. Set a jack under suspension member, and remove suspension member mounting bolts. Remove upper link, transverse link and stabilizer as a set. Remove upper link, transverse link and stabilizer from the suspension member. MEIA0019E INSPECTION AFTER REMOVAL Check suspension member for deformed parts, cracks, or any other damage. Replace if necessary. FSU-13 FRONT SUSPENSION MEMBER INSTALLATION ● ● Refer to FSU-5, "FRONT SUSPENSION ASSEMBLY" for tightening torque. Tighten in the reverse order of removal. After finishing work, perform final tightening of each part under unladen condition with tyres on level ground. Check wheel alignment. Refer to FSU-6, "Wheel Alignment" . FSU-14 SERVICE DATA AND SPECIFICATIONS (SDS) SERVICE DATA AND SPECIFICATIONS (SDS) Wheel Alignment PFP:00030 A BES0002R Drive type 2WD Camber B -0°48’ - 0°42’ (-0.80° - 0.70°) Caster 3°45’ - 5°15’ (3.75° - 5.25°) Kingpin offset 9°00’ - 10°30’ (9.00° - 10.50°) Toe-in C In 2 - 0 mm (0.08 - 0 in) Ball Joint BES0002S Axial end play 0mm (0 in) Sliding torque 0.5 - 4.9 N·m (0.05 - 0.5 kg-m, 5 - 43 in-lb) Spring scale measurement (ball stud cutout) 15.4 - 150.8 N (1.6 - 15.4 kg, 3.5 - 33.9 lb) Tightening Torque FSU BES0002T Unit: N·m (kg-m, ft-lb) Front Transverse link to suspension member M/T 98.5 (10, 73) A/T 137.5 (14, 101) Rear Steering knuckle to Transverse link 137.5 (14, 101) F G 37.1 (3.8, 27) Stabilizer connecting rod to Strut 44 (4.5, 32) Strut mounting insulator to Body 17.2 (1.8, 13) Strut piston rod lock nut 67.5 (6.9, 50) Strut to Steering knuckle 116 (12, 86) Upper link to Body Upper link to Suspension member D H I 64.5 (6.6, 48) M/T 98.5 (10, 73) A/T 137.5 (14, 101) Rear Upper link to Suspension member (A/T models) 75.5 (7.7, 56) Suspension member to Body 117.5 (12, 87) J K Suspension member stay to Body (rear) 65 (6.6, 48) Suspension member to Stabilizer clamp 31.5 (3.2, 23) L M FSU-15 SERVICE DATA AND SPECIFICATIONS (SDS) FSU-16 QUICK REFERENCE INDEX A GENERAL INFORMATION GI General Information B ENGINE EM Engine Mechanical LU Engine Lubrication System CO Engine Cooling System EC Engine Control System FL Fuel System EX Exhaust System ACC C TRANSMISSION/ TRANSAXLE CL Clutch MT Manual Transaxle AT D DRIVELINE/AXLE E SUSPENSION F BRAKES MODEL E11 SERIES G STEERING H RESTRAINTS BODY J AIR CONDITIONER K ELECTRICAL Automatic Transaxle FAX Front Axle RAX Rear Axle FSU Front Suspension RSU Rear Suspension WT Road Wheels & Tires BR Brake System PB Parking Brake System BRC Brake Control System PS Power Steering System STC Steering Control System SB SRS I Accelerator Control System Seat Belts Supplemental Restraint System (SRS) BL Body, Lock & Security System GW Glasses, Window System & Mirrors EI Exterior & Interior IP Instrument Panel SE Seat ATC Automatic Air Conditioner MTC Manual Air Conditioner SC Starting & Charging System LT Lighting System DI Driver Information System WW Wiper, Washer & Horn BCS Body Control System LAN LAN System AV Audio, Visual & Telephone System PG Power Supply, Ground & Circuit Elements L MAINTENANCE MA Maintenance M INDEX IDX Alphabetical Index © 2006 NISSAN EUROPE S.A.S. All rights reserved. No part of this Electronic Service Manual may be reproduced or stored in a retrieval system, or transmitted in any form, or by any means, electronic, mechanical, photocopying, recording or otherwise, without the prior written permission of Nissan Europe S.A.S., Paris, France. A B C D E F G H I J K L M FOREWORD This manual contains maintenance and repair procedures for the NISSAN NOTE, model E11 series. In order to assure your safety and the efficient functioning of the vehicle, this manual should be read thoroughly. It is especially important that the PRECAUTIONS in the GI section be completely understood before starting any repair task. All information in this manual is based on the latest product information at the time of publication. The right is reserved to make changes in specifications and methods at any time without notice. IMPORTANT SAFETY NOTICE The proper performance of service is essential for both the safety of the technician and the efficient functioning of the vehicle. The service methods in this Service Manual are described in such a manner that the service may be performed safely and accurately. Service varies with the procedures used, the skills of the technician and the tools and parts available. Accordingly, anyone using service procedures, tools or parts which are not specifically recommended by NISSAN must first be completely satisfied that neither personal safety nor the vehicle’s safety will be jeopardized by the service method selected. NISSAN EUROPE S.A.S. Service Engineering Section Paris, France GENERAL INFORMATION A GENERAL INFORMATION SECTION GI GENERAL INFORMATION GI B C D CONTENTS PRECAUTIONS .......................................................... 3 Description ............................................................... 3 Precautions for Supplemental Restraint System (SRS) “AIR BAG” and “SEAT BELT PRE-TENSIONER” .................................................................. 3 Precautions for NATS (NISSAN ANTI-THEFT SYSTEM) ........................................................................ 3 Maintenance Information .......................................... 3 RHD MODELS ...................................................... 3 LHD MODELS ....................................................... 4 PrecautionsforProcedureswithoutCowlTopCover..... 4 General Precautions ................................................ 4 Precautions for Three Way Catalyst ......................... 5 Precautions for Fuel ................................................. 5 GASOLINE ENGINE (REGULAR GASOLINE)..... 5 GASOLINE ENGINE (PREMIUM GASOLINE) ..... 6 DIESEL ENGINE ................................................... 6 Precautions for Multiport Fuel Injection System or Engine Control System ............................................ 6 Precautions for Turbocharger (If Equipped) ............. 6 Precautions for Hoses .............................................. 7 HOSE REMOVAL AND INSTALLATION ............... 7 HOSE CLAMPING ................................................ 7 Precautions for Engine Oils ...................................... 7 HEALTH PROTECTION PRECAUTIONS ............ 7 ENVIRONMENTAL PROTECTION PRECAUTIONS ................................................................... 8 Precautions for Air Conditioning ............................... 8 HOW TO USE THIS MANUAL ................................... 9 Description ............................................................... 9 Terms ....................................................................... 9 Units ......................................................................... 9 Contents ................................................................... 9 Relation between Illustrations and Descriptions ... 10 Components ............................................................11 RHD MODELS ...................................................... 3 How to Follow Trouble Diagnoses .......................... 12 DESCRIPTION .................................................... 12 HOW TO FOLLOW TEST GROUPS IN TROUBLE DIAGNOSES ............................................... 12 HARNESS WIRE COLOR AND CONNECTOR NUMBER INDICATION ....................................... 13 KEY TO SYMBOLS SIGNIFYING MEASUREMENTS OR PROCEDURES ............................... 14 How to Read Wiring Diagrams ............................... 16 CONNECTOR SYMBOLS ................................... 16 SAMPLE/WIRING DIAGRAM - EXAMPL - .......... 17 DESCRIPTION .................................................... 18 Abbreviations .......................................................... 23 SERVICE INFORMATION FOR ELECTRICAL INCIDENT ......................................................................... 25 How to Perform Efficient Diagnosis for an Electrical Incident ................................................................... 25 WORK FLOW ...................................................... 25 INCIDENT SIMULATION TESTS ........................ 25 CIRCUIT INSPECTION ....................................... 28 Control Units and Electrical Parts ........................... 33 PRECAUTIONS .................................................. 33 SMJ INSTALLATION ........................................... 34 CONSULT-II CHECKING SYSTEM .......................... 35 Description .............................................................. 35 Function and System Application ........................... 35 Nickel Metal Hydride Battery Replacement ............ 35 Checking Equipment .............................................. 36 CONSULT-II Start Procedure .................................. 36 CONSULT-II Data Link Connector (DLC) Circuit ... 38 INSPECTION PROCEDURE .............................. 39 LIFTING POINT ......................................................... 40 Commercial Service Tools ...................................... 40 Garage Jack, Safety Stand and 2-Pole Lift ............. 40 Board-On Lift .......................................................... 41 TOW TRUCK TOWING ............................................. 42 Tow Truck Towing ................................................... 42 TOWING AN AUTOMATIC TRANSAXLE MODEL WITH FOUR WHEELS ON GROUND... 42 Vehicle Recovery (Freeing a Stuck Vehicle) ........... 42 FRONT ................................................................ 42 REAR .................................................................. 43 TIGHTENING TORQUE OF STANDARD BOLTS ... 44 Tightening Torque Table ......................................... 44 GI-1 E F G H I J K L M IDENTIFICATION INFORMATION ............................ 45 Model Variation ....................................................... 45 IDENTIFICATION NUMBER ................................ 46 IDENTIFICATION PLATE .................................... 47 ENGINE SERIAL NUMBER (CR ENGINE) ......... 47 ENGINE SERIAL NUMBER (HR ENGINE) ......... 47 ENGINE IDENTIFICATION (K9K ENGINE) .........48 AUTOMATIC TRANSAXLE NUMBER .................48 Dimensions .............................................................48 Wheels & Tyres .......................................................48 TERMINOLOGY ........................................................49 ISO 15031-2 Terminology List .................................49 GI-2 PRECAUTIONS PRECAUTIONS Description PFP:00001 GI BAS0002D Observe the following precautions to ensure safe and proper servicing. These precautions are not described in each individual section. Precautions for Supplemental Restraint System (SRS) “AIR BAG” and “SEAT BELT PRE-TENSIONER” B BAS0002E The Supplemental Restraint System such as “AIR BAG” and “SEAT BELT PRE-TENSIONER”, used along with a front seat belt, helps to reduce the risk or severity of injury to the driver and front passenger for certain types of collision. Information necessary to service the system safely is included in the SRS and SB section of this Service Manual. WARNING: ● To avoid rendering the SRS inoperative, which could increase the risk of personal injury or death in the event of a collision which would result in air bag inflation, all maintenance must be performed by an authorized NISSAN/INFINITI dealer. ● Improper maintenance, including incorrect removal and installation of the SRS, can lead to personal injury caused by unintentional activation of the system. For removal of Spiral Cable and Air Bag Module, see the SRS section. ● Do not use electrical test equipment on any circuit related to the SRS unless instructed to in this Service Manual. SRS wiring harnesses can be identified by yellow and/or orange harnesses or harness connectors. Precautions for NATS (NISSAN ANTI-THEFT SYSTEM) BAS0004J If any of following part is replaced, always replace with new* one. If it's not (or fail to do so), the electrical system may not be operated properly. *: New one means a virgin control unit that has never been energized on-board. RHD MODELS ● ● ● ● BCM (Models without Intelligent Key system) Intelligent Key unit (Models with Intelligent Key system) ECM IPDM E/R GI-3 D E F G BAS0002F NATS will immobilize the engine if someone tries to start it without the registered key of NATS. Both of the originally supplied ignition key IDs have been NATS registered. The security indicator is located on the instrument panel. The indicator blinks when the immobilizer system is functioning. Therefore, NATS warns outsiders that the vehicle is equipped with the anti-theft system. ● When NATS detects trouble, the security indicator lamp lights up while ignition switch is in "ON" position. This lighting up indicates that the anti-theft is not functioning, so prompt service is required. ● When servicing NATS (trouble diagnoses, system initialization and additional registration of other NATS ignition key IDs), CONSULT-II hardware and CONSULT-II NATS software is necessary. Regarding the procedures of NATS initialization and NATS ignition key ID registration, refer to CONSULTII operation manual, NATS. Therefore, CONSULT-II NATS software (program card and operation manual) must be kept strictly confidential to maintain the integrity of the anti-theft function. ● When servicing NATS (trouble diagnoses, system initialization and additional registration of other NATS ignition key IDs), it may be necessary to re-register original key identification. Therefore, be sure to receive all keys from vehicle owner. A maximum of four or five key IDs can be registered into NATS. ● When failing to start the engine first time using the key of NATS, start as follows. 1. Leave the ignition key in "ON" position for approximately 5 seconds. 2. Turn ignition key to "OFF" or "LOCK" position and wait approximately 5 seconds. 3. Repeat step 1 and 2 again. 4. Restart the engine while keeping the key separate from any others on key-chain. Maintenance Information C H I J K L M PRECAUTIONS ● ● Combination meter EPS control unit LHD MODELS ● ● ● BCM (Models without Intelligent Key system) Intelligent Key unit (Models with Intelligent Key system) ECM Precautions for Procedures without Cowl Top Cover BAS0002G When performing the procedure after removing cowl top cover, cover the lower end of windshield with urethane, etc. PIIB3706J General Precautions ● BAS0002H Do not operate the engine for an extended period of time without proper exhaust ventilation. Keep the work area well ventilated and free of any inflammable materials. Special care should be taken when handling any inflammable or poisonous materials, such as gasoline, refrigerant gas, etc. When working in a pit or other enclosed area, be sure to properly ventilate the area before working with hazardous materials. Do not smoke while working on the vehicle. SGI285 ● ● Before jacking up the vehicle, apply wheel chocks or other tire blocks to the wheels to prevent the vehicle from moving. After jacking up the vehicle, support the vehicle weight with safety stands at the points designated for proper lifting before working on the vehicle. These operations should be done on a level surface. When removing a heavy component such as the engine or transaxle/transmission, be careful not to lose your balance and drop them. Also, do not allow them to strike adjacent parts, especially the brake tubes and master cylinder. SGI231 ● ● Before starting repairs which do not require battery power: Turn off ignition switch. Disconnect the negative battery terminal. If the battery terminals are disconnected, recorded memory of radio and each control unit is erased. SEF289H GI-4 PRECAUTIONS ● ● ● ● ● ● ● ● ● ● ● ● ● ● To prevent serious burns: Avoid contact with hot metal parts. GI Do not remove the radiator cap when the engine is hot. Dispose of drained oil or the solvent used for cleaning parts in an appropriate manner. B Do not attempt to top off the fuel tank after the fuel pump nozzle shuts off automatically. Continued refueling may cause fuel overflow, resulting in fuel C spray and possibly a fire. Clean all disassembled parts in the designated liquid or solvent SGI233 prior to inspection or assembly. D Replace oil seals, gaskets, packings, O-rings, locking washers, cotter pins, self-locking nuts, etc. with new ones. Replace inner and outer races of tapered roller bearings and needle bearings as a set. E Arrange the disassembled parts in accordance with their assembled locations and sequence. Do not touch the terminals of electrical components which use microcomputers (such as ECM). Static electricity may damage internal electronic components. F After disconnecting vacuum or air hoses, attach a tag to indicate the proper connection. Use only the fluids and lubricants specified in this manual. Use approved bonding agent, sealants or their equivalents when required. G Use tools and recommended special tools where specified for safe and efficient service repairs. When repairing the fuel, oil, water, vacuum or exhaust systems, check all affected lines for leaks. H Before servicing the vehicle: Protect fenders, upholstery and carpeting with appropriate covers. Take caution that keys, buckles or buttons do not scratch paint. I J SGI234 WARNING: To prevent ECM from storing the diagnostic trouble codes, do not carelessly disconnect the harness connectors which are related to the engine control system and TCM (transmission control module) system. The connectors should be disconnected only when working according to the WORK FLOW of TROUBLE DIAGNOSES in EC and AT sections. Precautions for Three Way Catalyst BAS0002I If a large amount of unburned fuel flows into the catalyst, the catalyst temperature will be excessively high. To prevent this, follow the instructions. ● Use unleaded gasoline only. Leaded gasoline will seriously damage the three way catalyst. ● When checking for ignition spark or measuring engine compression, make tests quickly and only when necessary. ● Do not run engine when the fuel tank level is low, otherwise the engine may misfire, causing damage to the catalyst. Do not place the vehicle on flammable material. Keep flammable material off the exhaust pipe and the three way catalyst. Precautions for Fuel BAS0002J GASOLINE ENGINE (REGULAR GASOLINE) ● Three way catalyst equipped models ... use unleaded gasoline with an octane rating of at least 91 RON (research octane number). GI-5 K L M PRECAUTIONS ● CAUTION: Do not use leaded gasoline. Using leaded gasoline will damage the three way catalyst. Except for the above models ... use unleaded or leaded gasoline with an octane rating of at least 88 RON (research octane number). Use unleaded gasoline if instructed on the fuel filler lid. GASOLINE ENGINE (PREMIUM GASOLINE) Use premium unleaded gasoline with an octane rating of at least 95 RON (research octane number). If premium unleaded gasoline is not available, regular unleaded gasoline with an octane rating of at least 91 RON (research octane number) can be used. However, for maximum vehicle performance, the use of premium unleaded gasoline is recommended. CAUTION: Do not use leaded gasoline. Using leaded gasoline will damage the three way catalyst. Using a fuel other than that specified could adversely affect the emission control devices and systems, and could also affect the warranty coverage validity. DIESEL ENGINE For Europe model; use diesel fuel of at least 50 cetane. ● Except for Europe model; use diesel fuel of at least 45 cetane. If two types of diesel fuel are available, use summer or winter fuel properly according to the following temperature conditions. ● Above -7°C (20°F) ··· Summer type diesel fuel. ● Below -7°C (20°F) ··· Winter type diesel fuel. CAUTION: ● Do not use home heating oil, gasoline or other alternate fuels in your diesel engine. The use of those can cause engine damage. ● Do not use summer fuel at temperature below -7°C (20°F). The cold temperature will cause wax to form in the fuel. As a result, it may prevent the engine from running smoothly. ● Do not add gasoline or other alternate fuels to diesel fuel. ● Precautions for Multiport Fuel Injection System or Engine Control System ● ● ● BAS0002K Before connecting or disconnecting any harness connector for the multiport fuel injection system or ECM: Turn ignition switch to “OFF” position. Disconnect negative battery terminal. Otherwise, there may be damage to ECM. Before disconnecting pressurized fuel line from fuel pump to injectors, be sure to release fuel pressure. Be careful not to jar components such as ECM and mass air flow sensor. SGI787 Precautions for Turbocharger (If Equipped) BAS0002L The turbocharger turbine revolves at extremely high speeds and becomes very hot. Therefore, it is essential to maintain a clean supply of oil flowing through the turbocharger and to follow all required maintenance instructions and operating procedures. ● Always use the recommended oil. Follow the instructions for proper time to change the oil and proper oil level. ● Avoid accelerating engine to a high rpm immediately after starting. ● If engine had been operating at high rpm for an extended period of time, let it idle for a few minutes prior to shutting if off. SGI292 GI-6 PRECAUTIONS Precautions for Hoses BAS0002M GI HOSE REMOVAL AND INSTALLATION ● To prevent damage to rubber hose, do not pry off rubber hose with tapered tool or screwdriver. B C D SMA019D ● E To reinstall the rubber hose securely, make sure that hose insertion length and orientation is correct. (If tube is equipped with hose stopper, insert rubber hose into tube until it butts up against hose stopper.) F G H SMA020D HOSE CLAMPING ● ● If old rubber hose is re-used, install hose clamp in its original position (at the indentation where the old clamp was). If there is a trace of tube bulging left on the old rubber hose, align rubber hose at that position. Discard old clamps; replace with new ones. I J K SMA021D ● After installing plate clamps, apply force to them in the direction of the arrow, tightening rubber hose equally all around. M SMA022D Precautions for Engine Oils BAS0002N Prolonged and repeated contact with used engine oil may cause skin cancer. Try to avoid direct skin contact with used oil. If skin contact is made, wash thoroughly with soap or hand cleaner as soon as possible. HEALTH PROTECTION PRECAUTIONS ● Avoid prolonged and repeated contact with oils, particularly used engine oils. GI-7 L PRECAUTIONS ● ● ● ● ● ● ● ● ● ● ● Wear protective clothing, including impervious gloves where practicable. Do not put oily rags in pockets. Avoid contaminating clothes, particularly underpants, with oil. Heavily soiled clothing and oil-impregnated footwear should not be worn. Overalls must be cleaned regularly. First aid treatment should be obtained immediately for open cuts and wounds. Use barrier creams, applying them before each work period, to help the removal of oil from the skin. Wash with soap and water to ensure all oil is removed (skin cleansers and nail brushes will help). Preparations containing lanolin replace the natural skin oils which have been removed. Do not use gasoline, kerosene, diesel fuel, gas oil, thinners or solvents for cleaning skin. If skin disorders develop, obtain medical advice without delay. Where practical, degrease components prior to handling. Where there is a risk of eye contact, eye protection should be worn, for example, chemical goggles or face shields; in addition an eye wash facility should be provided. ENVIRONMENTAL PROTECTION PRECAUTIONS For the service site in UK, burning used engine oil in small space heaters or boilers can be recommended only for units of approved design. The heating system must meet the requirements of HM Inspectorate of Pollution for small burners of less than 0.4 MW. If in doubt check with the appropriate local authority and/or manufacturer of the approved appliance. Dispose of used oil and used oil filters through authorized waste disposal contractors to licensed waste disposal sites, or to the waste oil reclamation trade. If in doubt, contact the local authority for advice on disposal facilities. It is illegal to pour used oil on to the ground, down sewers or drains, or into water sources. The regulations concerning pollution vary between regions. Precautions for Air Conditioning BAS0002O Use an approved refrigerant recovery unit any time the air conditioning system must be discharged. Refer to ATC/MTC section “HFC-134a (R-134a) Service Procedure”, “REFRIGERANT LINES” for specific instructions. GI-8 HOW TO USE THIS MANUAL HOW TO USE THIS MANUAL Description PFP:00008 GI BAS0002P This volume explains “Removal, Disassembly, Installation, Inspection and Adjustment” and “Trouble Diagnoses”. Terms ● BAS0002Q The captions WARNING and CAUTION warn you of steps that must be followed to prevent personal injury and/or damage to some part of the vehicle. WARNING indicates the possibility of personal injury if instructions are not followed. CAUTION indicates the possibility of component damage if instructions are not followed. BOLD TYPED STATEMENTS except WARNING and CAUTION give you helpful information. Standard value:Tolerance at inspection and adjustment. Limit value:The maximum or minimum limit value that should not be exceeded at inspection and adjustment. Units ● The UNITS given in this manual are primarily expressed as the SI UNIT (International System of Unit), and alternatively expressed in the metric system and in the yard/pound system. “Example” : 59 - 78 N-m (6.0 - 8.0 kg-m, 43 - 58 ft-lb) Contents ● A QUICK REFERENCE INDEX, a black tab (e.g. ) is provided on the first page. You can quickly find the first page of each section by matching it to the section's black tab. THE CONTENTS are listed on the first page of each section. THE TITLE is indicated on the upper portion of each page and shows the part or system. THE PAGE NUMBER of each section consists of two or three letters which designate the particular section and a number (e.g. “BR-5”). THE SMALL ILLUSTRATIONS show the important steps such as inspection, use of special tools, knacks of work and hidden or tricky steps which are not shown in the previous large illustrations. Assembly, inspection and adjustment procedures for the complicated units such as the automatic transaxle or transmission, etc. are presented in a step-by-step format where necessary. ● E F BAS0002S ALPHABETICAL INDEX is provided at the end of this manual so that you can rapidly find the item and page you are searching for. ● D G ● ● C BAS0002R Outer Socket Lock Nut ● B H I J K L M GI-9 HOW TO USE THIS MANUAL Relation between Illustrations and Descriptions BAS0004K The following sample explains the ralationship between the part description in an illustration, the part name in the text and the service procedures. SAIA0519E GI-10 HOW TO USE THIS MANUAL Components ● BAS0002T THE LARGE ILLUSTRATIONS are exploded views (see the following) and contain tightening torques, lubrication points, section number of the PARTS CATALOG (e.g. SEC. 440) and other information necessary to perform repairs. The illustrations should be used in reference to service matters only. When ordering parts, refer to the appropriate PARTS CATALOG . Components shown in an illustration may be identified by a circled number. When this style of illustration is used, the text description of the components will follow the illustration. GI B C D E F G H SFIA2959E 1. Union bolt 2. Copper washer 3. Brake hose 4. Cap 5. Bleed valve 6. Sliding pin bolt 7. Piston seal 8. Piston 9. Piston boot 10. Cylinder body 11. Sliding pin 12. Torque member mounting bolt 13. Washer 14. Sliding pin boot 15. Bushing 16. Torque member 17. Inner shim cover 18. Inner shim 19. Inner pad 20. Pad retainer 21. Pad wear sensor 22. Outer pad 23. Outer shim 24. Outer shim cover 1: PBC (Poly Butyl Cuprysil) grease or silicone-based grease 2: Rubber grease I J K L : Brake fluid Refer to GI section for additional symbol definitions. M SYMBOLS SAIA0749E GI-11 HOW TO USE THIS MANUAL How to Follow Trouble Diagnoses BAS0002U DESCRIPTION NOTICE: Trouble diagnoses indicate work procedures required to diagnose problems effectively. Observe the following instructions before diagnosing. 1. Before performing trouble diagnoses, read the “Preliminary Check”, the “Symptom Chart” or the “Work Flow”. 2. After repairs, re-check that the problem has been completely eliminated. 3. Refer to Component Parts and Harness Connector Location for the Systems described in each section for identification/location of components and harness connectors. 4. Refer to the Circuit Diagram for quick pinpoint check. If you need to check circuit continuity between harness connectors in more detail, such as when a sub-harness is used, refer to Wiring Diagram in each individual section and Harness Layout in PG section for identification of harness connectors. 5. When checking circuit continuity, ignition switch should be OFF. 6. Before checking voltage at connectors, check battery voltage. 7. After accomplishing the Diagnostic Procedures and Electrical Components Inspection, make sure that all harness connectors are reconnected as they were. HOW TO FOLLOW TEST GROUPS IN TROUBLE DIAGNOSES SAIA0256E 1. 2. Work and diagnostic procedure Start to diagnose a problem using procedures indicated in enclosed test groups. Questions and required results Questions and required results are indicated in bold type in test group. The meaning of are as follows: GI-12 HOW TO USE THIS MANUAL a. Battery voltage → 11 - 14V or approximately 12V b. Voltage : Approximately 0V → Less than 1V 3. 4. GI Symbol used in illustration Symbols included in illustrations refer to measurements or procedures. Before diagnosing a problem, familiarize yourself with each symbol. Refer to "Connector Symbols" in GI Section and "KEY TO SYMBOLS SIGNIFYING MEASUREMENTS OR PROCEDURES" below. Action items Next action for each test group is indicated based on result of each question. Test group number is shown in the left upper portion of each test group. HARNESS WIRE COLOR AND CONNECTOR NUMBER INDICATION B C D There are two types of harness wire color and connector number indication. TYPE 1: Harness Wire Color and Connector Number are Shown in Illustration ● ● ● E Letter designations next to test meter probe indicate harness wire color. Connector numbers in a single circle (e.g. M33) indicate harness connectors. Connector numbers in a double circle (e.g. F211) indicate component connectors. F G H I J K AGI070 L M GI-13 HOW TO USE THIS MANUAL TYPE 2: Harness Wire Color and Connector Number are Shown in Text SGI144A KEY TO SYMBOLS SIGNIFYING MEASUREMENTS OR PROCEDURES SAIA0750E GI-14 HOW TO USE THIS MANUAL GI B C D E F G H I J K L M SAIA0751E GI-15 HOW TO USE THIS MANUAL How to Read Wiring Diagrams BAS0002V CONNECTOR SYMBOLS Most of connector symbols in wiring diagrams are shown from the terminal side. ● Connector symbols shown from the terminal side are enclosed by a single line and followed by the direction mark. ● Connector symbols shown from the harness side are enclosed by a double line and followed by the direction mark. ● Certain systems and components, especially those related to OBD, may use a new style slide-locking type harness connector. For description and how to disconnect, refer to PG section, “Description”, “HARNESS CONNECTOR”. SAIA0257E ● Male and female terminals Connector guides for male terminals are shown in black and female terminals in white in wiring diagrams. SGI363 GI-16 HOW TO USE THIS MANUAL SAMPLE/WIRING DIAGRAM - EXAMPL ● GI For detail, refer to following “DESCRIPTION”. B C D E F G H I J K L M SGI091A GI-17 HOW TO USE THIS MANUAL Optional Splice SGI942 DESCRIPTION Number Item 1 Power condition 2 Fusible link 3 Fusible link/fuse location 4 Fuse 5 6 Current rating Connectors Description ● This shows the condition when the system receives battery positive voltage (can be operated). ● The double line shows that this is a fusible link. ● The open circle shows current flow in, and the shaded circle shows current flow out. ● This shows the location of the fusible link or fuse in the fusible link or fuse box. For arrangement, refer to PG section, POWER SUPPLY ROUTING. ● The single line shows that this is a fuse. ● The open circle shows current flow in, and the shaded circle shows current flow out. ● This shows the current rating of the fusible link or fuse. ● This shows that connector E3 is female and connector M1 is male. ● The G/R wire is located in the 1A terminal of both connectors. ● Terminal number with an alphabet (1A, 5B, etc.) indicates that the connector is SMJ connector. Refer to PG section, SMJ (SUPER MULTIPLE JUNCTION). 7 Optional splice ● The open circle shows that the splice is optional depending on vehicle application. 8 Splice ● The shaded circle shows that the splice is always on the vehicle. ● 9 Page crossing This arrow shows that the circuit continues to an adjacent page. ● The A will match with the A on the preceding or next page. 10 Common connector ● The dotted lines between terminals show that these terminals are part of the same connector. 11 Option abbreviation ● This shows that the circuit is optional depending on vehicle application. 12 Relay ● This shows an internal representation of the relay. For details, refer to PG section, STANDARDIZED RELAY. 13 Connectors ● This shows that the connector is connected to the body or a terminal with bolt or nut. GI-18 HOW TO USE THIS MANUAL Number Item Description ● 14 Wire color This shows a code for the color of the wire. BR = Brown OR or O = Orange P = Pink PU or V (Violet) = Purple GY or GR = Gray SB = Sky Blue CH = Dark Brown DG = Dark Green B = Black W = White R = Red G = Green L = Blue Y = Yellow LG = Light Green When the wire color is striped, the base color is given first, followed by the stripe color as shown below: Example: L/W = Blue with White Stripe 15 Option description 16 Switch 17 Assembly parts 18 19 20 Cell code ● This shows a description of the option abbreviation used on the page. ● This shows that continuity exists between terminals 1 and 2 when the switch is in the A position. Continuity exists between terminals 1 and 3 when the switch is in the B position. ● Connector terminal in component shows that it is a harness incorporated assembly. ● This identifies each page of the wiring diagram by section, system and wiring diagram page number. ● Arrow indicates electric current flow, especially where the direction of standard flow (vertically downward or horizontally from left to right) is difficult to follow. ● A double arrow “ cuit operation. Current flow arrow System branch ● This shows that the system branches to another system identified by cell code (section and system). ● This arrow shows that the circuit continues to another page identified by cell code. ● The C will match with the C on another page within the system other than the next or preceding pages. 22 Shielded line ● The line enclosed by broken line circle shows shield wire. 23 Component box in wave line ● This shows that another part of the component is also shown on another page (indicated by wave line) within the system. 24 Component name ● This shows the name of a component. ● This shows the connector number. ● The letter shows which harness the connector is located in. ● Example: M : main harness. For detail and to locate the connector, refer to PG section "Main Harness", “Harness Layout”. A coordinate grid is included for complex harnesses to aid in locating connectors. ● The line spliced and grounded under wire color shows that ground line is spliced at the grounded connector. ● This shows the ground connection. For detailed ground distribution information, refer to "Ground Distribution" in PG section. ● This area shows the connector faces of the components in the wiring diagram on the page. ● Connectors enclosed in broken line show that these connectors belong to the same component. ● This shows a code for the color of the connector. For code meaning, refer to wire color codes, Number 14 of this chart. ● This shows the arrangement of fusible link(s) and fuse(s), used for connector views of "POWER SUPPLY ROUTING" in PG section. The open square shows current flow in, and the shaded square shows current flow out. ● This shows that more information on the Super Multiple Junction (SMJ) and Joint Connectors (J/C) exists on the PG section. Refer to "Reference Area" for details. 26 Ground (GND) 27 Ground (GND) 28 Connector views 29 Common component 30 Connector color 31 Fusible link and fuse box 32 Reference area C D E F G H Page crossing Connector number B ” shows that current can flow in either direction depending on cir- 21 25 GI GI-19 I J K L M HOW TO USE THIS MANUAL Harness Indication ● ● Letter designations next to test meter probe indicate harness (connector) wire color. Connector numbers in a single circle M33 indicate harness connectors. AGI070 Component Indication Connector numbers in a double circle F211 indicate component connectors. Switch Positions Switches are shown in wiring diagrams as if the vehicle is in the “normal” condition. A vehicle is in the “normal” condition when: ● ignition switch is “OFF”, ● doors, hood and trunk lid/back door are closed, ● pedals are not depressed, and ● parking brake is released. SGI860 GI-20 HOW TO USE THIS MANUAL Detectable Lines and Non-Detectable Lines GI In some wiring diagrams, two kinds of lines, representing wires, with different weight are used. ● A line with regular weight (wider line) represents a “detectable line for DTC (Diagnostic Trouble Code)”. A “detectable line for DTC” is a circuit in which ECM can detect its malfunctions with the on board diagnostic system. ● A line with less weight (thinner line) represents a “non-detectable line for DTC”. A “non-detectable line for DTC” is a circuit in which ECM cannot detect its malfunctions with the on board diagnostic system. B C D E F G SGI862-B H I J K L M GI-21 HOW TO USE THIS MANUAL Multiple Switch The continuity of multiple switch is described in two ways as shown below. ● The switch chart is used in schematic diagrams. ● The switch diagram is used in wiring diagrams. SGI875 GI-22 HOW TO USE THIS MANUAL Reference Area The Reference Area of the wiring diagram contains references to additional electrical reference pages at the GI end of the manual. If connector numbers and titles are shown in the Reference Area of the wiring diagram, these connector symbols are not shown in the Connector Area. B C D E F G H I J K L M SGI092A Abbreviations BAS0002W The following ABBREVIATIONS are used: ABBREVIATION DESCRIPTION A/C Air Conditioner A/T Automatic Transaxle/Transmission ATF Automatic Transmission Fluid D1 Drive range 1st gear D2 Drive range 2nd gear GI-23 HOW TO USE THIS MANUAL ABBREVIATION DESCRIPTION D3 Drive range 3rd gear D4 Drive range 4th gear FR, RR Front, Rear LH, RH Left-Hand, Right-Hand M/T Manual Transaxle/Transmission OD Overdrive P/S Power Steering SAE Society of Automotive Engineers, Inc. SDS Service Data and Specifications SST Special Service Tools 2WD 2-Wheel Drive 22 2nd range 2nd gear 21 2nd range 1st gear 12 1st range 2nd gear 11 1st range 1st gear GI-24 SERVICE INFORMATION FOR ELECTRICAL INCIDENT SERVICE INFORMATION FOR ELECTRICAL INCIDENT How to Perform Efficient Diagnosis for an Electrical Incident PFP:00000 GI BAS0002X WORK FLOW B C D E F G SGI838 STEP DESCRIPTION H Get detailed information about the conditions and the environment when the incident occurred. The following are key pieces of information required to make a good analysis: STEP 1 STEP 2 WHAT Vehicle Model, Engine, Transmission/Transaxle and the System (i.e. Radio). WHEN Date, Time of Day, Weather Conditions, Frequency. WHERE Road Conditions, Altitude and Traffic Situation. HOW System Symptoms, Operating Conditions (Other Components Interaction). Service History and if any After Market Accessories have been installed. Operate the system, road test if necessary. Verify the parameter of the incident. If the problem cannot be duplicated, refer to “Incident Simulation Tests”. I J K Get the proper diagnosis materials together including: ● Power Supply Routing ● System Operation Descriptions ● Applicable Service Manual Sections ● Check for any Service Bulletins STEP 3 L M Identify where to begin diagnosis based upon your knowledge of the system operation and the customer comments. STEP 4 Inspect the system for mechanical binding, loose connectors or wiring damage. Determine which circuits and components are involved and diagnose using the Power Supply Routing and Harness Layouts. STEP 5 Repair or replace the incident circuit or component. STEP 6 Operate the system in all modes. Verify the system works properly under all conditions. Make sure you have not inadvertently created a new incident during your diagnosis or repair steps. INCIDENT SIMULATION TESTS Introduction Sometimes the symptom is not present when the vehicle is brought in for service. If possible, re-create the conditions present at the time of the incident. Doing so may help avoid a No Trouble Found Diagnosis. The following section illustrates ways to simulate the conditions/environment under which the owner experiences an electrical incident. The section is broken into the six following topics: ● Vehicle vibration GI-25 SERVICE INFORMATION FOR ELECTRICAL INCIDENT Heat sensitive Freezing ● Water intrusion ● Electrical load ● Cold or hot start up Get a thorough description of the incident from the customer. It is important for simulating the conditions of the problem. ● ● Vehicle Vibration The problem may occur or become worse while driving on a rough road or when engine is vibrating (idle with A/C on). In such a case, you will want to check for a vibration related condition. Refer to the following illustration. CONNECTORS & HARNESS Determine which connectors and wiring harness would affect the electrical system you are inspecting. Gently shake each connector and harness while monitoring the system for the incident you are trying to duplicate. This test may indicate a loose or poor electrical connection. HINT Connectors can be exposed to moisture. It is possible to get a thin film of corrosion on the connector terminals. A visual inspection may not reveal this without disconnecting the connector. If the problem occurs intermittently, perhaps the problem is caused by corrosion. It is a good idea to disconnect, inspect and clean the terminals on related connectors in the system. SENSORS & RELAYS Gently apply a slight vibration to sensors and relays in the system you are inspecting. This test may indicate a loose or poorly mounted sensor or relay. SGI839 ENGINE COMPARTMENT There are several reasons a vehicle or engine vibration could cause an electrical complaint. Some of the things to check for are: ● Connectors not fully seated. ● Wiring harness not long enough and is being stressed due to engine vibrations or rocking. ● Wires laying across brackets or moving components. ● Loose, dirty or corroded ground wires. ● Wires routed too close to hot components. To inspect components under the hood, start by verifying the integrity of ground connections. (Refer to Ground Inspection described later.) First check that the system is properly grounded. Then check for loose connection by gently shaking the wiring or components as previously explained. Using the wiring diagrams inspect the wiring for continuity. BEHIND THE INSTRUMENT PANEL An improperly routed or improperly clamped harness can become pinched during accessory installation. Vehicle vibration can aggravate a harness which is routed along a bracket or near a screw. GI-26 SERVICE INFORMATION FOR ELECTRICAL INCIDENT UNDER SEATING AREAS GI An unclamped or loose harness can cause wiring to be pinched by seat components (such as slide guides) during vehicle vibration. If the wiring runs under seating areas, inspect wire routing for possible damage or pinching. B Heat Sensitive The customer's concern may occur during hot weather or after car has sat for a short time. In such cases you will want to check for a heat sensitive condition. To determine if an electrical component is heat sensitive, heat the component with a heat gun or equivalent. Do not heat components above 60°C (140°F). If incident occurs while heating the unit, either replace or properly insulate the component. C D E SGI842 F Freezing The customer may indicate the incident goes away after the car warms up (winter time). The cause could be related to water freezing somewhere in the wiring/electrical system. There are two methods to check for this. The first is to arrange for the owner to leave his car overnight. Make sure it will get cold enough to demonstrate his complaint. Leave the car parked outside overnight. In the morning, do a quick and thorough diagnosis of those electrical components which could be affected. The second method is to put the suspect component into a freezer long enough for any water to freeze. Reinstall the part into the car and check for the reoccurrence of the incident. If it occurs, repair or replace the component. G H I SGI843 Water Intrusion J The incident may occur only during high humidity or in rainy/snowy weather. In such cases the incident could be caused by water intrusion on an electrical part. This can be simulated by soaking the car or running it through a car wash. Do not spray water directly on any electrical components. K L M SGI844 Electrical Load The incident may be electrical load sensitive. Perform diagnosis with all accessories (including A/C, rear window defogger, radio, fog lamps) turned on. SGI845 GI-27 SERVICE INFORMATION FOR ELECTRICAL INCIDENT Cold or Hot Start Up On some occasions an electrical incident may occur only when the car is started cold, or it may occur when the car is restarted hot shortly after being turned off. In these cases you may have to keep the car overnight to make a proper diagnosis. CIRCUIT INSPECTION Introduction In general, testing electrical circuits is an easy task if it is approached in a logical and organized method. Before beginning it is important to have all available information on the system to be tested. Also, get a thorough understanding of system operation. Then you will be able to use the appropriate equipment and follow the correct test procedure. You may have to simulate vehicle vibrations while testing electrical components. Gently shake the wiring harness or electrical component to do this. OPEN A circuit is open when there is no continuity through a section of the circuit. There are two types of shorts. SHORT ● SHORT CIRCUIT When a circuit contacts another circuit and causes the normal resistance to change. ● SHORT TO GROUND When a circuit contacts a ground source and grounds the circuit. NOTE: Refer to “How to Check Terminal” to probe or check terminal. Testing for “Opens” in the Circuit Before you begin to diagnose and test the system, you should rough sketch a schematic of the system. This will help you to logically walk through the diagnosis process. Drawing the sketch will also reinforce your working knowledge of the system. SGI846-A CONTINUITY CHECK METHOD The continuity check is used to find an open in the circuit. The digital multimeter (DMM) set on the resistance function will indicate an open circuit as over limit (no beep tone or no ohms symbol). Make sure to always start with the DMM at the highest resistance level. To help in understanding the diagnosis of open circuits, please refer to the previous schematic. ● Disconnect the battery negative cable. ● Start at one end of the circuit and work your way to the other end. (At the fuse block in this example) ● Connect one probe of the DMM to the fuse block terminal on the load side. ● Connect the other probe to the fuse block (power) side of SW1. Little or no resistance will indicate that portion of the circuit has good continuity. If there were an open in the circuit, the DMM would indicate an over limit or infinite resistance condition. (point A) ● Connect the probes between SW1 and the relay. Little or no resistance will indicate that portion of the circuit has good continuity. If there were an open in the circuit, the DMM would indicate an over limit or infinite resistance condition. (point B) ● Connect the probes between the relay and the solenoid. Little or no resistance will indicate that portion of the circuit has good continuity. If there were an open in the circuit, the DMM would indicate an over limit or infinite resistance condition. (point C) Any circuit can be diagnosed using the approach in the previous example. GI-28 SERVICE INFORMATION FOR ELECTRICAL INCIDENT VOLTAGE CHECK METHOD To help in understanding the diagnosis of open circuits please refer to the previous schematic. GI In any powered circuit, an open can be found by methodically checking the system for the presence of voltage. This is done by switching the DMM to the voltage function. ● Connect one probe of the DMM to a known good ground. B ● Begin probing at one end of the circuit and work your way to the other end. ● With SW1 open, probe at SW1 to check for voltage. voltage; open is further down the circuit than SW1. C no voltage; open is between fuse block and SW1 (point A). ● Close SW1 and probe at relay. voltage; open is further down the circuit than the relay. D no voltage; open is between SW1 and relay (point B). ● Close the relay and probe at the solenoid. voltage; open is further down the circuit than the solenoid. E no voltage; open is between relay and solenoid (point C). Any powered circuit can be diagnosed using the approach in the previous example. Testing for “Shorts” in the Circuit F To simplify the discussion of shorts in the system, please refer to the following schematic. G H I SGI847-A J RESISTANCE CHECK METHOD ● Disconnect the battery negative cable and remove the blown fuse. ● Disconnect all loads (SW1 open, relay disconnected and solenoid disconnected) powered through the fuse. ● Connect one probe of the DMM to the load side of the fuse terminal. Connect the other probe to a known good ground. ● With SW1 open, check for continuity. continuity; short is between fuse terminal and SW1 (point A). no continuity; short is further down the circuit than SW1. ● Close SW1 and disconnect the relay. Put probes at the load side of fuse terminal and a known good ground. Then, check for continuity. continuity; short is between SW1 and the relay (point B). no continuity; short is further down the circuit than the relay. ● Close SW1 and jump the relay contacts with jumper wire. Put probes at the load side of fuse terminal and a known good ground. Then, check for continuity. continuity; short is between relay and solenoid (point C). no continuity; check solenoid, retrace steps. VOLTAGE CHECK METHOD ● Remove the blown fuse and disconnect all loads (i.e. SW1 open, relay disconnected and solenoid disconnected) powered through the fuse. ● Turn the ignition key to the ON or START position. Verify battery voltage at the battery + side of the fuse terminal (one lead on the battery + terminal side of the fuse block and one lead on a known good ground). ● With SW1 open and the DMM leads across both fuse terminals, check for voltage. voltage; short is between fuse block and SW1 (point A). GI-29 K L M SERVICE INFORMATION FOR ELECTRICAL INCIDENT ● ● no voltage; short is further down the circuit than SW1. With SW1 closed, relay and solenoid disconnected and the DMM leads across both fuse terminals, check for voltage. voltage; short is between SW1 and the relay (point B). no voltage; short is further down the circuit than the relay. With SW1 closed, relay contacts jumped with fused jumper wire check for voltage. voltage; short is down the circuit of the relay or between the relay and the disconnected solenoid (point C). no voltage; retrace steps and check power to fuse block. Ground Inspection Ground connections are very important to the proper operation of electrical and electronic circuits. Ground connections are often exposed to moisture, dirt and other corrosive elements. The corrosion (rust) can become an unwanted resistance. This unwanted resistance can change the way a circuit works. Electronically controlled circuits are very sensitive to proper grounding. A loose or corroded ground can drastically affect an electronically controlled circuit. A poor or corroded ground can easily affect the circuit. Even when the ground connection looks clean, there can be a thin film of rust on the surface. When inspecting a ground connection follow these rules: ● Remove the ground bolt or screw. ● Inspect all mating surfaces for tarnish, dirt, rust, etc. ● Clean as required to assure good contact. ● Reinstall bolt or screw securely. ● Inspect for “add-on” accessories which may be interfering with the ground circuit. ● If several wires are crimped into one ground eyelet terminal, check for proper crimps. Make sure all of the wires are clean, securely fastened and providing a good ground path. If multiple wires are cased in one eyelet make sure no ground wires have excess wire insulation. For detailed ground distribution information, refer to “Ground Distribution” in PG section. SGI853 Voltage Drop Tests Voltage drop tests are often used to find components or circuits which have excessive resistance. A voltage drop in a circuit is caused by a resistance when the circuit is in operation. Check the wire in the illustration. When measuring resistance with DMM, contact by a single strand of wire will give reading of 0 ohms. This would indicate a good circuit. When the circuit operates, this single strand of wire is not able to carry the current. The single strand will have a high resistance to the current. This will be picked up as a slight voltage drop. Unwanted resistance can be caused by many situations as follows: ● Undersized wiring (single strand example) ● Corrosion on switch contacts ● Loose wire connections or splices. GI-30 SERVICE INFORMATION FOR ELECTRICAL INCIDENT If repairs are needed always use wire that is of the same or larger gauge. GI MEASURING VOLTAGE DROP — ACCUMULATED METHOD ● Connect the DMM across the connector or part of the circuit you want to check. The positive lead of the DMM should be closer to power and the negative lead closer to ground. ● Operate the circuit. ● The DMM will indicate how many volts are being used to “push” current through that part of the circuit. Note in the illustration that there is an excessive 4.1 volt drop between the battery and the bulb. B C D E F G H SGI974 MEASURING VOLTAGE DROP — STEP-BY-STEP The step-by-step method is most useful for isolating excessive drops in low voltage systems (such as those in “Computer Controlled Systems”). Circuits in the “Computer Controlled System” operate on very low amperage. The (Computer Controlled) system operations can be adversely affected by any variation in resistance in the system. Such resistance variation may be caused by poor connection, improper installation, improper wire gauge or corrosion. The step by step voltage drop test can identify a component or wire with too much resistance. I J K L M SAIA0258E GI-31 SERVICE INFORMATION FOR ELECTRICAL INCIDENT Control Unit Circuit Test System Description:When the switch is ON, the control unit lights up the lamp. MGI034A INPUT-OUTPUT VOLTAGE CHART Pin No. Item 1 Switch 2 Lamp Voltage value [V] Condition In case of high resistance such as single strand [V] * Switch ON Battery voltage Lower than battery voltage Approx. 8 (Example) Switch OFF Approx. 0 Approx. 0 Switch ON Battery voltage Approx. 0 (Inoperative lamp) Switch OFF Approx. 0 Approx. 0 The voltage value is based on the body ground. *:If high resistance exists in the switch side circuit (caused by a single strand), terminal 1 does not detect battery voltage. Control unit does not detect the switch is ON even if the switch does not turn ON. Therefore, the control unit does not supply power to light up the lamp. MGI035A INPUT-OUTPUT VOLTAGE CHART Pin No. 1 2 Item Lamp Switch Condition Voltage value [V] In case of high resistance such as single strand [V] * Switch ON Approx. 0 Battery voltage (Inoperative lamp) Switch OFF Battery voltage Battery voltage Switch ON Approx. 0 Higher than 0 Approx. 4 (Example) Switch OFF Approx. 5 Approx. 5 The voltage value is based on the body ground. *:If high resistance exists in the switch side circuit (caused by a single strand), terminal 2 does not detect approx. 0V. Control unit does not detect the switch is ON even if the switch does not turn ON. Therefore, the control unit does not control ground to light up the lamp. GI-32 SERVICE INFORMATION FOR ELECTRICAL INCIDENT Control Units and Electrical Parts BAS0002Y GI PRECAUTIONS ● ● ● ● ● Never reverse polarity of battery terminals. Install only parts specified for a vehicle. Before replacing the control unit, check the input and output and functions of the component parts. Do not apply excessive force when disconnecting a connector. If a connector is installed by tightening bolts, loosen bolt mounting it, then take it out by hand. B C D SAIA0251E ● E Before installing a connector, make sure the terminal is not bent or damaged, and then correctly connect it. When installing a connector by tightening bolts, fix it by tightening the mounting bolt until the painted projection of the connector becomes even with the surface. F G H SAIA0252E ● For removal of the lever type connector, pull the lever up to the direction pointed to by the arrow A in the figure, and then remove the connector. I J K SAIA0253E ● For installation of the lever type connector, pull down the lever to the direction pointed by the arrow B in the figure, and then push the connector until a clicking noise is heard. M SAIA0254E GI-33 L SERVICE INFORMATION FOR ELECTRICAL INCIDENT ● ● ● ● ● ● ● Do not apply excessive shock to the control unit by dropping or hitting it. Be careful to prevent condensation in the control unit due to rapid temperature changes and do not let water or rain get on it. If water is found in the control unit, dry it fully and then install it in the vehicle. Be careful not to let oil to get on the control unit connector. Avoid cleaning the control unit with volatile oil. Do not disassemble the control unit, and do not remove the upper and lower covers. SAIA0255E When using a DMM, be careful not to let test probes get close to each other to prevent the power transistor in the control unit from damaging battery voltage because of short circuiting. When checking input and output signals of the control unit, use the specified check adapter. SEF348N SMJ INSTALLATION To install SMJ, tighten bolts until orange “fulltight” mark appears and then retighten to specified torque as required. SMJ :3 - 5 N·m (0.3 - 0.5 kg-m, 26 - 43 in-lb) CAUTION: Do not overtighten bolts, otherwise, they may be damaged. CEL969 GI-34 CONSULT-II CHECKING SYSTEM CONSULT-II CHECKING SYSTEM Description ● ● PFP:00000 GI BAS0002Z CONSULT-II is a hand-held type tester. When it is connected with a diagnostic connector equipped on the vehicle side, it will communicate with the control unit equipped in the vehicle and then enable various kinds of diagnostic tests. Refer to “CONSULT-II Software Operation Manual” for more information. Function and System Application ABS (Including ESP) EPS IPDM E/R BCM INTELLIGENT KEY NATS*1 This mode enables a technician to adjust some devices faster and more accurately by following the indications on CONSULT-II. x x – – – – x x x Self-diagnostic results Self-diagnostic results can be read and erased quickly. x x x x x x x x x Trouble diagnostic record Current self-diagnostic results and all trouble diagnostic records previously stored can be read. – – x – – – – – – Data monitor Input/Output data in the ECU can be read. x x – x x x – x x Function A/T Work support Diagnostic test mode ENGINE AIR BAG BAS00030 B C D E F G H CAN diagnosis support monitor Indicates the communication condition of CAN communication line. x x – x x x x x – Active test Diagnostic Test Mode in which CONSULT-II drives some actuators apart from the ECUs and also shifts some parameters in a specified range. x – – x – x x x – DTC & SRT confirmation The results of SRT (System Readiness Test) and the self-diagnosis status/result can be confirmed. x*2 – – – – – – – – DTC work support Select the operating condition to confirm Diagnosis Trouble Codes. – x – – – – – – – ECU part number ECU part number can be read. x x – x x – x x – ECU discriminated No. Classification number of a replacement ECU can be read to prevent an incorrect ECU from being installed. – – x – – – – – – Function test Conducted by CONSULT-II instead of a technician to determine whether each system is “OK” or “NG”. x*2 x x x – – – – – Control unit initialization All registered ignition key IDs in NATS components can be initialized and new IDs can be registered. – – – – – – – – x Self-function check ECU checks its own NATS communication interface. – – – – – – – – x Configuration The vehicle configuration can be read and written on brand-new BCM and IPDM E/R – – – – – x x – – I J K M x: Applicable *1: Nissan Anti-Theft System *2: Petrol engine models Nickel Metal Hydride Battery Replacement BAS00031 CONSULT-II contains a nickel metal hydride battery. When replacing the battery obey the following: WARNING: Replace the nickel metal hydride battery with Genuine CONSULT-II battery only. Use of another battery may present a risk of fire or explosion. The battery may present a fire or chemical burn hazard if mistreated. Do not recharge, disassemble or dispose of in fire. Keep the battery out of reach of children and discard used battery conforming to the local regulations. GI-35 L CONSULT-II CHECKING SYSTEM Checking Equipment BAS00032 When ordering the following equipment, contact your NISSAN distributor. Tool name Description NISSAN CONSULT-II 1. CONSULT-II unit (Tester internal soft: Resident version 3.3.0) and accessories 2. Program card AED06A and AEN06A (For NATS) To confirm the best combination of these softwares, refer to CONSULT-II Operation Manual. 3. CONSULT-II CONVERTER 4. “CONSULT-II Pigtail” Cable SAIA0363E NOTE: ● The CONSULT-II must be used in conjunction with a program card. CONSULT-II does not require loading (Initialization) procedure. ● Be sure the CONSULT-II is turned off before installing or removing a program card. CAUTION: ● If CONSULT-II is used with no connection of CONSULT-II CONVERTER, malfunctions might be detected in self-diagnosis depending on control unit which carries out CAN communication. ● If CONVERTER is not connected with CONSULT-II, vehicle occur the “FAIL-SAFE MODE” which is “LIGHT UP the HEADLIGHT” and/or “Cooling FAN ROTATING” when CONSULT-II is started. ● Previous CONSULT-II “I” and “Y” DLC-I and DLC-II cables should NOT be used anymore because their DDL connector pins can be damaged during cable swapping. CONSULT-II Start Procedure BAS00033 NOTE: Turning ignition switch off when performing CAN diagnosis could cause CAN memory to be erased. 1. Connect CONSULT-II and CONSULT-II CONVERTER to the data link connector. PAIA0070E 2. 3. If necessary, turn on the ignition switch. Touch “START(NISSAN BASED VECL)” or “System Shortcut” (e.g.: Engine) on the screen. BCIA0029E GI-36 CONSULT-II CHECKING SYSTEM 4. Touch necessary system on “SELECT SYSTEM” screen. If necessary system is not indicated, check power supply and ground of system control unit. If it is normal, refer to GI-38, "CONSULT-II Data Link Connector (DLC) Circuit" . GI B C BCIA0030E D 5. Select the desired part to be diagnosed on the “SELECT DIAG MODE” screen. E F G BCIA0031E H I J K L M GI-37 CONSULT-II CHECKING SYSTEM CONSULT-II Data Link Connector (DLC) Circuit BAS00034 MAWA0021E GI-38 CONSULT-II CHECKING SYSTEM INSPECTION PROCEDURE If the CONSULT-II cannot diagnose the system properly, check the following items. Symptom Check item ● CONSULT-II DLC power supply circuit (Terminal 8) and ground circuit (Terminal 4) (For detailed circuit, refer to “MIL & Data Link Connectors Wiring Diagram” in EC section.) ● CONSULT-II DLC cable and CONSULT-II CONVERTER ● CONSULT-II program card (Check the appropriate CONSULT-II program card for the system. Refer to “Checking Equipment”.) ● Power supply and ground circuit for the control unit of the system (For detailed circuit, refer to wiring diagram for each system.) ● Open or short circuit between the system and CONSULT-II DLC (For detailed circuit, refer to wiring diagram for each system.) ● Open or short circuit CAN communication line. Refer to LAN-3, "Precautions When Using CONSULT-II" . CONSULT-II cannot access any system. CONSULT-II cannot access individual system. (Other systems can be accessed.) GI NOTE: The DDL1 and DDL2 circuits from DLC pins 12, 13, 14 and 15 may be connected to more than one system. A short in a DDL circuit connected to a control unit in one system may affect CONSULT-II access to other systems. B C D E F G H I J K L M GI-39 LIFTING POINT LIFTING POINT Commercial Service Tools PFP:00000 BAS00035 Tool name Description Board on lift attachment S-NT001 Safety stand attachment S-NT002 CAUTION: ● Every time the vehicle is lifted up, maintain the complete vehicle curb condition. ● Since the vehicle's center of gravity changes when removing main parts on the front side (engine, transmission, suspension etc.), support a jack up point on the rear side garage jack with a mission jack or equivalent. ● Since the vehicle's center of gravity changes when removing main parts on the rear side (rear axle, suspension, etc.), support a jack up point on the front side garage jack with a mission jack or equivalent. ● Be careful not to smash or do not do anything that would affect piping parts. Garage Jack, Safety Stand and 2-Pole Lift BAS00036 WARNING: ● Park the vehicle on a level surface when using the jack. Make sure to avoid damaging pipes, tubes, etc. under the vehicle. ● Never get under the vehicle while it is supported only by the jack. Always use safety stands when you have to get under the vehicle. ● Place wheel chocks at both front and back of the wheels on the ground. ● When lifting the vehicle, open the lift arms as wide as possible and ensure that the front and rear of the vehicle are well balanced. ● When setting the lift arm, do not allow the arm to contact the brake tubes, brake cable, fuel lines and sill spoiler. GI-40 LIFTING POINT GI B C D E F MAIB0076E 1. Safety stand point and lift up point (front) 4. Garage jack point (rear) 2. Safety stand point and lift up point (rear) Board-On Lift 3. Garage jack point (front) G BAS00038 CAUTION: Make sure vehicle is empty when lifting. ● The board-on lift attachment set at front end of vehicle should be set on the front of the sill under the front door opening. ● Position attachments at front and rear ends of board-on lift. H I J K MAIB0030E L M GI-41 TOW TRUCK TOWING TOW TRUCK TOWING Tow Truck Towing PFP:00000 BAS00039 CAUTION: ● All applicable local laws regarding the towing operation must be obeyed. ● It is necessary to use proper towing equipment to avoid possible damage to the vehicle during towing operation. Towing is in accordance with Towing Procedure Manual at dealer. ● Always attach safety chains before towing. ● When towing, make sure that the transmission, steering system and power train are in good order. If any unit is damaged, dollies must be used. NISSAN recommends that the vehicle is towed with the driving (front) wheels off the ground as illustrated. MAIB0077E TOWING AN AUTOMATIC TRANSAXLE MODEL WITH FOUR WHEELS ON GROUND CAUTION: Never tow an automatic transaxle model with four wheels on the ground as this may cause serious and expensive damage to the transaxle. Vehicle Recovery (Freeing a Stuck Vehicle) BAS0003A FRONT Use the towing hook only, not other parts of the vehicle. Otherwise, the vehicle body will be damaged. ● Use the towing hook only to free a vehicle stuck in sand, snow, mud, etc. Never tow the vehicle for a long distance using only the towing hook. ● The towing hook is under tremendous force when used to free a stuck vehicle. Always pull the cable straight out from the front or rear of the vehicle. Never pull on the hook at an angle. ● Stand clear of a stuck vehicle. WARNING: MAIB0078E ● Do not spin the tyres at high speed. This could cause them to explode and result in serious injury. Parts of the vehicle could also overheat and be damaged. ● Install removable towing hook securely using wheel nut wrench. ● GI-42 TOW TRUCK TOWING REAR GI Recovery hook is not available. B C MAIB0079E D E F G H I J K L M GI-43 TIGHTENING TORQUE OF STANDARD BOLTS TIGHTENING TORQUE OF STANDARD BOLTS Tightening Torque Table Grade 4T 7T 9T Bolt size Bolt diameter * mm PFP:00000 BAS0003B Tightening torque (Without lubricant) Pitch mm Hexagon head bolt N·m kg-m Hexagon flange bolt ft-lb in-lb N·m kg-m ft-lb in-lb M6 6.0 1.0 5.5 0.56 4 49 7 0.71 5 62 M8 8.0 1.25 13.5 1.4 10 — 17 1.7 13 — 1.0 13.5 1.4 10 — 17 1.7 13 — M10 10.0 1.5 28 2.9 21 — 35 3.6 26 — 1.25 28 2.9 21 — 35 3.6 26 — M12 12.0 1.75 45 4.6 33 — 55 5.6 41 — 1.25 45 4.6 33 — 65 6.6 48 — M14 14.0 1.5 80 8.2 59 — 100 10 74 — M6 6.0 1.0 9 0.92 7 80 11 1.1 8 97 1.25 22 2.2 16 — 28 2.9 21 — M8 8.0 1.0 22 2.2 16 — 28 2.9 21 — 1.5 45 4.6 33 — 55 5.6 41 — M10 10.0 1.25 45 4.6 33 — 55 5.6 41 — 1.75 80 8.2 59 — 100 10 74 — M12 12.0 1.25 80 8.2 59 — 100 10 74 — M14 14.0 1.5 130 13 96 — 170 17 125 — M6 6.0 1.0 11 1.1 8 — 13.5 1.4 10 — 1.25 28 2.9 21 — 35 3.6 26 — M8 8.0 1.0 28 2.9 21 — 35 3.6 26 — 1.5 55 5.6 41 — 80 8.2 59 — M10 10.0 1.25 55 5.6 41 — 80 8.2 59 — 1.75 100 10 74 — 130 13 96 — M12 12.0 1.25 100 10 74 — 130 13 96 — M14 14.0 1.5 170 17 125 — 210 21 155 — *: Nominal diameter 1. Special parts are excluded. 2. This standard is applicable to bolts having the following marks embossed on the bolt head. MGI044A GI-44 IDENTIFICATION INFORMATION IDENTIFICATION INFORMATION Model Variation Body 5-door PFP:00010 GI BAS0003C RHD LHD Engine FDLARBF-EEA FDLALBF-EGA FDLAREF-EEA FDLALEF-EGA FDTARBF-EEA FDTALBF-EGA FDTAREF-EEA FDTALEF-EGA FDTARTF-EEA FDTALTF-EGA Transaxle Grade B Visia CR14DE Acenta JH3 Visia C Acenta Tekna HR16DE D FDTARBA-EEA FDTALBA-EGA Visia FDTAREA-EEA FDTALEA-EGA FDTARTA-EEA FDTALTA-EGA Tekna FTKARBF-EEE FTKALBF-EGE Visia FTKAREF-EEE FTKALEF-EGE FTKARBF-EEA FTKALBF-EGA FTKAREF-EEA FTKALEF-EGA FTKARTF-EEA FTKALTF-EGA RE4F03B K9K 50 kW JH3 Acenta Acenta F Visia K9K 63 kW JR5 E Acenta Tekna G Prefix and suffix designations: H I J K L M MAIB0073E GI-45 IDENTIFICATION INFORMATION IDENTIFICATION NUMBER MAIB0074E VEHICLE IDENTIFICATION NUMBER ARRANGEMENT MAIB0075E GI-46 IDENTIFICATION INFORMATION IDENTIFICATION PLATE GI B C D E F MAIB0019E G ENGINE SERIAL NUMBER (CR ENGINE) H I J MAIA0032E ENGINE SERIAL NUMBER (HR ENGINE) K L M STI0429 GI-47 IDENTIFICATION INFORMATION ENGINE IDENTIFICATION (K9K ENGINE) Identification is engravFD on the cylinder block which carries: ● A: engine type, ● B: engine type approval letter, ● D: Renault code, ● E: engine suffix, ● F: engine fabrication number, ● G: engine assembly plant. YGI008 AUTOMATIC TRANSAXLE NUMBER SGI113A Dimensions BAS0003D Unit: mm (in) Overall length 4,085 (160.83) Overall width 1,690 (66.54) Overall height 1,625 (63.98) Front tread 1,470 (57.87) Rear tread 1,460 (57.48) Wheelbase 2,600 (102.36) Wheels & Tyres BAS0003E Conventional Spare Road wheel size/offset mm (in) 15 × 5.5J Steel/45 (1.77) 15 × 5.5J Alminium/45 (1.77) 16 × 6J Aluminum/45 (1.77) 14 × 4T Steel/40 (1.57) 15 × 4T Steel/40 (1.57) Tyre size 175/65R15 185/65R15 185/55R16 T125/70D14 T125/70D15 GI-48 TERMINOLOGY TERMINOLOGY ISO 15031-2 Terminology List PFP:00011 GI BAS0003F All emission related terms used in this publication in accordance with ISO 15031-2 are listed. Accordingly, new terms, new acronyms/abbreviations and old terms are listed in the following chart. NEW ACRONYM / ABBREVIATION NEW TERM Air cleaner ACL B OLD TERM Air cleaner Barometric pressure BARO *** Barometric pressure sensor-BCDD BAROS-BCDD BCDD Camshaft position CMP *** Camshaft position sensor CMPS Crank angle sensor Canister *** Canister Carburetor CARB Carburetor Charge air cooler CAC Intercooler Closed loop CL Closed loop Closed throttle position switch CTP switch Idle switch Clutch pedal position switch CPP switch Clutch switch Continuous fuel injection system CFI system *** Continuous trap oxidizer system CTOX system *** Crankshaft position CKP *** Crankshaft position sensor CKPS *** Data link connector DLC *** Data link connector for CONSULT-II DLC for CONSULT-II Diagnostic connector for CONSULT-II Diagnostic test mode DTM Diagnostic mode Diagnostic test mode selector DTM selector Diagnostic mode selector Diagnostic test mode I DTM I Mode I Diagnostic test mode II DTM II Mode II Diagnostic trouble code DTC Malfunction code Direct fuel injection system DFI system *** Distributor ignition system DI system Ignition timing control Early fuel evaporation-mixture heater EFE-mixture heater Mixture heater Early fuel evaporation system EFE system Mixture heater control Electrically erasable programmable read only memory EEPROM *** Electronic ignition system EI system Ignition timing control Engine control EC *** C D E F G H I J K L M Engine control module ECM ECCS control unit Engine coolant temperature ECT Engine temperature Engine coolant temperature sensor ECTS Engine temperature sensor Engine modification EM *** Engine speed RPM Engine speed Erasable programmable read only memory EPROM *** Evaporative emission canister EVAP canister Canister Evaporative emission system EVAP system Canister control solenoid valve Exhaust gas recirculation valve EGR valve EGR valve GI-49 TERMINOLOGY NEW ACRONYM / ABBREVIATION NEW TERM OLD TERM Exhaust gas recirculation control-BPT valve EGRC-BPT valve BPT valve Exhaust gas recirculation control-solenoid valve EGRC-solenoid valve EGR control solenoid valve EGRT sensor Exhaust gas temperature sensor Flash electrically erasable programmable read only memory FEEPROM *** Flash erasable programmable read only memory FEPROM *** Flexible fuel sensor FFS *** Flexible fuel system FF system *** Fuel pressure regulator *** Pressure regulator Fuel pressure regulator control solenoid valve *** PRVR control solenoid valve Fuel trim FT *** Heated Oxygen sensor HO2S Exhaust gas sensor Idle air control system IAC system Idle speed control Idle air control valve-air regulator IACV-air regulator Air regulator Idle air control valve-auxiliary air control valve IACV-AAC valve Auxiliary air control (AAC) valve Idle air control valve-FICD solenoid valve IACV-FICD solenoid valve FICD solenoid valve Idle air control valve-idle up control solenoid valve IACV-idle up control solenoid valve Idle up control solenoid valve Exhaust gas recirculation temperature sensor EGR temperature sensor Idle speed control-FI pot ISC-FI pot FI pot Idle speed control system ISC system *** Ignition control IC *** Ignition control module ICM *** Indirect fuel injection system IFI system *** Intake air IA Air Intake air temperature sensor IAT sensor Air temperature sensor Knock *** Detonation Knock sensor KS Detonation sensor Malfunction indicator lamp MIL Check engine light Manifold absolute pressure MAP *** Manifold absolute pressure sensor MAPS *** Manifold differential pressure MDP *** Manifold differential pressure sensor MDPS *** Manifold surface temperature MST *** Manifold surface temperature sensor MSTS *** Manifold vacuum zone MVZ *** Manifold vacuum zone sensor MVZS *** Mass air flow sensor MAFS Air flow meter Mixture control solenoid valve MC solenoid valve Air-fuel ratio control solenoid valve Multiport fuel injection System MFI system Fuel injection control GI-50 TERMINOLOGY NEW ACRONYM / ABBREVIATION NEW TERM OLD TERM Nonvolatile random access memory NVRAM *** On board diagnostic system OBD system Self-diagnosis Open loop OL Open loop Oxidation catalyst OC Catalyst Oxidation catalytic converter system OC system *** Oxygen sensor O2S Exhaust gas sensor Park position switch *** Park switch Park/neutral position switch PNP switch Park/neutral switch Inhibitor switch Neutral position switch Periodic trap oxidizer system PTOX system *** Positive crankcase ventilation PCV Positive crankcase ventilation Positive crankcase ventilation valve PCV valve PCV valve Powertrain control module PCM *** Programmable read only memory PROM *** Pulsed secondary air injection control solenoid valve PAIRC solenoid valve AIV control solenoid valve Pulsed secondary air injection system PAIR system Air induction valve (AIV) control Pulsed secondary air injection valve PAIR valve Air induction valve Random access memory RAM *** Read only memory ROM *** Scan tool ST *** Secondary air injection pump AIR pump *** Secondary air injection system AIR system *** Sequential multiport fuel injection system SFI system Sequential fuel injection Service reminder indicator SRI *** Simultaneous multiport fuel injection system *** Simultaneous fuel injection Smoke puff limiter system SPL system *** Supercharger SC *** Supercharger bypass SCB *** System readiness test SRT *** Thermal vacuum valve TVV Thermal vacuum valve Three way catalyst TWC Catalyst Three way catalytic converter system TWC system *** Three way + oxidation catalyst TWC + OC Catalyst Three way + oxidation catalytic converter system TWC + OC system *** Throttle body TB Throttle chamber SPI body Throttle body fuel injection system TBI system Fuel injection control Throttle position TP Throttle position Throttle position sensor TPS Throttle sensor Throttle position switch TP switch Throttle switch Torque converter clutch solenoid valve TCC solenoid valve Lock-up cancel solenoid Lock-up solenoid GI-51 GI B C D E F G H I J K L M TERMINOLOGY NEW ACRONYM / ABBREVIATION NEW TERM OLD TERM Transmission control module TCM A/T control unit Turbocharger TC Turbocharger Vehicle speed sensor VSS Vehicle speed sensor Volume air flow sensor VAFS Air flow meter Warm up oxidation catalyst WU-OC Catalyst Warm up oxidation catalytic converter system WU-OC system *** Warm up three way catalyst WU-TWC Catalyst Warm up three way catalytic converter system WU-TWC system *** Wide open throttle position switch WOTP switch Full switch ***: Not applicable GI-52 GLASSES, WINDOW SYSTEM & MIRRORS I BODY SECTION GW GLASSES, WINDOW SYSTEM & MIRRORS A B C D CONTENTS PRECAUTIONS .......................................................... 3 Precautions for Supplemental Restraint System (SRS) “AIR BAG” and “SEAT BELT PRE-TENSIONER” .................................................................. 3 Maintenance Information .......................................... 3 RHD MODELS ...................................................... 3 LHD MODELS ....................................................... 3 PrecautionsforProcedureswithoutCowlTopCover..... 3 Precautions .............................................................. 3 WINDSHIELD GLASS ................................................ 5 Removal and Installation .......................................... 5 REMOVAL ............................................................. 5 INSTALLATION ..................................................... 6 SIDE WINDOW GLASS .............................................. 8 Removal and Installation .......................................... 8 REMOVAL ............................................................. 8 INSTALLATION ..................................................... 8 BACK DOOR WINDOW GLASS .............................. 10 Removal and Installation ........................................ 10 REMOVAL ........................................................... 10 INSTALLATION ....................................................11 REAR WINDOW DEFOGGER .................................. 12 Component Parts and Harness Connector Location... 12 System Description ................................................ 12 CAN Communication .............................................. 14 SYSTEM DESCRIPTION .................................... 14 CAN Communication Unit ...................................... 14 Schematic .............................................................. 15 Wiring Diagram — DEF — ..................................... 16 Terminal and Reference Value for BCM ................. 19 Terminal and Reference Value for IPDM E/R ......... 19 Work Flow .............................................................. 19 CONSULT-II Inspection Procedure ........................ 19 DATA MONITOR ................................................. 19 ACTIVE TEST ..................................................... 20 Trouble Diagnoses Symptom Chart ....................... 20 Check BCM Power Supply and Ground Circuit ...... 21 Check Rear Window Defogger Switch Circuit / With Auto A/C ................................................................. 22 Check Rear Window Defogger Switch Circuit / With- out Auto A/C ........................................................... 23 Check Rear Window Defogger Power Supply Circuit .......................................................................... 25 Check Rear Window Defogger Circuit .................... 26 Check Door Mirror Defogger Power Supply Circuit... 27 Check Driver Side Door Mirror Defogger Circuit ... 28 CheckPassengerSideDoorMirrorDefoggerCircuit ... 29 Filament Check ....................................................... 30 Filament Repair ...................................................... 31 REPAIR EQUIPMENT ......................................... 31 REPAIRING PROCEDURE ................................. 31 POWER WINDOW SYSTEM .................................... 32 Component Parts and Harness Connector Location... 32 System Description (With Front Power Window) ... 32 DRIVER DOOR ................................................... 32 PASSENGER DOOR [FRONT POWER WINDOW SWITCH (PASSENGER SIDE) OPERATION] ................................................................... 33 PASSENGER DOOR (POWER WINDOW MAIN SWITCH OPERATION) ....................................... 33 AUTO OPERATION ............................................. 34 POWER WINDOW LOCK ................................... 34 ANTI-PINCH SYSTEM ........................................ 34 INITIALIZATION .................................................. 34 System Description (With Front & Rear Power Window) ........................................................................ 35 DRIVER DOOR ................................................... 35 PASSENGER DOOR [FRONT POWER WINDOW SWITCH (PASSENGER SIDE) OPERATION] ................................................................... 36 PASSENGER DOOR (POWER WINDOW MAIN SWITCH OPERATION) ....................................... 36 REAR DOOR (RH OR LH) [REAR POWER WINDOW SWITCH (RH OR LH) OPERATION] ......... 37 REAR DOOR (RH OR LH) (POWER WINDOW MAIN SWITCH OPERATION) ............................. 37 AUTO OPERATION ............................................. 38 POWER WINDOW LOCK ................................... 38 ANTI-PINCH SYSTEM ........................................ 38 GW-1 E F G H GW J K L M INITIALIZATION .................................................. 38 Schematic/With Front Power Window .................... 40 Wiring Diagram — WINDOW —/With Front Power Window ................................................................... 41 Schematic/With Front & Rear Power Window ........ 44 Wiring Diagram — WINDOW —/With Front & Rear Power Window ........................................................ 45 Terminal and Reference Value for BCM ................. 49 Terminal and Reference Value for Power Window Main Switch/With Front Power Window (For LHD Models) ................................................................... 49 Terminal and Reference Value for Power Window Main Switch/With Front Power Window (For RHD Models) ................................................................... 50 Terminal and Reference Value for Power Window Main Switch/With Front & Rear Power Window ...... 51 Work Flow ............................................................... 52 Trouble Diagnosis Symptom Chart ......................... 53 Check BCM Power Supply and Ground Circuit ...... 54 Check Power Window Main Switch Power Supply and Ground Circuit ................................................. 55 WITH FRONT POWER WINDOW ....................... 55 WITH FRONT & REAR POWER WINDOW ........ 56 Check Front Power Window Motor (Driver Side) Circuit .......................................................................... 58 WITH FRONT POWER WINDOW ....................... 58 WITH FRONT & REAR POWER WINDOW ........ 60 Check Front Power Window Motor (Passenger Side) Circuit ............................................................ 61 WITH FRONT POWER WINDOW ....................... 61 WITH FRONT & REAR POWER WINDOW ........ 65 Check Rear Power Window Motor RH Circuit ........ 68 Check Rear Power Window Motor LH Circuit ......... 71 Check Limit Switch Circuit (Driver Side) ................. 75 WITH FRONT POWER WINDOW ....................... 75 WITH RFONT & REAR POWER WINDOW ........ 78 Check Encoder Circuit (Driver Side) ....................... 80 WITH FRONT POWER WINDOW .......................80 WITH FRONT & REAR POWER WINDOW .........85 Check Power Window Lock Switch .........................88 FRONT DOOR GLASS AND REGULATOR .............89 Removal and Installation .........................................89 DOOR GLASS .....................................................89 REGULATOR ASSENBLY ...................................90 Inspection after Installation .....................................91 SYSTEM INITIALIZATION ...................................91 INSPECT THE FUNCTION OF THE ANTIPINCH SYSTEM. .................................................92 FITTING INSPECTION ........................................92 REAR DOOR GLASS AND REGULATOR ...............93 Removal and Installation .........................................93 DOOR GLASS .....................................................93 REGULATOR ASSEMBLY ...................................94 INSPECTION AFTER INSTALLATION ................95 DOOR MIRROR .........................................................96 Wiring Diagram — MIRROR — LHD Models (With Retract) ...................................................................96 Wiring Diagram — MIRROR — RHD Models (With Retract) ...................................................................98 Wiring Diagram — MIRROR — LHD Models (Without Retract) ........................................................... 100 Removal and Installation ....................................... 101 REMOVAL .......................................................... 101 INSTALLATION .................................................. 101 Disassembly and Assembly .................................. 102 DISASSEMBLY .................................................. 102 ASSEMBLY ........................................................ 103 INSIDE MIRROR ..................................................... 104 Removal and Installation ....................................... 104 REMOVAL .......................................................... 104 INSTALLATION .................................................. 104 Removal and Installation (With Rain Sensor) ....... 104 REMOVAL .......................................................... 104 INSTALLATION .................................................. 104 GW-2 PRECAUTIONS PRECAUTIONS PFP:00001 Precautions for Supplemental Restraint System (SRS) “AIR BAG” and “SEAT BELT PRE-TENSIONER” A BIS000MM The Supplemental Restraint System such as “AIR BAG” and “SEAT BELT PRE-TENSIONER”, used along with a front seat belt, helps to reduce the risk or severity of injury to the driver and front passenger for certain types of collision. Information necessary to service the system safely is included in the SRS and SB section of this Service Manual. WARNING: ● To avoid rendering the SRS inoperative, which could increase the risk of personal injury or death in the event of a collision which would result in air bag inflation, all maintenance must be performed by an authorized NISSAN/INFINITI dealer. ● Improper maintenance, including incorrect removal and installation of the SRS, can lead to personal injury caused by unintentional activation of the system. For removal of Spiral Cable and Air Bag Module, see the SRS section. ● Do not use electrical test equipment on any circuit related to the SRS unless instructed to in this Service Manual. SRS wiring harnesses can be identified by yellow and/or orange harnesses or harness connectors. Maintenance Information B C D E F BIS0016I If any of following part is replaced, always replace with new* one. If it's not (or fail to do so), the electrical system may not be operated properly. *: New one means a virgin control unit that has never been energized on-board. G RHD MODELS H ● ● ● ● ● ● BCM (Models without Intelligent Key system) Intelligent Key unit (Models with Intelligent Key system) ECM IPDM E/R Combination meter EPS control unit GW J LHD MODELS ● ● ● BCM (Models without Intelligent Key system) Intelligent Key unit (Models with Intelligent Key system) ECM Precautions for Procedures without Cowl Top Cover K L BIS000MN When performing the procedure after removing cowl top cover, cover the lower end of windshield with urethane, etc. M PIIB3706J Precautions ● ● ● ● BIS000MO When removing or disassembling any part, be careful not to damage or deform it. Protect parts, which may get in the way with cloth. When removing parts with a screwdriver or other tool, protect parts by wrapping them with vinyl or tape. Keep removed parts protected with cloth. If a clip is deformed or damaged, replace it. GW-3 PRECAUTIONS If an unreusable part is removed, replace it with a new one. Tighten bolts and nuts firmly to the specified torque. ● After re-assembly has been completed, make sure each part functions correctly. ● Remove stains in the following way. Water-soluble stains: Dip a soft cloth in warm water, and then squeeze it tightly. After wiping the stain, wipe with a soft dry cloth. Oil stain: Dissolve a synthetic detergent in warm water (density of 2 to 3% or less), dip the cloth, then clean off the stain with the cloth. Next, dip the cloth in fresh water and squeeze it tightly. Then clean off the detergent completely. Then wipe the area with a soft dry cloth. ● Do not use any organic solvent, such as thinner or benzine. ● ● GW-4 WINDSHIELD GLASS WINDSHIELD GLASS Removal and Installation PFP:72712 A BIS000MP B C D E F G H GW J K L M MIIB1430E 1. Windshield molding 2. Windshield glass 4. Dam sealant 5. Sealant 6. 3. Clip Primer 7. Mirror base 8. Roof side outer panel 9. Body side outer panel 10. Rain sensor base REMOVAL 1. 2. 3. 4. Remove inside mirror. Refer to GW-104, "INSIDE MIRROR" Remove front pillar garnish. Refer to EI-26, "BODY SIDE TRIM" Remove headlining. Refer to EI-30, "HEADLINER" . Remove front wiper arm. Refer to WW-42, "Removal and Installation of Front Wiper Arms, Adjustment of Wiper Arms Stop Location" GW-5 WINDSHIELD GLASS 5. Remove cowl top cover. Refer to EI-12, "COWL TOP" . 6. Apply a protective tape around the windshield glass to protect the painted surface from damage. 7. Remove glass using piano wire or power cutting tool A and an inflatable pump bag B. NOTE: If a windshield glass will be reused, mark the body and the glass with mating marks. WARNING: When cutting the glass from the vehicle, always wear safety glasses and heavy gloves to help prevent glass splinters from entering your eyes or cutting your hands. CAUTION: ● When a windshield glass is reused, do not use a cutting knife or power cutting tool. ● Be careful not to scratch the glass when removing. ● Do not set or stand the glass on its edge. Small chips may develop into cracks. PIIB5779E 8. Remove the windshield glass, using suction lifter. INSTALLATION The dam rubber should be installed in position. ● Use a genuine Nissan Urethane Adhesive Kit (if available) or equivalent and follow the instructions furnished with it. ● While the urethane adhesive is curing, open a door window. This will prevent the glass from being forced out by passenger compartment air pressure when a door is closed. ● The fastener and the molding must be installed securely so that it is in position and leaves no gap. Install the moldings in order of lower to upper corner, connect joint, and then corner to center. ● Inform the customer that the vehicle should remain stationary until the urethane adhesive has completely cured (preferably 24 hours). Curing time varies with temperature and humidity. WARNING: ● Keep heat and open flames away as primers and adhesive are flammable. ● The materials contained in the kit are harmful if swallowed, and may irritate skin and eyes. Avoid contact with the skin and eyes. ● Use in an open, well ventilated location. Avoid breathing the vapors. They can be harmful if inhaled. If affected by vapor inhalation, immediately move to an area with fresh air. ● Driving the vehicle before the urethane adhesive has completely cured may affect the performance of the windshield in case of an accident. CAUTION: ● Do not use an adhesive which is past its usable term. Shelf life of this product is limited to six months after the date of manufacture. Carefully adhere to the expiration or manufacture date printed on the box. ● Keep primers and adhesive in a cool, dry place. Ideally, they should be stored in a refrigerator. ● Do not leave primers or adhesive cartridge unattended with their caps open or off. ● The vehicle should not be driven for at least 24 hours or until the urethane adhesive has completely cured. Curing time varies depending on temperature and humidity. The curing time will increase under lower temperature and lower humidity. ● Repairing Water Leaks Leaks can be repaired without removing and reinstalling glass. GW-6 WINDSHIELD GLASS If water is leaking between the urethane adhesive material and body or glass, determine the extent of leakage. This can be done by applying water to the windshield area while pushing glass outward. To stop the leak, apply primer (if necessary) and then urethane adhesive to the leak point. A B C D E F G H GW J K L M GW-7 SIDE WINDOW GLASS SIDE WINDOW GLASS Removal and Installation PFP:83300 BIS000MQ MIIB1431E 1. Side window glass 2. Sealant 3. Primer 4. Body side outer panel 5. Spacer 6. Clip REMOVAL 1. Remove rear pillar finisher. Refer to EI-26, "BODY SIDE TRIM" 2. Apply a protective tape around the side window glass to protect the painted surface from damage. Remove side window glass using piano wire or power cutting tool and an inflatable pump bag. WARNING: When cutting the glass from the vehicle, always wear safety glasses and heavy gloves to help prevent glass splinters from entering your eyes or cutting your hands. CAUTION: ● Be careful not to scratch the glass when removing. ● Do not set or stand the glass on its edge. Small chips may develop into cracks. INSTALLATION ● Use a genuine Nissan Urethane Adhesive Kit (if available) or equivalent and follow the instructions furnished with it. GW-8 SIDE WINDOW GLASS While the urethane adhesive is curing, open a door window. This will prevent the glass from being forced out by passenger room air pressure when a door is closed. ● The molding must be installed securely so that it is in position and leaves no gap. ● Inform the customer that the vehicle should remain stationary until the urethane adhesive has completely cured (preferably 24 hours). Curing time varies with temperature and humidity. WARNING: ● Keep heat and open flames away as primers and adhesive are flammable. ● The materials contained in the kit are harmful if swallowed, and may irritate skin and eyes. Avoid contact with the skin and eyes. ● Use in an open, well ventilated location. Avoid breathing the vapors. They can be harmful if inhaled. If affected by vapor inhalation, immediately move to an area with fresh air. ● Driving the vehicle before the urethane adhesive has completely cured may affect the performance of the side window in case of an accident. CAUTION: ● Do not use an adhesive which is past its usable term. Shelf life of this product is limited to six months after the date of manufacture. Carefully adhere to the expiration or manufacture date printed on the box. ● Keep primers and adhesive in a cool, dry place. Ideally, they should be stored in a refrigerator. ● Do not leave primers or adhesive cartridge unattended with their caps open or off. ● The vehicle should not be driven for at least 24 hours or until the urethane adhesive has completely cured. Curing time varies depending on temperature and humidities. The curing time will increase under lower temperature and lower humidity. ● Repairing Water Leaks A B C D E F G H Leaks can be repaired without removing and reinstalling glass. If water is leaking between the urethane adhesive material and body or glass, determine the extent of leakage. This can be done by applying water to the side window area while pushing glass outward. GW To stop the leak, apply primer (if necessary) and then urethane adhesive to the leak point. J K L M GW-9 BACK DOOR WINDOW GLASS BACK DOOR WINDOW GLASS Removal and Installation PFP:90300 BIS000MR MIIB1432E 1. Back door window molding 2. Back door window glass 3. Clip 4. Spacer 5. Sealant 6. Primer 7. Back door outer panel REMOVAL 1. 2. 3. Remove back door finisher inner. Refer to EI-22, "BACK DOOR TRIM" . Remove rear wiper arm. Refer to WW-69, "Removal and Installation of Rear Wiper Arm, Adjustment of Wiper Arm Stop Location" Apply protective tape around windshield glass to protect the painted surface from damage. GW-10 BACK DOOR WINDOW GLASS 4. After removing molding, remove glass using cutting knife or power cutting tool and an inflatable pump bag. A B C D PIIB0908E 5. NOTE: If a back door window glass is to be reused, mark the body and the glass with mating marks. WARNING: When cutting the glass from the vehicle, always wear safety glasses and heavy gloves to help prevent glass splinters from entering your eyes or cutting your hands. CAUTION: ● When a rear window glass is reused, do not use a cutting knife or power cutting tool. ● Be careful not to scratch the glass when removing. ● Do not set or stand the glass on its edge. Small chips may develop into cracks. Remove the back door window glass, using suction liter. E F G H INSTALLATION Use a genuine Nissan Urethane Adhesive Kit (if available) or equivalent and follow the instructions furnished with it. GW ● While the urethane adhesive is curing, open a door window. This will prevent the glass from being forced out by passenger room air pressure when a door is closed. ● The molding must be installed securely so that it is in position and leaves no gap. J ● Inform the customer that the vehicle should remain stationary until the urethane adhesive has completely cured (preferably 24 hours). Curing time varies with temperature and humidity. WARNING: K ● Keep heat and open flames away as primers and adhesive are flammable. ● The materials contained in the kit are harmful if swallowed, and may irritate skin and eyes. Avoid contact with the skin and eyes. L ● Use in an open, well ventilated location. Avoid breathing the vapors. They can be harmful if inhaled. If affected by vapor inhalation, immediately move to an area with fresh air. ● Driving the vehicle before the urethane adhesive has completely cured may affect the perforM mance of the back door window glass in case of an accident. CAUTION: ● Do not use an adhesive which is past its usable term. Shelf life of this product is limited to six months after the date of manufacture. Carefully adhere to the expiration or manufacture date printed on the box. ● Keep primers and adhesive in a cool, dry place. Ideally, they should be stored in a refrigerator. ● Do not leave primers or adhesive cartridge unattended with their caps open or off. ● The vehicle should not be driven for at least 24 hours or until the urethane adhesive has completely cured. Curing time varies depending on temperature and humidity. The curing time will increase under lower temperature and lower humidity. ● Repairing Water Leaks Leaks can be repaired without removing and reinstalling glass. If water is leaking between the urethane adhesive material and body or glass, determine the extent of leakage. This can be done by applying water to the side window area while pushing glass outward. To stop the leak, apply primer (if necessary) and then urethane adhesive to the leak point. GW-11 REAR WINDOW DEFOGGER REAR WINDOW DEFOGGER Component Parts and Harness Connector Location PFP:25350 BIS000MS MIIB1361E 1. BCM (Body Control Module) M57, M59 2. Rear Window defogger switch (Built in A/C auto amp.) M64, M65 (With auto A/C models) 4. Rear window defogger connector B49 5. IPDM E/R E11,E12 System Description 3. Rear Window defogger switch (Built in heater control panel) M62 (Without auto A/C models) BIS000MT The rear window defogger system is controlled by BCM (Body Control Module) and IPDM E/R (Intelligent Power Distribution Module Engine Room). The rear window defogger operates only for approximately 15 minutes. Power is at all times supplied ● through 15A fuse [No. 55, and 56, located in the IPDM E/R] ● to rear window defogger relay ● through 20A fuse [No. 61 (with gasoline engine) and 62, located in the fuse block (J/B)] ● to IPDM E/R ● through 40A fusible link [letter J , located in the fuse block (J/B)] ● to BCM terminal 74 and 79 ● through 10A fuse [No. 7, located in the fuse block (J/B)] ● to A/C auto amp terminal 1. With the ignition switch turned to ON or START position, Power is supplied ● through 10A fuse [No. 5, located in the fuse block (J/B)] ● to BCM terminal 24 ● to A/C auto amp terminal 17. Ground is supplied GW-12 REAR WINDOW DEFOGGER to BCM terminal 2 and 70 A through body grounds M21, and M66. ● to A/C auto amp terminal 10 (with auto A/C) ● to heater control panel terminal 8 (without auto A/C) B ● through body grounds M21 and M66. ● to internal CPU of IPDM E/R terminal 3 and 54 ● through body grounds E28 and E44. C When rear window defogger switch is turned to ON, Ground is supplied ● to BCM terminal 4 D ● through A/C auto amp terminal 14 (with auto A/C) ● through heater control panel terminal 3 (without auto A/C) ● through A/C auto amp terminal 10 (with auto A/C) E ● through heater control panel terminal 8 (without auto A/C) ● through body grounds M21 and M66. F Then rear window defogger switch is illuminated. Then BCM recognizes that rear window defogger switch is turned to ON. Then it sends rear window defogger switch signals to IPDM E/R via DATA LINE (CAN-H, CAN-L). When IPDM receives rear window defogger switch signals, G Ground is supplied ● to rear window defogger relay terminal ● through internal CPU of IPDM E/R terminal H ● through internal CPU of IPDM E/R and IPDM E/R terminal 54 ● through body grounds E28 and E44. GW and then rear window defogger relay is energized. When rear window defogger relay is turned ON, Power is supplied, J ● through rear window defogger relay terminals ● through IPDM E/R terminal 8 ● to rear window defogger terminal 1. K Rear window defogger is grounded. With power and ground supplied, rear window defogger filaments heat and defog the rear window. When rear window defogger relay is turned to ON, Power is supplied (with mirror defogger) L ● through rear window defogger relay terminal ● through IPDM E/R terminal 8 M ● through 10A fuse [No. 2, located in the fuse block (J/B)] ● to door mirror defogger (Driver side and passenger side) terminal 2. Door mirror defogger (Driver side and passenger side) terminal 3 is grounded through body grounds M21 and M66. With power and ground supplied, door mirror defogger filaments heat and defog the mirror. ● ● GW-13 REAR WINDOW DEFOGGER CAN Communication BIS000MU SYSTEM DESCRIPTION CAN (Controller Area Network) is a serial communication line for real time application. It is an on-vehicle multiplex communication line with high data communication speed and excellent error detection ability. Many electronic control units are equipped onto a vehicle, and each control unit shares information and links with other control units during operation (not independent). In CAN communication, control units are connected with 2 communication lines (CAN H line, CAN L line) allowing a high rate of information transmission with less wiring. Each control unit transmits/receives data but selectively reads required data only. CAN Communication Unit BIS000MV Refer to LAN-27, "CAN Communication Unit" . GW-14 REAR WINDOW DEFOGGER Schematic BIS000MW A B C D E F G H GW J K L M MIWA0670E GW-15 REAR WINDOW DEFOGGER Wiring Diagram — DEF — BIS000MX MIWA0671E GW-16 REAR WINDOW DEFOGGER A B C D E F G H GW J K L M MIWA0672E GW-17 REAR WINDOW DEFOGGER MIWA0673E GW-18 REAR WINDOW DEFOGGER Terminal and Reference Value for BCM BIS000MY A Terminal Wire color 2 B Ground W Rear window defogger switch signal 4 Item Signal Input/ Output Condition Voltage (V) (Approx.) — — 0 Input B When rear window defogger switch is pressed. 0 When rear window defogger switch is OFF. 5 Input/ Output 19 L CAN- H 24 O Ignition switch ON or START 39 Y CAN- L Input/ Output — — 70 B Ground — — 0 74 Y BAT power supply Input — Battery voltage 79 Y BAT power supply Input — Battery voltage Input — C Ignition switch (ON or START position) Battery voltage Terminal and Reference Value for IPDM E/R Condition Voltage (V) (Approx.) — — 0 When rear window defogger switch is ON. Battery voltage When rear window defogger switch is OFF. 0 Input/ Output — — — — 0 Input/ Output — — Wire color 3 B Ground (Power) 8 R Rear window defogger relay output signal Output 52 L CAN- H 54 B Ground (Signal) 58 Y CAN- L Item 4. 5. F H GW K BIS000N0 Check the symptom and customer's requests. Understand the outline of system. Refer to GW-12, "System Description" . According to the trouble diagnosis chart, repair or replace the cause of the malfunction. Refer to GW-20, "Trouble Diagnoses Symptom Chart" . Does rear window defogger operate normally? YES: GO TO 5, NO: GO TO 3. INSPECTION END. CONSULT-II Inspection Procedure BIS000N1 Inspection Item, Diagnosis Mode Description DATA MONITOR The input/output data of the BCM is displayed in real time. ACTIVE TEST The BCM sends a drive signal to electronic components to check their operation. Refer to GI-36, "CONSULT-II Start Procedure" . DATA MONITOR Display Item List Monitor item “Operation” REAR DEF SW G J Work Flow 1. 2. 3. E BIS000MZ Signal Input/ Output Terminal D — “ON / OFF” Content Displays “Press (ON) / others (OFF)” status determined with the rear window defogger switch. GW-19 L M REAR WINDOW DEFOGGER Monitor item “Operation” Content IGN ON SW “ON / OFF” Displays “IGN SW ON (ON) / OFF (OFF)” status determined with the ignition switch signal. ENGINE STATUS “STOP / STALL / RUN / CRA ” Displays “Engine stop (STOP) / engine stall (STALL) / engine running (RUN) / engine cranking (CRA) ” as judged from engine status. ACTIVE TEST Display Item List Test item Content REAR DEFOGGER Gives a drive signal to the rear window defogger to activate it. Trouble Diagnoses Symptom Chart ● BIS000N2 Check that other systems using the signal of the following systems operate normally. Symptom Diagnoses / service procedure Refer to page 1. Check BCM power supply and ground circuit. GW-21 2. Check IPDM E/R auto active test. PG-22 3. Check rear window defogger switch circuit (with auto A/C). GW-22 3. Check rear window defogger switch circuit (without auto A/C). GW-23 4. Check rear window defogger power supply circuit. GW-25 5. Replace IPDM E/ R. PG-37 1. Check BCM power supply and ground circuit. GW-21 2. Check IPDM E/R auto active test. PG-22 3. Check rear window defogger switch circuit (with auto A/C). GW-22 3. Check rear window defogger switch circuit (without auto A/C). GW-23 4. Check rear window defogger power supply circuit. GW-25 5. Check rear window defogger circuit. GW-26 6. Check filament. GW-30 7. Replace IPDM E/ R. PG-37 1. Check rear window defogger circuit. GW-26 2. Check filament. GW-30 Both of door mirror defoggers do not operated but rear window defogger operate. (With door mirror defogger) 1. Check door mirror defogger power supply circuit. GW-27 Driver side door mirror defogger does not operated. (With door mirror defogger) 1. Check driver side door mirror defogger circuit. GW-28 Passenger side door mirror defogger does not operated. (With door mirror defogger) 1. Check passenger side door mirror defogger circuit. GW-29 Rear window defogger and door mirror defogger do not operate. (With door mirror defogger) Rear window defogger does not operated. (without door mirror defogger) Rear window defogger does not operate but both of door mirror defoggers operate. (With door mirror defogger) GW-20 REAR WINDOW DEFOGGER Check BCM Power Supply and Ground Circuit BIS000N3 First perform the “SELF-DIAG RESULTS” in “BCM” with CONSULT-II, then perform the each trouble diagnosis of malfunction system indicated “SELF-DIAG RESULTS” of “BCM”, Refer to BCS-9, "CONSULT-II Function (BCM)" . 1. FUSE INSPECTION Check 10A fuse [No. 5, located in fuse block (J/B)] ● Check 40A fusible link (letter J located in the fuse and fusible link box). NOTE: Refer to GW-12, "Component Parts and Harness Connector Location" . OK or NG OK >> GO TO 2. NG >> If fuse is blown out, be sure to eliminate cause of malfunction before installing new fuse. Refer to PG-4, "POWER SUPPLY ROUTING CIRCUIT" . A B ● C D E 2. CHECK POWER SUPPLY CIRCUIT 1. 2. F Turn ignition switch ON. Check voltage between BCM connector M57, M59 terminal 24, 74, 79 and ground. 24 – Ground 74 – Ground 79 – Ground G :Battery voltage. :Battery voltage. :Battery voltage. H OK or NG OK >> GO TO 3. NG >> Check BCM power supply circuit for open or short. GW MIIB0667E J 3. CHECK GROUND CIRCUIT 1. 2. 3. K Turn ignition switch OFF. Disconnect BCM connector. Check continuity between BCM connector M57, M59 terminal 2, 70 and ground. 2 – Ground 70 – Ground L :Continuity should exist. :Continuity should exist. M OK or NG OK >> Power supply and ground circuit is OK. NG >> Check BCM ground circuit for open or short. MIIB0093E GW-21 REAR WINDOW DEFOGGER Check Rear Window Defogger Switch Circuit / With Auto A/C BIS000N4 1. CHECK REAR WINDOW DEFOGGER SWITCH OPERATION With CONSULT-II Check (“REAR DEF SW”, “IGN ON SW”) in DATA MONITOR mode with CONSULT-II. Refer to GW-19 . When engine is running ENGINE STATUS :RUN When rear defogger switch is turned to ON REAR DEF SW :ON When ignition switch is turned to ON IGN ON SW :ON MKIB0549E Without CONSULT-II 1. Turn ignition switch ON. 2. Check voltage between BCM connector ground. Connector Terminal (Wire color) (+) M57 Voltage (V) (Approx.) Condition (–) 4 Ground Rear window defogger switch is pressed. 0 Rear window defogger switch is OFF. 5 OK or NG OK >> Rear window defogger switch check is OK. NG >> GO TO 2. MIIB0094E 2. CHECK REAR WINDOW DEFOGGER SWITCH CIRCUIT HARNESS CONTINUITY 1. 2. 3. Turn ignition switch OFF. Disconnect BCM and A/C auto amp connector. Check continuity between BCM connector and A/C auto amp connector. A 4. B Continuity BCM connector Terminal A/C auto amp connector Terminal M57 4 M64 14 Yes Check continuity between BCM connector and ground. A Continuity BCM connector Terminal M57 4 Ground No OK or NG OK >> GO TO 3. NG >> Repair or replace harness between BCM and A/C auto amp. GW-22 MIIB1362E REAR WINDOW DEFOGGER 3. CHECK BCM OUTPUT SIGNAL 1. 2. 3. A Connect BCM connector. Turn ignition switch ON. Check voltage between BCM connector M57 terminal 4 and ground. 4 – Ground B :Approx. 5 C OK or NG OK >> Replace rear window defogger switch. Refer to ATC112, "Removal and Installation of Controller" NG >> Replace BCM. D MIIB0094E Check Rear Window Defogger Switch Circuit / Without Auto A/C E BIS000N5 1. CHECK REAR WINDOW DEFOGGER SWITCH OPERATION F With CONSULT-II Check (“REAR DEF SW”, “IGN ON SW”) in DATA MONITOR mode with CONSULT-II. Refer to GW-19 . G When engine is running ENGINE STATUS :RUN When rear defogger switch is turned to ON REAR DEF SW :ON When ignition switch is turned to ON IGN ON SW :ON H GW MKIB0549E 1. 2. Without CONSULT-II Turn ignition switch ON. Check voltage between BCM connector ground. Terminal (Wire color) Connector M57 (+) 4 (–) Ground K Voltage (V) (Approx.) Condition J Rear window defogger switch is pressed. 0 Rear window defogger switch is OFF. 5 L M OK or NG OK >> Rear window defogger switch check is OK. NG >> GO TO 2. GW-23 MIIB0094E REAR WINDOW DEFOGGER 2. CHECK REAR WINDOW DEFOGGER SWITCH CIRCUIT HARNESS CONTINUITY 1. 2. 3. Turn ignition switch OFF. Disconnect BCM and heater control panel connector. Check continuity between BCM connector and heater control panel connector. A 4. B BCM connector Terminal Heater control panel connector Terminal M57 4 M62 3 Continuity Yes Check continuity between BCM connector and ground A BCM connector Terminal M57 4 Ground Continuity No MIIB1363E OK or NG OK >> GO TO 3. NG >> Repair or replace harness between BCM and heater control panel. 3. CHECK BCM OUTPUT SIGNAL 1. 2. 3. Connect BCM connector. Turn ignition switch ON. Check voltage between BCM connector M57 terminal 4 and ground. 4 – Ground :Approx. 5 OK or NG OK >> Replace heater control panel. Refer to MTC-62, "Removal and Installation" . NG >> Replace BCM. MIIB0094E GW-24 REAR WINDOW DEFOGGER Check Rear Window Defogger Power Supply Circuit BIS000N6 1. CHECK FUSE A Check if any of the following fuses for IPDM E/R are blown. COMPONENT PARTS AMPERE FUSE NO. 15A #55 15A #56 20A #61 20A #62 IPDM E/R B C D NOTE: Refer to GW-12, "Component Parts and Harness Connector Location" . OK or NG OK >> GO TO 2. NG >> If fuse is blown, be sure to eliminate cause of malfunction before installing new fuse, refer to GW12, "Component Parts and Harness Connector Location" . E F 2. CHECK REAR WINDOW DEFOGGER RELAY Check rear window defogger relay in “ACTIVE TEST” mode with CONSULT-II. Refer to G Do you hear of the operation sound of rear window defogger relay. OK or NG OK >> GO TO 3. NG >> Replace IPDM E/R. H GW PIIA0208E J 3. CHECK REAR WINDOW DEFOGGER RELAY OUTPUT SIGNAL 1. 2. K Turn rear window defogger switch ON. Check voltage between IPDM E/R connector E11 terminal 8 and ground. 8 – Ground : Battery voltage L OK or NG OK >> Rear window defogger power supply circuit check is OK. NG >> Check connector for damage and loose connection. M MIIB0096E GW-25 REAR WINDOW DEFOGGER Check Rear Window Defogger Circuit BIS000N7 1. CHECK REAR WINDOW DEFOGGER POWER SUPPLY CIRCUIT 1. 2. 3. 4. Turn ignition switch OFF. Disconnect rear window defogger connector. Turn ignition switch ON. Check voltage between rear window defogger connector and ground. Terminal (Wire color) Connector B49 (+) 1 (–) Condition Voltage (V) (Approx.) Rear window defogger switch ON. Battery voltage Rear window defogger switch OFF. 0 Ground OK or NG OK >> GO TO 2. NG >> Repair or replace harness between IPDM E/R and rear window defogger. PIIA4234E 2. CHECK HARNESS CONTINUITY 1. 2. 3. Turn ignition switch OFF. Disconnect IPDM E/R connector. Check continuity between IPDM E/R connector E11 terminal 8 and rear window defogger connector B49 terminal 1. 8–1 4. :Continuity should exist. Check continuity between IPDM E/R connector E11 terminal 8 and ground. 8 – Ground :Continuity should not exist. OK or NG OK >> Check the condition of the harness and the connector. NG >> Repair or replace harness. MIIB0097E GW-26 REAR WINDOW DEFOGGER Check Door Mirror Defogger Power Supply Circuit BIS000N8 1. CHECK FUSE A Check if any of the following fuse for Fuse block (J/B) are blown. COMPONENT PARTS AMPERE FUSE NO. Fuse block (J/B) 10A #2 B NOTE: Refer to GW-12, "Component Parts and Harness Connector Location" . C OK or NG OK >> GO TO 2. NG >> If fuse is blown, be sure to eliminate cause of malfunction before installing new fuse, refer to GW12, "Component Parts and Harness Connector Location" . D 2. CHECK DOOR MIRROR DEFOGGER POWER SUPPLY CIRCUIT 1 E 1. 2. F Turn ignition switch ON. Check voltage between door mirror connector and ground. Door mirror connector D5 (driver side) D25 (passenger side) Terminal (+) Voltage (V) (Approx.) Condition (–) 2 Ground 2 Rear window defogger switch ON Battery voltage Rear window defogger switch OFF 0 OK or NG OK >> GO TO 3. NG >> Check harness between IPDM E/R and door mirror. G H MIIB1364E GW 3. CHECK DOOR MIRROR DEFOGGER GROUND CIRCUIT 1. 2. 3. J Turn ignition switch OFF. Disconnect door mirror connector. Check continuity between door mirror connector and ground. A Door mirror connector D5 (driver side) K Continuity Terminal L Ground 3 Yes D25 (passenger side) M OK or NG OK >> INSPECTION END. NG >> Repair or replace harness. MIIB1365E GW-27 REAR WINDOW DEFOGGER Check Driver Side Door Mirror Defogger Circuit BIS000N9 1. CHECK DOOR MIRROR DEFOGGER POWER SUPPLY CIRCUIT 1. 2. Turn ignition switch ON. Check voltage between door mirror (driver side) connector and ground. Door mirror (driver side) connector Terminal (+) D5 2 Voltage (V) (Approx.) Condition (–) Ground Rear window defogger switch ON Battery voltage Rear window defogger switch OFF 0 OK or NG OK >> GO TO 2. NG >> Repair or replace harness between fuse block (J/B) and door mirror (driver side). MIIB1364E 2. CHECK DOOR MIRROR DEFOGGER GROUND CIRCUIT 1. 2. 3. Turn ignition switch OFF. Disconnect door mirror (driver side) connector. Check continuity between door mirror (driver side) connector and ground. Door mirror connector Terminal D5 (driver side) 3 Ground Continuity Yes OK or NG OK >> GO TO 3 NG >> Repair or replace harness between door mirror (driver side) and ground. MIIB1365E 3. CHECK DOOR MIRROR DEFOGGER Check continuity between each door mirror connector terminal. Terminal Door mirror connector D5 (driver side) Continuity (+) (–) 2 3 Yes OK or NG OK >> Check the condition of the harness and the connector. NG >> Replace door mirror (driver side). MIIB1366E GW-28 REAR WINDOW DEFOGGER Check Passenger Side Door Mirror Defogger Circuit BIS000NA 1. CHECK DOOR MIRROR DEFOGGER POWER SUPPLY CIRCUIT 1. 2. A Turn ignition switch ON. Check voltage between door mirror (passenger side) connector and ground. Door mirror (passenger side) connector Terminal (+) D25 2 Voltage (V) (Approx.) Condition (–) Ground B Rear window defogger switch ON Battery voltage Rear window defogger switch OFF 0 C D OK or NG OK >> GO TO 2. NG >> Repair or replace harness between fuse block (J/B) and door mirror (passenger side). E MIIB1364E F 2. CHECK DOOR MIRROR DEFOGGER GROUND CIRCUIT 1. 2. 3. Turn ignition switch OFF. Disconnect door mirror (passenger side) connector. Check continuity between door mirror (passenger side) connector and ground. G H A Continuity Door mirror connector Terminal D5 (passenger side) 3 Ground GW Yes OK or NG OK >> GO TO 3 NG >> Repair or replace harness between door mirror (passenger side) and ground. J MIIB1365E K 3. CHECK DOOR MIRROR DEFOGGER L Check continuity between each door mirror connector terminal. Terminal Door mirror connector D5 (passenger side) Continuity (+) (–) 2 3 M Yes OK or NG OK >> Check the condition of the harness and the connector. NG >> Replace door mirror (passenger side). MIIB1366E GW-29 REAR WINDOW DEFOGGER Filament Check 1. BIS000NB When measuring voltage, wrap tin foil around the top of the negative probe. Then press the foil against the wire with your finger. SEL122R 2. Attach probe circuit tester (in Volt range) to middle portion of each filament. SEL263 3. 4. If a filament is burned out, circuit tester registers 0 or battery voltage. To locate burned out point, move probe to left and right along filament. Test needle will swing abruptly when probe passes the point. SEL265 GW-30 REAR WINDOW DEFOGGER Filament Repair BIS000NC A REPAIR EQUIPMENT ● ● ● ● ● ● Conductive silver composition (Dupont No. 4817 or equivalent) Ruler 30 cm (11.8 in) long Drawing pen Heat gun Alcohol Cloth B C REPAIRING PROCEDURE 1. 2. 3. D Wipe broken heat wire and its surrounding area clean with a cloth dampened in alcohol. Apply a small amount of conductive silver composition to tip of drawing pen. Shake silver composition container before use. Place ruler on glass along broken line. Deposit conductive silver composition on break with drawing pen. Slightly overlap existing heat wire on both sides [preferably 5 mm (0.20 in)] of the break. E F PIIA0215E 4. After repair has been completed, check repaired wire for continuity. This check should be conducted 10 minutes after silver composition is deposited. Do not touch repaired area while test is being conducted. G H GW J SEL012D K 5. Apply a constant stream of hot air directly to the repaired area for approximately 20 minutes with a heat gun. A minimum distance of 3 cm (1.2 in) should be kept between repaired area and hot air outlet. If a heat gun is not available, let the repaired area dry for 24 hours. L M SEL013D GW-31 POWER WINDOW SYSTEM POWER WINDOW SYSTEM Component Parts and Harness Connector Location PFP:25401 BIS000UI MIIB1426E 1. BCM M57, M59 (View with instrument upper panel removed) 2. Power window main switch D8, D9 4. Front power window motor (driver side) D4 5. Rear power window motor RH D64 3. Rear power window switch RH D63 System Description (With Front Power Window) Power is supplied at all times ● to BCM terminal 74 and 79 ● through 40A fusible link (letter J , located in the fuse and fusible link box), and ● to power window main switch terminal 5 (LHD models) or 6 (RHD models) ● through 40A fusible link (letter J , located in the fuse and fusible link box). Ground is supplied at all times ● to BCM terminal 2 and 70 ● through body grounds M21 and M66. ● to power window main switch terminal 12 ● through body grounds M21 and M66. With ignition switch in ON or START position, power is supplied ● to BCM terminal 24 ● through 10A fuse [No. 5, located in the fuse block (J/B)], and ● to power window main switch terminal 1, front power window switch (passenger side) terminal 1 ● through BCM terminal 78. DRIVER DOOR Window Up When the driver side switch in the power window main switch is operated in the up position, Power is supplied ● to front power window motor (driver side) terminal 3 ● through power window main switch terminal 6 (LHD models) or 4 (RHD models) ● through CPU of power window main switch. Ground is supplied ● to front power window motor (driver side) terminal 4 ● through power window main switch terminal 7 GW-32 BIS000UJ POWER WINDOW SYSTEM through CPU of power window main switch. Then, the motor raises the window until the switch is released. ● A Window Down When the driver side switch in the power window main switch is operated in the down position Power is supplied ● to front power window motor (driver side) terminal 4 ● through power window main switch terminal 7. ● through CPU of power window main switch. Ground is supplied ● to front power window motor (driver side) terminal 3 ● through power window main switch terminal 6 (LHD models) or 4 (RHD models). ● through CPU of power window main switch. Then, the motor lowers the window until the switch is released. PASSENGER DOOR [FRONT POWER WINDOW SWITCH (PASSENGER SIDE) OPERATION] Window Up When the front power window switch (passenger side) is operated in the up position, Power is supplied ● to front power window motor (passenger side) terminal 2 ● through front power window switch (passenger side) terminal 5 and 1 ● through BCM terminal 78. Ground is supplied ● to front power window motor (passenger side) terminal 1 ● through front power window switch (passenger side) terminal 4 and 3 ● through power window main switch terminal 9 (LHD models) or 5 (RHD models) ● through power window lock switch ● through power window main switch terminal 12 ● through body ground M21 and M66. Then, the motor raises the window until the switch is released. B C D E F G H GW J K Window Down When the front power window switch (passenger side) is operated in the down position, Power is supplied ● to front power window motor (passenger side) terminal 1 ● through front power window switch (passenger side) terminal 4 and 1 ● through BCM terminal 78. Ground is supplied ● to front power window motor (passenger side) terminal 2 ● through front power window switch (passenger side) terminal 5. ● through power window main switch terminal 2 (LHD models) or 13 (RHD models) ● through power window lock switch ● through power window main switch terminal 12 ● through body ground M21 and M66. Then, the motor lowers the window until the switch is released. PASSENGER DOOR (POWER WINDOW MAIN SWITCH OPERATION) Window Up When the passenger side switch in the power window main switch is operated in the up position Power is supplied ● to front power window motor (passenger side) terminal 2 ● through front power window switch (passenger side) terminal 5 and 2 GW-33 L M POWER WINDOW SYSTEM through power window main switch terminal 1 and 2 (LHD models) or 13 (RHD models) through BCM terminal 78. Ground is supplied ● to front power window motor (passenger side) terminal 1 ● through front power window switch (passenger side) terminal 4 and 3 ● through power window main switch terminal 9 (LHD models) or 5 (RHD models) ● through power window lock switch ● through power window main switch terminal 12 ● through body ground M21 and M66. Then, the motor raises the window until the switch is released. ● ● Window Down When the passenger side switch in the power window main switch is operated in the down position, Power is supplied ● to front power window motor (passenger side) terminal 1 ● through front power window switch (passenger side) terminal 4 and 3 ● through power window main switch terminal 1 and 9 (LHD models) or 5 (RHD models) ● through BCM terminal 78. Ground is supplied ● to front power window motor (passenger side) terminal 2 ● through front power window switch (passenger side) terminal 5 and 2 ● to power window main switch terminal 2 (LHD models) or 13 (RHD models). ● through power window lock switch ● through power window main switch terminal 12 ● through body ground M21 and M66. Then, the motor raises the window until the switch is released. AUTO OPERATION The power window AUTO feature enables the driver to open or close the window without holding the window switch in the down or up position. POWER WINDOW LOCK The power window lock is designed to lock operation of all windows except for driver door window. When power window lock switch is in LOCK position, ground of passenger and rear power window switches in the power window main switch are disconnected. This prevents the power window motors from operating. ANTI-PINCH SYSTEM Power window main switch monitors the power window motor operation and the power window position (full closed or other) for driver side power window by the signals from encoder and limit switch in front power window motor (driver side). When power window main switch detects interruption during the following close operation, ● automatic close operation when ignition switch is in the “ON” position power window main switch controls power window motor (driver side) for open and the power window will be lowered about 150 mm (5.91 in). INITIALIZATION Perform the initialization when the following operations are performed or when the auto up operation is not performed. Refer to GW-91, "SYSTEM INITIALIZATION" . ● When the power supply to the power window main switch or power window motor is cut off by the removal of battery terminal or the battery fuse is blown. ● Disconnection and connection of power window main switch harness connector. ● Removal and installation of regulator assembly. ● Removal and installation of motor from regulator assembly. ● Operation of regulator assembly as an independent unit. GW-34 POWER WINDOW SYSTEM ● ● ● Removal and installation of glass. Removal and installation of door glass run. CAUTION: The following operations are not performed under the condition that the initialization is not performed yet. Auto up operation System Description (With Front & Rear Power Window) BIS000V0 Power is supplied at all times ● to BCM terminal 74 and 79 ● through 40A fusible link (letter J , located in the fuse and fusible link box), and ● to power window main switch terminal 19 ● through 40A fusible link (letter J , located in the fuse and fusible link box). Ground is supplied at all times ● to BCM terminal 2 and 70 ● through body grounds M21 and M66. ● to power window main switch terminal 17 ● through body grounds M21 and M66. With ignition switch in ON or START position, power is supplied ● to BCM terminal 24 ● through 10A fuse [No. 5, located in the fuse block (J/B)], and ● to power window main switch terminal 10, front power window switch (passenger side) terminal 1 and rear power window switch (RH and LH) terminal 1. ● trough BCM terminal 78 A B C D E F G H GW DRIVER DOOR Window Up When the driver side switch in the power window main switch is operated in the up position, Power is supplied ● to front power window motor (driver side) terminal 3 ● through power window main switch terminal 16 ● through CPU of power window main switch. Ground is supplied ● to front power window motor (driver side) terminal 4 ● through power window main switch terminal 12 ● through CPU of power window main switch. Then, the motor raises the window until the switch is released. Window Down When the driver side switch in the power window main switch is operated in the down position Power is supplied ● to front power window motor (driver side) terminal 4 ● through power window main switch terminal 12. ● through CPU of power window main switch. Ground is supplied ● to front power window motor (driver side) terminal 3 ● through power window main switch terminal 16. ● through CPU of power window main switch. Then, the motor lowers the window until the switch is released. GW-35 J K L M POWER WINDOW SYSTEM PASSENGER DOOR [FRONT POWER WINDOW SWITCH (PASSENGER SIDE) OPERATION] Window Up When the front power window switch (passenger side) is operated in the up position, Power is supplied ● to front power window motor (passenger side) terminal 2 ● through front power window switch (passenger side) terminal 5 and 1 ● through BCM terminal 78. Ground is supplied ● to front power window motor (passenger side) terminal 1 ● through front power window switch (passenger side) terminal 4 and 3 ● through power window main switch terminal 11 ● through power window lock switch ● through power window main switch terminal 17 ● through body ground M21 and M66. Then, the motor raises the window until the switch is released. Window Down When the front power window switch (passenger side) is operated in the down position, Power is supplied ● to front power window motor (passenger side) terminal 1 ● through front power window switch (passenger side) terminal 4 and 1 ● through BCM terminal 78. Ground is supplied ● to front power window motor (passenger side) terminal 2 ● through front power window switch (passenger side) terminal 5. ● through power window main switch terminal 8 ● through power window lock switch ● through power window main switch terminal 17 ● through body ground M21 and M66. Then, the motor lowers the window until the switch is released. PASSENGER DOOR (POWER WINDOW MAIN SWITCH OPERATION) Window Up When the passenger side switch in the power window main switch is operated in the up position Power is supplied ● to front power window motor (passenger side) terminal 2 ● through front power window switch (passenger side) terminal 5 and 2 ● through power window main switch terminal 8 and 10 ● through BCM terminal 78. Ground is supplied ● to front power window motor (passenger side) terminal 1 ● through front power window switch (passenger side) terminal 4 and 3 ● through power window main switch terminal 11 ● through power window lock switch ● through power window main switch terminal 17 ● through body ground M21 and M66. Then, the motor raises the window until the switch is released. Window Down When the passenger side switch in the power window main switch is operated in the down position, Power is supplied ● to front power window motor (passenger side) terminal 1 GW-36 POWER WINDOW SYSTEM through front power window switch (passenger side) terminal 4 and 3 through power window main switch terminal 11 and 10 ● through BCM terminal 78. Ground is supplied ● to front power window motor (passenger side) terminal 2 ● through front power window switch (passenger side) terminal 5 and 2 ● to power window main switch terminal 8. ● through power window lock switch ● through power window main switch terminal 17 ● through body ground M21 and M66. Then, the motor raises the window until the switch is released. ● ● REAR DOOR (RH OR LH) [REAR POWER WINDOW SWITCH (RH OR LH) OPERATION] Window Up When the rear power window switch (RH or LH) is operated in the up position, Power is supplied ● to rear power window motor (RH or LH) terminal 2 ● through rear power window switch (RH or LH) terminal 5 and 1 ● through BCM terminal 78. Ground is supplied ● to rear power window motor (RH or LH) terminal 1 ● through rear power window switch (RH or LH) terminal 4 and 3 ● through power window main switch terminal 5 (RH) or 3 (LH). ● through power window lock switch ● through power window main switch terminal 17 ● through body ground M21 and M66. Then, the motor raises the window until the switch is released. A B C D E F G H GW J Window Down When the rear power window switch (RH or LH) is operated in the down position, Power is supplied ● to rear power window motor (RH or LH) terminal 1 ● through rear power window switch (RH or LH) terminal 4 and 1 ● through BCM terminal 78. Ground is supplied ● to rear power window motor (RH or LH) terminal 2 ● through rear power window switch (RH or LH) terminal 5 and 2 ● through power window main switch terminal 7 (RH) or 1 (LH). ● through power window lock switch ● through power window main switch terminal 17 ● through body ground M21 and M66. Then, the motor lowers the window until the switch is released. REAR DOOR (RH OR LH) (POWER WINDOW MAIN SWITCH OPERATION) Window Up When the rear RH or LH switch in the power window main switch is operated in the up position, Power is supplied ● to rear power window motor (RH or LH) terminal 2 ● through rear power window switch (RH or LH) terminal 5 and 2 ● through power window main switch terminal 7 (RH) or 1 (LH). ● through power window main switch terminal 10 GW-37 K L M POWER WINDOW SYSTEM ● through BCM terminal 78. Ground is supplied ● to rear power window motor (RH or LH) terminal 1 ● through rear power window switch (RH or LH) terminal 4 and 3 ● through power window main switch terminal 5 (RH) or 3 (LH) ● through power window lock switch ● through power window main switch terminal 17 ● through body ground M21 and M66. Then, the motor raises the window until the switch is released. Window Down When the rear RH or LH switch in the power window main switch is operated in the down position, Power is supplied ● to rear power window motor (RH or LH) terminal 1 ● through rear power window switch (RH or LH) terminal 4 and 3 ● through power window main switch terminal 5 (RH) or 3 (LH). ● through power window main switch terminal 10 ● through BCM terminal 78. Ground is supplied ● to rear power window motor (RH or LH) terminal 2 ● through rear power window switch (RH or LH) terminal 5 and 2 ● to power window main switch terminal 7 (RH) or 1 (LH) ● through power window lock switch ● through power window main switch terminal 17 ● through body ground M21 and M66. Then, the motor raises the window until the switch is released. AUTO OPERATION The power window AUTO feature enables the driver to open or close the window without holding the window switch in the down or up position. POWER WINDOW LOCK The power window lock is designed to lock operation of all windows except for driver door window. When power window lock switch is in LOCK position, ground of passenger and rear power window switches in the power window main switch are disconnected. This prevents the power window motors from operating. ANTI-PINCH SYSTEM Power window main switch monitors the power window motor operation and the power window position (full closed or other) for driver side power window by the signals from encoder and limit switch in front power window motor (driver side). When power window main switch detects interruption during the following close operation, ● automatic close operation when ignition switch is in the “ON” position power window main switch controls power window motor (driver side) for open and the power window will be lowered about 150 mm (5.91 in). INITIALIZATION Perform the initialization when the following operations are performed or when the auto up operation is not performed. Refer to GW-91, "SYSTEM INITIALIZATION" . ● When the power supply to the power window main switch or power window motor is cut off by the removal of battery terminal or the battery fuse is blown. ● Disconnection and connection of power window main switch harness connector. ● Removal and installation of regulator assembly. ● Removal and installation of motor from regulator assembly. ● Operation of regulator assembly as an independent unit. GW-38 POWER WINDOW SYSTEM ● ● ● Removal and installation of glass. Removal and installation of door glass run. CAUTION: The following operations are not performed under the condition that the initialization is not performed yet. Auto up operation A B C D E F G H GW J K L M GW-39 POWER WINDOW SYSTEM Schematic/With Front Power Window BIS000UK MIWA0674E GW-40 POWER WINDOW SYSTEM Wiring Diagram — WINDOW —/With Front Power Window BIS000UL A B C D E F G H GW J K L M MIWA0675E GW-41 POWER WINDOW SYSTEM MIWA0676E GW-42 POWER WINDOW SYSTEM A B C D E F G H GW J K L M MIWA0677E GW-43 POWER WINDOW SYSTEM Schematic/With Front & Rear Power Window BIS000V1 MIWA0678E GW-44 POWER WINDOW SYSTEM Wiring Diagram — WINDOW —/With Front & Rear Power Window BIS000V2 A B C D E F G H GW J K L M MIWA0679E GW-45 POWER WINDOW SYSTEM MIWA0680E GW-46 POWER WINDOW SYSTEM A B C D E F G H GW J K L M MIWA0681E GW-47 POWER WINDOW SYSTEM MIWA0682E GW-48 POWER WINDOW SYSTEM Terminal and Reference Value for BCM BIS000UM A Terminal Wire color 2 B Signal input/output Item Ground — 24 O Ignition switch (ON or START) 70 B Ground (power) 74 Y Battery power supply (BCM) 78 L Power window power supply (IGN) Voltage [V] (Approx.) Condition Ignition switch ON Ignition switch (ON or START position) Input — 0 Battery voltage Ignition switch ON Input — Ignition switch (ON or START position) Output 0 Y Battery power supply (power window) Input — C Battery voltage Battery voltage Other than above 79 B D 0 Battery voltage Terminal and Reference Value for Power Window Main Switch/With Front Power Window (For LHD Models) E BIS000V4 Terminal Wire color 1 W 2 3 W G Item Rap signal Front power window motor (passenger side) UP signal Encoder power supply Signal input/output Input Condition Ignition switch ON Battery voltage Ignition switch OFF 0 When passenger side switch in power window main switch is operated in UP position. Output Output F Voltage [V] (Approx.) G Battery voltage Other than above (Power window lock switch is unlock position.) 0 Ignition switch ON 10 H GW J 4 W Encoder pulse signal Input When power window motor operates. K OCC3383D 5 W Battery power supply Input 6 R Front power window motor (driver side) UP signal Output When driver side switch in power window main switch is operated in UP position. Battery voltage Output When driver side switch in power window main switch is operated in DOWN position. Battery voltage When passenger side switch in power window main switch is operated in DOWN position. Battery voltage 7 9 11 GR W V Front power window motor (driver side) DOWN signal Front power window motor (passenger side) DOWN signal Limit switch signal Output Input — Battery voltage M Other than above (Power window lock switch is unlock position.) 0 Driver side door window is between fully-open position and just before fully-closed position (ON) 0 Driver side door window is between just before fully-closed position and fully-closed position (OFF) 5 GW-49 L POWER WINDOW SYSTEM Terminal Wire color 12 W 13 LG Signal input/output Condition Voltage [V] (Approx.) Ground — — 0 Limit switch and encoder ground — — 0 Item Terminal and Reference Value for Power Window Main Switch/With Front Power Window (For RHD Models) BIS000V3 Terminal Wire color 1 W Rap signal 2 G Encoder power supply 3 4 5 V R W Item Limit switch signal Front power window motor (driver side) UP signal Front power window motor (passenger side) DOWN signal Signal input/output Input Output Input Output Output 6 W Battery power supply Input 7 GR Front power window motor (driver side) DOWN signal Output 9 W Encoder pulse signal Input Condition Voltage [V] (Approx.) Ignition switch ON Battery voltage Ignition switch OFF 0 Ignition switch ON 10 Driver side door window is between fully-open position and just before fully-closed position (ON) 0 Driver side door window is between just before fully-closed position and fully-closed position (OFF) 5 When driver side switch in power window main switch is operated in UP position. Battery voltage When passenger side switch in power window main switch is operated in DOWN position. Battery voltage Other than above (Power window lock switch is unlock position.) — When driver side switch in power window main switch is operated in DOWN position. 0 Battery voltage Battery voltage When power window motor operates. OCC3383D 11 LG Limit switch and encoder ground — — 0 12 W Ground — — 0 13 W Front power window motor (passenger side) UP signal When passenger side switch in power window main switch is operated in UP position. Output Other than above (Power window lock switch is unlock position.) GW-50 Battery voltage 0 POWER WINDOW SYSTEM Terminal and Reference Value for Power Window Main Switch/With Front & Rear Power Window BIS000UN Terminal 1 2 3 5 7 8 9 10 11 12 Wire color W LG W W W W V W W GR Item Rear power window motor LH UP signal Limit switch and encoder ground Rear power window motor LH DOWN signal Rear power window motor RH DOWN signal Rear power window motor RH UP signal Front power window motor (passenger side) UP signal Limit switch signal Rap signal Front power window motor (passenger side) DOWN signal Front power window motor (driver side) DOWN signal Signal input/output Condition When rear LH switch in power window main switch is operated in UP position. Output Other than above (Power window lock switch is unlock position.) — Output Output Output Output — Input Output Battery voltage C 0 0 D Battery voltage E Other than above (Power window lock switch is unlock position.) 0 F When rear RH switch in power window main switch is operated in DOWN position. Battery voltage Other than above (Power window lock switch is unlock position.) 0 When rear RH switch in power window main switch is operated in UP position. Battery voltage Other than above (Power window lock switch is unlock position.) 0 When passenger side switch in power window main switch is operated in UP position. GW J Battery voltage K 0 L 0 Driver side door window is between just before fully-closed position and fully-closed position (OFF) 5 M Ignition switch ON Battery voltage Ignition switch OFF 0 Battery voltage Other than above (Power window lock switch is unlock position.) 0 When driver side switch in power window main switch is operated in DOWN position. Battery voltage GW-51 G H Driver side door window is between fully-open position and just before fully-closed position (ON) When passenger side switch in power window main switch is operated in DOWN position. Output B When rear LH switch in power window main switch is operated in DOWN position. Other than above (Power window lock switch is unlock position.) Input Voltage [V] (Approx.) A POWER WINDOW SYSTEM Terminal Wire color 13 W Item Encoder pulse signal Signal input/output Input Condition Voltage [V] (Approx.) When power window motor operates. OCC3383D 15 G Encoder power supply Output Ignition switch ON 16 R Front power window motor (driver side) UP signal Output When driver side switch in power window main switch is operated in UP position. 17 W Ground 19 W Battery power supply 3. 4. 5. Battery voltage — — 0 Input — Battery voltage Work Flow 1. 2. 10 BIS000UO Check the symptom and customer's requests. Understand the outline of system. Refer to GW-32, "System Description (With Front Power Window)" or GW-35, "System Description (With Front & Rear Power Window)" . According to the trouble diagnosis chart, repair or replace the cause of the malfunction. Refer to GW-53, "Trouble Diagnosis Symptom Chart" . Does power window system operate normally? YES: GO TO 5. NO: GO TO 3. INSPECTION END GW-52 POWER WINDOW SYSTEM Trouble Diagnosis Symptom Chart BIS000UP A Make sure other systems using the signal of the following systems operate normally. Symptom Repair order 1. Check BCM power supply and ground circuit None of the power windows can be operated using any switch. Driver side power window alone does not operated. Refer to page GW-54 2. Check power window main switch power supply and ground circuit GW-55*1 1. Check front power window motor (driver side) circuit GW-58*1 2. Replace power window main switch GW-56*2 EI-20 Rear RH side power window alone does not operated. 1. Check rear power window motor RH circuit GW-68 Rear LH side power window alone does not operated. 1. Check rear power window motor LH circuit GW-71 GW-65*2 1. Door window sliding part malfunction ● Glass run rubber wear or deformation ● Sash is tilted too much, or not enough 2. Limit switch adjustment Anti-pinch system does not operate normally (driver side). 3. Check limit switch circuit (driver side) 4. Check encoder circuit (driver side) 5. Replace power window main switch Power window lock switch does not function. 1. Check power window lock switch Auto operation does not operate but manual operates normally (driver side). 1. Check encoder circuit (driver side) 2. Replace power window main switch D GW-61*1 Front passenger side power window alone does not operated. A foreign material adheres to window glass or glass run rubber C GW-60*2 1. Check front power window motor (passenger side) circuit ● B E F — G GW-91 GW-75*1 H GW-78*2 GW-80*1 GW-85*2 GW EI-20 GW-88 J GW-80*1 GW-85*2 EI-20 K *1: With front power window *2: With front & rear power window L M GW-53 POWER WINDOW SYSTEM Check BCM Power Supply and Ground Circuit BIS000UQ 1. CHECK FUSE 10A fuse [No.5, located in fuse block (J/B)] 40A fusible link (letter J , located in the fuse and fusible link box) NOTE: Refer to PG-4, "POWER SUPPLY ROUTING CIRCUIT" . OK or NG OK >> GO TO 2. NG >> If fuse is blown out, be sure to eliminate cause of malfunction before installing new fuse. Refer to PG-4, "POWER SUPPLY ROUTING CIRCUIT" . ● ● 2. CHECK POWER SUPPLY CIRCUIT Check voltage between BCM connector and ground. Terminal BCM connector (+) M57 24 74 M59 Voltage [V] (Approx.) Condition (–) ON Ground Ignition switch Battery voltage OFF 79 OK or NG OK >> GO TO 3. NG >> Check BCM power supply circuit for open or short. MIIB1385E 3. CHECK GROUND CIRCUIT 1. 2. 3. Turn ignition switch OFF. Disconnect BCM connector. Check continuity between BCM connector and ground. BCM connector Terminal M57 2 M59 70 Continuity Ground Yes OK or NG OK >> BCM power supply and ground circuit are OK. NG >> Check BCM ground circuit for open. MIIB1386E GW-54 POWER WINDOW SYSTEM Check Power Window Main Switch Power Supply and Ground Circuit BIS000UR A WITH FRONT POWER WINDOW 1. CHECK POWER SUPPLY CIRCUIT B Check voltage between power window main switch connector and ground. [LHD models] Power window main switch connector (+) Voltage [V] (Approx.) Condition (–) D 1 D8 C Terminal Ground Ignition switch 5 ON Battery voltage OFF MIIB1387E E [RHD models] F Power window main switch connector Terminal (–) 1 D8 Voltage [V] (Approx.) Condition (+) 6 G ON Ground Ignition switch OFF Battery voltage H OK or NG OK >> GO TO 2. NG >> GO TO 3. MIIB1389E GW 2. CHECK GROUND CIRCUIT 1. 2. 3. J Turn ignition switch OFF. Disconnect power window main switch connector. Check continuity between power window main switch connector and ground. Power window main switch connector Terminal D8 12 Ground K Continuity L Yes OK or NG OK >> Power window main switch power supply and ground circuit are OK. NG >> Repair or replace harness. M MIIB1390E GW-55 POWER WINDOW SYSTEM 3. CHECK HARNESS CONTINUITY 1. 2. Disconnect BCM connector. Check continuity between BCM connector and power window main switch connector. A 3. B BCM connector Terminal Power window main switch connector Terminal M59 78 D8 1 Continuity Yes Check continuity between BCM connector and ground. A MIIB1388E BCM connector Terminal M59 78 Continuity Ground No OK or NG OK >> GO TO 4. NG >> Repair or replace harness. 4. CHECK BCM OUTPUT SIGNAL 1. 2. 3. Connect BCM connector. Turn ignition switch ON. Check voltage between BCM connector and ground. Terminal (+) (–) Voltage [V] (Approx.) 78 Ground Battery voltage BCM connector M59 OK or NG OK >> Check condition of harness and connector. NG >> Replace BCM. MIIB1394E WITH FRONT & REAR POWER WINDOW 1. CHECK POWER SUPPLY CIRCUIT Check voltage between power window main switch connector D8, D9 terminal 10, 19 and ground. Connector Terminal (Wire color) (+) D8 10 D9 19 Ignition switch condition (-) Ground ON Voltage [V] (Approx.) Battery voltage OFF OK or NG OK >> GO TO 2. NG >> GO TO 3. PIIB1144E GW-56 POWER WINDOW SYSTEM 2. CHECK GROUND CIRCUIT 1. 2. 3. A Turn ignition switch OFF. Disconnect power window main switch connector. Check continuity between power window main switch connector D9 terminal 17 and ground. 17 – Ground B : Continuity should exist. C OK or NG OK >> Power window main switch power supply and ground circuit are OK. NG >> Repair or replace harness. D PIIA4172E E 3. CHECK HARNESS CONTINUITY 1. 2. A 3. F Disconnect BCM connector. Check continuity between BCM connector and power window main switch connector. G B BCM connector Terminal Power window main switch connector Terminal M59 78 D8 10 Continuity H Yes GW Check continuity between BCM connector and ground. A MIIB1392E BCM connector Terminal M59 78 Continuity Ground J No OK or NG OK >> GO TO 4. NG >> Repair or replace harness. K 4. CHECK BCM OUTPUT SIGNAL L 1. 2. 3. M Connect BCM connector. Turn ignition switch ON. Check voltage between BCM connector and ground. Terminal BCM connector M59 (+) (–) Voltage [V] (Approx.) 78 Ground Battery voltage OK or NG OK >> Check condition of harness and connector. NG >> Replace BCM. MIIB1394E GW-57 POWER WINDOW SYSTEM Check Front Power Window Motor (Driver Side) Circuit BIS000US WITH FRONT POWER WINDOW 1. CHECK POWER WINDOW MAIN SWITCH OUTPUT SIGNAL 1. 2. 3. 4. Turn ignition switch OFF. Disconnect front power window motor (driver side) connector. Turn ignition switch ON. Check voltage between front power window motor (driver side) connector and ground. Front power window motor (driver side) connector Terminal Voltage [V] (Approx.) Condition (+) (–) 3 D4 Ground 4 Power window main switch UP Battery voltage DOWN 0 UP 0 DOWN Battery voltage OK or NG OK >> Replace front power window motor (driver side). NG >> GO TO 2. GW-58 MIIB1395E POWER WINDOW SYSTEM 2. CHECK HARNESS CONTINUITY A [LHD models] 1. Turn ignition switch OFF. 2. Disconnect power window main switch connector. 3. Check continuity between power window main switch connector and front power window motor (driver side) connector. B C A Power window main switch connector B Terminal Front power window motor (driver side) connector 6 D8 4. Continuity Terminal D 3 D4 7 E Yes 4 Check continuity between power window main switch connector and ground. MIIB1396E F A Continuity Power window main switch connector Terminal G Ground 6 D8 No 7 H [RHD models] 1. Turn ignition switch OFF. 2. Disconnect power window main switch connector. 3. Check continuity between power window main switch connector and front power window motor (driver side) connector. A Power window main switch connector J B Terminal Front power window motor (driver side) connector 4 D8 K Continuity Terminal L 3 D4 7 4. GW Yes 4 Check continuity between power window main switch connector and ground. MIIB1391E A Power window main switch connector D8 Continuity Terminal Ground 4 No 7 OK or NG OK >> Replace power window motor. NG >> Repair or replace harness between power window main switch and front power window motor (driver side). GW-59 M POWER WINDOW SYSTEM WITH FRONT & REAR POWER WINDOW 1. CHECK POWER WINDOW MAIN SWITCH OUTPUT SIGNAL 1. 2. 3. 4. Turn ignition switch OFF. Disconnect front power window motor (driver side) connector. Turn ignition switch ON. Check voltage between front power window motor (driver side) connector and ground. Front power window motor (driver side) connector Terminal (+) (–) 3 D4 Voltage [V] (Approx.) Condition Ground Power window main switch 4 UP Battery voltage DOWN 0 UP 0 DOWN Battery voltage MIIB1395E OK or NG OK >> Replace front power window motor (driver side). NG >> GO TO 2. 2. CHECK HARNESS CONTINUITY 1. 2. 3. Turn ignition switch OFF. Disconnect power window main switch connector. Check continuity between power window main switch connector and front power window motor (driver side) connector. A Power window main switch connector B Terminal Front power window motor (driver side) connector 12 D8 Continuity Terminal 4 D4 16 4. Yes 3 Check continuity between power window main switch connector and ground. MIIB1393E A Power window main switch connector Continuity Terminal Ground 12 D8 No 16 OK or NG OK >> Replace power window motor. NG >> Repair or replace harness between power window main switch and front power window motor (driver side). GW-60 POWER WINDOW SYSTEM Check Front Power Window Motor (Passenger Side) Circuit BIS000UT A WITH FRONT POWER WINDOW 1. CHECK POWER WINDOW SWITCH OUTPUT SIGNAL 1. 2. 3. 4. B Turn ignition switch OFF. Disconnect front power window motor (passenger side) connector. Turn ignition switch ON. Check voltage between front power window motor (passenger side) connector and ground. Front power window motor (passenger side) connector C Terminal D Voltage [V] (Approx.) Condition (+) (–) 1 D23 Ground Switch* 2 UP 0 DOWN Battery voltage UP Battery voltage DOWN 0 E F MIIB1397E *: Power window main switch or front power window switch (passenger side) G OK or NG OK >> Replace front power window motor (passenger side). NG >> GO TO 2. H 2. CHECK FRONT POWER WINDOW SWITCH 1. 2. 3. Turn ignition switch OFF. Disconnect front power window switch (passenger side) connector. Check continuity between front power window switch (passenger side) terminal 1, 2, 3 and 4, 5. Terminals Switch condition 5 UP 4 DOWN 2 5 No operation 3 4 No operation 1 GW J Continuity K Yes L OK or NG OK >> GO TO 3. NG >> Replace front power window switch (passenger side). GW-61 PIIB0612E M POWER WINDOW SYSTEM 3. CHECK HARNESS CONTINUITY 1 1. Check continuity between front power window switch (passenger side) connector and front power window motor (passenger side) connector. A B Front power window switch (passenger side) connector Front power window motor (passenger side) connector Terminal 4 D27 Continuity Terminal 1 D23 5 2. Yes 2 MIIB1398E Check continuity between front power window switch (passenger side) connector and ground. A Front power window switch (passenger side) connector Continuity Terminal Ground 4 D27 No 5 OK or NG OK >> GO TO 4. NG >> Repair or replace harness. 4. CHECK FRONT POWER WINDOW SWITCH POWER SUPPLY 1. 2. Turn ignition switch ON. Check voltage between front power window switch (passenger side) connector D27 terminal 1 and ground. 1 – Ground : Battery voltage OK or NG OK >> GO TO 6. NG >> GO TO 5. PIIB0608E GW-62 POWER WINDOW SYSTEM 5. CHECK HARNESS CONTINUITY 2 1. 2. 3. A B BCM connector Front power window switch (passenger side) connector Terminal D27 1 Terminal M59 4. A Turn ignition switch OFF. Disconnect BCM connector. Check continuity between BCM connector and front power window switch (passenger side) connector. 78 B C Continuity D Yes Check continuity between BCM connector and ground. MIIB1399E A E Continuity BCM connector Terminal M59 78 Ground No OK or NG OK >> Check condition of harness and connector. NG >> Repair or replace harness. F G H GW J K L M GW-63 POWER WINDOW SYSTEM 6. CHECK HARNESS CONTINUITY 3 [LHD models] 1. Disconnect power window main switch connector. 2. Check continuity between power window main switch connector and front power window switch (passenger side) connector. A Power window main switch connector B Terminal Front power window switch (passenger side) connector 2 D8 3. Continuity Terminal 2 D27 9 Yes 3 Check continuity between power window main switch connector and ground. MIIB1400E A Power window main switch connector Continuity Terminal Ground 2 D8 No 9 [RHD models] 1. Disconnect power window main switch connector. 2. Check continuity between power window main switch connector and front power window switch (passenger side) connector. A Power window main switch connector B Terminal Front power window switch (passenger side) connector 13 D8 Continuity Terminal 2 D27 5 3. Yes 3 Check continuity between power window main switch connector and ground. A Power window main switch connector Continuity Terminal Ground 13 D8 No 5 OK or NG OK >> GO TO 7. NG >> Repair or replace harness. GW-64 MIIB1402E POWER WINDOW SYSTEM 7. CHECK POWER WINDOW MAIN SWITCH OUTPUT SIGNAL 1. 2. 3. A Connect power window main switch connector. Turn ignition switch ON. Check voltage between power window main switch connector and ground when operating passenger side switch in power window main switch. [LHD models] Power window main switch connector Terminal (–) 2 D8 Ground 9 Power window main switch C Voltage [V] (Approx.) Condition (+) B UP Battery voltage DOWN 0 UP 0 DOWN Battery voltage D MIIB1401E F [RHD models] Power window main switch connector E Terminal Voltage [V] (Approx.) Condition (+) (–) 13 D8 Ground 5 Power window main switch UP Battery voltage DOWN 0 UP 0 DOWN Battery voltage OK or NG OK >> Check condition of harness and connector. NG >> Replace power window main switch. G H MIIB1403E GW J WITH FRONT & REAR POWER WINDOW 1. CHECK POWER WINDOW SWITCH OUTPUT SIGNAL 1. 2. 3. 4. K Turn ignition switch OFF. Disconnect front power window motor (passenger side) connector. Turn ignition switch ON. Check voltage between front power window motor (passenger side) connector and ground. Front power window motor (passenger side) connector L M Terminal Voltage [V] (Approx.) Condition (+) (–) 1 D23 Ground 2 Switch* UP 0 DOWN Battery voltage UP Battery voltage DOWN 0 *: Power window main switch or front power window switch (passenger side) OK or NG OK >> Replace front power window motor (passenger side). NG >> GO TO 2. GW-65 MIIB1397E POWER WINDOW SYSTEM 2. CHECK FRONT POWER WINDOW SWITCH 1. 2. 3. Turn ignition switch OFF. Disconnect front power window switch (passenger side) connector. Check continuity between front power window switch (passenger side) terminal 1, 2, 3 and 4, 5. Terminals Switch condition 5 UP 4 DOWN 2 5 No operation 3 4 No operation 1 Continuity Yes OK or NG OK >> GO TO 3. NG >> Replace front power window switch (passenger side). PIIB0612E 3. CHECK HARNESS CONTINUITY 1 1. Check continuity between front power window switch (passenger side) connector and front power window motor (passenger side) connector. A B Front power window switch (passenger side) connector Front power window motor (passenger side) connector Terminal 4 D27 2. Continuity Terminal 1 D23 5 Yes 2 MIIB1398E Check continuity between front power window switch (passenger side) connector and ground. A Front power window switch (passenger side) connector Continuity Terminal Ground 4 D27 No 5 OK or NG OK >> GO TO 4. NG >> Repair or replace harness. 4. CHECK FRONT POWER WINDOW SWITCH POWER SUPPLY 1. 2. Turn ignition switch ON. Check voltage between front power window switch (passenger side) connector D27 terminal 1 and ground. 1 – Ground : Battery voltage OK or NG OK >> GO TO 6. NG >> GO TO 5. PIIB0608E GW-66 POWER WINDOW SYSTEM 5. CHECK HARNESS CONTINUITY 2 1. 2. 3. A B BCM connector Front power window switch (passenger side) connector Terminal D27 1 Terminal M59 4. A Turn ignition switch OFF. Disconnect BCM connector. Check continuity between BCM connector and front power window switch (passenger side) connector. 78 B C Continuity D Yes Check continuity between BCM connector and ground. MIIB1399E A Continuity BCM connector Terminal M59 78 Ground F No OK or NG OK >> Check condition of harness and connector. NG >> Repair or replace harness. G 6. CHECK HARNESS CONTINUITY 3 1. 2. 3. H Disconnect power window main switch connector. Check continuity between power window main switch connector D8 terminal 8, 11 and front power window switch (passenger side) connector D27 terminal 2, 3. 8–2 11 – 3 GW : Continuity should exist. : Continuity should exist. J Check continuity between power window main switch connector D8 terminal 8, 11 and ground. 8 – Ground 11 – Ground E : Continuity should not exist. : Continuity should not exist. OK or NG OK >> GO TO 7. NG >> Repair or replace harness. K PIIB0609E L M GW-67 POWER WINDOW SYSTEM 7. CHECK POWER WINDOW MAIN SWITCH OUTPUT SIGNAL 1. 2. 3. Connect power window main switch connector. Turn ignition switch ON. Check voltage between power window main switch connector and ground when operating passenger side switch in power window main switch. Terminals (Wire color) Connector (+) (-) 8 D8 Ground 11 Switch condition Voltage [V] (Approx.) UP Battery voltage DOWN 0 UP 0 DOWN Battery voltage PIIB0610E OK or NG OK >> Check condition of harness and connector. NG >> Replace power window main switch. Check Rear Power Window Motor RH Circuit BIS000UU 1. CHECK POWER WINDOW SWITCH OUTPUT SIGNAL 1. 2. 3. 4. Turn ignition switch OFF. Disconnect rear power window motor RH connector. Turn ignition switch ON. Check voltage between rear power window motor RH connector and ground. Rear power window motor RH connector Terminal Voltage [V] (Approx.) Condition (+) (–) 1 D64 Ground 2 Switch* UP 0 DOWN Battery voltage UP Battery voltage DOWN 0 MIIB1404E *: Power window main switch or rear power window switch RH. OK or NG OK >> Replace rear power window motor RH. NG >> GO TO 2. GW-68 POWER WINDOW SYSTEM 2. CHECK REAR POWER WINDOW SWITCH 1. 2. 3. A Turn ignition switch OFF. Disconnect rear power window switch RH connector. Check continuity between rear power window switch RH terminal 1, 2, 3 and 4, 5. Terminals Switch condition 5 UP 4 DOWN 2 5 No operation 3 4 No operation 1 B Continuity C Yes D OK or NG OK >> GO TO 3. NG >> Replace rear power window switch RH. PIIA4186E 3. CHECK HARNESS CONTINUITY 1 1. F Check continuity between rear power window switch RH connector and rear power window motor RH connector. A Rear power window switch RH connector G B Terminal Rear power window motor RH connector Continuity H Yes GW Terminal 4 D63 2. E 1 D64 5 2 Check continuity between rear power window switch RH connector and ground. MIIB1405E J A Rear power window switch RH connector Continuity Terminal K Ground 4 D63 No 5 L OK or NG OK >> GO TO 4. NG >> Repair or replace harness. M 4. CHECK REAR POWER WINDOW SWITCH POWER SUPPLY 1. 2. Turn ignition switch ON. Check voltage between rear power window switch RH connector D63 terminal 1 and ground. 1 – Ground : Battery voltage OK or NG OK >> GO TO 6. NG >> GO TO 5. PIIB0615E GW-69 POWER WINDOW SYSTEM 5. CHECK HARNESS CONTINUITY 2 1. 2. 3. Turn ignition switch OFF. Disconnect BCM connector. Check continuity between BCM connector and rear power window switch RH connector. A 4. B BCM connector Terminal Rear power window switch RH connector M59 78 D63 Continuity Terminal 1 Yes Check continuity between BCM connector and ground. A MIIB1399E BCM connector Terminal M59 78 Ground Continuity No OK or NG OK >> Check condition of harness and connector. NG >> Repair or replace harness. 6. CHECK HARNESS CONTINUITY 3 1. 2. Disconnect power window main switch connector. Check continuity between power window main switch connector D8 terminal 5, 7 and rear power window switch RH connector D63 terminal 2, 3. 5–3 7–2 3. : Continuity should exist. : Continuity should exist. Check continuity between power window main switch connector D8 terminal 5, 7 and ground. 5 – Ground 7 – Ground : Continuity should not exist. : Continuity should not exist. OK or NG OK >> GO TO 7. NG >> Repair or replace harness. GW-70 PIIB0619E POWER WINDOW SYSTEM 7. CHECK POWER WINDOW MAIN SWITCH OUTPUT SIGNAL 1. 2. 3. A Connect power window main switch connector. Turn ignition switch ON. Check voltage between power window main switch connector and ground when operating rear RH switch in power window main switch. C Terminals (Wire color) Connector (+) (-) 5 D8 B Ground 7 Switch condition Voltage [V] (Approx.) UP 0 DOWN Battery voltage UP Battery voltage DOWN 0 D PIIA4189E OK or NG OK >> Check condition of harness and connector. NG >> Replace power window main switch. F Check Rear Power Window Motor LH Circuit BIS000UV 1. CHECK POWER WINDOW SWITCH OUTPUT SIGNAL 1. 2. 3. 4. G Turn ignition switch OFF. Disconnect rear power window motor LH connector. Turn ignition switch ON. Check voltage between rear power window motor LH connector and ground. Rear power window motor LH connector Terminal (–) 1 D44 Ground 2 Switch* H GW Voltage [V] (Approx.) Condition (+) E UP 0 DOWN Battery voltage UP Battery voltage DOWN 0 J K MIIB1404E *: Power window main switch or rear power window switch LH. OK or NG OK >> Replace rear power window motor LH. NG >> GO TO 2. GW-71 L M POWER WINDOW SYSTEM 2. CHECK REAR POWER WINDOW SWITCH 1. 2. 3. Turn ignition switch OFF. Disconnect rear power window switch LH connector. Check continuity between rear power window switch LH terminal 1, 2, 3 and 4, 5. Terminals Switch condition 5 UP 4 DOWN 2 5 No operation 3 4 No operation 1 Continuity Yes OK or NG OK >> GO TO 3. NG >> Replace rear power window switch LH. PIIA4186E 3. CHECK HARNESS CONTINUITY 1 1. Check continuity between rear power window switch LH connector and rear power window motor LH connector. A Rear power window switch LH connector B Terminal Rear power window motor LH connector Continuity Terminal 4 D43 2. 1 D44 5 Yes 2 Check continuity between rear power window switch LH connector and ground. MIIB1405E A Rear power window switch LH connector Continuity Terminal Ground 4 D43 No 5 OK or NG OK >> GO TO 4. NG >> Repair or replace harness. 4. CHECK REAR POWER WINDOW SWITCH POWER SUPPLY 1. 2. Turn ignition switch ON. Check voltage between rear power window switch LH connector D43 terminal 1 and ground. 1 – Ground : Battery voltage OK or NG OK >> GO TO 6. NG >> GO TO 5. PIIB0615E GW-72 POWER WINDOW SYSTEM 5. CHECK HARNESS CONTINUITY 2 1. 2. 3. A 4. A Turn ignition switch OFF. Disconnect BCM connector. Check continuity between BCM connector and rear power window switch LH connector. B B BCM connector Terminal Rear power window switch LH connector M59 78 D43 C Continuity Terminal 1 D Yes Check continuity between BCM connector and ground. A MIIB1399E BCM connector Terminal M59 78 Ground E Continuity No F OK or NG OK >> Check condition of harness and connector. NG >> Repair or replace harness. G 6. CHECK HARNESS CONTINUITY 3 1. 2. 1–2 3–3 3. H Disconnect power window main switch connector. Check continuity between power window main switch connector D8 terminal 1, 3 and rear power window switch LH connector D43 terminal 2, 3. GW : Continuity should exist. : Continuity should exist. J Check continuity between power window main switch connector D8 terminal 1, 3 and ground. 1 – Ground 3 – Ground : Continuity should not exist. : Continuity should not exist. OK or NG OK >> GO TO 7. NG >> Repair or replace harness. K PIIB0616E L M GW-73 POWER WINDOW SYSTEM 7. CHECK POWER WINDOW MAIN SWITCH OUTPUT SIGNAL 1. 2. 3. Connect power window main switch connector. Turn ignition switch ON. Check voltage between power window main switch connector and ground when operating rear LH switch in power window main switch. Terminals (Wire color) Connector (+) (-) 1 D8 Ground 3 Switch condition Voltage [V] (Approx.) UP Battery voltage DOWN 0 UP 0 DOWN Battery voltage OK or NG OK >> Check condition of harness and connector. NG >> Replace power window main switch. GW-74 PIIA4187E POWER WINDOW SYSTEM Check Limit Switch Circuit (Driver Side) BIS000UW A WITH FRONT POWER WINDOW 1. CHECK POWER WINDOW MAIN SWITCH LIMIT SWITCH SIGNAL 1. 2. B Turn ignition switch ON. Check voltage between power window main switch connector and ground. [LHD models] C Power window main switch connector D8 Terminal Voltage [V] (Approx.) Condition (+) (–) 11 Ground Driver side door window is between fully-open position and just before fully-closed position (ON) 0 Driver side door window is between just before fullyclosed position and fullyclosed position (OFF) 5 D E MIIB1406E G [RHD models] Power window main switch connector D8 F Terminal 3 (–) Ground H Voltage [V] (Approx.) Condition (+) GW Driver side door window is between fully-open position and just before fully-closed position (ON) 0 Driver side door window is between just before fullyclosed position and fullyclosed position (OFF) 5 J MIIB1411E K OK or NG OK >> Limit switch circuit is OK. NG >> GO TO 2. L 2. CHECK POWER WINDOW MAIN SWITCH OUTPUT VOLTAGE 1 1. 2. 3. 4. M Turn ignition switch OFF. Disconnect front power window motor (driver side) connector. Turn ignition switch ON. Check voltage between front power window motor (driver side) connector and ground. Front power window motor (driver side) connector (+) (–) Voltage [V] (Approx.) D4 1 Ground 5 Terminal OK or NG OK >> GO TO 5. NG >> GO TO 3. MIIB1407E GW-75 POWER WINDOW SYSTEM 3. CHECK HARNESS CONTINUITY 1 1. 2. 3. Turn ignition switch OFF. Disconnect power window main switch connector. Check continuity between power window main switch connector and front power window motor (driver side) connector. [LHD models] A Power window main switch connector D8 B Terminal Front power window motor (driver side) connector Terminal 11 D4 1 Continuity Yes MIIB1408E [RHD models] A Power window main switch connector D8 B Terminal Front power window motor (driver side) connector Terminal 3 D4 1 Continuity Yes OK or NG OK >> GO TO 4. NG >> Repair or replace harness. MIIB1412E 4. CHECK POWER WINDOW MAIN SWITCH OUTPUT VOLTAGE 2 1. 2. Turn ignition switch ON. Check voltage between power window main switch connector and ground. [LHD models] Terminal Power window main switch connector (+) (–) Voltage [V] (Approx.) D8 11 Ground 5 MIIB1406E [RHD models] Terminal Power window main switch connector (+) (–) Voltage [V] (Approx.) D8 3 Ground 5 OK or NG OK >> Check condition of harness and connector. NG >> Replace power window main switch. MIIB1411E GW-76 POWER WINDOW SYSTEM 5. CHECK GROUND CIRCUIT 1. 2. 3. A Turn ignition switch OFF. Disconnect front power window motor (driver side) connector. Check continuity between front power window motor (driver side) connector and ground. Front power window motor (driver side) connector Terminal D4 2 B C Continuity Ground Yes OK or NG OK >> Replace front power window motor (driver side). NG >> GO TO 6. D MIIB1409E E 6. CHECK HARNESS CONTINUITY 2 1. 2. F Disconnect power window main switch connector. Check continuity between power window main switch connector and front power window motor (driver side) connector. [LHD models] A Power window main switch connector D8 G B H Terminal Front power window motor (driver side) connector Terminal 13 D4 2 Continuity GW Yes MIIB1410E J [RHD models] A B Power window main switch connector Terminal D8 11 K Front power window motor (driver side) connector Terminal D4 2 Continuity L Yes OK or NG OK >> Replace power window main switch. NG >> Repair or replace harness. M MIIB1413E GW-77 POWER WINDOW SYSTEM WITH RFONT & REAR POWER WINDOW 1. CHECK POWER WINDOW MAIN SWITCH LIMIT SWITCH SIGNAL 1. 2. Turn ignition switch ON. Check voltage between power window main switch connector and ground. Terminals (Wire color) Connector (+) D8 (-) 9 Ground Voltage [V] (Approx.) Condition Driver side door window is between fully-open position and just before fully-closed position (ON) 0 Driver side door window is between just before fullyclosed position and fullyclosed position (OFF) 5 PIIA4194E OK or NG OK >> Limit switch circuit is OK. NG >> GO TO 2. 2. CHECK POWER WINDOW MAIN SWITCH OUTPUT VOLTAGE 1 1. 2. 3. 4. Turn ignition switch OFF. Disconnect front power window motor (driver side) connector. Turn ignition switch ON. Check voltage between front power window motor (driver side) connector and ground. Front power window motor (driver side) connector Terminal (+) (–) Voltage [V] (Approx.) D4 1 Ground 5 OK or NG OK >> GO TO 5. NG >> GO TO 3. MIIB1407E 3. CHECK HARNESS CONTINUITY 1 1. 2. 3. Turn ignition switch OFF. Disconnect power window main switch connector. Check continuity between power window main switch connector and front power window motor (driver side) connector. A Power window main switch connector D8 B Terminal Front power window motor (driver side) connector Terminal 9 D4 1 Continuity OK or NG OK >> GO TO 4. NG >> Repair or replace harness. Yes MIIB1414E GW-78 POWER WINDOW SYSTEM 4. CHECK POWER WINDOW MAIN SWITCH OUTPUT VOLTAGE 2 1. 2. A Turn ignition switch ON. Check voltage between power window main switch connector D8 terminal 9 and ground. 9 – Ground B : Approx. 5V OK or NG OK >> Check condition of harness and connector. NG >> Replace power window main switch. C D PIIA4194E E 5. CHECK GROUND CIRCUIT 1. 2. 3. Turn ignition switch OFF. Disconnect front power window motor (driver side) connector. Check continuity between front power window motor (driver side) connector and ground. Front power window motor (driver side) connector Terminal D4 2 F G Continuity Ground H Yes OK or NG OK >> Replace front power window motor (driver side). NG >> GO TO 6. GW MIIB1409E J 6. CHECK HARNESS CONTINUITY 2 1. 2. Disconnect power window main switch connector. Check continuity between power window main switch connector and front power window motor (driver side) connector. A K B Power window main switch connector Terminal D8 2 L Front power window motor (driver side) connector Terminal D4 2 Continuity M OK or NG OK >> Replace power window main switch. NG >> Repair or replace harness. Yes MIIB1415E GW-79 POWER WINDOW SYSTEM Check Encoder Circuit (Driver Side) BIS000UX WITH FRONT POWER WINDOW 1. CHECK ENCODER SIGNAL 1. 2. Turn ignition switch ON. Check signal between power window main switch connector and ground with oscilloscope. [LHD models] Power window main switch connector D8 Terminal Signal (Reference value) Condition (+) 4 (–) Ground MIIB1416E When power window motor operates OCC3383D [RHD models] Power window main switch connector D8 Terminal Signal (Reference value) Condition (+) (–) 9 Ground When power window motor operates MIIB1421E OCC3383D OK or NG OK >> Encoder circuit is OK. NG >> GO TO 2. 2. CHECK ENCODER POWER SUPPLY 1. 2. 3. 4. Turn ignition switch OFF. Disconnect front power window motor (driver side) connector. Turn ignition switch ON. Check voltage between front power window motor (driver side) connector and ground. Front power window motor (driver side) connector Terminal (+) (–) Voltage [V] (Approx.) D4 5 Ground 10 OK or NG OK >> GO TO 4. NG >> GO TO 3. MIIB1417E GW-80 POWER WINDOW SYSTEM 3. CHECK HARNESS CONTINUITY 1 A [LHD models] 1. Turn ignition switch OFF. 2. Disconnect power window main switch. 3. Check continuity between power window main switch connector and front power window motor (driver side) connector. B C A 4. Power window main switch connector D8 B Terminal Front power window motor (driver side) connector Terminal 3 D4 5 Continuity D Yes Check continuity between power window main switch connector and ground. E MIIB1418E F A Continuity Power window main switch connector Terminal D8 3 Ground G No [RHD models] 1. Turn ignition switch OFF. 2. Disconnect power window main switch. 3. Check continuity between power window main switch connector and front power window motor (driver side) connector. A 4. Power window main switch connector D8 H GW B J Terminal Front power window motor (driver side) connector Terminal 2 D4 5 Continuity K Yes Check continuity between power window main switch connector and ground. MIIB1422E L A Power window main switch connector Terminal D8 2 Ground Continuity No OK or NG OK >> Replace power window main switch. NG >> Repair or replace harness. GW-81 M POWER WINDOW SYSTEM 4. CHECK POWER WINDOW MAIN SWITCH OUTPUT VOLTAGE 1. Check voltage between front power window motor (driver side) connector and round. Front power window motor (driver side) connector (+) (–) Voltage [V] (Approx.) D4 6 Ground 5 Terminal OK or NG OK >> GO TO 6. NG >> GO TO 5. MIIB1419E GW-82 POWER WINDOW SYSTEM 5. CHECK HARNESS CONTINUITY 2 A [LHD models] 1. Turn ignition switch OFF. 2. Disconnect power window main switch connector. 3. Check continuity between power window main switch connector and front power window motor (driver side) connector. B C A 4. Power window main switch connector D8 B Terminal Front power window motor (driver side) connector Terminal 4 D4 6 Continuity D Yes Check continuity between power window main switch connector and ground. E MIIB1420E F A Continuity Power window main switch connector Terminal D8 4 Ground G No [RHD models] 1. Turn ignition switch OFF. 2. Disconnect power window main switch connector. 3. Check continuity between power window main switch connector and front power window motor (driver side) connector. A 4. Power window main switch connector D8 H GW B J Terminal Front power window motor (driver side) connector Terminal 9 D4 6 Continuity K Yes Check continuity between power window main switch connector and ground. MIIB1423E L A Power window main switch connector Terminal D8 9 Ground Continuity No OK or NG OK >> Replace power window main switch. NG >> Repair or replace harness. GW-83 M POWER WINDOW SYSTEM 6. CHECK GROUND CIRCUIT 1. 2. Turn ignition switch OFF. Check continuity between front power window motor (driver side) connector and ground. Front power window motor (driver side) connector Terminal D4 2 Continuity Ground Yes OK or NG OK >> Replace front power window motor (driver side). NG >> GO TO 7. MIIB1409E 7. CHECK HARNESS CONTINUITY 3 1. 2. Disconnect power window main switch connector. Check continuity between power window main switch connector and front power window motor (driver side) connector. [LHD models] A Power window main switch connector D8 B Terminal Front power window motor (driver side) connector Terminal 13 D4 2 Continuity Yes MIIB1410E [RHD models] A Power window main switch connector D8 B Terminal Front power window motor (driver side) connector Terminal 11 D4 2 Continuity Yes OK or NG OK >> Replace power window main switch. NG >> Repair or replace harness. MIIB1413E GW-84 POWER WINDOW SYSTEM WITH FRONT & REAR POWER WINDOW A 1. CHECK ENCODER SIGNAL 1. 2. Turn ignition switch ON. Check signal between power window main switch connector and ground with oscilloscope. Connector Terminals (Wire color) Signal (Reference value) Condition (+) (-) 13 Ground B C D D8 opening E OCC3383D PIIA4205E OK or NG OK >> Encoder circuit is OK. NG >> GO TO 2. F 2. CHECK ENCODER POWER SUPPLY 1. 2. 3. 4. G Turn ignition switch OFF. Disconnect front power window motor (driver side) connector. Turn ignition switch ON. Check voltage between front power window motor (driver side) connector and ground. Front power window motor (driver side) connector Terminal (+) (–) Voltage [V] (Approx.) D4 5 Ground 10 H GW J OK or NG OK >> GO TO 4. NG >> GO TO 3. K MIIB1417E L M GW-85 POWER WINDOW SYSTEM 3. CHECK HARNESS CONTINUITY 1 1. 2. 3. Turn ignition switch OFF. Disconnect power window main switch. Check continuity between power window main switch connector and front power window motor (driver side) connector. A 4. B Power window main switch connector Terminal Front power window motor (driver side) connector D8 15 D4 Terminal 5 Continuity Yes Check continuity between power window main switch connector and ground. MIIB1424E A Power window main switch connector Terminal D8 15 Ground Continuity No OK or NG OK >> Replace power window main switch. NG >> Repair or replace harness. 4. CHECK POWER WINDOW MAIN SWITCH OUTPUT VOLTAGE 1. Check voltage between front power window motor (driver side) connector and round. Front power window motor (driver side) connector Terminal (+) (–) Voltage [V] (Approx.) D4 6 Ground 5 OK or NG OK >> GO TO 6. NG >> GO TO 5. MIIB1419E GW-86 POWER WINDOW SYSTEM 5. CHECK HARNESS CONTINUITY 2 1. 2. 3. A 4. A Turn ignition switch OFF. Disconnect power window main switch connector. Check continuity between power window main switch connector and front power window motor (driver side) connector. B B Power window main switch connector Terminal D8 13 C Front power window motor (driver side) connector Terminal D4 6 Continuity D Yes Check continuity between power window main switch connector and ground. MIIB1425E E A Power window main switch connector Terminal D8 13 F Continuity Ground No G OK or NG OK >> Replace power window main switch. NG >> Repair or replace harness. H 6. CHECK GROUND CIRCUIT 1. 2. Turn ignition switch OFF. Check continuity between front power window motor (driver side) connector and ground. GW J Front power window motor (driver side) connector Terminal D4 2 Continuity Ground Yes K OK or NG OK >> Replace front power window motor (driver side). NG >> GO TO 7. L MIIB1409E 7. CHECK HARNESS CONTINUITY 3 1. 2. M Disconnect power window main switch connector. Check continuity between power window main switch connector and front power window motor (driver side) connector. A B Power window main switch connector Terminal Front power window motor (driver side) connector Terminal D8 2 D4 2 Continuity OK or NG OK >> Replace power window main switch. NG >> Repair or replace harness. Yes MIIB1415E GW-87 POWER WINDOW SYSTEM Check Power Window Lock Switch BIS0014S 1. CHECK POWER WINDOW LOCK SIGNAL Exchanges for a normal power window main switch, and check operation. Does power window lock operate? YES >> Replace power window main switch. NO >> Check condition of harness and connector. GW-88 FRONT DOOR GLASS AND REGULATOR FRONT DOOR GLASS AND REGULATOR Removal and Installation PFP:80300 A BIS000O1 B C D E F G H GW PIIB5343J 1. Pull handle bracket 2. Inner pad 3. Door glass 4. Lower sash (rear) 5. Regulator assembly 6. Power window motor 7. 8. Lower sash (front) Door glass run J K DOOR GLASS Removal 1. 2. 3. 4. 5. 6. 7. Remove front door finisher. Refer to EI-20, "DOOR FINISHER" . Remove pull handle bracket. Fully close door glass. Disconnect front speaker harness connector, and then remove sealing screen. NOTE: If sealing screen is reused, cut butyl tape in a way that leaves it on sealing screen. Remove clip, and then remove inner pad. While supporting door glass, operate power window switch to raise/lower door glass until glass bolts can be seen. Remove door glass bolts. L M MIIB1434E GW-89 FRONT DOOR GLASS AND REGULATOR 8. While holding door glass, raise glass up from rear edge while pulling glass out of sash toward the inside of the door. SIIA1779J 9. Remove lower sash (rear). 10. Remove door glass run. 11. Remove lower sash (front). Installation Install in the reverse order of removal. REGULATOR ASSENBLY Removal 1. 2. 3. 4. 5. 6. Remove front door finisher. Refer to EI-20, "DOOR FINISHER" . Remove pull handle bracket. Disconnect front speaker harness connector, and then remove sealing screen. NOTE: If sealing screen is reused, cut butyl tape in a way that leaves it on sealing screen. Remove clips, and then remove inner pad. Operate the power window main switch to raise/lower the door window until the glass mounting bolts can be seen. Remove the glass mounting bolts. MIIB1434E 7. Raise up the door glass and hold with a suction lifter A. PIIB3510J GW-90 FRONT DOOR GLASS AND REGULATOR 8. Remove power window motor bolts. A B C MIIB1435E D 9. Disconnect the harness connector for the power window motor, and remove regulator assembly. Installation E Install in the reverse order of removal. Inspection after Removal Check the regulator assembly for the following. If a failure is detected, replace or grease it. ● Wire wear ● Regulator assembly deformation ● Grease condition on each sliding part Apply grease (Nissan MP Special Grease No. 2) to the areas indicted by the arrows in the figure. F G H SIIA1781J Inspection after Installation GW BIS0014Y SYSTEM INITIALIZATION If any of the following work has been done, initialize the system. ● Electric power supply to power window switch or motor is interrupted by blown fuse or disconnecting battery cable, etc. ● Removal and installation of the regulator assembly. ● Removal and installation of the motor from the regulator assembly. ● Removal and installation of the harness connector of the power window switch. ● Operate the regulator assembly as a unit. ● Removal and installation of the door glass. ● Removal and installation of the door glass run. Initialization After installing each component to the vehicle, follow the steps below. 1. Disconnect the minus terminal of battery or disconnect power window switch's harness connector temporarily, then reconnect after at least 1 minute. 2. Turn ignition switch ON. 3. Press and hold the Driver Down window switch until the window glass has reached the Lower Mechanical limit. 4. Release the Driver Down window switch. 5. Pull and hold the Driver Up window switch (to the second 'detent') until the window glass gas reached the Upper Mechanical limit and continue to hold the Driver Up window switch for a further 5 seconds after the glass has reached the Upper Mechanical limit (it is necessary that this whole operation is done with one continuous pull of the Driver Up switch). 6. Release the Driver Up window switch. 7. Inspection of the anti-pinch system function. GW-91 J K L M FRONT DOOR GLASS AND REGULATOR INSPECT THE FUNCTION OF THE ANTI-PINCH SYSTEM. 1. 2. 3. Fully open the door glass. Place a wooden piece (wooden hammer handle etc.) at near fully closed position. Carry out fully closing operation with auto up switch. ● Check that the glass reverses without pinching the wooden piece, is lowered approx.150mm (5.91in) or for 2 seconds and then stops. ● The glass should not be raised with power window main switch operated while it is reversing or lowering. CAUTION: ● Do not inspect with pinching a part of workers body, a hand etc. Work carefully not to be pinched. ● Check that auto up function is normal before inspection following the system initialization. FITTING INSPECTION ● ● Make sure glass is securely fit into door glass run groove. Lower glass slightly (approximately 10 to 20 mm), and confirm clearance to the sash is parallel. If clearance between glass and sash is not parallel, loosen bolts for regulator assembly, glass, and carrier plate, and then correct glass position. GW-92 REAR DOOR GLASS AND REGULATOR REAR DOOR GLASS AND REGULATOR Removal and Installation PFP:82300 A BIS000O2 B C D E F G H GW PIIB5346J 1. Pull handle bracket 2. Corner inner cover 3. Lower sash (rear) 4. Door glass 5. Regulator assembly 6. Power window motor 7. Door glass run 8. Lower sash (front) J K DOOR GLASS Removal 1. 2. 3. 4. 5. 6. Fully open door glass. Remove rear door finisher. Refer to EI-20, "DOOR FINISHER" . Remove pull handle bracket. Remove rear speaker harness connector. Remove inner corner cover. Remove sealing screen. NOTE: If sealing screen is reused, cut butyl tape in a way that leaves it on sealing screen. 7. Remove lower sash (rear) bolts, and remove lower sash (rear). 8. While supporting door glass, operate power window switch to raise/lower door glass until glass bolts can be seen. 9. Remove door glass bolts. 10. Pull door glass up to remove it. L M PIIB5348J GW-93 REAR DOOR GLASS AND REGULATOR 11. Pull out and remove door glass run from door panel. 12. Remove lower sash (front) bolts, and then remove lower sash (front). Installation Install in the reverse order of removal. REGULATOR ASSEMBLY Removal 1. 2. 3. 4. 5. 6. Remove rear door finisher. Refer to EI-20, "DOOR FINISHER" . Remove pull handle bracket. Remove rear speaker harness connector. Remove sealing screen. NOTE: If sealing screen is reused, cut butyl tape in a way that leaves it on sealing screen. Operate power window switch to raise/lower door glass until glass bolts can be seen. Remove door glass bolts. PIIB5348J 7. Raise up the door glass and hold with a suction lifter A. PIIB3511J 8. Remove regulator assembly bolts to remove assembly out of door panel. PIIB5347J Installation Install in the reverse order of removal. GW-94 REAR DOOR GLASS AND REGULATOR Installation after Removal A Check the regulator assembly for the following. If a failure is detected, replace or grease it. ● Gear wear ● Regulator assembly deformation ● Grease condition on each sliding part Apply grease (Nissan MP Special Grease No. 2) to the areas indicted by the arrows in the figure. B C PIIB5349J INSPECTION AFTER INSTALLATION FITTING INSPECTION ● ● D E Make sure the window is seated in the groove of the glass run. Lower glass slightly (approximately 10 to 20 mm), and confirm clearance to the sash is parallel. If clearance between glass and sash is not parallel, loosen bolts for regulator assembly, glass, and main channel, and then correct glass position. F G H GW J K L M GW-95 DOOR MIRROR DOOR MIRROR Wiring Diagram — MIRROR — LHD Models (With Retract) PFP:96301 BIS000O3 MIWA0683E GW-96 DOOR MIRROR A B C D E F G H GW J K L M MIWA0684E GW-97 DOOR MIRROR Wiring Diagram — MIRROR — RHD Models (With Retract) BIS000O4 MIWA0685E GW-98 DOOR MIRROR A B C D E F G H GW J K L M MIWA0686E GW-99 DOOR MIRROR Wiring Diagram — MIRROR — LHD Models (Without Retract) BIS000UH MIWA0687E GW-100 DOOR MIRROR Removal and Installation BIS000O5 A B C D E F G H GW MIIB1429E 1. Corner cover 2. Door mirror assembly CAUTION: Be careful not to damage mirror body. J REMOVAL 1. 2. 3. 4. Remove front door finisher. Refer to EI-20, "DOOR FINISHER" . Remove corner cover. Disconnect door mirror harness connector. (Electric door mirrors only) Remove door mirror bolts and door mirror assembly. K L INSTALLATION Install in the reverse order of removal. M GW-101 DOOR MIRROR Disassembly and Assembly BIS000O6 MIIB1427E 1. Mirror body (mirror holder) 2. Mirror housing assembly 3. Cover DISASSEMBLY 1. 2. 3. 4. 5. 6. Place the mirror body with mirror glass facing upward. Put a strip of protective tape B on mirror body. As shown in the figure, insert a small slotted screwdriver A into the recess between mirror base (mirror holder)(1) and mirror holder bracket (2) and push up two pawls (3) to remove mirror holder lower half side. NOTE: Insert screwdriver into recesses, and push up while rotating (twist) to make work easier. CAUTION: PIIB8320J When pushing up the tabs, do not forcibly push up only 1 concave but try to push up using 2 concave positions. Remove two terminals of mirror heater attachment. Lightly lift up lower side of mirror surface from mirror surface, and detach two pawls of upper side as if pulling it out. Remove mirror surface from mirror body. NOTE: Be certain not to allow grease on sealing agent in center of mirror body assembly (actuator) or back side of mirror surface (mirror holder). Remove cover. MIIB1428E GW-102 DOOR MIRROR ASSEMBLY A Install in the reverse order of removal. CAUTION: ● Engage upper tabs of mirror glass (mirror holder) with power unit. Then, press lower part of mirror glass down until lower part snaps into place and engages lower tabs. ● After finishing work, visually confirm that lower tabs (2) at the bottom of mirror face are securely engaged. B C D MIIB0206E E F G H GW J K L M GW-103 INSIDE MIRROR INSIDE MIRROR Removal and Installation PFP:96321 BIS000O7 REMOVAL Pull the inside mirror upward to remove it. MIIB1057E INSTALLATION Install in the reverse order of removal. Removal and Installation (With Rain Sensor) BIS000O8 REMOVAL Slide the inside mirror downward to remove. MIIB0991E INSTALLATION Install in the reverse order of removal. GW-104 ALPHABETICAL INDEX A A/C air flow ....................................... ATC-24, MTC-21 A/C component layout ...................... ATC-16, MTC-16 A/C compressor mounting .............. ATC-140, MTC-86 A/C compressor precaution .................. ATC-8, MTC-8 A/C control operation (auto A/C) ...................... ATC-22 A/C control operation (manual A/C) ................ MTC-20 A/C controller .................................................. MTC-62 A/C diagnostic work flow (auto A/C) ................ ATC-97 A/C HFC134a (R134a) system precaution ....... ATC-4, MTC-4 A/C HFC134a (R134a) system service procedure ....... ATC-135, MTC-81 A/C HFC134a (R134a) system service tools .. ATC-12, MTC-12 A/C HFC134a system service equipment precaution ... ATC-8, MTC-8 A/C lubricant (R134a) ........ ATC-5, ATC-17, ATC-151, MTC-5, MTC-17, MTC-97 A/C operational check ....................... ATC-55, MTC-34 A/C self-diagnoses (auto A/C) .......... ATC-46, ATC-97 A/C service data specification ......... ATC-151, MTC-97 A/C trouble diagnoses (manual A/C) .............. MTC-23 A/C unit assembly ........................... ATC-118, MTC-65 A/C, A - Wiring diagram ................................... ATC-31 A/C, M - Wiring diagram ................................. MTC-26 A/T fluid checking .................................. AT-18, MA-56 A/T fluid replacement ............................. AT-19, MA-57 A/T fluid temperature sensor ........................... AT-114 A/T IND - Wiring diagram .................................... DI-49 A/T indicator ........................................................ DI-48 A/T shift control system ................................... AT-332 A/T shift lock system ........................................ AT-338 A/T shift lock system - Wiring diagram ............ AT-339 A/T trouble diagnoses ........................................ AT-40 A/T Wiring diagram AT - BA/FTS ....... AT-181, AT-236 A/T Wiring diagram AT - CAN ............ AT-103, AT-258 A/T Wiring diagram AT - ENG SS ...... AT-122, AT-242 A/T Wiring diagram AT - FTS .......................... AT-111 A/T Wiring diagram AT - LPSV .......... AT-154, AT-252 A/T Wiring diagram AT - MAIN .......... AT-194, AT-261 A/T Wiring diagram AT - NONDTC .................. AT-296 A/T Wiring diagram AT - OVRCSV .... AT-172, AT-226 A/T Wiring diagram AT - PNP/SW ................... AT-106 A/T Wiring diagram AT - PT/SEN ...... AT-187, AT-246 A/T Wiring diagram AT - SSV/A ......... AT-160, AT-216 A/T Wiring diagram AT - SSV/B ......... AT-165, AT-221 A/T Wiring diagram AT - TCV ............ AT-143, AT-231 A/T Wiring diagram AT - VSS A/T ..... AT-117, AT-205 A/T Wiring diagram AT - VSSMTR .... AT-177, AT-210 ABS - Wiring diagram ..................................... BRC-13 ABS sensor rotor .............................................. RAX-5 Accelerator pedal position (APP) sensor ........ EC-383, EC-392, EC-409, EC-699, EC-708, EC-725, EC-1172, EC-1181, EC-1197, EC-1492, EC-1501, EC-1517, EC-1751, EC-1837, EC-1855 Accelerator pedal released position learning .... EC-69, EC-486, EC-857, EC-1278 Air bag .... SRS-3, SRS-36, SRS-40, SRS-42, SRS-44 Air bag disposal .............................................. SRS-49 Air bleeding (hydraulic clutch) .............................. CL-8 Air bleeding for brake system ............................ BR-10 Air cleaner and air duct ..................... EM-118, EM-245 Air cleaner filter ................................. EM-119, EM-246 Air cleaner filter replacement(CR) ..................... MA-34 Air cleaner filter replacement(HR) ..................... MA-44 Air cleaner filter replacement(K9K) ................... MA-52 Air conditioner cut control EC-821, EC-1255, EC-1618 Air flow meter - See Mass air flow sensor ....... EC-935, EC-1354 Air mix door control linkage adjustment ......... MTC-37, MTC-71 Air mix. door motor ......................... ATC-64, ATC-125 Alternator ........................................................... SC-15 Ambient sensor ............................... ATC-99, ATC-114 Angular tightening application ........... EM-105, EM-227 Antenna ............................................................. AV-11 AP/SEN - Wiring diagram .. EC-156, EC-339, EC-560, EC-656 APPS - Wiring diagram . EC-1752, EC-1838, EC-1856 APPS1 - Wiring diagram .. EC-385, EC-701, EC-1174, EC-1494 APPS2 - Wiring diagram .. EC-394, EC-710, EC-1183, EC-1503 APPS3 - Wiring diagram .. EC-411, EC-727, EC-1199, EC-1519 Audio .................................................................... AV-3 AUDIO - Wiring diagram ...................................... AV-4 Auto air conditioner - Wiring diagram ............. ATC-31 Auto amp .......................... ATC-44, ATC-57, ATC-112 Auto wiper .......................................................... WW-4 Automatic amplifier ........................... ATC-44, ATC-57 Automatic transaxle number ............................... GI-48 Automatic transmission fluid replacement ........ MA-56 Axle ................................................................... MA-60 B Back door trim ..................................................... EI-22 Back door window ............................................ GW-10 Back window .................................................... GW-10 BACK/L - Wiring diagram ................................. LT-131 Back-up lamp ................................................... LT-131 Barometric pressure (BARO) sensor ............. EC-1863 Basic inspection .... EC-66, EC-483, EC-851, EC-1272 Battery ................................................................. SC-5 BCM (Body control module) .............................. BCS-3 Blower motor ..... ATC-71, ATC-123, MTC-39, MTC-69 Blower resistor ................................................ MTC-73 Board computer .................................................. DI-21 Board-on lift ........................................................ GI-41 Brake booster .................................................... BR-17 Brake fluid change ............................................... BR-9 Brake fluid level ................................................ MA-58 Brake fluid level and line check ........................... BR-9 Brake hydraulic line ........................................... BR-11 Brake inspection ............................................... MA-58 IDX-2 ALPHABETICAL INDEX Brake lines and cables inspection ..................... MA-58 Brake master cylinder ........................................ BR-14 Brake pedal ......................................................... BR-6 Brake switch .... EC-377, EC-693, EC-1167, EC-1487, EC-1820, EC-1850 BRK/SW - Wiring diagram EC-379, EC-695, EC-1168, EC-1488, EC-1821, EC-1851 Bulb specifications ............................................ LT-183 Bumper, front ......................................................... EI-4 Bumper, rear .......................................................... EI-8 C Camshaft ......................................................... EM-151 Camshaft inspection ......................... EM-157, EM-325 Camshaft position sensor (CMPS) EC-1075, EC-1778 Camshaft position sensor (PHASE) . EC-257, EC-616, EC-1049, EC-1413 CAN - Wiring diagram ......... EC-135, EC-550, EC-926, EC-1345, EC-1706, LAN-23, LAN-38, LAN-51, LAN-65, LAN-79, LAN-94, LAN-108, LAN-123, LAN-136, LAN-150, LAN-164 CAN (Controller Area Network) .......... AT-39, BRC-48, LAN-21 CAN communication ........... EC-134, EC-137, EC-549, EC-552, EC-822, EC-925, EC-928, EC-1256, EC-1344, EC-1347, EC-1624, EC-1705, AT-39, AT-102, BRC-48, LT-89, LAN-21 Canister-See EVAP canister EC-43, EC-472, EC-826, EC-1260 CD/CHG - Wiring diagram ................................... AV-4 CHARGE - Wiring diagram ........ SC-16, SC-17, SC-18 Charging system ................................................ SC-15 Chassis and body maintenance ........................ MA-55 Circuit breaker ................................................... PG-17 CKPS - Wiring diagram ................................. EC-1775 Closed loop control EC-34, EC-463, EC-818, EC-1252 Clutch cover ............................................ CL-11, CL-12 Clutch disc ......................................................... CL-11 Clutch master cylinder ......................................... CL-9 Clutch pedal ......................................................... CL-6 CMPS - Wiring diagram ................................. EC-1779 Coil spring (front) ............................................... FSU-8 Coil spring (rear) ............................................... RSU-9 Collision diagnosis ........................................... SRS-58 Combination lamp, rear, removal and installation ........ LT-149 Combination switch ........................................... WW-8 COMM - Wiring diagram ..................................... DI-24 Component Location (auto A/C) ...................... ATC-28 Component Location (manual A/C) ................ MTC-25 Compression pressure .................................... EM-173 Compressor mounting .................... ATC-140, MTC-86 Conformity check ........................................... EC-1680 Connecting rod ................................. EM-208, EM-327 Connecting rod bearing clearance ................... EM-211 Connecting rod bushing clearance .................. EM-208 CONSULT for ABS ......................................... BRC-19 CONSULT for engine ........................ EC-102, EC-519 CONSULT general information ........................... GI-35 CONSULT-II for engine ................... EC-891, EC-1312 Control units (terminal arrangement) ................. PG-90 Controller Area Network (CAN) ......... AT-39, BRC-48, LAN-21 Converter housing installation ........... AT-358, AT-465 COOL/F - Wiring diagram EC-349, EC-666, EC-1135, EC-1456, EC-1866 Coolant mixture ratio ......................................... MA-26 Coolant replacement ......................................... MA-49 Cooling circuit (engine) ........................... CO-7, CO-26 Cooling fan ............................... CO-14, CO-33, CO-52 Cooling fan control ......................................... EC-1620 Cooling fan motor ......... EC-1130, EC-1451, EC-1864 Cooling fan relay ........... EC-1130, EC-1451, EC-1864 Cowl top .............................................................. EI-12 Crankcase ventilation system - See Positive crankcase ventilation .............. EC-45, EC-474, EC-828, EC-1262 Crankshaft ......................... EM-189, EM-211, EM-328 Crankshaft position sensor (POS) .... EC-250, EC-609, EC-1042, EC-1405 Crankshaft position sensor (TDC) ................. EC-1774 Cylinder block ................................... EM-189, EM-329 Cylinder head ..................... EM-173, EM-177, EM-276 Cylinder head bolt tightening EM-176, EM-277, EM-321 A B C D E F G H D Data link connector EC-448, EC-800, EC-893, EC-900, EC-1313 Data link connector for Consult .......... EC-104, EC-521 Diagnosis sensor unit ..................................... SRS-48 Diagnostic trouble code (DTC) for OBD system EC-22, EC-49, EC-451, EC-477, EC-803, EC-833, EC-1239, EC-1265, EC-1601 Diagnostic trouble code (DTC) inspection priority chart EC-80, EC-497, EC-869, EC-1290 Dimensions ......................................................... GI-48 Door glass ................................ GW-5, GW-89, GW-93 Door mirror ........................................................ GW-96 Door trim ............................................................. EI-20 Drive belt ........................................... EM-114, EM-242 Drive belt inspection ......................................... MA-49 Drive computer ........................................ DI-21, DI-24 Drive shaft (front) ............................................. FAX-10 Driver air bag .................................................. SRS-36 Dropping resistor (A/T) ...................... AT-158, AT-256 DTC work support .............................. EC-109, EC-898 Duct and grilles ............................... ATC-130, MTC-76 E ECM input/output signal ....... EC-95, EC-512, EC-883, EC-902, EC-1304, EC-1321, EC-1673 ECM power supply EC-128, EC-282, EC-543, EC-626, EC-918, EC-1337, EC-1816 ECM relay ...................................................... EC-1845 ECM/PW - Wiring diagram EC-283, EC-627, EC-1817 ECMRLY - Wiring diagram ............................ EC-1846 IDX-3 I J K L IDX ALPHABETICAL INDEX ECTS - Wiring diagram ...... EC-168, EC-567, EC-949, EC-1363, EC-1728 EGR function ................................. EC-1622, EC-1791 EGR volume control valve ............................. EC-1795 EGR volume control valve control position sensor ....... EC-1800, EC-1805 EGRC/V - Wiring diagram ............. EC-1792, EC-1796, EC-1801, EC-1806 Electric throttle control actuator ........ EC-291, EC-293, EC-305, EC-635, EC-637, EC-649, EC-1082, EC-1084, EC-1430, EC-1433 Electrical diagnoses ............................................ GI-12 Electrical load signal circuit EC-419, EC-735, EC-1207, EC-1528 Electrical unit ..................................................... PG-90 Electrical units location ...................................... PG-82 Electronic ignition (EI) system EC-36, EC-465, EC-819, EC-1253 Engine control circuit diagram EC-93, EC-510, EC-881, EC-1302, EC-1671 Engine control component parts location .......... EC-86, EC-503, EC-875, EC-1296, EC-1668 Engine control module (ECM) ........... EC-279, EC-623, EC-928, EC-1072, EC-1347, EC-1420, EC-1423, EC-1825, EC-1826, EC-1828 Engine control system diagram ....... EC-816, EC-1250 Engine control system diagram and chart ........ EC-33, EC-462, EC-1609 Engine coolant ........................... CO-8, CO-27, CO-48 Engine coolant temperature sensor (ECTS) ... EC-166, EC-565, EC-947, EC-1361, EC-1727 Engine fail-safe system ........ EC-81, EC-498, EC-870, EC-1291 Engine oil ...................................... LU-6, LU-16, LU-23 Engine oil filter replacement(CR) ...................... MA-35 Engine oil filter replacement(HR) ...................... MA-46 Engine oil filter replacement(K9K) .................... MA-54 Engine oil precautions .......................................... GI-7 Engine oil replacement(CR) .............................. MA-34 Engine oil replacement(HR) .............................. MA-45 Engine oil replacement(K9K) ............................ MA-53 Engine removal ................................. EM-184, EM-279 Engine room cover ............................ EM-121, EM-241 Engine serial number .......................................... GI-47 ETC1 - Wiring diagram .... EC-294, EC-638, EC-1085, EC-1434 ETC2 - Wiring diagram .... EC-301, EC-645, EC-1092, EC-1441 ETC3 - Wiring diagram .... EC-306, EC-650, EC-1097, EC-1446 EVAP canister ....... EC-43, EC-472, EC-826, EC-1260 EVAP canister purge volume control solenoid valve .... EC-40, EC-270, EC-469, EC-737, EC-1063, EC-1530 EVAP vapor lines inspection(CR) ..................... MA-37 EVAP vapor lines inspection(HR) ..................... MA-48 Evaporative emission (EVAP) system EC-40, EC-469, EC-823, EC-1257 Exhaust manifold .............................. EM-124, EM-253 Exhaust system inspection ..................... EX-3, MA-55 F F/FOG - Wiring diagram .................................... LT-76 F/PUMP - Wiring diagram EC-428, EC-751, EC-1216, EC-1544, EC-1760 Floor trim ............................................................. EI-29 Flow charts ......................................................... GI-25 Fluid temperature sensor (A/T) ........................ AT-114 Fluids ................................................................ MA-24 Fluorescent leak detector .............. ATC-147, MTC-93 Flywheel (clutch) ................................................ CL-13 Flywheel runout .............................................. EM-214 Fog lamp, front ................................................... LT-73 Freeze frame data . EC-50, EC-478, EC-834, EC-893, EC-1266, EC-1314 FRO2 - Wiring diagram .... EC-757, EC-764, EC-1550, EC-1558 Front axle ........................................................... FAX-6 Front bumper ........................................................ EI-4 Front disc brake ................................................. BR-21 Front fog lamp .................................................... LT-73 Front passenger air bag .................................. SRS-40 Front seat ............................................................. SE-7 Front seat belt ............................................ SB-3, SB-4 Front seat belt pre-tensioner SB-2, SB-3, SB-4, SRS-3 Front side air bag ............................................ SRS-42 Front suspension .............................................. FSU-5 Front washer ...................................................... WW-4 Front wiper ......................................................... WW-4 FRPS - Wiring diagram .................................. EC-1737 FTS - Wiring diagram ..................................... EC-1733 FUEL - Wiring diagram .... EC-220, EC-228, EC-1014, EC-1021 Fuel check valve ................................. EC-40, EC-469 Fuel cut control (at no load high engine speed) EC-36, EC-465, EC-820, EC-1254 Fuel filter ........................................................ EC-1625 Fuel filter replacement ....................................... FL-26 Fuel gauge ......................................................... FL-29 Fuel injection control system ......................... EC-1612 Fuel injection system ....... EC-218, EC-226, EC-1012, EC-1019, EC-1719 Fuel injector . EC-1209, EC-1537, EC-1625, EC-1740, EC-1745 Fuel injector and fuel tube .............................. EM-135 Fuel line inspection ................................... FL-3, FL-14 Fuel line inspection(CR) ................................... MA-33 Fuel line inspection(HR) ................................... MA-44 Fuel line inspection(K9K) .................................. MA-52 Fuel precautions ................................................... GI-5 Fuel pressure check EC-71, EC-488, EC-860, EC-1281 Fuel pressure release .......... EC-71, EC-488, EC-860, EC-1281 Fuel pump ........ EC-427, EC-750, EC-1215, EC-1543, EC-1721, EC-1759 Fuel pump and gauge ............................... FL-4, FL-15 Fuel rail pressure sensor ............................... EC-1736 Fuel system ................................... FL-3, FL-14, FL-25 Fuel tank ........................................ FL-8, FL-19, FL-31 IDX-4 ALPHABETICAL INDEX Fuel tank vacuum relief valve .......... EC-826, EC-1260 Fuel temperature sensor ............................... EC-1732 Fuse ................................................................... PG-17 Fuse and fusible link box ................................... PG-96 Fusible link ......................................................... PG-17 G Garage jack and safety stand ............................. GI-40 Generator .......................................................... SC-15 Generator - See Alternator ................................ SC-15 Generic scan tool (GST) .................... EC-111, EC-900 GLOW - Wiring diagram ................ EC-1785, EC-1789 Glow control system ...... EC-1619, EC-1784, EC-1788 Glow plug ........................................ EM-260, EC-1620 Grease ............................................................... MA-24 Grille - See Exterior ............................................. EI-10 Ground distribution ............................................ PG-38 H H/AIM - Wiring diagram ...................................... LT-68 H/LAMP - Wiring diagram ................................... LT-11 Harness connector ............................................ PG-88 Harness layout ................................................... PG-48 Hazard warning lamp .......................................... LT-98 Headlamp aiming control .................................... LT-68 Headlamp leveler - See Headlamp aiming control ....... LT-68 Headlamp washer ............................................ WW-73 Headlining - See Roof trim .................................. EI-30 Heated oxygen sensor 1 ..... EC-178, EC-185, EC-195, EC-310, EC-316, EC-577, EC-584, EC-756, EC-959, EC-967, EC-977, EC-1101, EC-1107, EC-1373, EC-1381, EC-1549 Heated oxygen sensor 1 heater ....... EC-143, EC-763, EC-985, EC-1557 Heated oxygen sensor 2 ..... EC-203, EC-210, EC-322, EC-330, EC-591, EC-768, EC-991, EC-998, EC-1113, EC-1121, EC-1388, EC-1563 Heated oxygen sensor 2 heater ....... EC-149, EC-774, EC-1006, EC-1569 Heated seat ......................................................... SE-4 Height (Dimensions) ........................................... GI-48 HFC134a (R134a) system precaution .. ATC-4, MTC-4 HFC134a (R134a) system service procedure ATC-135, MTC-81 HFC134a (R134a) system service tools ......... ATC-12, MTC-12 HFC134a system service equipment precaution .......... ATC-8, MTC-8 HLC - Wiring diagram ...................................... WW-75 HO2S1 - Wiring diaram ...... EC-180, EC-188, EC-198, EC-579, EC-586, EC-961, EC-970, EC-980, EC-1375, EC-1383 HO2S1H - Wiring diagram ................. EC-145, EC-987 HO2S2 - Wiring diagram .... EC-205, EC-213, EC-325, EC-333, EC-593, EC-993, EC-1001, EC-1116, EC-1124, EC-1390 HO2S2H - Wiring diagram ............... EC-151, EC-1008 Horn ................................................................. WW-89 HORN - Wiring diagram ................................... WW-89 How to erase DTC ......................................... EC-1628 How to erase DTC for OBD system .... EC-57, EC-478, EC-841, EC-1267 HSEAT - Wiring diagram ..................................... SE-5 I IATS - Wiring diagram ...... EC-163, EC-944, EC-1716 IATSEN - Wiring diagram ................ EC-780, EC-1576 Identification plate ............................................... GI-47 Idle air volume learning ........ EC-69, EC-486, EC-858, EC-1279 Idle speed EC-66, EC-483, EC-851, EC-856, EC-1272, EC-1277 Idle speed control (ISC) ................................. EC-1616 Ignition coil ......... EM-132, EC-433, EC-784, EC-1221, EC-1580 Ignition control system ..... EC-433, EC-784, EC-1221, EC-1580 Ignition timing ......... EC-66, EC-483, EC-851, EC-856, EC-1272, EC-1277 IGNSYS - Wiring diagram EC-434, EC-785, EC-1222, EC-1581 In vehicle sensor ........................... ATC-102, ATC-115 INJECT - Wiring diagram . EC-422, EC-745, EC-1210, EC-1538, EC-1741, EC-1746 Injector .............. EC-421, EC-744, EC-1209, EC-1537 Injector adjustment value ............................... EC-1731 Injector adjustment value registration ............ EC-1625 Intake air system ................................ EC-338, EC-654 Intake air temperature sensor ........... EC-161, EC-779, EC-942, EC-1575, EC-1715 Intake door control linkage adjustment ........... ATC-70, MTC-38, MTC-70 Intake door motor ............................ ATC-68, ATC-124 Intake manifold ............................................... EM-120 Intake sensor ................................ ATC-108, ATC-117 Intake valve timing control . EC-139, EC-554, EC-930, EC-1349 Intake valve timing control solenoid valve ...... EC-286, EC-630, EC-930, EC-1077, EC-1349, EC-1425 Interior lamp ...................................................... LT-150 IPDM (Intelligent power distribution module engine room) ................................................................. PG-18 ISO 15031-2 Terminology ................................... GI-49 ISO 15031-5 Service $01 - 09 ............. EC-47, EC-830 IVC - Wiring diagram ....... EC-287, EC-631, EC-1078, EC-1426 K Keyless entry system - See Multi-remote control system BL-111 Knock sensor (KS) ........... EC-246, EC-605, EC-1038, EC-1401, EC-1770 Knuckle spindle .................................................. FAX-6 IDX-5 A B C D E F G H I J K L IDX ALPHABETICAL INDEX KS - Wiring diagram ......... EC-247, EC-606, EC-1039, EC-1402, EC-1771 L Length (Dimensions) ........................................... GI-48 Line pressure test (A/T) ..................................... AT-56 Liquid gasket application ....... EM-106, EM-228, LU-3, LU-13, CO-3, CO-22 Location of electrical units ................................. PG-82 Lubricant (R134a) A/C ....... ATC-5, ATC-17, ATC-151, MTC-5, MTC-17, MTC-97 Lubricants ......................................................... MA-24 Lubrication circuit (engine) ....................... LU-5, LU-15 Lubrication oil A/C ........................... ATC-151, MTC-97 Lubrication-locks, hinges and hood latches ...... MA-61 Luggage compartment trim ................................. EI-32 M MAFS - Wiring diagram .. EC-937, EC-1356, EC-1723 Magnet clutch ................................... ATC-78, MTC-43 MAIN - Wiring diagram ...... EC-128, EC-543, EC-918, EC-1337, EC-1698 Malfunction indicator (MI) .................... EC-58, EC-479 Malfunction indicator lamp (MIL) ...... EC-843, EC-1268 Manifold absolute pressure (MAP) sensor ...... EC-155, EC-559 Manual air conditioner - Wiring diagram ......... MTC-26 Mass air flow sensor (MAFS) .......... EC-935, EC-1354, EC-1722 Master cylinder (brake) ...................................... BR-14 MIL data link connectors circuit ..... EC-1236, EC-1596 MIL/DL - Wiring diagram .. EC-448, EC-800, EC-1236, EC-1596, EC-1869 Mirror, door ....................................................... GW-96 Mirror, out side .................................................. GW-96 Misfire ............................. EC-240, EC-1032, EC-1768 Mode door control linkage adjustment ............ ATC-62, MTC-36, MTC-72 Mode door motor ............................ ATC-60, ATC-126 Model variation ................................................... GI-45 Molding - See Exterior ................... EI-16, EI-17, EI-19 Multiport fuel injection (MFI) system ... EC-34, EC-463, EC-817, EC-1251 Multiport fuel injection precautions ....................... GI-6 Multi-remote control system ............................. BL-111 N NATS - Wiring diagram .................................... BL-219 NATS (Nissan anti-theft system) precautions ....... GI-3 NVH troubleshooting (BR) ......................... BR-5, PB-2 NVH troubleshooting (RSU) .............................. RSU-4 NVH troubleshooting (ST) .................................... PS-4 O Oil cooler (engine) ............................................. LU-27 Oil filter ......................................... LU-9, LU-19, LU-25 Oil pan (engine) ................................ EM-127, EM-257 Oil pressure (engine) ................... LU-6, LU-16, LU-23 Oil pump (engine) .................................. LU-10, LU-26 Oil seal replacement (engine) ......................... EM-170 Oil vapour rebreathing ................................... EC-1622 On board diagnostic system EC-47, EC-476, EC-830, EC-1264, EC-1628 Out side mirror ................................................. GW-96 Overdrive control switch ..... AT-197, AT-202, AT-288, AT-293 Overheat .......... EC-345, EC-662, EC-1130, EC-1451, EC-1864 Oversize piston ............................................... EM-210 P Park/Neutral position switch ............ EC-371, EC-688, EC-1158, EC-1479 Park/neutral position switch (A/T) ..... AT-105, AT-197, AT-288 Parking brake control ........................................... PB-3 PCV (positive crankcase ventilation) . EC-45, EC-474, EC-828, EC-1262 PGC/V - Wiring diagram . EC-272, EC-1065, EC-1531 PHASE - Wiring diagram . EC-259, EC-618, EC-1051, EC-1415 Piston assembly ................................ EM-210, EM-326 Piston pin inspection ....................................... EM-326 Piston ring inspection ........................ EM-207, EM-327 Piston to bore clearance ................................. EM-210 PNP/SW - Wiring diagram EC-373, EC-689, EC-1160, EC-1480 POS - Wiring diagram ...... EC-252, EC-611, EC-1044, EC-1407 POWER - Wiring diagram ................................... PG-5 Power door lock ................................................. BL-16 Power socket ................................................... WW-91 Power steering gear ............................................. PS-9 Power supply routing .......................................... PG-4 Power transistor ............................................ ATC-127 Power window ........................ GW-32, GW-89, GW-93 Precations for Leak detection dye ... ATC-11, MTC-11 Precautions (General) ........................................... GI-4 PRGVLV - Wirng diagram ................................ EC-738 R R/FOG - Wiring diagram .................................... LT-90 Radiator ................................... CO-12, CO-31, CO-51 Radiator fan - See Cooling fan ......................... CO-52 Radio - See Audio ................................................ AV-3 Rain sensor ........................................................ WW-4 Rear axle .......................................................... RAX-5 Rear bumper ......................................................... EI-8 Rear combination lamp removal and installation .......... LT-149 Rear drum brake ................................................ BR-27 Rear seat ........................................................... SE-12 IDX-6 ALPHABETICAL INDEX Rear seat belt ...................................................... SB-4 Rear suspension ............................................... RSU-5 Rear washer .................................................... WW-49 Rear window defogger ...................................... GW-12 Rear wiper ....................................................... WW-49 Refrigerant connection precaution ........ ATC-5, MTC-5 Refrigerant discharging evacuating charging ATC-135, MTC-81 Refrigerant general precaution ............. ATC-4, MTC-4 Refrigerant lines ............................. ATC-135, MTC-81 Refrigerant pressure sensor ............. EC-443, EC-794, EC-1231, EC-1590, EC-1811, ATC-85, MTC-51 Refrigeration cycle ............................ ATC-15, MTC-15 Removal and installation (A/T) ........................ AT-356 Road test ........................ AT-58, AT-61, AT-64, AT-65 Road wheel size ................................................. GI-48 Rocker cover .................................... EM-140, EM-270 Roof trim .............................................................. EI-30 Room lamp - See Interior lamp ......................... LT-150 ROOM/L - Wiring diagram ................................ LT-155 RP/SEN - Wiring diagram . EC-444, EC-795, EC-1232, EC-1591, EC-1812 RRO2 - Wiring diagram .... EC-769, EC-775, EC-1564, EC-1570 S S/LOCK - Wiring diagram BL-21, BL-27, BL-65, BL-72 Seat belt inspection ................................. SB-5, MA-61 Seat belt pre-tensioner .............................. SB-3, SB-4 Seat belt pre-tensioner disposal ...................... SRS-49 Seat belt, front ........................................... SB-3, SB-4 Seat belt, rear ...................................................... SB-4 Seat, front ............................................................ SE-7 Seat, rear ........................................................... SE-12 Self-diagnostic results ..................... EC-893, EC-1313 SEN/PW - Wiring diagram EC-364, EC-681, EC-1151, EC-1472, EC-1830 Sheft warning system ....................................... BL-214 SHIFT - Wiring diagram ................................... AT-339 Shift lock system .............................................. AT-338 Shift schedule .................................................... AT-67 Shock absorber (front) ....................................... FSU-8 Shock absorber (rear) ....................................... RSU-7 Side air bag ...................................... SRS-42, SRS-44 Side air bag (satellite) sensor .......................... SRS-46 Side curtain air bag .......................................... SRS-44 Side trim .............................................................. EI-26 SMJ (super multiple junction) ............................ PG-92 Spare tire size ..................................................... GI-48 Spark plug ....................................................... EM-133 Spark plug replacement(CR) ............................. MA-36 Spark plug replacement(HR) ............................. MA-47 Specification value EC-117, EC-532, EC-907, EC-1326 Spiral cable ...................................................... SRS-38 Spot lamp ......................................................... LT-171 SRS - See Supplemental Restraint System ...... SRS-5 SRS - Wiring diagram ....................... SRS-11, SRS-12 SRS Trouble diagnoses ..................................... SRS-8 Stabilizer bar (front) ......................................... FSU-11 Stall test (A/T) .................................................... AT-53 Standardized relay ............................................. PG-93 START - Wiring diagram ........................ SC-46, SC-48 Starter ................................................................ SC-45 Starting system .................................................. SC-45 Steering gear and linkage inspection ................ MA-60 Steering linkage ................................................... PS-9 Steering wheel and column ....................... PS-5, PS-7 Steering wheel play ............................................. PS-5 Steering wheel turning force ................................ PS-5 Stop lamp .......................................................... LT-129 Stop lamp switch EC-377, EC-693, EC-1167, EC-1487, EC-1820, EC-1850 STOP/L - Wiring diagram .................................. LT-129 Sunload sensor ............................. ATC-105, ATC-116 Super lock .......................................................... BL-59 Supplemental Restraint System ....................... SRS-5 Supplemental restraint system - Wiring diagram .......... SRS-11, SRS-12 Suspension ....................................................... MA-60 Symbols and abbreviations ...................... GI-11, GI-23 Symptom matrix chart .......... EC-82, EC-499, EC-871, EC-1292 SYSTEM ........................................................... BRC-6 System readiness test (SRT) code ...... EC-51, EC-834 T TC boost control solnoid valve ....................... EC-1710 TC boost sensor ............................................ EC-1763 TCBST-Wiring diagram .................................. EC-1764 TCC/V - Wiring diagram ................................. EC-1711 TCM inspection table ......................................... AT-80 THEFT - Wiring diagram .................................. BL-214 Thermo control amp ........................................ MTC-64 Thermostat ............................................ CO-19, CO-38 Three way catalyst function ............. EC-264, EC-1056 Three way catalyst precautions ............................ GI-5 Throttle control motor ... EC-1084, EC-1096, EC-1433, EC-1445 Throttle control motor relay EC-299, EC-643, EC-1084, EC-1090, EC-1433, EC-1439 Throttle position sensor (TPS) .......... EC-171, EC-233, EC-359, EC-361, EC-402, EC-570, EC-598, EC-676, EC-678, EC-718, EC-953, EC-1026, EC-1146, EC-1148, EC-1191, EC-1367, EC-1395, EC-1467, EC-1469, EC-1511 Throttle valve closed position learning EC-69, EC-486, EC-857, EC-1279 Tie-rod ................................................................. PS-9 Tie-rod ball joints ................................................. PS-9 Tightening torque of standard bolts .................... GI-44 Timing belt ...................................................... EM-272 Timing chain ................................................... EM-142 Tire size .............................................................. GI-48 Torque converter installation ............. AT-358, AT-465 Tow truck towing ................................................. GI-42 TPS1 - Wiring diagram .... EC-235, EC-600, EC-1028, IDX-7 A B C D E F G H I J K L IDX ALPHABETICAL INDEX EC-1397 TPS2 - Wiring diagram ...... EC-173, EC-572, EC-955, EC-1369 TPS3 - Wiring diagram .... EC-404, EC-720, EC-1193, EC-1513 Tread-FR&RR (Dimensions) ............................... GI-48 Trouble diagnoses .............................................. GI-12 Trouble diagnosis-Basic test procedure ........ EC-1660 Trouble diagnosis-Symptom .......................... EC-1634 Turbocharger .................................................. EM-253 Turbocharger precautions ..................................... GI-6 TURN - Wiring diagram .................................... LT-101 Turn signal lamp ................................................. LT-98 Two trip detection logic ........ EC-47, EC-476, EC-830, EC-1264 WIPER - Wiring diagram .................................. WW-13 Wiring Diagram (Cell code) list ......................... PG-79 Wiring diagrams .................................................. GI-16 Wrist pin - See Piston pin inspection .............. EM-206 V Vacuum hose (brake system) ............................ BR-19 Vacuum hose drawing (Engine control) ............ EC-92, EC-509, EC-880, EC-1301, EC-1611 Vacuum pump ................................................. EM-261 Valve clearance ................. EM-166, EM-292, EM-324 Valve guide ....................................... EM-179, EM-322 Valve lifter ....................................................... EM-160 Valve seat ......................................... EM-181, EM-322 Valve spring ...................................... EM-182, EM-324 VDC -Wiring diagram ...................................... BRC-54 Vehicle identification number .............................. GI-46 Vehicle recovery (freeing a stuck vehicle) .......... GI-42 Vehicle speed sensor (VSS) ............. EC-277, EC-799, EC-1070, EC-1595, EC-1810 Ventilation air filter .......................... ATC-129, MTC-75 Viscosity number (SAE) .................................... MA-25 W WARN - Wiring diagram .......................... DI-34, DI-40 Warning chime .................................................... DI-53 Warning lamps .................................................... DI-33 Water pump ............................. CO-17, CO-36, CO-54 Wheel alignment (front) ..................................... FSU-6 Wheel alignment (rear) ..................................... RSU-6 Wheel bearing (front) ......................................... FAX-6 Wheel bearing (rear) ......................................... RAX-5 Wheel hub (front) ............................................... FAX-6 Wheel hub (rear) ............................................... RAX-5 Wheel sensor (VDC) ....................................... BRC-86 Wheel sensors (ABS) ..................................... BRC-36 Wheel size .......................................................... GI-48 Wheelbase (Dimensions) .................................... GI-48 Width (Dimensions) ............................................ GI-48 WINDOW - Wiring diagram ................. GW-41, GW-45 Window antenna ................................................ AV-11 Window, back ................................................... GW-10 Window, back door ........................................... GW-10 Window, door ...................................... GW-89, GW-93 Windshield .......................................................... GW-5 WIP/R - Wiring diagram ..................... WW-51, WW-54 IDX-8 INSTRUMENT PANEL I BODY SECTION IP INSTRUMENT PANEL A B C D CONTENTS PRECAUTIONS .......................................................... 2 Precautions for Supplemental Restraint System (SRS) “AIR BAG” and “SEAT BELT PRE-TENSIONER” .................................................................. 2 Precautions .............................................................. 2 CLIP AND FASTENER ............................................... 3 List of Table .............................................................. 3 INSTRUMENT PANEL ASSEMBLY ........................... 4 Component Parts Location ....................................... 4 Removal and Installation .......................................... 5 WORK ITEM TABLE ............................................. 5 REMOVAL ............................................................. 6 REMOVAL AND INSTALLATION OF INSTRU- MENT PAD .......................................................... 10 Disassembly and Assembly .................................... 11 GLOVE BOX ASSEMBLY ......................................... 12 Removal And Installation ........................................ 12 REMOVAL ........................................................... 12 INSTALLATION ................................................... 12 Disassembly And Assembly ................................... 12 DISASSEMBLY ................................................... 12 ASSEMBLY ......................................................... 12 CENTER CONSOLE ASSEMBLY ............................ 13 Removal And Installation ........................................ 13 REMOVAL ........................................................... 13 INSTALLATION ................................................... 13 Disassembly And Assembly ................................... 13 E F G H IP J K L M IP-1 PRECAUTIONS PFP:00001 PRECAUTIONS Precautions for Supplemental Restraint System (SRS) “AIR BAG” and “SEAT BELT PRE-TENSIONER” BIS000TY The Supplemental Restraint System such as “AIR BAG” and “SEAT BELT PRE-TENSIONER”, used along with a front seat belt, helps to reduce the risk or severity of injury to the driver and front passenger for certain types of collision. Information necessary to service the system safely is included in the SRS and SB section of this Service Manual. WARNING: ● To avoid rendering the SRS inoperative, which could increase the risk of personal injury or death in the event of a collision which would result in air bag inflation, all maintenance must be performed by an authorized NISSAN/INFINITI dealer. ● Improper maintenance, including incorrect removal and installation of the SRS, can lead to personal injury caused by unintentional activation of the system. For removal of Spiral Cable and Air Bag Module, see the SRS section. ● Do not use electrical test equipment on any circuit related to the SRS unless instructed to in this Service Manual. SRS wiring harnesses can be identified by yellow and/or orange harnesses or harness connectors. Precautions BIS000TZ Disconnect both battery cables in advance. Disconnect air bag system line in advance. ● Never tamper with or force air bag lid open, as this may adversely affect air bag performance. ● Be careful not to scratch pad and other parts. ● When removing or disassembling any part, be careful not to damage or deform it. Protect parts, which may get in the way with cloth. ● When removing parts with a screwdriver or other tool, protect parts by wrapping them with vinyl or tape. ● Keep removed parts protected with cloth. ● If a clip is deformed or damaged, replace it. ● If an unreusable part is removed, replace it with a new one. ● Tighten bolts and nuts firmly to the specified torque. ● After re-assembly has been completed, make sure each part functions correctly. ● Remove stains in the following way. Water-soluble stains: Dip a soft cloth in warm water, and then squeeze it tightly. After wiping the stain, wipe with a soft dry cloth. Oil stain: Dissolve a synthetic detergent in warm water (density of 2 to 3% or less), dip the cloth, then clean off the stain with the cloth. Next, dip the cloth in fresh water and squeeze it tightly. Then clean off the detergent completely. Then wipe the area with a soft dry cloth. ● Do not use any organic solvent, such as thinner or benzine. ● ● IP-2 CLIP AND FASTENER CLIP AND FASTENER List of Table Symbol No. PFP:76906 A BIS000U0 Shape Removal and installation B C D E MIIB0017E F G H IP J K L M IP-3 INSTRUMENT PANEL ASSEMBLY INSTRUMENT PANEL ASSEMBLY Component Parts Location PFP:68200 BIS000U1 MIIB9296E IP-4 INSTRUMENT PANEL ASSEMBLY 1. Steering member 2. Upper instrument panel 3. Passenger air bag module* 4. Side ventilator grille (LH) 5. Instrument pad (driver side) 6. Instrument pad (passenger side) 7. Side ventilator grille (RH) 8. Instrument side mask (LH) 9. Instrument panel 10. Instrument side mask (RH) 11. Instrument panel stay (LHD only) 12. Instrument member bracket (RH) 13. Combination meter 14. Audio unit bracket (LH) 15. Audio unit (CD changer) 16. Audio unit bracket (RH) 17. Audio unit bracket (LH) 18. Deck pocket 19. Audio unit (CD) 20. Audio unit bracket (RH) 21. Switch panel finisher 22. Cluster lid A 23. Cluster lid C upper mask 24. Glove box cover assembly 25. Glove box lid 26. Fuse block lid 27. Cluster lid C (CD changer) 28. Cluster lid C (CD) 29. Steering column cover upper 30. Steering column protector 31. Steering column cover lower 32. Steering lock escutcheon 33. Central ventilator grille (LH) 34. Cluster lid C lower mask 35. Central ventilator grille (RH) 36. Air conditioner finisher 37. Instrument finisher lower 38. Instrument panel stay cover 39. Cup holder 40. Instrument panel stay finisher (LHD only) 41. Center console 42. Console mask A B C D E *: Refer to SRS section. F : Insertion : Pawl : Plastic clip G : Metal clip Removal and Installation BIS000U2 WORK ITEM TABLE Component Parts Location Instrument panel Instrument pad (passenger side) Instrument pad (driver side) Upper instrument panel Combination meter A. Front pillar garnish IP-6 [1] [1] [1] B. Upper instrument panel IP-6 [2] [2] [2] C. Steering lock escutcheon IP-6 [3] [3] D. Instrument finisher lower IP-6 [4] [4] E. Switch panel finisher IP-6 [5] [5] F. Steering column cover upper IP-7 [6] [6] [1] [1] G. Steering column cover lower IP-7 [7] [7] [2] [2] H. Combination switch IP-7 [8] [8] I. Cluster lid A IP-7 [9] [9] [3] [3] J. Combination meter IP-7 [ 10 ] [ 10 ] [4] [4] K. Cluster lid C IP-8 [ 11 ] [ 11 ] [5] L. Air conditioner finisher IP-9 [ 12 ] [ 12 ] [6] M. Instrument pad (driver side) IP-9 [ 13 ] [ 13 ] [7] N. Center consol IP-9 [ 14 ] [ 14 ] O. Instrument panel stay cover IP-9 [ 15 ] [ 15 ] P. Glove box lid IP-9 Q. Glove box cover assembly IP-10 [ 16 ] [ 16 ] R. Instrument side mask IP-10 [ 17 ] [ 17 ] S. Steering wheel IP-10 [ 18 ] [ 18 ] T. Instrument panel IP-10 [ 19 ] [ 19 ] U. Instrument pad (passenger side) IP-10 [ 20 ] IP-5 Audio unit H IP J K L M [1] INSTRUMENT PANEL ASSEMBLY [ ]: The number shows the removal order. REMOVAL A. Front Pillar Garnish Refer to EI-26, "BODY SIDE TRIM" in EI section. B. Upper Instrument Panel 1. 2. 3. Disconnect sunload sensor harness connector and remove the sunload sensor (if equipped). Refer to ATC-116, "Removal and Installation" . Lift up the upper instrument panel on one side to disengage metal clips. Remove the upper instrument panel. MIIB9300E C. Steering Lock Escutcheon Pull to release steering lock escutcheon from the steering column cover. CAUTION: To install, align key cylinder end bottom protrusion with escutcheon inside notch and install. D. Instrument Finisher Lower Disengage upper plastic clips, and pull carefully rearward to remove avoiding interference with surrounding surfaces. MIIB9315E E. Switch Panel Finisher 1. Remove fuse block lid. MIIB9310E IP-6 INSTRUMENT PANEL ASSEMBLY 2. 3. Push the switch panel finisher to rear direction as shown. Disconnect harness connectors and remove the switch panel finisher. A B C MIIB9301E D F. Steering Column Cover Upper 1. Tilt down the steering column, and remove screw (1) facing front of vehicle. 2. Disengage hooks and remove. CAUTION: Pull out being careful of interference with surrounding objects. E G. Steering Column Cover Lower F Remove screws (3), and pull downward to remove. CAUTION: Pull out being careful of interference with surrounding objects. G H. Combination Switch Refer to LT-112, "Removal and Installation" . H I. Cluster Lid A Pull the cluster lid A to rearward direction and remove. CAUTION: Pull out being careful of interference with surrounding objects. IP J K MIIB9302E L J. Combination Meter 1. 2. 3. 4. 5. Remove screw (1). Pull rearward to disengage plastic clips as shown. Disconnect harness connectors. Lift up the lower side of combination meter to rotate the combination meter from the vertical to horizontal position. Remove the combination meter from the instrument pad. M MIIB9303E IP-7 INSTRUMENT PANEL ASSEMBLY K. Cluster Lid C 1. 2. Remove cluster lid C upper mask and remove upper fixing screws. Remove cluster lid C lower mask and remove lower fixing screws. MIIB9313E 3. 4. Pull rearward to release the cluster lid from instrument panel and pad. Disconnect antenna connector and audio harness connector. MIIB9314E After removal: ● Separate the central ventilator grille LH and RH. Refer to ATC-130, "Removal and Installation" and MTC76, "Removal and Installation" . ● For (A) audio unit models, remove screws (4) securing audio unit bracket LH and RH to release deck pocket and audio unit. ● For (B) audio unit models, remove screws (2) securing audio unit bracket LH and RH to release audio unit. MIIB9311E IP-8 INSTRUMENT PANEL ASSEMBLY L. Air Conditioner Finisher Refer to ATC-112, "Removal and Installation of Controller" MTC-62, "Removal and Installation" . A and B C MIIB9308E D M. Instrument Pad (Driver Side) Pull rearward to disengage metal clips from the instrument panel. CAUTION: Pull out being careful of interference with surrounding objects. After removal and if necessary, remove the side ventilator grille. Refer to ATC-130, "Removal and Installation" and MTC-76, "Removal and Installation" . E F N. Center Console Refer to IP-13, "Removal And Installation" . G O. Instrument Panel Stay Cover 1. Remove instrument panel stay finisher. H IP J MIIB9305E 2. 3. 4. Remove mounting clips LH and RH. Pull instrument stay cover to rearward to disengage plastic clips. Disconnect power supply or cigar lighter harness connector if equipped. 5. Remove instrument stay cover. After removal, if necessary, remove screws securing the cup holder to the instrument stay cover, and remove cup holder. L M MIIB9304E P. Glove Box Lid. Refer to IP-12, "GLOVE BOX ASSEMBLY" . IP-9 K INSTRUMENT PANEL ASSEMBLY Q. Glove Box Cover Assembly 1. 2. Remove screws shown in the figure and remove the glove box assembly. After removal, separate parts if necessary. Refer to IP-12, "GLOVE BOX ASSEMBLY" . MIIB9307E R. Instrument Side Mask 1. 2. 3. 4. From inner side of instrument panel, push to disengage pawls as shown. Disconnect airbag cut-off switch from harness (passenger side only). Disengage airbag cut-off switch from instrument side mask (passenger side only). Pull out inserted area of instrument side mask and remove from vehicle. MIIB9306E S. Steering Wheel Refer to SRS-36, "DRIVER AIR BAG MODULE" and SRS-38, "SPIRAL CABLE" . T. Instrument Panel 1. 2. 3. 4. Remove the fuel filler lid opener. Refer to BL-212, "Removal and Installation of Fuel Filler Lid Opener" . Tilt down steering column. Remove screws, refer to IP-11, "Disassembly and Assembly" , and remove instrument panel and pad from passenger door opening. NOTE: This operation requires two workers. After removal, separate parts. Refer to IP-11, "Disassembly and Assembly" . U. Instrument Pad (Passenger Side) Remove mountings screws (3) securing the instrument pad to the instrument panel, and release metal clips and remove the instrument pad (passenger side) from the Instrument panel. Refer to IP-11, "Disassembly and Assembly" . After removal and if necessary, remove the side ventilator grille. Refer to ATC-130, "Removal and Installation" and MTC-76, "Removal and Installation" . REMOVAL AND INSTALLATION OF INSTRUMENT PAD Driver Side: 1. 2. 3. 4. 5. 6. 7. Remove the steering column upper cover. Refer to IP-7, "F. Steering Column Cover Upper" . Remove the steering column lower cover. Refer to IP-7, "G. Steering Column Cover Lower" . Remove the cluster lid A. Refer to IP-7, "I. Cluster Lid A" . Remove the combination meter. Refer to IP-7, "J. Combination Meter" . Remove the cluster lid C. Refer to IP-8, "K. Cluster Lid C" . Remove the air conditioner finisher. Refer to IP-9, "L. Air Conditioner Finisher" . Remove the instrument pad (driver side). Refer to IP-9, "M. Instrument Pad (Driver Side)" . Passenger Side: 1. Remove the instrument panel assembly. Refer to IP-6, "REMOVAL" . IP-10 INSTRUMENT PANEL ASSEMBLY 2. Remove the instrument pad (passenger side). Refer to IP-10, "U. Instrument Pad (Passenger Side)" . A Installation Install in the reverse order of removal. B Disassembly and Assembly BIS000U3 C D E F G H IP J MIIB9298E 1. Instrument pad (driver side) 2. Instrument pad (passenger side) 3. Instrument panel K : Metal clip L M IP-11 GLOVE BOX ASSEMBLY GLOVE BOX ASSEMBLY Removal And Installation PFP:68510 BIS0014W REMOVAL 1. Remove the glove box assembly. Refer to IP-10, "Q. Glove Box Cover Assembly" . INSTALLATION Install in the reverse order of removal. Disassembly And Assembly BIS0014X MIIB9297E 1. Spring assembly 4. Air conditioner inlet 2. Glove box cover 3. Glove box lid DISASSEMBLY 1. 2. 3. Remove spring assembly screw. Push glove box lid hooks to disengage glove box lid from the glove box cover. Remove the air conditioner inlet from the glove box cover. MIIB9312E ASSEMBLY Assembly is in the reverse order of disassembly. IP-12 CENTER CONSOLE ASSEMBLY CENTER CONSOLE ASSEMBLY Removal And Installation PFP:96910 A BIS0014U REMOVAL 1. Remove shift knob from the shift lever (for manual transmission vehicles only). Refer to MT-12, "Removal and Installation of Control Device and Cable" (JH3), MT-42, "Removal and Installation of Control Device and Cable" (JR5). 2. Engage the shift knob in neutral position (for automatic transmission only). 3. Remove console mask. Refer to IP-13, "Disassembly And Assembly" . 4. Pull up parking brake lever, and remove finisher from the lever. 5. Remove the armrest (if equipped) from the driver seat (for manual transmission vehicles only). Refer to SE-7, "Component Parts Location" . 6. Remove power socket or cigar lighter from the center console and disconnect harness connector. 7. Slide front seat to access to the center console rear fixing screws. 8. Lift up the front side of the center console to disengage fixing clips. 9. Disconnect all harness connectors. 10. Remove the center console. B C D E F G MIIB9309E H INSTALLATION Install in the reverse order of removal. IP Disassembly And Assembly BIS0014V J K L M MIIB9299E 1. Control lever finisher 2. Coin compartment 3. Console mask 4. Switch holder 5. Cup holder 6. Power socket 7. Power socket finisher 8. Center console IP-13 CENTER CONSOLE ASSEMBLY IP-14 LAN SYSTEM K ELECTRICAL SECTION LAN LAN SYSTEM A B C D CONTENTS CAN PRECAUTIONS .......................................................... 3 Precautions for Supplemental Restraint System (SRS) “AIR BAG” and “SEAT BELT PRE-TENSIONER” .................................................................. 3 Maintenance Information .......................................... 3 RHD MODELS ...................................................... 3 LHD MODELS ....................................................... 3 Precautions When Using CONSULT-II ..................... 3 CHECK POINTS FOR USING CONSULT-II ......... 3 Precautions for Trouble Diagnosis ........................... 4 CAN SYSTEM ....................................................... 4 Precautions for Harness Repair ............................... 4 CAN SYSTEM ....................................................... 4 TROUBLE DIAGNOSES WORK FLOW .................... 5 When Displaying CAN Communication System Errors ....................................................................... 5 WHEN A MALFUNCTION IS DETECTED BY CAN COMMUNICATION SYSTEM ....................... 5 WHEN A MALFUNCTION IS DETECTED EXCEPT CAN COMMUNICATION SYSTEM ........ 5 TROUBLE DIAGNOSIS FLOW CHART ............... 6 Diagnosis Procedure ................................................ 7 SELECTING CAN SYSTEM TYPE (HOW TO USE SPECIFICATION TABLE) ............................. 7 ACQUISITION OF DATA BY CONSULT-II ............ 8 HOW TO USE CHECK SHEET TABLE ................ 9 CAN Diagnostic Support Monitor ........................... 15 DESCRIPTION OF “CAN DIAG SUPPORT MNTR” SCREEN FOR ECM ............................... 15 DESCRIPTION OF “CAN DIAG SUPPORT MNTR” SCREEN FOR INTELLIGENT KEY UNIT... 17 DESCRIPTION OF “CAN DIAG SUPPORT MNTR” SCREEN FOR EPS CONTROL UNIT ... 17 DESCRIPTION OF “CAN DIAG SUPPORT MNTR” SCREEN FOR BCM ............................... 18 DESCRIPTION OF “CAN DIAG SUPPORT MNTR” SCREEN FOR ABS ACTUATOR AND ELECTRIC UNIT (CONTROL UNIT) ................... 18 DESCRIPTION OF “CAN DIAG SUPPORT MNTR” SCREEN FOR TCM ................................ 20 DESCRIPTION OF “CAN DIAG SUPPORT MNTR” SCREEN FOR IPDM E/R ....................... 20 CAN COMMUNICATION ........................................... 21 System Description ................................................. 21 Component Parts and Harness Connector Location... 21 LHD MODEL ....................................................... 21 RHD MODEL ....................................................... 22 Wiring Diagram — CAN — ..................................... 23 CR14DE/HR16DE MODEL ................................. 23 K9K MODEL ........................................................ 25 CAN Communication Unit ....................................... 27 TYPE 1/TYPE 2 ................................................... 28 TYPE 3/TYPE 4 ................................................... 30 TYPE 5/TYPE 6 ................................................... 32 TYPE 7/TYPE 8 ................................................... 34 TYPE 9/TYPE 10 ................................................. 36 CAN SYSTEM (TYPE 1) ........................................... 38 Component Parts and Harness Connector Location... 38 Wiring Diagram — CAN — ..................................... 38 Check Sheet ........................................................... 38 Check Sheet ........................................................... 39 CHECK SHEET RESULTS (EXAMPLE) ............. 41 CAN SYSTEM (TYPE 2) ........................................... 51 Component Parts and Harness Connector Location... 51 Wiring Diagram — CAN — ..................................... 51 Check Sheet ........................................................... 51 Check Sheet ........................................................... 52 CHECK SHEET RESULTS (EXAMPLE) ............. 54 CAN SYSTEM (TYPE 3) ........................................... 65 Component Parts and Harness Connector Location... 65 Wiring Diagram — CAN — ..................................... 65 Check Sheet ........................................................... 65 Check Sheet ........................................................... 66 CHECK SHEET RESULTS (EXAMPLE) ............. 68 CAN SYSTEM (TYPE 4) ........................................... 79 Component Parts and Harness Connector Location... 79 Wiring Diagram — CAN — ..................................... 79 LAN-1 E F G H I J LAN L M Check Sheet ........................................................... 79 Check Sheet ........................................................... 80 CHECK SHEET RESULTS (EXAMPLE) ............. 82 CAN SYSTEM (TYPE 5) ........................................... 94 ComponentParts and Harness Connector Location... 94 Wiring Diagram — CAN — ..................................... 94 Check Sheet ........................................................... 94 Check Sheet ........................................................... 95 CHECK SHEET RESULTS (EXAMPLE) ............. 97 CAN SYSTEM (TYPE 6) ......................................... 108 ComponentParts and Harness Connector Location. 108 Wiring Diagram — CAN — ................................... 108 Check Sheet ......................................................... 108 Check Sheet ......................................................... 109 CHECK SHEET RESULTS (EXAMPLE) ............111 CAN SYSTEM (TYPE 7) ......................................... 123 ComponentParts and Harness Connector Location. 123 Wiring Diagram — CAN — ................................... 123 Check Sheet ......................................................... 123 Check Sheet ......................................................... 124 CHECK SHEET RESULTS (EXAMPLE) ........... 126 CAN SYSTEM (TYPE 8) ......................................... 136 ComponentParts and Harness Connector Location. 136 Wiring Diagram — CAN — ................................... 136 Check Sheet ......................................................... 136 Check Sheet ......................................................... 137 CHECK SHEET RESULTS (EXAMPLE) ........... 139 CAN SYSTEM (TYPE 9) ......................................... 150 ComponentParts and Harness Connector Location. 150 Wiring Diagram — CAN — ................................... 150 Check Sheet ......................................................... 150 Check Sheet ......................................................... 151 CHECK SHEET RESULTS (EXAMPLE) ............ 153 CAN SYSTEM (TYPE 10) ........................................ 164 ComponentParts and Harness Connector Location.164 Wiring Diagram — CAN — ................................... 164 Check Sheet ......................................................... 164 Check Sheet ......................................................... 165 CHECK SHEET RESULTS (EXAMPLE) ............ 167 TROUBLE DIAGNOSIS FOR SYSTEM .................. 179 Inspection Between Data Link Connector and ABS Actuator and Electric Unit (Control Unit) Circuit .... 179 ECM Circuit Inspection ......................................... 180 Data Link Connector Circuit Inspection ................. 182 Data Link Connector and CAN Communication Circuit Inspection ....................................................... 182 Combination Meter Circuit Inspection ................... 184 Intelligent Key Unit Circuit Inspection ................... 184 Steering Angle Sensor Circuit Inspection .............. 185 EPS Control Unit Circuit Inspection ...................... 185 BCM Circuit Inspection ......................................... 186 ABS Actuator and Electric Unit (Control Unit) Circuit Inspection .............................................................. 186 TCM Circuit Inspection .......................................... 187 IPDM E/R Circuit Inspection ................................. 188 CAN Communication Circuit Inspection ................ 188 IPDM E/R Ignition Relay Circuit Inspection ........... 190 LAN-2 PRECAUTIONS [CAN] PRECAUTIONS PFP:00001 Precautions for Supplemental Restraint System (SRS) “AIR BAG” and “SEAT BELT PRE-TENSIONER” [CAN] A BKS001IN The Supplemental Restraint System such as “AIR BAG” and “SEAT BELT PRE-TENSIONER”, used along with a front seat belt, helps to reduce the risk or severity of injury to the driver and front passenger for certain types of collision. Information necessary to service the system safely is included in the SRS and SB section of this Service Manual. WARNING: ● To avoid rendering the SRS inoperative, which could increase the risk of personal injury or death in the event of a collision which would result in air bag inflation, all maintenance must be performed by an authorized NISSAN/INFINITI dealer. ● Improper maintenance, including incorrect removal and installation of the SRS, can lead to personal injury caused by unintentional activation of the system. For removal of Spiral Cable and Air Bag Module, see the SRS section. ● Do not use electrical test equipment on any circuit related to the SRS unless instructed to in this Service Manual. SRS wiring harnesses can be identified by yellow and/or orange harnesses or harness connectors. Maintenance Information B C D E F BKS0028M If any of following part is replaced, always replace with new* one. If it's not (or fail to do so), the electrical system may not be operated properly. *: New one means a virgin control unit that has never been energized on-board. G RHD MODELS H ● ● ● ● ● ● BCM (Models without Intelligent Key system) Intelligent Key unit (Models with Intelligent Key system) ECM IPDM E/R Combination meter EPS control unit I J LHD MODELS ● ● ● BCM (Models without Intelligent Key system) Intelligent Key unit (Models with Intelligent Key system) ECM Precautions When Using CONSULT-II LAN L BKS001IO When connecting CONSULT-II to data link connector, connect them through CONSULT-II CONVERTER. CAUTION: If CONSULT-II is used with no connection of CONSULT-II CONVERTER, malfunctions might be detected in self-diagnosis depending on control unit which carry out CAN communication. CHECK POINTS FOR USING CONSULT-II 1. – – 2. – – 3. 4. 5. Has CONSULT-II been used without connecting CONSULT-II CONVERTER on this vehicle? If YES, GO TO 2. If NO, GO TO 5. Is there any indication other than indications relating to CAN communication system in the self-diagnostic results? If YES, GO TO 3. If NO, GO TO 4. Based on self-diagnostic results unrelated to CAN communication, carry out the inspection. Malfunctions may be detected in self-diagnosis depending on control units carrying out CAN communication. Therefore, erase the self-diagnosis results. Diagnose CAN communication system. Refer to LAN-5, "TROUBLE DIAGNOSES WORK FLOW" . LAN-3 M PRECAUTIONS [CAN] Precautions for Trouble Diagnosis BKS001IP CAN SYSTEM ● ● ● Do not apply voltage of 7.0 V or higher to the measurement terminals. Use the tester with its open terminal voltage being 7.0 V or less. Be sure to turn ignition switch OFF and disconnect the battery cable from the negative terminal before checking the circuit. Precautions for Harness Repair BKS001IQ CAN SYSTEM ● Solder the repaired parts, and wrap with tape. [Frays of twisted line must be within 110 mm (4.33 in).] PKIA0306E ● Do not perform bypass wire connections for the repair parts. (The spliced wire will become separated and the characteristics of twisted line will be lost.) PKIA0307E LAN-4 TROUBLE DIAGNOSES WORK FLOW [CAN] TROUBLE DIAGNOSES WORK FLOW When Displaying CAN Communication System Errors PFP:00004 A BKS001HW WHEN A MALFUNCTION IS DETECTED BY CAN COMMUNICATION SYSTEM ● ● ● CAN communication line is open. (CAN-H, CAN-L, or both) CAN communication line is shorted. (Ground, between CAN lines, or other harnesses) The areas related to CAN communication of unit is malfunctioning. WHEN A MALFUNCTION IS DETECTED EXCEPT CAN COMMUNICATION SYSTEM ● ● ● Removal and installation of parts: When the units that perform CAN communication or the sensors related to CAN communication are removed and installed, malfunction may be detected (or DTC other than CAN communication may be detected). Fuse blown out (removed): CAN communication of the unit may be stopped at such time. Low voltage: If the voltage decreases because of battery discharge when ignition switch is ON, malfunction may be detected by self-diagnosis according to the units. B C D E F G H I J LAN L M LAN-5 TROUBLE DIAGNOSES WORK FLOW [CAN] TROUBLE DIAGNOSIS FLOW CHART Depending on the control unit which performs CAN communication, “U1010” may be indicated as the result of self-diagnosis. Replace the control unit if “U1010” is indicated. PKIC9387E ● ● ● ● ● Step 1: Refer to LAN-7, "SELECTING CAN SYSTEM TYPE (HOW TO USE SPECIFICATION TABLE)" . Step 2: Refer to LAN-8, "ACQUISITION OF DATA BY CONSULT-II" . Step 3: Refer to LAN-9, "HOW TO USE CHECK SHEET TABLE" . Step 4: Refer to LAN-10, "Example of Filling in Check Sheet When Initial Conditions Are Reproduced" . Step 5: Refer to LAN-179, "TROUBLE DIAGNOSIS FOR SYSTEM" . LAN-6 TROUBLE DIAGNOSES WORK FLOW [CAN] Diagnosis Procedure BKS001HX A SELECTING CAN SYSTEM TYPE (HOW TO USE SPECIFICATION TABLE) Determine CAN system type from the equipment of the vehicle to select applicable check sheet. B C D E F G PKIC9395E H I J LAN L M LAN-7 TROUBLE DIAGNOSES WORK FLOW [CAN] ACQUISITION OF DATA BY CONSULT-II Attach the data acquired by CONSULT-II on the check sheet determined according to CAN system type. PKIC9388E LAN-8 TROUBLE DIAGNOSES WORK FLOW [CAN] HOW TO USE CHECK SHEET TABLE A B C D E F PKIC9389E 1. 2. Unit names displayed on CONSULT-II. G “No indication”: Put a check mark to it if the unit name described in step 1 is not displayed on “SELECT SYSTEM” screen of CONSULT-II. (Unit communicating with CONSULT-II via CAN communication line) “–”: Column not used (Unit communicating with CONSULT-II excluding CAN communication line) H 3. “NG”: Display “NG” when malfunction is detected in the initial diagnosis of the diagnosed unit. Replace the unit if “NG” is displayed. “–”: Column not used (Initial diagnosis is not performed.) I NOTE: It is unnecessary to replace ABS actuator and electric unit (control unit) when “NG” on “INITIAL DIAG” of “ABS” is indicated at this stage. “NG” is indicated not only when malfunctioning ABS actuator and electric J unit (control unit) but also other parts. See check sheet results for the system diagnosis. 4. “UNKWN”: Display “UNKWN” when the diagnosed unit does not transmit the data normally. Put a check mark to it if “UNKWN” is displayed on CONSULT-II. LAN “–”: Column not used (transmit diagnosis is not performed.) 5. “UNKWN”: Display “UNKWN” when the diagnosed unit does not receive the data normally. Put a check mark to it if “UNKWN” is displayed on CONSULT-II. “–”: Column not used (It is not necessary for CAN communication trouble diagnosis.) L NOTE: CAN communication diagnosis checks if CAN communication works normally. (Contents of data are not diagnosed.) M ● When the initial conditions are reproduced, refer to LAN-10, "Example of Filling in Check Sheet When Initial Conditions Are Reproduced" . ● When the initial conditions are not reproduced, refer to LAN-13, "Example of Filling in Check Sheet When Initial Conditions Are Not Reproduced" . LAN-9 TROUBLE DIAGNOSES WORK FLOW [CAN] Example of Filling in Check Sheet When Initial Conditions Are Reproduced PKIC9390E 1. 2. Put a check mark to “No indication” if some of unit names listed on the column of diagnosis system selection screen of a check sheet table are not displayed on “SELECT SYSTEM” screen attached to the check sheet. NOTE: Do not put a check mark on items in the column of “No indication” on the check sheet when displaying all items on “SELECT SYSTEM” screen. Confirm the unit name that “UNKWN” is displayed from the copy of “CAN DIAG SUPPORT MNTR” screen of “ENGINE” attached to the check sheet, and then put a check mark to the check sheet table. NOTE: In “CAN DIAG SUPPORT MNTR” screen, “UNKWN” is displayed on “TRNSMIT DIAG”, “VDC/TCS/ABS”, “BCM/SEC”, “EPS” and “IPDM E/R”. Put a check mark to it. LAN-10 TROUBLE DIAGNOSES WORK FLOW [CAN] A B C D E F G H PKIC9391E 3. I Confirm the unit name that “UNKWN” is displayed on the copy of “CAN DIAG SUPPORT MNTR” screen of “INTELLIGENT KEY”, “EPS”, “BCM”, “ABS” and “IPDM E/R” as well as “ENGINE”. And then, put a check mark to the check sheet table. J NOTE: ● For “INTELLIGENT KEY”, “UNKWN” is displayed on “ECM”. Put a check mark to it. ● For “EPS”, “UNKWN” is displayed on “ECM”. Put a check mark to it. LAN ● For “BCM”, “UNKWN” is displayed on “ECM”. Put a check mark to it. ● For “ABS”, “UNKWN” is displayed on “ECM”. Put a check mark to it. ● For “IPDM E/R”, “UNKWN” is displayed on “ECM”. Put a check mark to it. L M LAN-11 TROUBLE DIAGNOSES WORK FLOW [CAN] PKIC9392E NOTE: There is a case that some of “CAN DIAG SUPPORT MNTR” and “SELF-DIAG RESULTS” are not needed for diagnosis. In the case, “UNKWN” and “CAN COMM CIRCUIT [U1000]” in “Check sheet results (example)” change to “–”. Then, ignore check marks on the check sheet table. 4. Perform system diagnosis for possible causes identified. 5. Perform diagnosis again after inspection and repair. Make sure that repair is completely performed, and then end the procedure. Start CAN system trouble diagnosis if this procedure can be confirmed. Refer to LAN-27, "CAN Communication Unit" . LAN-12 TROUBLE DIAGNOSES WORK FLOW [CAN] Example of Filling in Check Sheet When Initial Conditions Are Not Reproduced A B C D E F G H PKIC9393E 1. I See “SELF-DIAG RESULTS” of all units attached to the check sheet. If “CAN COMM CIRCUIT”, “CAN COMM CIRCUIT [U1000]” or “CAN COMM CIRCUIT [U1001]” is displayed, put a check mark to the applicable column of self-diagnostic results of the check sheet table. J NOTE: ● For “ENGINE”, “CAN COMM CIRCUIT [U1001]” is displayed. Put a check mark to it. ● For “INTELLIGENT KEY”, “CAN COMM CIRCUIT [U1000]” is displayed. Put a check mark to it. LAN ● For “EPS”, “CAN COMM CIRCUIT [U1000]” is displayed. Put a check mark to it. ● For “BCM”, “CAN COMM CIRCUIT [U1000]” is displayed. Put a check mark to it. L ● For “ABS”, “CAN COMM CIRCUIT [U1000]” is displayed. Put a check mark to it. ● For “IPDM E/R”, “CAN COMM CIRCUIT [U1000]” is displayed. Put a check mark to it. M LAN-13 TROUBLE DIAGNOSES WORK FLOW [CAN] PKIC9394E NOTE: There is a case that some of “CAN DIAG SUPPORT MNTR” and “SELF-DIAG RESULTS” are not needed for diagnosis. In the case, “UNKWN” and “CAN COMM CIRCUIT [U1000]” in “Check sheet results (example)” change to “–”. Then, ignore check marks on the check sheet table. 2. For the selected possible causes, it is expected that malfunctions have been found in the past. LAN-14 TROUBLE DIAGNOSES WORK FLOW [CAN] CAN Diagnostic Support Monitor BKS001HY A DESCRIPTION OF “CAN DIAG SUPPORT MNTR” SCREEN FOR ECM CR14DE/HR16DE model B C D PKIC9371E E “SELECT SYSTEM” screen “CAN DIAG SUPPORT MNTR” screen Description TRANSMIT DIAG Make sure of normal transmission. OK/UNKWN/– VDC/TCS/ABS Make sure of normal reception from ABS actuator and electric unit (control unit). OK/UNKWN/– Make sure of normal reception from combination meter. (ESP model) OK/UNKWN/– METER/M&A METER/M&A is not diagnosed. (ABS model) BCM/SEC ENGINE Present Make sure of normal reception from BCM. F G – OK/UNKWN/– ICC ICC is not diagnosed. – HVAC HVAC is not diagnosed. – TCM Make sure of normal reception from TCM. (A/T model) EPS Past H OK/0/1 – 39/– I OK/UNKWN/– TCM is not diagnosed. (M/T model) – EPS is not diagnosed. – IPDM E/R Make sure of normal reception from IPDM E/R. e4WD e4WD is not diagnosed. – AWD/4WD AWD/4WD is not diagnosed. – J OK/UNKWN/– Display Results (Present) LAN L ● OK: Normal ● UNKWN: The diagnosed unit does not transmit or receive the applicable data normally. ● –: There is no received unit or the unit is not in the condition that reception diagnosis is performed. Display Results (Past) ● OK: Normal ● 0: There is malfunction now. ● 1 – 39: Displays when it is normal at present and finds malfunction in the past. It increases like 0→1→2...38→39 after returning to the normal condition whenever IGN OFF→ON. If it is over 39, it is fixed to 39 until the self-diagnostic results are erased. It returns to 0 when malfunction is detected again in the process. ● –: Undiagnosed LAN-15 M TROUBLE DIAGNOSES WORK FLOW [CAN] K9K model PKIC9372E “SELECT SYSTEM” screen ENGINE “CAN DIAG SUPPORT MNTR” screen Description Present TRANSMIT DIAG Make sure of normal transmission. OK/UNKWN/– VDC/TCS/ABS Make sure of normal reception from ABS actuator and electric unit (control unit). OK/UNKWN/– Make sure of normal reception from combination meter. (ESP model) OK/UNKWN/– METER/M&A METER/M&A is not diagnosed. (ABS model) BCM/SEC Make sure of normal reception from BCM. TCM TCM is not diagnosed. IPDM E/R Make sure of normal reception from IPDM E/R. Past OK/0/1 – 39/– – OK/UNKWN/– – OK/UNKWN/– Display Results (Present) ● OK: Normal ● UNKWN: The diagnosed unit does not transmit or receive the applicable data normally. ● –: There is no received unit or the unit is not in the condition that reception diagnosis is performed. Display Results (Past) ● OK: Normal ● 0: There is malfunction now. ● 1 – 39: Displays when it finds malfunction in the past even if it is normal or there is a malfunction at present. Also, displays when diagnosis is not performed. It increase like 0→1→2...38→39 after returning to the normal condition whenever IGN OFF→ON. If it is over 39, it is fixed to 39 until the self-diagnostic results are erased. Keep this condition until resetting it. ● –: Undiagnosed LAN-16 TROUBLE DIAGNOSES WORK FLOW [CAN] DESCRIPTION OF “CAN DIAG SUPPORT MNTR” SCREEN FOR INTELLIGENT KEY UNIT A B C PKIC9373E “SELECT SYSTEM” screen INTELLIGENT KEY D “CAN DIAG SUPPORT MNTR” screen Description Present INITIAL DIAG Make sure that microcomputer in ECU works normally. OK/NG TRANSMIT DIAG Make sure of normal transmission. OK/UNKWN ECM Make sure of normal reception from ECM. OK/UNKWN METER/M&A Make sure of normal reception from combination meter. OK/UNKWN BCM/SEC Make sure of normal reception from BCM. OK/UNKWN Display Results (Present) E F G ● OK: Normal ● NG: Malfunction ● UNKWN: The diagnosed unit does not transmit or receive the applicable data normally. H DESCRIPTION OF “CAN DIAG SUPPORT MNTR” SCREEN FOR EPS CONTROL UNIT I J LAN PKIC9374E “SELECT SYSTEM” screen “CAN DIAG SUPPORT MNTR” screen Description Present TRANSMIT DIAG Make sure of normal transmission. OK/UNKWN ECM Make sure of normal reception from ECM. OK/UNKWN VDC/TCS/ABS Make sure of normal reception from ABS actuator and electric unit (control unit). OK/UNKWN METER/M&A Make sure of normal reception from combination meter. OK/UNKWN EPS Display Results (Present) ● OK: Normal ● NG: Malfunction ● UNKWN: The diagnosed unit does not transmit or receive the applicable data normally. LAN-17 L M TROUBLE DIAGNOSES WORK FLOW [CAN] DESCRIPTION OF “CAN DIAG SUPPORT MNTR” SCREEN FOR BCM PKIC9375E “SELECT SYSTEM” screen BCM “CAN DIAG SUPPORT MNTR” screen Description Present TRANSMIT DIAG Make sure of normal transmission. OK/UNKWN ECM Make sure of normal reception from ECM. OK/UNKWN IPDM E/R Make sure of normal reception from IPDM E/R. OK/UNKWN METER/M&A Make sure of normal reception from combination meter. OK/UNKWN I-KEY Make sure of normal reception from Intelligent Key unit. OK/UNKWN VDC/TCS/ABS Make sure of normal reception from ABS actuator and electric unit (control unit). OK/UNKWN Display Results (Present) ● OK: Normal ● NG: Malfunction ● UNKWN: The diagnosed unit does not transmit or receive the applicable data normally. DESCRIPTION OF “CAN DIAG SUPPORT MNTR” SCREEN FOR ABS ACTUATOR AND ELECTRIC UNIT (CONTROL UNIT) ABS model PKIC9376E “SELECT SYSTEM” screen ABS “CAN DIAG SUPPORT MNTR” screen Description Present INITIAL DIAG Make sure that microcomputer in ECU works normally. OK/NG ECM Make sure of normal reception from ECM. OK/UNKWN Display Results (Present) ● OK: Normal ● NG: Malfunction ● UNKWN: The diagnosed unit does not transmit or receive the applicable data normally. LAN-18 TROUBLE DIAGNOSES WORK FLOW [CAN] ESP model A B C PKIC9377E “SELECT SYSTEM” screen ABS “CAN DIAG SUPPORT MNTR” screen D Description Present TRANSMIT DIAG Make sure of normal transmission. OK/UNKWN/– ECM Make sure of normal reception from ECM. OK/UNKWN/– METER/M&A Make sure of normal reception from combination meter. OK/UNKWN/– TCM TCM is not diagnosed. STRG Make sure of normal reception from steering angle sensor. Past E OK/0/1 – 39/– F – OK/UNKWN/– G Display Results (Present) ● OK: Normal ● UNKWN: The diagnosed unit does not transmit or receive the applicable data normally. ● –: There is no received unit or the unit is not in the condition that reception diagnosis is performed. Display Results (Past) H I ● OK: Normal ● 0: There is malfunction now. ● 1 – 39: Displays when it finds malfunction in the past even if it is normal or there is a malfunction at present. Also, displays when diagnosis is not performed. It increase like 0→1→2...38→39 after returning to the normal condition whenever IGN OFF→ON. If it is over 39, it is fixed to 39 until the self-diagnostic results are erased. Keep this condition until resetting it. ● –: Undiagnosed J LAN L M LAN-19 TROUBLE DIAGNOSES WORK FLOW [CAN] DESCRIPTION OF “CAN DIAG SUPPORT MNTR” SCREEN FOR TCM PKIC9378E “SELECT SYSTEM” screen A/T “CAN DIAG SUPPORT MNTR” screen Description Present INITIAL DIAG Make sure that microcomputer in ECU works normally. OK/NG TRANSMIT DIAG Make sure of normal transmission. OK/UNKWN ECM Make sure of normal reception from ECM. OK/UNKWN VDC/TCS/ABS VDC/TCS/ABS is not diagnosed. UNKWN METER/M&A Make sure of normal reception from combination meter. OK/UNKWN ICC/e4WD ICC/e4WD is not diagnosed. UNKWN Display Results (Present) ● OK: Normal ● NG: Malfunction ● UNKWN: The diagnosed unit does not transmit or receive the applicable data normally. DESCRIPTION OF “CAN DIAG SUPPORT MNTR” SCREEN FOR IPDM E/R PKIC9379E “SELECT SYSTEM” screen IPDM E/R “CAN DIAG SUPPORT MNTR” screen Description Present TRANSMIT DIAG Make sure of normal transmission. OK/UNKWN BCM/SEC Make sure of normal reception from BCM. OK/UNKWN ECM Make sure of normal reception from ECM. OK/UNKWN Display Results (Present) ● OK: Normal ● UNKWN: The diagnosed unit does not transmit or receive the applicable data normally. LAN-20 CAN COMMUNICATION [CAN] CAN COMMUNICATION System Description PFP:23710 A BKS0014C CAN (Controller Area Network) is a serial communication line for real time application. It is an on-vehicle multiplex communication line with high data communication speed and excellent error detection ability. Many electronic control units are equipped onto a vehicle, and each control unit shares information and links with other control units during operation (not independent). In CAN communication, control units are connected with 2 communication lines (CAN-H line, CAN-L line) allowing a high rate of information transmission with less wiring. Each control unit transmits/receives data but selectively reads required data only. Component Parts and Harness Connector Location B C BKS001IR LHD MODEL D E F G H I J LAN L PKIC9435E 1. TCM E106 2. BCM M57 3. ABS actuator and electric unit (control unit) E32 (ABS model) ABS actuator and electric unit (control unit) E33 (ESP model) 4. Intelligent Key unit M60 5. IPDM E/R E12 6. ECM E40 7. EPS control unit M25 8. Combination meter M27 9. Data link connector M14 10. Steering angle sensor M40 LAN-21 M CAN COMMUNICATION [CAN] RHD MODEL PKIC9434E 1. Steering angle sensor M40 2. Data link connector M14 3. Combination meter M27 4. EPS control unit M25 5. Intelligent Key unit M60 6. ABS actuator and electric unit (control unit) E32 (ABS model) ABS actuator and electric unit (control unit) E33 (ESP model) 7. IPDM E/R E12 8. ECM E40 9. TCM E106 10. BCM M57 LAN-22 CAN COMMUNICATION [CAN] Wiring Diagram — CAN — BKS001IS A CR14DE/HR16DE MODEL B C D E F G H I J LAN L M MKWA4293E LAN-23 CAN COMMUNICATION [CAN] MKWA4294E LAN-24 CAN COMMUNICATION [CAN] K9K MODEL A B C D E F G H I J LAN L M MKWA4295E LAN-25 CAN COMMUNICATION [CAN] MKWA4296E LAN-26 CAN COMMUNICATION [CAN] CAN Communication Unit BKS001IT A Go to CAN system, when selecting your car model from the following table. Body type Hatchback Axle 2WD Engine HR16DE K9K M/T A/T M/T Transmission Brake control ABS CAN system type CAN system trouble diagnosis ESP × Intelligent Key system B CR14DE/HR16DE ABS × ABS × C ESP × × 1 2 3 4 5 6 7 8 9 10 LAN38 LAN51 LAN65 LAN79 LAN94 LAN108 LAN123 LAN136 LAN150 LAN164 D ×: Applicable E NOTE: Confirming the presence of the following items helps to identify CAN system type. ● Model with ESP F G H SKIB8664E ● I Model with Intelligent Key system J LAN L SKIB8665E M LAN-27 CAN COMMUNICATION [CAN] TYPE 1/TYPE 2 System diagram ● Type 1 MKIB1738E ● Type 2 MKIB1737E Input/output signal chart T: Transmit R: Receive Signals ECM Combination meter Intelligent Key unit* EPS control unit BCM ABS actuator and electric unit (control unit) IPDM E/R A/C compressor request signal T R Cooling fan speed request signal T R Engine coolant temperature signal T R Engine speed signal T R Engine status signal T Fuel consumption monitor signal T R MI signal T R R R R T Vehicle speed signal R R R R LAN-28 R T R CAN COMMUNICATION [CAN] Signals ECM Combination meter Intelligent Key unit* R Buzzer output signal R A IPDM E/R B T T KEY indicator signal R T LOCK indicator signal R T R EPS warning indicator signal BCM T Door lock/unlock request signal EPS operation signal EPS control unit ABS actuator and electric unit (control unit) C R D T R T A/C switch signal R T Blower fan motor switch signal R T Day time light request signal E T Door lock/unlock status signal R F R T R T R T R Front wiper request signal T R Headlamp washer request signal T R R T R T R Position lights request signal R T R Rear fog lamp status signal R T Door switch signal R Front fog lamp request signal R High beam request signal Low beam request signal Rear window defogger switch signal R T R T R Sleep/wake up signal R Turn indicator signal R ABS warning lamp signal R T Brake warning lamp signal R T Front wiper stop position signal R Low beam status signal R T R LAN-29 L T T *: with Intelligent Key system model only J T T Rear window defogger control signal I LAN R R H T High beam status signal Oil pressure switch signal G M CAN COMMUNICATION [CAN] TYPE 3/TYPE 4 System diagram ● Type 3 PKIC8680E ● Type 4 PKIC8679E Input/output signal chart T: Transmit R: Receive Signals ECM Combination meter A/C compressor request signal T Accelerator pedal position signal T Cooling fan speed request signal T Engine coolant temperature signal T R Engine speed signal T R Engine status signal T Fuel consumption monitor signal T R MI signal T R Parking brake switch signal Intelligent Key unit * Steering angle sensor EPS control unit BCM ABS actuator and electric unit (control unit) IPDM E/R R R R R R R T R LAN-30 CAN COMMUNICATION [CAN] Signals Vehicle speed signal ECM Combination meter R R R T Intelligent Key unit* EPS control unit R Door lock/unlock request signal BCM R R R R Buzzer output signal B T R C T T R T LOCK indicator signal R T Steering angle signal R D R T EPS warning indicator signal A IPDM E/R T KEY indicator signal EPS operation signal Steering angle sensor ABS actuator and electric unit (control unit) E R T R T F A/C switch signal R T Blower fan motor switch signal R T Day time light request signal T Door lock/unlock status signal R R T R T R T R Front wiper request signal T R Headlamp washer request signal T R T R T R R Door switch signal R Front fog lamp request signal R High beam request signal R Low beam request signal Position lights request signal R T Rear fog lamp status signal R T Rear window defogger switch signal R T R T R Sleep/wake up signal R Turn indicator signal R ABS warning lamp signal R T Brake warning lamp signal R T ESP OFF indicator signal R T ESP warning lamp signal R T SLIP indicator lamp signal R T R T R T Low beam status signal R T Rear window defogger control signal R T R T *: with Intelligent Key system model only LAN-31 I J LAN M High beam status signal Oil pressure switch signal H L T Front wiper stop position signal G CAN COMMUNICATION [CAN] TYPE 5/TYPE 6 System diagram ● Type 5 MKIB1736E ● Type 6 MKIB1735E Input/output signal chart T: Transmit R: Receive Signals ECM Combination meter Intelligent Key unit * EPS control unit BCM ABS actuator and electric unit (control unit) TCM A/C compressor request signal T Accelerator pedal position signal T R Closed throttle position signal T R Cooling fan speed request signal T Engine and A/T integrated control signal IPDM E/R R R T R R T Engine coolant temperature signal T R Engine speed signal T R LAN-32 R CAN COMMUNICATION [CAN] Signals ECM Combination meter Engine status signal T Fuel consumption monitor signal T R MI signal T R Wide open throttle position signal T Intelligent Key unit * EPS control unit BCM ABS actuator and electric unit (control unit) A TCM B R C R Overdrive control switch signal T R Stop lamp switch signal T R Vehicle speed signal R R R T R R R R Buzzer output signal T KEY indicator signal R T LOCK indicator signal R T Door lock/unlock request signal T R EPS warning lamp signal D E T R T R EPS operation signal IPDM E/R F R G T R H T A/C switch signal R T Blower fan motor switch signal R T Day time light request signal I T Door lock/unlock status signal R R T R T R T R Front wiper request signal T R Headlamp washer request signal T R T R T R R Door switch signal R Front fog lamp request signal R High beam request signal R Low beam request signal Position lights request signal R T Rear fog lamp status signal R T Rear window defogger switch signal R T R R Turn indicator signal R ABS warning lamp signal R T Brake warning lamp signal R T A/T position indicator signal R OD OFF indicator signal Output shaft revolution signal T T R T R T R T Front wiper stop position signal R T High beam status signal R T Low beam status signal R T LAN-33 LAN L M T Sleep/wake up signal A/T self-diagnosis signal R J CAN COMMUNICATION [CAN] Signals ECM Oil pressure switch signal Rear window defogger control signal Combination meter Intelligent Key unit* R R EPS control unit BCM ABS actuator and electric unit (control unit) TCM IPDM E/R T T *: with Intelligent Key system model only TYPE 7/TYPE 8 System diagram ● Type 7 ● Type 8 MKIB1738E MKIB1737E LAN-34 CAN COMMUNICATION [CAN] Input/output signal chart T: Transmit R: Receive Signals ECM Combination meter Intelligent Key unit* EPS control unit BCM ABS actuator and electric unit (control unit) IPDM E/R A/C compressor request signal T R Cooling fan speed request signal T R Engine coolant temperature signal T R Engine coolant temperature warning lamp signal T R Engine speed signal T R Engine status signal T Glow indicator signal T R Fuel consumption monitor signal T R MI signal T R R R Vehicle speed signal R E F R R R T R G T R T Door lock/unlock request signal T KEY indicator signal R T LOCK indicator signal R T EPS warning indicator signal R H R I T Day time light request signal T Door lock/unlock status signal R J R T R T R T R Front wiper request signal T R Headlamp washer request signal T R T R T R R Door switch signal R Front fog lamp request signal R High beam request signal R Low beam request signal Position lights request signal R T Rear fog lamp status signal R T Rear window defogger switch signal Sleep/wake up signal Starter signal R R R T R T R T R ABS warning lamp signal R T Brake warning lamp signal R T Front wiper stop position signal T R R *: with Intelligent Key system model only LAN-35 LAN L M Turn indicator signal Oil pressure switch signal C D R Buzzer output signal B R R T A T T CAN COMMUNICATION [CAN] TYPE 9/TYPE 10 System diagram ● Type 9 PKIC8680E ● Type 10 PKIC8679E Input/output signal chart T: Transmit R: Receive Signals ECM Combination meter. A/C compressor request signal T Accelerator pedal position signal T Cooling fan speed request signal T Engine coolant temperature signal T R Engine coolant temperature warning lamp signal T R Engine speed signal T R Engine status signal T Fuel consumption monitor signal T Intelligent Key unit * Steering angle sensor EPS control unit BCM ABS actuator and electric unit (control unit) IPDM E/R R R R R R R R LAN-36 CAN COMMUNICATION [CAN] Signals ECM Combination meter. Glow indicator signal T R MI signal T R R R R T Vehicle speed signal Intelligent Key unit* Steering angle sensor EPS control unit R Door lock/unlock request signal R R T R D T T R T LOCK indicator signal R T Steering angle sensor signal R T R E R T R Door switch signal R Front fog lamp request signal R F T Day time light request signal Door lock/unlock status signal B T KEY indicator signal EPS warning indicator signal A IPDM E/R C R R Buzzer output signal BCM ABS actuator and electric unit (control unit) G T T R T R Front wiper request signal T R Headlamp washer request signal T R T R T R R High beam request signal R R R Low beam request signal Position lights request signal R T Rear fog lamp status signal R T Rear window defogger switch signal Sleep/wake up signal R Turn indicator signal R Starter signal R T R T R I J LAN T R T L ABS warning lamp signal R T Brake warning lamp signal R T ESP OFF indicator signal R T ESP warning lamp signal R T SLIP indicator lamp signal R M T Front wiper stop position signal Oil pressure switch signal H R R T T *: with Intelligent Key system model only LAN-37 CAN SYSTEM (TYPE 1) [CAN] CAN SYSTEM (TYPE 1) Component Parts and Harness Connector Location PFP:23710 BKS001IU Refer to LAN-21, "Component Parts and Harness Connector Location" . Wiring Diagram — CAN — BKS001IW Refer to LAN-23, "Wiring Diagram — CAN —" . Check Sheet BKS001LE Refer to LAN-39, "Check Sheet" . LAN-38 CAN SYSTEM (TYPE 1) [CAN] Check Sheet BKS001IX A NOTE: If a check mark is put on “NG” on “INITIAL DIAG (Initial diagnosis)”, replace the control unit. B C D E F G H I J LAN L M PKIC9195E LAN-39 CAN SYSTEM (TYPE 1) [CAN] PKIC9192E LAN-40 CAN SYSTEM (TYPE 1) [CAN] CHECK SHEET RESULTS (EXAMPLE) A NOTE: If a check mark is put on “NG” on “INITIAL DIAG (Initial diagnosis)”, replace the control unit. Case 1 Check harness between data link connector and ABS actuator and electric unit (control unit). Refer to LAN179, "Inspection Between Data Link Connector and ABS Actuator and Electric Unit (Control Unit) Circuit" . B C D E F G PKIC9271E H I J LAN L M MKIB1813E LAN-41 CAN SYSTEM (TYPE 1) [CAN] Case 2 Check ECM circuit. Refer to LAN-180, "ECM Circuit Inspection" . PKIC9272E MKIB1815E LAN-42 CAN SYSTEM (TYPE 1) [CAN] Case 3 A Check data link connector circuit. Refer to LAN-182, "Data Link Connector Circuit Inspection" . B C D E F PKIC9273E G H I J LAN MKIB1817E L M LAN-43 CAN SYSTEM (TYPE 1) [CAN] Case 4 Check combination meter circuit. Refer to LAN-184, "Combination Meter Circuit Inspection" . PKIC9274E MKIB1819E LAN-44 CAN SYSTEM (TYPE 1) [CAN] Case 5 A Check EPS control unit circuit. Refer to LAN-185, "EPS Control Unit Circuit Inspection" . B C D E F PKIC9275E G H I J LAN MKIB1821E L M LAN-45 CAN SYSTEM (TYPE 1) [CAN] Case 6 Check BCM circuit. Refer to LAN-186, "BCM Circuit Inspection" . PKIC9276E MKIB1823E LAN-46 CAN SYSTEM (TYPE 1) [CAN] Case 7 Check ABS actuator and electric unit (control unit) circuit. Refer to LAN-186, "ABS Actuator and Electric Unit (Control Unit) Circuit Inspection" . A B C D E F PKIC9277E G H I J LAN L MKIB1825E M LAN-47 CAN SYSTEM (TYPE 1) [CAN] Case 8 Check IPDM E/R circuit. Refer to LAN-188, "IPDM E/R Circuit Inspection" . PKIC9278E MKIB1827E LAN-48 CAN SYSTEM (TYPE 1) [CAN] Case 9 A Check CAN communication circuit. Refer to LAN-188, "CAN Communication Circuit Inspection" . B C D E F PKIC9279E Case 10 Check IPDM E/R ignition relay circuit continuously sticks “OFF”. Refer to LAN-190, "IPDM E/R Ignition Relay Circuit Inspection" . G H I J LAN L PKIC9280E M LAN-49 CAN SYSTEM (TYPE 1) [CAN] Case 11 Check IPDM E/R ignition relay circuit continuously sticks “ON”. Refer to LAN-190, "IPDM E/R Ignition Relay Circuit Inspection" . PKIC9281E LAN-50 CAN SYSTEM (TYPE 2) [CAN] CAN SYSTEM (TYPE 2) Component Parts and Harness Connector Location PFP:23710 A BKS001IY Refer to LAN-21, "Component Parts and Harness Connector Location" . B Wiring Diagram — CAN — BKS001J0 Refer to LAN-23, "Wiring Diagram — CAN —" . Check Sheet BKS001LF C Refer to LAN-52, "Check Sheet" . D E F G H I J LAN L M LAN-51 CAN SYSTEM (TYPE 2) [CAN] Check Sheet BKS001J1 NOTE: If a check mark is put on “NG” on “INITIAL DIAG (Initial diagnosis)”, replace the control unit. PKIC9196E LAN-52 CAN SYSTEM (TYPE 2) [CAN] A B C D E F G H I J LAN L M PKIC9146E LAN-53 CAN SYSTEM (TYPE 2) [CAN] CHECK SHEET RESULTS (EXAMPLE) NOTE: If a check mark is put on “NG” on “INITIAL DIAG (Initial diagnosis)”, replace the control unit. Case 1 Check harness between data link connector and ABS actuator and electric unit (control unit). Refer to LAN179, "Inspection Between Data Link Connector and ABS Actuator and Electric Unit (Control Unit) Circuit" . PKIC9284E MKIB1790E LAN-54 CAN SYSTEM (TYPE 2) [CAN] Case 2 A Check ECM circuit. Refer to LAN-180, "ECM Circuit Inspection" . B C D E F PKIC9285E G H I J LAN MKIB1792E L M LAN-55 CAN SYSTEM (TYPE 2) [CAN] Case 3 Check data link connector circuit. Refer to LAN-182, "Data Link Connector Circuit Inspection" . PKIC9286E MKIB1794E LAN-56 CAN SYSTEM (TYPE 2) [CAN] Case 4 A Check combination meter circuit. Refer to LAN-184, "Combination Meter Circuit Inspection" . B C D E F PKIC9287E G H I J LAN MKIB1796E L M LAN-57 CAN SYSTEM (TYPE 2) [CAN] Case 5 Check Intelligent Key unit circuit. Refer to LAN-184, "Intelligent Key Unit Circuit Inspection" . PKIC9288E MKIB1798E LAN-58 CAN SYSTEM (TYPE 2) [CAN] Case 6 A Check EPS control unit circuit. Refer to LAN-185, "EPS Control Unit Circuit Inspection" . B C D E F PKIC9289E G H I J LAN MKIB1800E L M LAN-59 CAN SYSTEM (TYPE 2) [CAN] Case 7 Check BCM circuit. Refer to LAN-186, "BCM Circuit Inspection" . PKIC9290E MKIB1802E LAN-60 CAN SYSTEM (TYPE 2) [CAN] Case 8 Check ABS actuator and electric unit (control unit) circuit. Refer to LAN-186, "ABS Actuator and Electric Unit (Control Unit) Circuit Inspection" . A B C D E F PKIC9291E G H I J LAN L MKIB1804E M LAN-61 CAN SYSTEM (TYPE 2) [CAN] Case 9 Check IPDM E/R circuit. Refer to LAN-188, "IPDM E/R Circuit Inspection" . PKIC9292E MKIB1806E LAN-62 CAN SYSTEM (TYPE 2) [CAN] Case 10 A Check CAN communication circuit. Refer to LAN-188, "CAN Communication Circuit Inspection" . B C D E F PKIC9293E Case 11 Check IPDM E/R ignition relay circuit continuously sticks “OFF”. Refer to LAN-190, "IPDM E/R Ignition Relay Circuit Inspection" . G H I J LAN L PKIC9294E M LAN-63 CAN SYSTEM (TYPE 2) [CAN] Case 12 Check IPDM E/R ignition relay circuit continuously sticks “ON”. Refer to LAN-190, "IPDM E/R Ignition Relay Circuit Inspection" . PKIC9295E LAN-64 CAN SYSTEM (TYPE 3) [CAN] CAN SYSTEM (TYPE 3) Component Parts and Harness Connector Location PFP:23710 A BKS001J2 Refer to LAN-21, "Component Parts and Harness Connector Location" . B Wiring Diagram — CAN — BKS001J4 Refer to LAN-23, "Wiring Diagram — CAN —" . Check Sheet BKS001LG C Refer to LAN-66, "Check Sheet" . D E F G H I J LAN L M LAN-65 CAN SYSTEM (TYPE 3) [CAN] Check Sheet BKS001J5 NOTE: If a check mark is put on “NG” on “INITIAL DIAG (Initial diagnosis)”, replace the control unit. PKIC9197E LAN-66 CAN SYSTEM (TYPE 3) [CAN] A B C D E F G H I J LAN L M PKIC9192E LAN-67 CAN SYSTEM (TYPE 3) [CAN] CHECK SHEET RESULTS (EXAMPLE) NOTE: If a check mark is put on “NG” on “INITIAL DIAG (Initial diagnosis)”, replace the control unit. Case 1 Check harness between data link connector and ABS actuator and electric unit (control unit). Refer to LAN179, "Inspection Between Data Link Connector and ABS Actuator and Electric Unit (Control Unit) Circuit" . PKIC9296E PKIC8690E LAN-68 CAN SYSTEM (TYPE 3) [CAN] Case 2 A Check ECM circuit. Refer to LAN-180, "ECM Circuit Inspection" . B C D E F PKIC9297E G H I J LAN PKIC8691E L M LAN-69 CAN SYSTEM (TYPE 3) [CAN] Case 3 Check data link connector circuit. Refer to LAN-182, "Data Link Connector Circuit Inspection" . PKIC9298E PKIC8692E LAN-70 CAN SYSTEM (TYPE 3) [CAN] Case 4 A Check combination meter circuit. Refer to LAN-184, "Combination Meter Circuit Inspection" . B C D E F PKIC9299E G H I J LAN PKIC8693E L M LAN-71 CAN SYSTEM (TYPE 3) [CAN] Case 5 Check steering angle sensor circuit. Refer to LAN-185, "Steering Angle Sensor Circuit Inspection" . PKIC9300E PKIC9283E LAN-72 CAN SYSTEM (TYPE 3) [CAN] Case 6 A Check EPS control unit circuit. Refer to LAN-185, "EPS Control Unit Circuit Inspection" . B C D E F PKIC9301E G H I J LAN PKIC8694E L M LAN-73 CAN SYSTEM (TYPE 3) [CAN] Case 7 Check BCM circuit. Refer to LAN-186, "BCM Circuit Inspection" . PKIC9302E PKIC8695E LAN-74 CAN SYSTEM (TYPE 3) [CAN] Case 8 Check ABS actuator and electric unit (control unit) circuit. Refer to LAN-186, "ABS Actuator and Electric Unit (Control Unit) Circuit Inspection" . A B C D E F PKIC9303E G H I J LAN L PKIC8696E M LAN-75 CAN SYSTEM (TYPE 3) [CAN] Case 9 Check IPDM E/R circuit. Refer to LAN-188, "IPDM E/R Circuit Inspection" . PKIC9304E PKIC8697E LAN-76 CAN SYSTEM (TYPE 3) [CAN] Case 10 A Check CAN communication circuit. Refer to LAN-188, "CAN Communication Circuit Inspection" . B C D E F PKIC9305E Case 11 Check IPDM E/R ignition relay circuit continuously sticks “OFF”. Refer to LAN-190, "IPDM E/R Ignition Relay Circuit Inspection" . G H I J LAN L PKIC9306E M LAN-77 CAN SYSTEM (TYPE 3) [CAN] Case 12 Check IPDM E/R ignition relay circuit continuously sticks “ON”. Refer to LAN-190, "IPDM E/R Ignition Relay Circuit Inspection" . PKIC9307E LAN-78 CAN SYSTEM (TYPE 4) [CAN] CAN SYSTEM (TYPE 4) Component Parts and Harness Connector Location PFP:23710 A BKS001J6 Refer to LAN-21, "Component Parts and Harness Connector Location" . B Wiring Diagram — CAN — BKS001J8 Refer to LAN-23, "Wiring Diagram — CAN —" . Check Sheet BKS001LH C Refer to LAN-80, "Check Sheet" . D E F G H I J LAN L M LAN-79 CAN SYSTEM (TYPE 4) [CAN] Check Sheet BKS001J9 NOTE: If a check mark is put on “NG” on “INITIAL DIAG (Initial diagnosis)”, replace the control unit. PKIC9198E LAN-80 CAN SYSTEM (TYPE 4) [CAN] A B C D E F G H I J LAN L M PKIC9146E LAN-81 CAN SYSTEM (TYPE 4) [CAN] CHECK SHEET RESULTS (EXAMPLE) NOTE: If a check mark is put on “NG” on “INITIAL DIAG (Initial diagnosis)”, replace the control unit. Case 1 Check harness between data link connector and ABS actuator and electric unit (control unit). Refer to LAN179, "Inspection Between Data Link Connector and ABS Actuator and Electric Unit (Control Unit) Circuit" . PKIC9308E PKIC8681E LAN-82 CAN SYSTEM (TYPE 4) [CAN] Case 2 A Check ECM circuit. Refer to LAN-180, "ECM Circuit Inspection" . B C D E F PKIC9309E G H I J LAN PKIC8682E L M LAN-83 CAN SYSTEM (TYPE 4) [CAN] Case 3 Check data link connector circuit. Refer to LAN-182, "Data Link Connector Circuit Inspection" . PKIC9310E PKIC8683E LAN-84 CAN SYSTEM (TYPE 4) [CAN] Case 4 A Check combination meter circuit. Refer to LAN-184, "Combination Meter Circuit Inspection" . B C D E F PKIC9311E G H I J LAN PKIC8684E L M LAN-85 CAN SYSTEM (TYPE 4) [CAN] Case 5 Check Intelligent Key unit circuit. Refer to LAN-184, "Intelligent Key Unit Circuit Inspection" . PKIC9312E PKIC8685E LAN-86 CAN SYSTEM (TYPE 4) [CAN] Case 6 A Check steering angle sensor circuit. Refer to LAN-185, "Steering Angle Sensor Circuit Inspection" . B C D E F PKIC9313E G H I J LAN PKIC9282E L M LAN-87 CAN SYSTEM (TYPE 4) [CAN] Case 7 Check EPS control unit circuit. Refer to LAN-185, "EPS Control Unit Circuit Inspection" . PKIC9314E PKIC8686E LAN-88 CAN SYSTEM (TYPE 4) [CAN] Case 8 A Check BCM circuit. Refer to LAN-186, "BCM Circuit Inspection" . B C D E F PKIC9315E G H I J LAN PKIC8687E L M LAN-89 CAN SYSTEM (TYPE 4) [CAN] Case 9 Check ABS actuator and electric unit (control unit) circuit. Refer to LAN-186, "ABS Actuator and Electric Unit (Control Unit) Circuit Inspection" . PKIC9316E PKIC8688E LAN-90 CAN SYSTEM (TYPE 4) [CAN] Case 10 A Check IPDM E/R circuit. Refer to LAN-188, "IPDM E/R Circuit Inspection" . B C D E F PKIC9317E G H I J LAN PKIC8689E L M LAN-91 CAN SYSTEM (TYPE 4) [CAN] Case 11 Check CAN communication circuit. Refer to LAN-188, "CAN Communication Circuit Inspection" . PKIC9318E Case 12 Check IPDM E/R ignition relay circuit continuously sticks “OFF”. Refer to LAN-190, "IPDM E/R Ignition Relay Circuit Inspection" . PKIC9319E LAN-92 CAN SYSTEM (TYPE 4) [CAN] Case 13 Check IPDM E/R ignition relay circuit continuously sticks “ON”. Refer to LAN-190, "IPDM E/R Ignition Relay Circuit Inspection" . A B C D E F PKIC9320E G H I J LAN L M LAN-93 CAN SYSTEM (TYPE 5) [CAN] CAN SYSTEM (TYPE 5) Component Parts and Harness Connector Location PFP:23710 BKS001JA Refer to LAN-21, "Component Parts and Harness Connector Location" . Wiring Diagram — CAN — BKS001JC Refer to LAN-23, "Wiring Diagram — CAN —" . Check Sheet BKS001LI Refer to LAN-95, "Check Sheet" . LAN-94 CAN SYSTEM (TYPE 5) [CAN] Check Sheet BKS001L4 A NOTE: If a check mark is put on “NG” on “INITIAL DIAG (Initial diagnosis)”, replace the control unit. B C D E F G H I J LAN L M PKIC9199E LAN-95 CAN SYSTEM (TYPE 5) [CAN] PKIC9193E LAN-96 CAN SYSTEM (TYPE 5) [CAN] CHECK SHEET RESULTS (EXAMPLE) A NOTE: If a check mark is put on “NG” on “INITIAL DIAG (Initial diagnosis)”, replace the control unit. Case 1 Check harness between data link connector and ABS actuator and electric unit (control unit). Refer to LAN179, "Inspection Between Data Link Connector and ABS Actuator and Electric Unit (Control Unit) Circuit" . B C D E F G PKIC9244E H I J LAN L M MKIB1767E LAN-97 CAN SYSTEM (TYPE 5) [CAN] Case 2 Check ECM circuit. Refer to LAN-180, "ECM Circuit Inspection" . PKIC9245E MKIB1769E LAN-98 CAN SYSTEM (TYPE 5) [CAN] Case 3 A Check data link connector circuit. Refer to LAN-182, "Data Link Connector Circuit Inspection" . B C D E F PKIC9246E G H I J LAN MKIB1771E L M LAN-99 CAN SYSTEM (TYPE 5) [CAN] Case 4 Check combination meter circuit. Refer to LAN-184, "Combination Meter Circuit Inspection" . PKIC9247E MKIB1773E LAN-100 CAN SYSTEM (TYPE 5) [CAN] Case 5 A Check EPS control unit circuit. Refer to LAN-185, "EPS Control Unit Circuit Inspection" . B C D E F PKIC9248E G H I J LAN MKIB1775E L M LAN-101 CAN SYSTEM (TYPE 5) [CAN] Case 6 Check BCM circuit. Refer to LAN-186, "BCM Circuit Inspection" . PKIC9249E MKIB1777E LAN-102 CAN SYSTEM (TYPE 5) [CAN] Case 7 Check ABS actuator and electric unit (control unit) circuit. Refer to LAN-186, "ABS Actuator and Electric Unit (Control Unit) Circuit Inspection" . A B C D E F PKIC9250E G H I J LAN L MKIB1779E M LAN-103 CAN SYSTEM (TYPE 5) [CAN] Case 8 Check TCM circuit. Refer to LAN-187, "TCM Circuit Inspection" . PKIC9251E MKIB1781E LAN-104 CAN SYSTEM (TYPE 5) [CAN] Case 9 A Check IPDM E/R circuit. Refer to LAN-188, "IPDM E/R Circuit Inspection" . B C D E F PKIC9252E G H I J LAN MKIB1783E L M LAN-105 CAN SYSTEM (TYPE 5) [CAN] Case 10 Check CAN communication circuit. Refer to LAN-188, "CAN Communication Circuit Inspection" . PKIC9253E Case 11 Check IPDM E/R ignition relay circuit continuously sticks “OFF”. Refer to LAN-190, "IPDM E/R Ignition Relay Circuit Inspection" . PKIC9254E LAN-106 CAN SYSTEM (TYPE 5) [CAN] Case 12 Check IPDM E/R ignition relay circuit continuously sticks “ON”. Refer to LAN-190, "IPDM E/R Ignition Relay Circuit Inspection" . A B C D E F PKIC9255E G H I J LAN L M LAN-107 CAN SYSTEM (TYPE 6) [CAN] CAN SYSTEM (TYPE 6) Component Parts and Harness Connector Location PFP:23710 BKS001JE Refer to LAN-21, "Component Parts and Harness Connector Location" . Wiring Diagram — CAN — BKS001JG Refer to LAN-23, "Wiring Diagram — CAN —" . Check Sheet BKS001LJ Refer to LAN-109, "Check Sheet" . LAN-108 CAN SYSTEM (TYPE 6) [CAN] Check Sheet BKS001JH A NOTE: If a check mark is put on “NG” on “INITIAL DIAG (Initial diagnosis)”, replace the control unit. B C D E F G H I J LAN L M PKIC9132E LAN-109 CAN SYSTEM (TYPE 6) [CAN] PKIC9194E LAN-110 CAN SYSTEM (TYPE 6) [CAN] CHECK SHEET RESULTS (EXAMPLE) A NOTE: If a check mark is put on “NG” on “INITIAL DIAG (Initial diagnosis)”, replace the control unit. Case 1 Check harness between data link connector and ABS actuator and electric unit (control unit). Refer to LAN179, "Inspection Between Data Link Connector and ABS Actuator and Electric Unit (Control Unit) Circuit" . B C D E F G PKIC9256E H I J LAN L M MKIB1742E LAN-111 CAN SYSTEM (TYPE 6) [CAN] Case 2 Check ECM circuit. Refer to LAN-180, "ECM Circuit Inspection" . PKIC9257E MKIB1744E LAN-112 CAN SYSTEM (TYPE 6) [CAN] Case 3 A Check data link connector circuit. Refer to LAN-182, "Data Link Connector Circuit Inspection" . B C D E F PKIC9258E G H I J LAN MKIB1746E L M LAN-113 CAN SYSTEM (TYPE 6) [CAN] Case 4 Check combination meter circuit. Refer to LAN-184, "Combination Meter Circuit Inspection" . PKIC9259E MKIB1748E LAN-114 CAN SYSTEM (TYPE 6) [CAN] Case 5 A Check Intelligent Key unit circuit. Refer to LAN-184, "Intelligent Key Unit Circuit Inspection" . B C D E F PKIC9260E G H I J LAN MKIB1750E L M LAN-115 CAN SYSTEM (TYPE 6) [CAN] Case 6 Check EPS control unit circuit. Refer to LAN-185, "EPS Control Unit Circuit Inspection" . PKIC9261E MKIB1752E LAN-116 CAN SYSTEM (TYPE 6) [CAN] Case 7 A Check BCM circuit. Refer to LAN-186, "BCM Circuit Inspection" . B C D E F PKIC9262E G H I J LAN MKIB1754E L M LAN-117 CAN SYSTEM (TYPE 6) [CAN] Case 8 Check ABS actuator and electric unit (control unit) circuit. Refer to LAN-186, "ABS Actuator and Electric Unit (Control Unit) Circuit Inspection" . PKIC9263E MKIB1756E LAN-118 CAN SYSTEM (TYPE 6) [CAN] Case 9 A Check TCM circuit. Refer to LAN-187, "TCM Circuit Inspection" . B C D E F PKIC9264E G H I J LAN MKIB1758E L M LAN-119 CAN SYSTEM (TYPE 6) [CAN] Case 10 Check IPDM E/R circuit. Refer to LAN-188, "IPDM E/R Circuit Inspection" . PKIC9265E MKIB1760E LAN-120 CAN SYSTEM (TYPE 6) [CAN] Case 11 A Check CAN communication circuit. Refer to LAN-188, "CAN Communication Circuit Inspection" . B C D E F PKIC9266E Case 12 Check IPDM E/R ignition relay circuit continuously sticks “OFF”. Refer to LAN-190, "IPDM E/R Ignition Relay Circuit Inspection" . G H I J LAN L PKIC9267E M LAN-121 CAN SYSTEM (TYPE 6) [CAN] Case 13 Check IPDM E/R ignition relay circuit continuously sticks “ON”. Refer to LAN-190, "IPDM E/R Ignition Relay Circuit Inspection" . PKIC9268E LAN-122 CAN SYSTEM (TYPE 7) [CAN] CAN SYSTEM (TYPE 7) Component Parts and Harness Connector Location PFP:23710 A BKS001JI Refer to LAN-21, "Component Parts and Harness Connector Location" . B Wiring Diagram — CAN — BKS001JK Refer to LAN-23, "Wiring Diagram — CAN —" . Check Sheet BKS001LK C Refer to LAN-124, "Check Sheet" . D E F G H I J LAN L M LAN-123 CAN SYSTEM (TYPE 7) [CAN] Check Sheet BKS001L8 NOTE: If a check mark is put on “NG” on “INITIAL DIAG (Initial diagnosis)”, replace the control unit. PKIC9200E LAN-124 CAN SYSTEM (TYPE 7) [CAN] A B C D E F G H I J LAN L M PKIC9192E LAN-125 CAN SYSTEM (TYPE 7) [CAN] CHECK SHEET RESULTS (EXAMPLE) NOTE: If a check mark is put on “NG” on “INITIAL DIAG (Initial diagnosis)”, replace the control unit. Case 1 Check harness between data link connector and ABS actuator and electric unit (control unit). Refer to LAN179, "Inspection Between Data Link Connector and ABS Actuator and Electric Unit (Control Unit) Circuit" . PKIC9321E MKIB1813E LAN-126 CAN SYSTEM (TYPE 7) [CAN] Case 2 A Check ECM circuit. Refer to LAN-180, "ECM Circuit Inspection" . B C D E F PKIC9322E G H I J LAN MKIB1815E L M LAN-127 CAN SYSTEM (TYPE 7) [CAN] Case 3 Check data link connector circuit. Refer to LAN-182, "Data Link Connector and CAN Communication Circuit Inspection" . PKIC9323E MKIB1817E LAN-128 CAN SYSTEM (TYPE 7) [CAN] Case 4 A Check combination meter circuit. Refer to LAN-184, "Combination Meter Circuit Inspection" . B C D E F PKIC9324E G H I J LAN MKIB1819E L M LAN-129 CAN SYSTEM (TYPE 7) [CAN] Case 5 Check EPS control unit circuit. Refer to LAN-185, "EPS Control Unit Circuit Inspection" . PKIC9325E MKIB1821E LAN-130 CAN SYSTEM (TYPE 7) [CAN] Case 6 A Check BCM circuit. Refer to LAN-186, "BCM Circuit Inspection" . B C D E F PKIC9326E G H I J LAN MKIB1823E L M LAN-131 CAN SYSTEM (TYPE 7) [CAN] Case 7 Check ABS actuator and electric unit (control unit) circuit. Refer to LAN-186, "ABS Actuator and Electric Unit (Control Unit) Circuit Inspection" . PKIC9327E MKIB1825E LAN-132 CAN SYSTEM (TYPE 7) [CAN] Case 8 A Check IPDM E/R circuit. Refer to LAN-188, "IPDM E/R Circuit Inspection" . B C D E F PKIC9328E G H I J LAN MKIB1827E L M LAN-133 CAN SYSTEM (TYPE 7) [CAN] Case 9 Check CAN communication circuit. Refer to LAN-182, "Data Link Connector and CAN Communication Circuit Inspection" . PKIC9329E Case 10 Check IPDM E/R ignition relay circuit continuously sticks “OFF”. Refer to LAN-190, "IPDM E/R Ignition Relay Circuit Inspection" . PKIC9330E LAN-134 CAN SYSTEM (TYPE 7) [CAN] Case 11 Check IPDM E/R ignition relay circuit continuously sticks “ON”. Refer to LAN-190, "IPDM E/R Ignition Relay Circuit Inspection" . A B C D E F PKIC9331E G H I J LAN L M LAN-135 CAN SYSTEM (TYPE 8) [CAN] CAN SYSTEM (TYPE 8) Component Parts and Harness Connector Location PFP:23710 BKS001JM Refer to LAN-21, "Component Parts and Harness Connector Location" . Wiring Diagram — CAN — BKS001JO Refer to LAN-23, "Wiring Diagram — CAN —" . Check Sheet BKS001LL Refer to LAN-137, "Check Sheet" . LAN-136 CAN SYSTEM (TYPE 8) [CAN] Check Sheet BKS001L9 A NOTE: If a check mark is put on “NG” on “INITIAL DIAG (Initial diagnosis)”, replace the control unit. B C D E F G H I J LAN L M PKIC9201E LAN-137 CAN SYSTEM (TYPE 8) [CAN] PKIC9146E LAN-138 CAN SYSTEM (TYPE 8) [CAN] CHECK SHEET RESULTS (EXAMPLE) A NOTE: If a check mark is put on “NG” on “INITIAL DIAG (Initial diagnosis)”, replace the control unit. Case 1 Check harness between data link connector and ABS actuator and electric unit (control unit). Refer to LAN179, "Inspection Between Data Link Connector and ABS Actuator and Electric Unit (Control Unit) Circuit" . B C D E F G PKIC9332E H I J LAN L M MKIB1790E LAN-139 CAN SYSTEM (TYPE 8) [CAN] Case 2 Check ECM circuit. Refer to LAN-180, "ECM Circuit Inspection" . PKIC9333E MKIB1792E LAN-140 CAN SYSTEM (TYPE 8) [CAN] Case 3 Check data link connector circuit. Refer to LAN-182, "Data Link Connector and CAN Communication Circuit Inspection" . A B C D E F PKIC9334E G H I J LAN L MKIB1794E M LAN-141 CAN SYSTEM (TYPE 8) [CAN] Case 4 Check combination meter circuit. Refer to LAN-184, "Combination Meter Circuit Inspection" . PKIC9335E MKIB1796E LAN-142 CAN SYSTEM (TYPE 8) [CAN] Case 5 A Check Intelligent Key unit circuit. Refer to LAN-184, "Intelligent Key Unit Circuit Inspection" . B C D E F PKIC9336E G H I J LAN MKIB1798E L M LAN-143 CAN SYSTEM (TYPE 8) [CAN] Case 6 Check EPS control unit circuit. Refer to LAN-185, "EPS Control Unit Circuit Inspection" . PKIC9337E MKIB1800E LAN-144 CAN SYSTEM (TYPE 8) [CAN] Case 7 A Check BCM circuit. Refer to LAN-186, "BCM Circuit Inspection" . B C D E F PKIC9338E G H I J LAN MKIB1802E L M LAN-145 CAN SYSTEM (TYPE 8) [CAN] Case 8 Check ABS actuator and electric unit (control unit) circuit. Refer to LAN-186, "ABS Actuator and Electric Unit (Control Unit) Circuit Inspection" . PKIC9339E MKIB1804E LAN-146 CAN SYSTEM (TYPE 8) [CAN] Case 9 A Check IPDM E/R circuit. Refer to LAN-188, "IPDM E/R Circuit Inspection" . B C D E F PKIC9340E G H I J LAN MKIB1806E L M LAN-147 CAN SYSTEM (TYPE 8) [CAN] Case 10 Check CAN communication circuit. Refer to LAN-182, "Data Link Connector and CAN Communication Circuit Inspection" . PKIC9341E Case 11 Check IPDM E/R ignition relay circuit continuously sticks “OFF”. Refer to LAN-190, "IPDM E/R Ignition Relay Circuit Inspection" . PKIC9342E LAN-148 CAN SYSTEM (TYPE 8) [CAN] Case 12 Check IPDM E/R ignition relay circuit continuously sticks “ON”. Refer to LAN-190, "IPDM E/R Ignition Relay Circuit Inspection" . A B C D E F PKIC9343E G H I J LAN L M LAN-149 CAN SYSTEM (TYPE 9) [CAN] CAN SYSTEM (TYPE 9) Component Parts and Harness Connector Location PFP:23710 BKS001JY Refer to LAN-21, "Component Parts and Harness Connector Location" . Wiring Diagram — CAN — BKS001K0 Refer to LAN-23, "Wiring Diagram — CAN —" . Check Sheet BKS001LM Refer to LAN-151, "Check Sheet" . LAN-150 CAN SYSTEM (TYPE 9) [CAN] Check Sheet BKS001L5 A NOTE: If a check mark is put on “NG” on “INITIAL DIAG (Initial diagnosis)”, replace the control unit. B C D E F G H I J LAN L M PKIC9202E LAN-151 CAN SYSTEM (TYPE 9) [CAN] PKIC9192E LAN-152 CAN SYSTEM (TYPE 9) [CAN] CHECK SHEET RESULTS (EXAMPLE) A NOTE: If a check mark is put on “NG” on “INITIAL DIAG (Initial diagnosis)”, replace the control unit. Case 1 Check harness between data link connector and ABS actuator and electric unit (control unit). Refer to LAN179, "Inspection Between Data Link Connector and ABS Actuator and Electric Unit (Control Unit) Circuit" . B C D E F G PKIC9344E H I J LAN L M PKIC8690E LAN-153 CAN SYSTEM (TYPE 9) [CAN] Case 2 Check ECM circuit. Refer to LAN-180, "ECM Circuit Inspection" . PKIC9345E PKIC8691E LAN-154 CAN SYSTEM (TYPE 9) [CAN] Case 3 Check data link connector circuit. Refer to LAN-182, "Data Link Connector and CAN Communication Circuit Inspection" . A B C D E F PKIC9346E G H I J LAN L PKIC8692E M LAN-155 CAN SYSTEM (TYPE 9) [CAN] Case 4 Check combination meter circuit. Refer to LAN-184, "Combination Meter Circuit Inspection" . PKIC9347E PKIC8693E LAN-156 CAN SYSTEM (TYPE 9) [CAN] Case 5 A Check steering angle sensor circuit. Refer to LAN-185, "Steering Angle Sensor Circuit Inspection" . B C D E F PKIC9348E G H I J LAN PKIC9283E L M LAN-157 CAN SYSTEM (TYPE 9) [CAN] Case 6 Check EPS control unit circuit. Refer to LAN-185, "EPS Control Unit Circuit Inspection" . PKIC9349E PKIC8694E LAN-158 CAN SYSTEM (TYPE 9) [CAN] Case 7 A Check BCM circuit. Refer to LAN-186, "BCM Circuit Inspection" . B C D E F PKIC9350E G H I J LAN PKIC8695E L M LAN-159 CAN SYSTEM (TYPE 9) [CAN] Case 8 Check ABS actuator and electric unit (control unit) circuit. Refer to LAN-186, "ABS Actuator and Electric Unit (Control Unit) Circuit Inspection" . PKIC9351E PKIC8696E LAN-160 CAN SYSTEM (TYPE 9) [CAN] Case 9 A Check IPDM E/R circuit. Refer to LAN-188, "IPDM E/R Circuit Inspection" . B C D E F PKIC9352E G H I J LAN PKIC8697E L M LAN-161 CAN SYSTEM (TYPE 9) [CAN] Case 10 Check CAN communication circuit. Refer to LAN-182, "Data Link Connector and CAN Communication Circuit Inspection" . PKIC9353E Case 11 Check IPDM E/R ignition relay circuit continuously sticks “OFF”. Refer to LAN-190, "IPDM E/R Ignition Relay Circuit Inspection" . PKIC9354E LAN-162 CAN SYSTEM (TYPE 9) [CAN] Case 12 Check IPDM E/R ignition relay circuit continuously sticks “ON”. Refer to LAN-190, "IPDM E/R Ignition Relay Circuit Inspection" . A B C D E F PKIC9355E G H I J LAN L M LAN-163 CAN SYSTEM (TYPE 10) [CAN] CAN SYSTEM (TYPE 10) Component Parts and Harness Connector Location PFP:23710 BKS001K2 Refer to LAN-21, "Component Parts and Harness Connector Location" . Wiring Diagram — CAN — BKS001K4 Refer to LAN-23, "Wiring Diagram — CAN —" . Check Sheet BKS001LN Refer to LAN-165, "Check Sheet" . LAN-164 CAN SYSTEM (TYPE 10) [CAN] Check Sheet BKS001LA A NOTE: If a check mark is put on “NG” on “INITIAL DIAG (Initial diagnosis)”, replace the control unit. B C D E F G H I J LAN L M PKIC9203E LAN-165 CAN SYSTEM (TYPE 10) [CAN] PKIC9146E LAN-166 CAN SYSTEM (TYPE 10) [CAN] CHECK SHEET RESULTS (EXAMPLE) A NOTE: If a check mark is put on “NG” on “INITIAL DIAG (Initial diagnosis)”, replace the control unit. Case 1 Check harness between data link connector and ABS actuator and electric unit (control unit). Refer to LAN179, "Inspection Between Data Link Connector and ABS Actuator and Electric Unit (Control Unit) Circuit" . B C D E F G PKIC9356E H I J LAN L M PKIC8681E LAN-167 CAN SYSTEM (TYPE 10) [CAN] Case 2 Check ECM circuit. Refer to LAN-180, "ECM Circuit Inspection" . PKIC9357E PKIC8682E LAN-168 CAN SYSTEM (TYPE 10) [CAN] Case 3 Check data link connector circuit. Refer to LAN-182, "Data Link Connector and CAN Communication Circuit Inspection" . A B C D E F PKIC9358E G H I J LAN L PKIC8683E M LAN-169 CAN SYSTEM (TYPE 10) [CAN] Case 4 Check combination meter circuit. Refer to LAN-184, "Combination Meter Circuit Inspection" . PKIC9359E PKIC8684E LAN-170 CAN SYSTEM (TYPE 10) [CAN] Case 5 A Check Intelligent Key unit circuit. Refer to LAN-184, "Intelligent Key Unit Circuit Inspection" . B C D E F PKIC9360E G H I J LAN PKIC8685E L M LAN-171 CAN SYSTEM (TYPE 10) [CAN] Case 6 Check steering angle sensor circuit. Refer to LAN-185, "Steering Angle Sensor Circuit Inspection" . PKIC9361E PKIC9282E LAN-172 CAN SYSTEM (TYPE 10) [CAN] Case 7 A Check EPS control unit circuit. Refer to LAN-185, "EPS Control Unit Circuit Inspection" . B C D E F PKIC9362E G H I J LAN PKIC8686E L M LAN-173 CAN SYSTEM (TYPE 10) [CAN] Case 8 Check BCM circuit. Refer to LAN-186, "BCM Circuit Inspection" . PKIC9363E PKIC8687E LAN-174 CAN SYSTEM (TYPE 10) [CAN] Case 9 Check ABS actuator and electric unit (control unit) circuit. Refer to LAN-186, "ABS Actuator and Electric Unit (Control Unit) Circuit Inspection" . A B C D E F PKIC9364E G H I J LAN L PKIC8688E M LAN-175 CAN SYSTEM (TYPE 10) [CAN] Case 10 Check IPDM E/R circuit. Refer to LAN-188, "IPDM E/R Circuit Inspection" . PKIC9365E PKIC8689E LAN-176 CAN SYSTEM (TYPE 10) [CAN] Case 11 Check CAN communication circuit. Refer to LAN-182, "Data Link Connector and CAN Communication Circuit Inspection" . A B C D E F PKIC9366E Case 12 G Check IPDM E/R ignition relay circuit continuously sticks “OFF”. Refer to LAN-190, "IPDM E/R Ignition Relay Circuit Inspection" . H I J LAN L PKIC9367E LAN-177 M CAN SYSTEM (TYPE 10) [CAN] Case 13 Check IPDM E/R ignition relay circuit continuously sticks “ON”. Refer to LAN-190, "IPDM E/R Ignition Relay Circuit Inspection" . PKIC9368E LAN-178 TROUBLE DIAGNOSIS FOR SYSTEM [CAN] TROUBLE DIAGNOSIS FOR SYSTEM PFP:00000 Inspection Between Data Link Connector and ABS Actuator and Electric Unit (Control Unit) Circuit A BKS001I5 1. CHECK CONNECTOR B 1. 2. 3. C Turn ignition switch OFF. Disconnect the battery cable from the negative terminal. Check following terminals and connectors for damage, bend and loose connection (connector side and harness side). – Harness connector M1 – Harness connector E101 OK or NG OK >> GO TO 2. NG >> Repair terminal or connector. 2. CHECK HARNESS FOR OPEN CIRCUIT 1. 2. Connector G B Terminal Connector 6 M14 E F Disconnect harness connector M1. Check continuity between data link connector (A) and harness connector (B). A D 14 M1 Terminal Continuity 4A Yes 3A Yes H I OK or NG OK >> GO TO 3. NG >> Repair harness. PKIC9436E J LAN L M LAN-179 TROUBLE DIAGNOSIS FOR SYSTEM [CAN] 3. CHECK HARNESS FOR OPEN CIRCUIT ABS model 1. Disconnect ABS actuator and electric unit (control unit) connector. 2. Check continuity between harness connector (A) and ABS actuator and electric unit (control unit) harness connector (B). A Connector B Terminal Connector Terminal 4A E101 E32 3A Continuity 26 Yes 15 Yes PKIC9437E ESP model 1. Disconnect ABS actuator and electric unit (control unit) connector. 2. Check continuity between harness connector (A) and ABS actuator and electric unit (control unit) harness connector (B). A Connector B Terminal Connector 4A E101 3A E33 Terminal Continuity 26 Yes 15 Yes PKIC9437E OK or NG OK >> Connect all the connectors and diagnose again. Refer to LAN-5, "TROUBLE DIAGNOSES WORK FLOW" . NG >> Repair harness. ECM Circuit Inspection BKS001I9 1. CHECK CONNECTOR 1. 2. 3. Turn ignition switch OFF. Disconnect the battery cable from the negative terminal. Check following terminals and connectors for damage, bend and loose connection (control module side and harness side). – ECM connector – Harness connector E101 – Harness connector M1 OK or NG OK >> GO TO 2. NG >> Repair terminal or connector. LAN-180 TROUBLE DIAGNOSIS FOR SYSTEM [CAN] 2. CHECK HARNESS FOR OPEN CIRCUIT A CR14DE model 1. Disconnect ECM connector. 2. Check resistance between ECM harness connector terminals. ECM connector E40 Resistance (Approx.) Terminal 94 B 86 C 108 – 132 Ω D PKIA9860E HR16DE model 1. Disconnect ECM connector. 2. Check resistance between ECM harness connector terminals. ECM connector E40 84 F Resistance (Approx.) Terminal 83 E G 108 – 132 Ω H I PKIC0706E J K9K model 1. Disconnect ECM connector. 2. Check resistance between ECM harness connector terminals. ECM connector E40 Terminal 1 LAN Resistance (Approx.) 7 108 – 132 Ω L M PKIC9438E OK or NG OK >> Replace ECM. NG >> Repair harness between ECM and data link connector. LAN-181 TROUBLE DIAGNOSIS FOR SYSTEM [CAN] Data Link Connector Circuit Inspection BKS001IE 1. CHECK CONNECTOR 1. 2. 3. Turn ignition switch OFF. Disconnect the battery cable from the negative terminal. Check data link connector and terminals for damage, bend and loose connection (connector side and harness side). OK or NG OK >> GO TO 2. NG >> Repair terminal or connector. 2. CHECK HARNESS FOR OPEN CIRCUIT Check resistance between data link connector terminals. Data link connector M14 Resistance (Approx.) Terminal 6 14 54 – 66 Ω OK or NG OK >> Diagnose again. Refer to LAN-5, "TROUBLE DIAGNOSES WORK FLOW" . NG >> Repair harness between data link connector and combination meter. SKIA6868E Data Link Connector and CAN Communication Circuit Inspection BKS001M6 1. CHECK CONNECTOR 1. 2. 3. Turn ignition switch OFF. Disconnect the battery cable from the negative terminal. Check data link connector and terminals for damage, bend and loose connection (connector side and harness side). OK or NG OK >> GO TO 2. NG >> Repair terminal or connector. 2. CHECK HARNESS FOR OPEN CIRCUIT Check resistance between data link connector terminals. Data link connector M14 Terminal 6 Continuity 14 Yes OK or NG OK >> GO TO 3. NG >> Repair harness between data link connector and combination meter. SKIA6868E 3. CHECK CONNECTOR Disconnect the harness connector for each unit on the CAN network and check terminals for deformation, disconnection, looseness or damage. OK or NG OK >> GO TO 4. NG >> Repair terminal or connector as necessary. LAN-182 TROUBLE DIAGNOSIS FOR SYSTEM [CAN] 4. CHECK HARNESS FOR SHORT CIRCUIT A With all module and control unit connectors disconnected, check continuity between data link connector terminals. B Data link connector Terminal M14 6 Continuity 14 No OK or NG OK >> GO TO 5. NG >> ● Repair harness. ● Replace harness if shielded lines are used for the harness. C D SKIA6868E 5. CHECK HARNESS FOR SHORT CIRCUIT E Check continuity between data link connector terminals and ground. Data link connector F Terminal Continuity Ground 6 M14 No 14 G No OK or NG OK >> GO TO 6. NG >> ● Repair harness. ● Replace harness if shielded lines are used for the harness. H PKIA9872E I 6. ECM AND IPDM E/R INTERNAL CIRCUIT INSPECTION 1. 2. Terminal 1 3. J Remove ECM and IPDM E/R from vehicle. Check resistance between ECM terminals. Resistance (Approx.) LAN 108 – 132 Ω 7 Check resistance between IPDM E/R terminals. L Terminal 52 Resistance (Approx.) 58 108 – 132 Ω OK or NG OK >> GO TO 7. NG >> Replace ECM and/or IPDM E/R. LKIA0037E 7. CHECK SYMPTOM 1. Fill in described symptoms on the column “Symptom” in the check sheet. 2. Connect all connectors, and then make sure that the symptom is reproduced. Check results Reproduced>>GO TO 8. Not reproduced>>Refer to LAN-13, "Example of Filling in Check Sheet When Initial Conditions Are Not Reproduced" . LAN-183 M TROUBLE DIAGNOSIS FOR SYSTEM [CAN] 8. UNIT REPRODUCIBILITY INSPECTION Perform the following procedure for each unit on the CAN network, and then perform reproducibility test. 1. Turn ignition switch OFF. 2. Disconnect the battery cable from the negative terminal. 3. Disconnect the unit connector. 4. Connect the battery cable to the negative terminal. 5. Make sure that the symptom filled in the “Symptom” of the check sheet is reproduced. NOTE: Malfunction (related to a unit that the connector is disconnected) is reproduced. Do not confuse the malfunction with the symptom filled in the column of “Symptom” on the check sheet. Inspection results Reproduced>>Connect the disconnected connector. Check other units applying the above procedure. Not reproduced>>Replace the unit that the connector is disconnected. Combination Meter Circuit Inspection BKS001IF 1. CHECK CONNECTOR 1. 2. 3. Turn ignition switch OFF. Disconnect the battery cable from the negative terminal. Check terminals and connector of combination meter for damage, bend and loose connection (meter side and harness side). OK or NG OK >> GO TO 2. NG >> Repair terminal or connector. 2. CHECK HARNESS FOR OPEN CIRCUIT 1. 2. Disconnect combination meter connector. Check resistance between combination meter harness connector terminals. combination meter connector M27 Resistance (Approx.) Terminal 1 54 – 66 Ω 2 OK or NG OK >> Replace combination meter NG >> Repair harness between combination meter and data link connector. PKIC0707E Intelligent Key Unit Circuit Inspection BKS001IA 1. CHECK CONNECTOR 1. 2. 3. Turn ignition switch OFF. Disconnect the battery cable from the negative terminal. Check terminals and connector of Intelligent Key unit for damage, bend and loose connection (unit side and harness side). OK or NG OK >> GO TO 2. NG >> Repair terminal or connector. LAN-184 TROUBLE DIAGNOSIS FOR SYSTEM [CAN] 2. CHECK HARNESS FOR OPEN CIRCUIT 1. 2. A Disconnect Intelligent Key unit connector. Check resistance between Intelligent Key unit harness connector terminals. Intelligent Key unit connector M60 Resistance (Approx.) Terminal 2 B C 54 – 66 Ω 3 OK or NG OK >> Replace Intelligent Key unit. NG >> Repair harness between Intelligent Key unit and data link connector. D PKIB5312E E Steering Angle Sensor Circuit Inspection BKS001IG 1. CHECK CONNECTOR 1. 2. 3. Turn ignition switch OFF. Disconnect the battery cable from the negative terminal. Check terminals and connector of steering angle sensor for damage, bend and loose connection (sensor side and harness side). OK or NG OK >> GO TO 2. NG >> Repair terminal or connector. 2. CHECK HARNESS FOR OPEN CIRCUIT 1. 2. M40 3 4 H J Resistance (Approx.) Terminal G I Disconnect steering angle sensor connector. Check resistance between steering angle sensor harness connector terminals. Steering angle sensor connector F LAN 54 – 66 Ω OK or NG OK >> Replace steering angle sensor. NG >> Repair harness between steering angle sensor and data link connector. L PKIC9439E M EPS Control Unit Circuit Inspection BKS001ID 1. CHECK CONNECTOR 1. 2. 3. Turn ignition switch OFF. Disconnect the battery cable from the negative terminal. Check terminals and connector of display control unit for damage, bend and loose connection (control unit side and harness side). OK or NG OK >> GO TO 2. NG >> Repair terminal or connector. LAN-185 TROUBLE DIAGNOSIS FOR SYSTEM [CAN] 2. CHECK HARNESS FOR OPEN CIRCUIT 1. 2. Disconnect EPS control unit connector. Check resistance between EPS control unit harness connector terminals. EPS control unit connector M25 Resistance (Approx.) Terminal 9 16 54 – 66 Ω OK or NG OK >> Replace EPS control unit. NG >> Repair harness between EPS control unit and data link connector. PKIC0708E BCM Circuit Inspection BKS001IC 1. CHECK CONNECTOR 1. 2. 3. Turn ignition switch OFF. Disconnect the battery cable from the negative terminal. Check terminals and connector of BCM for damage, bend and loose connection (control module side and harness side). OK or NG OK >> GO TO 2. NG >> Repair terminal or connector. 2. CHECK HARNESS FOR OPEN CIRCUIT 1. 2. Disconnect BCM connector. Check resistance between BCM harness connector terminals. BCM connector M57 Resistance (Approx.) Terminal 19 39 54 – 66 Ω OK or NG OK >> Replace BCM. Refer to BCS-17, "Removal and Installation of BCM" . NG >> Repair harness between BCM and data link connector. PKIC9440E ABS Actuator and Electric Unit (Control Unit) Circuit Inspection BKS001IJ 1. CHECK CONNECTOR 1. 2. 3. Turn ignition switch OFF. Disconnect the battery cable from the negative terminal. Check terminals and connector of ABS actuator and electric unit (control unit) for damage, bend and loose connection (control unit side and harness side). OK or NG OK >> GO TO 2. NG >> Repair terminal or connector. LAN-186 TROUBLE DIAGNOSIS FOR SYSTEM [CAN] 2. CHECK HARNESS FOR OPEN CIRCUIT A ABS model 1. Disconnect ABS actuator and electric unit (control unit) connector. 2. Check resistance between ABS actuator and electric unit (control unit) harness connector terminals. ABS actuator and electric unit (control unit) connector E32 C Resistance (Approx.) Terminal 26 B 15 54 – 66 Ω D PKIC9441E ESP model 1. Disconnect ABS actuator and electric unit (control unit) connector. 2. Check resistance between ABS actuator and electric unit (control unit) harness connector terminals. E F G ABS actuator and electric unit (control unit) connector E33 Resistance (Approx.) Terminal 26 15 H 54 – 66 Ω I PKIC9441E J OK or NG OK >> Replace ABS actuator and electric unit (control unit). NG >> Repair harness between ABS actuator and electric unit (control unit) and IPDM E/R. LAN TCM Circuit Inspection BKS001IB 1. CHECK CONNECTOR 1. 2. 3. Turn ignition switch OFF. Disconnect the battery cable from the negative terminal. Check terminals and connector of TCM for damage, bend and loose connection (control module side and harness side). OK or NG OK >> GO TO 2. NG >> Repair terminal or connector. LAN-187 L M TROUBLE DIAGNOSIS FOR SYSTEM [CAN] 2. CHECK HARNESS FOR OPEN CIRCUIT 1. 2. Disconnect TCM connector. Check resistance between TCM harness connector terminals. TCM connector E106 Resistance (Approx.) Terminal 5 54 – 66 Ω 6 OK or NG OK >> Replace TCM. NG >> Repair harness between TCM and IPDM E/R. PKIB5313E IPDM E/R Circuit Inspection BKS001IK 1. CHECK CONNECTOR 1. 2. 3. Turn ignition switch OFF. Disconnect the battery cable from the negative terminal. Check terminals and connector of IPDM E/R for damage, bend and loose connection (control module side and harness side). OK or NG OK >> GO TO 2. NG >> Repair terminal or connector. 2. CHECK HARNESS FOR OPEN CIRCUIT 1. 2. Disconnect IPDM E/R connector. Check resistance between IPDM E/R harness connector terminals. IPDM E/R connector E12 Resistance (Approx.) Terminal 52 108 – 132 Ω 58 OK or NG OK >> Replace IPDM E/R. NG >> Repair harness between IPDM E/R and ABS actuator and electric unit (control unit). PKIC9442E CAN Communication Circuit Inspection BKS001IL 1. CHECK CONNECTOR 1. 2. 3. Turn ignition switch OFF. Disconnect the battery cable from the negative terminal. Disconnect the harness connector for each unit on the CAN network and check terminals for deformation, disconnection, looseness or damage. OK or NG OK >> GO TO 2. NG >> Repair terminal or connector as necessary. LAN-188 TROUBLE DIAGNOSIS FOR SYSTEM [CAN] 2. CHECK HARNESS FOR SHORT CIRCUIT A With all module and control unit connectors disconnected, check continuity between data link connector terminals. B Data link connector Terminal M14 6 Continuity 14 No OK or NG OK >> GO TO 3. NG >> ● Repair harness. ● Replace harness if shielded lines are used for the harness. C D SKIA6868E 3. CHECK HARNESS FOR SHORT CIRCUIT E Check continuity between data link connector terminals and ground. Data link connector F Terminal Continuity Ground 6 M14 No 14 G No OK or NG OK >> GO TO 4. NG >> ● Repair harness. ● Replace harness if shielded lines are used for the harness. H PKIA9872E I 4. ECM AND IPDM E/R INTERNAL CIRCUIT INSPECTION 1. 2. ECM 3. J Remove ECM and IPDM E/R from vehicle. Check resistance between ECM terminals. Resistance (Approx.) Terminal CR14DE 94 86 108 – 132 Ω HR16DE 84 83 108 – 132 Ω LAN L Check resistance between IPDM E/R terminals. Terminal 52 Resistance (Approx.) 58 108 – 132 Ω LKIA0037E OK or NG OK >> GO TO 5. NG >> Replace ECM and/or IPDM E/R. 5. CHECK SYMPTOM 1. Fill in described symptoms on the column “Symptom” in the check sheet. 2. Connect all connectors, and then make sure that the symptom is reproduced. Check results Reproduced>>GO TO 6. Not reproduced>>Refer to LAN-13, "Example of Filling in Check Sheet When Initial Conditions Are Not Reproduced" . LAN-189 M TROUBLE DIAGNOSIS FOR SYSTEM [CAN] 6. UNIT REPRODUCIBILITY INSPECTION Perform the following procedure for each unit on the CAN network, and then perform reproducibility test. 1. Turn ignition switch OFF. 2. Disconnect the battery cable from the negative terminal. 3. Disconnect the unit connector. 4. Connect the battery cable to the negative terminal. 5. Make sure that the symptom filled in the “Symptom” of the check sheet is reproduced. NOTE: Malfunction (related to a unit that the connector is disconnected) is reproduced. Do not confuse the malfunction with the symptom filled in the column of “Symptom” on the check sheet. Inspection results Reproduced>>Connect the disconnected connector. Check other units applying the above procedure. Not reproduced>>Replace the unit that the connector is disconnected. IPDM E/R Ignition Relay Circuit Inspection BKS001IM Check the following. If no malfunction is found, replace the IPDM E/R. ● IPDM E/R power supply circuit. Refer to PG-34, "Check IPDM E/R Power Supply and Ground Circuit" . ● Ignition power supply circuit. Refer to PG-12, "IGNITION POWER SUPPLY — IGNITION SW. IN “ON” AND/OR “START”" . LAN-190 LIGHTING SYSTEM K ELECTRICAL SECTION LT LIGHTING SYSTEM A B C D CONTENTS PRECAUTIONS .......................................................... 5 Precautions for Supplemental Restraint System (SRS) “AIR BAG” and “SEAT BELT PRE-TENSIONER” .................................................................. 5 Maintenance Information .......................................... 5 RHD MODELS ...................................................... 5 LHD MODELS ....................................................... 5 General Precautions for Service Operations ............ 5 HEADLAMP -CONVENTIONAL TYPE- ..................... 7 Component Parts and Harness Connector Location..... 7 System Description .................................................. 7 OUTLINE ............................................................... 7 HEADLAMP OPERATION .................................... 8 COMBINATIONSWITCHREADING FUNCTION..... 9 AUTO LIGHT OPERATION ................................... 9 FRIENDRY LIGHTING FUNCTION ...................... 9 EXTERIORLAMPBATTERYSAVERCONTROL..... 9 FAIL-SAFE FUNCTION ......................................... 9 CAN Communication System Description ................ 9 CAN Communication Unit ........................................ 9 Schematic .............................................................. 10 Wiring Diagram — H/LAMP — ................................11 Terminals and Reference Values for BCM ............. 15 Terminals and Reference Values for IPDM E/R ..... 17 How to Perform Trouble Diagnoses ....................... 17 Preliminary Check .................................................. 18 CHECK POWER SUPPLY AND GROUND CIRCUIT .................................................................... 18 CONSULT-II Functions (BCM) ............................... 19 CONSULT-II INSPECTION PROCEDURE ......... 19 CONSULT-II Application Items (BCM) .................... 19 WORK SUPPORT ............................................... 19 DATA MONITOR ................................................. 19 ACTIVE TEST ..................................................... 20 CONSULT-II Functions (IPDM E/R) ....................... 20 CONSULT-II INSPECTION PROCEDURE ......... 20 CONSULT-II Application Items (IPDM E/R) ............ 20 DATA MONITOR ................................................. 20 ACTIVE TEST ..................................................... 20 Headlamp High Beam Does Not Illuminate (Both Sides) ..................................................................... 21 Headlamp High Beam Does Not Illuminate (One Side) ....................................................................... 23 Headlamp Low Beam Does Not Illuminate (Both Sides) ..................................................................... 25 Headlamp Low Beam Does Not Illuminate (One Side) ....................................................................... 27 Headlamps Do Not Turn OFF ................................. 29 Aiming Adjustment .................................................. 30 PREPARATION BEFORE ADJUSTING .............. 30 LOW BEAM AND HIGH BEAM ........................... 30 Bulb Replacement .................................................. 32 HEADLAMP (HIGH/LOW) ................................... 32 PARKING (CLEARANCE) LAMP ........................ 32 FRONT TURN SIGNAL LAMP ............................ 32 Removal and Installation ........................................ 32 REMOVAL ........................................................... 32 INSTALLATION ................................................... 33 Disassembly and Assembly .................................... 34 DISASSEMBLY ................................................... 34 ASSEMBLY ......................................................... 34 HEADLAMP - DAYTIME LIGHT SYSTEM - ............. 35 Component Parts and Harness Connector Location... 35 System Description ................................................. 35 OUTLINE ............................................................. 35 HEADLAMP OPERATION ................................... 36 DAYTIME LIGHT OPERATION ........................... 37 COMBINATIONSWITCHREADING FUNCTION... 37 AUTO LIGHT OPERATION ................................. 37 FRIENDRY LIGHTING FUNCTION ..................... 37 EXTERIORLAMPBATTERYSAVERCONTROL... 37 FAIL-SAFE FUNCTION ....................................... 37 CAN Communication System Description .............. 37 CAN Communication Unit ....................................... 37 Schematic ............................................................... 38 Wiring Diagram — DTRL — ................................... 39 Terminals and Reference Values for BCM .............. 42 Terminals and Reference Values for IPDM E/R ...... 43 How to Perform Trouble Diagnosis ......................... 43 Preliminary Check .................................................. 44 LT-1 E F G H I J LT L M INSPECTION FOR POWER SUPPLY AND GROUND CIRCUIT ............................................. 44 CONSULT-II Functions (BCM) ................................ 45 CONSULT-II INSPECTION PROCEDURE .......... 45 CONSULT-II Application Items (BCM) .................... 45 WORK SUPPORT ............................................... 45 DATA MONITOR .................................................. 45 ACTIVE TEST ..................................................... 46 CONSULT-II Functions (IPDM E/R) ........................ 46 CONSULT-II INSPECTION PROCEDURE .......... 46 CONSULT-II Application Items (IPDM E/R) ............ 46 DATA MONITOR .................................................. 46 ACTIVE TEST ..................................................... 46 Daytime Light Control Does Not Operate Properly... 47 RH High beam Does Not Illuminate ........................ 48 RH Low Beam Does Not Illuminate ........................ 50 Headlamp High Beam Does Not Illuminate (Both Sides) ..................................................................... 51 Headlamp Low Beam Does Not Illuminate (Both Sides) ..................................................................... 51 Headlamp LH High Beam Does Not Illuminate ....... 51 Headlamp LH Low Beam Does Not Illuminate ....... 51 Headlamps Do Not Turn OFF ................................. 51 Aiming Adjustment .................................................. 51 Bulb Replacement .................................................. 51 Removal and Installation ........................................ 51 Disassembly and Assembly .................................... 51 AUTO LIGHT SYSTEM ............................................. 52 ComponentParts and Harness Connector Location... 52 System Description ................................................. 52 OUTLINE ............................................................. 52 COMBINATIONSWITCHREADING FUNCTION... 53 FRIENDRY LIGHTING FUNCTION ..................... 53 EXTERIORLAMPBATTERYSAVERCONTROL... 53 CAN Communication System Description .............. 53 CAN Communication Unit ....................................... 53 Major Components and Functions .......................... 53 Schematic ............................................................... 54 Wiring Diagram — AUTO/L — ................................ 55 Terminals and Reference Values for BCM .............. 59 Terminals and Reference Values for IPDM E/R ...... 61 How to Proceed With Trouble Diagnosis ................ 61 Preliminary Check .................................................. 62 CHECK POWER SUPPLY AND GROUND CIRCUIT .................................................................... 62 CONSULT-II Functions (BCM) ................................ 63 CONSULT-II INSPECTION PROCEDURE .......... 63 CONSULT-II Application Items ............................... 63 WORK SUPPORT ............................................... 63 DATA MONITOR .................................................. 64 ACTIVE TEST ..................................................... 64 Light and rain sensor System Inspection ................ 65 Removal and Installation of Light and Rain Sensor... 67 REMOVAL ........................................................... 67 INSTALLATION OF LIGHT AND RAIN SENSOR... 67 INSTALLATION OF LIGHT AND RAIN SENSOR HOUSING ............................................................ 67 HEADLAMP AIMING CONTROL .............................. 68 Schematic ............................................................... 68 Wiring Diagram—H/AIM— ......................................69 Removal and Installation .........................................72 REMOVAL ............................................................72 INSTALLATION ....................................................72 Switch Circuit Inspection .........................................72 FRONT FOG LAMP ...................................................73 ComponentParts and Harness Connector Location...73 System Description .................................................73 OUTLINE .............................................................73 FOG LAMP OPERATION ....................................74 COMBINATIONSWITCHREADINGFUNCTION...74 EXTERIORLAMPBATTERYSAVERCONTROL...74 FAIL-SAFE FUNCTION .......................................74 CAN Communication System Description ..............74 CAN Communication Unit .......................................74 Schematic ...............................................................75 Wiring Diagram — F/FOG — ..................................76 Terminals and Reference Values for BCM ..............79 Terminals and Reference Values for IPDM E/R ......80 How to Proceed With Trouble Diagnosis ................80 Preliminary Check ...................................................81 CHECK POWER SUPPLY AND GROUND CIRCUIT .....................................................................81 CONSULT-II Functions (BCM) ................................82 CONSULT-II Functions (IPDM E/R) ........................82 Front Fog lamps Do Not Illuminate (Both Sides) ...82 Front Fog Lamp Does Not Illuminate (One Side) ...85 Aiming Adjustment ..................................................86 Bulb Replacement ...................................................86 Removal and Installation .........................................87 REMOVAL ............................................................87 INSTALLATION ....................................................87 REAR FOG LAMP .....................................................88 ComponentParts and Harness Connector Location...88 System Description .................................................88 OUTLINE .............................................................88 COMBINATIONSWITCHREADINGFUNCTION...89 CAN Communication System Description ..............89 CAN Communication Unit .......................................89 Wiring Diagram — R/FOG — ..................................90 Terminals and Reference Values for BCM ..............92 How to Proceed With Trouble Diagnosis ................93 Preliminary Check ...................................................94 CHECK POWER SUPPLY AND GROUND CIRCUIT .....................................................................94 CONSULT-II Functions (BCM) ................................94 Rear Fog Lamp Does Not Operate .........................95 Bulb Replacement ...................................................97 Removal and Installation .........................................97 REMOVAL ............................................................97 INSTALLATION ....................................................97 TURN SIGNAL AND HAZARD WARNING LAMPS...98 ComponentParts and Harness Connector Location...98 System Description .................................................98 TURN SIGNAL OPERATION ...............................98 HAZARD LAMP OPERATION .............................99 COMBINATIONSWITCHREADINGFUNCTION.100 CAN Communication System Description ............ 100 CAN Communication Unit ..................................... 100 LT-2 Wiring Diagram — TURN — ................................ 101 Terminals and Reference Values for BCM ........... 103 How to Proceed With Trouble Diagnosis .............. 104 Preliminary Check ................................................ 105 CHECK POWER SUPPLY AND GROUND CIRCUIT .................................................................. 105 CONSULT-II Functions (BCM) ............................. 106 CONSULT-II INSPECTION PROCEDURE ....... 106 CONSULT-II Application Items ............................. 106 WORK SUPPORT ............................................. 106 DATA MONITOR ............................................... 106 ACTIVE TEST ................................................... 106 Turn Signal Lamp Does Not Operate ................... 107 Hazard Warning Lamp Does Not Operate But Turn Signal Lamp Operates ......................................... 109 Bulb Replacement (Front Turn Signal Lamp) ........ 111 Bulb Replacement (Rear Turn Signal Lamp) ........ 111 Bulb Replacement (Side Turn Signal Lamp) ......... 111 Removal and Installation of Front Turn Signal Lamp.. 111 Removal and Installation of Rear Turn Signal Lamp.. 111 Removal and Installation of Side Turn Signal Lamp.. 111 REMOVAL .......................................................... 111 INSTALLATION .................................................. 111 LIGHTING AND TURN SIGNAL SWITCH ...............112 Removal and Installation .......................................112 REMOVAL ..........................................................112 INSTALLATION ..................................................112 HAZARD SWITCH ...................................................113 Removal and Installation .......................................113 REMOVAL ..........................................................113 INSTALLATION ..................................................113 COMBINATION SWITCH .........................................114 System Description ...............................................114 COMBINATIONSWITCHREADING FUNCTION..114 Wiring Diagram — COMBSW — ...........................117 Terminals and Reference Values for BCM ............118 Reference Values for BCM (Input) ....................... 121 CONSULT-II Function (BCM) ............................... 124 CONSULT-II INSPECTION PROCEDURE ....... 124 CONSULT-II Application Items ............................. 124 DATA MONITOR ............................................... 124 Combination Switch Inspection ............................ 125 Removal and Installation ...................................... 128 STOP LAMP ........................................................... 129 Wiring Diagram — STOP/L — .............................. 129 Bulb Replacement of High-Mounted Stop Lamp . 130 BulbReplacementofRearCombinationLamp(Stop Lamp) ................................................................... 130 Removal and Installation of High-Mounted Stop Lamp .................................................................... 130 REMOVAL ......................................................... 130 INSTALLATION ................................................. 130 Removal and Installation of Rear Combination Lamp (Stop Lamp) ................................................ 130 BACK-UP LAMP .................................................... 131 Wiring Diagram — BACK/L — ............................. 131 Bulb Replacement ................................................ 133 Removal and Installation ...................................... 133 PARKING, LICENSE PLATE AND TAIL LAMPS ... 134 Component Parts and Harness Connector Location. 134 System Description ............................................... 134 OPERATION BY LIGHTING SWITCH ............... 134 COMBINATIONSWITCHREADING FUNCTION. 135 EXTERIORLAMPBATTERYSAVERCONTROL. 135 FAIL-SAFE FUNCTION ..................................... 135 CAN Communication System Description ............ 135 CAN Communication Unit ..................................... 135 Schematic ............................................................. 136 Wiring Diagram — TAIL/L — ................................ 137 Terminals and Reference Values for BCM ............ 140 Terminals and Reference Values for IPDM E/R .... 141 How to Proceed With Trouble Diagnosis .............. 141 Preliminary Check ................................................ 142 CHECK POWER SUPPLY AND GROUND CIRCUIT .................................................................. 142 CONSULT-II Functions (BCM) .............................. 143 CONSULT-II Functions (IPDM E/R) ...................... 143 Parking, License Plate and Tail Lamps Do Not Illuminate ................................................................... 143 Parking, License Plate and Tail Lamps Do Not Turn OFF (After Approx. 10 Minutes) ........................... 147 Bulb Replacement ................................................ 148 PARKING LAMP ................................................ 148 LICENSE PLATE LAMP .................................... 148 TAIL LAMP ........................................................ 148 Removal and Installation ...................................... 148 PARKING LAMP ................................................ 148 LICENSE PLATE LAMP .................................... 148 TAIL LAMP ........................................................ 148 REAR COMBINATION LAMP ................................. 149 Bulb Replacement ................................................ 149 Removal and Installation ...................................... 149 REMOVAL ......................................................... 149 INSTALLATION ................................................. 149 INTERIOR ROOM LAMP ........................................ 150 Component Parts and Harness Connector Location. 150 System Description ............................................... 150 POWER SUPPLY AND GROUND .................... 150 SWITCH OPERATION ...................................... 151 INTERIOR ROOM LAMP TIMER OPERATION. 152 INTERIOR ROOM LAMP BATTERY SAVER CONTROL ......................................................... 152 Schematic ............................................................. 153 —MODELS WITHOUT PERSONAL LAMP— ... 153 —MODELS WITH PERSONAL LAMP— ........... 154 Wiring Diagram — ROOM/L — ............................ 155 —MODELS WITHOUT PERSONAL LAMP— ... 155 —MODELS WITH PERSONAL LAMP— ........... 159 Terminals and Reference Values for BCM ............ 163 How to Proceed With Trouble Diagnosis .............. 164 Preliminary Check ................................................ 165 CHECK POWER SUPPLY AND GROUND CIRCUIT .................................................................. 165 CONSULT-II Functions (BCM) .............................. 166 CONSULT-II INSPECTION PROCEDURE ........ 166 CONSULT-II Application Items ............................. 166 DATA MONITOR ............................................... 166 ACTIVE TEST ................................................... 166 LT-3 A B C D E F G H I J LT L M Map Lamp Control Does Not Operate .................. 167 Personal Lamp Control Does Not Operate (Models With Personal Lamp) ............................................ 169 Bulb Replacement ................................................ 171 MAP LAMP, PERSONAL LAMP ........................ 171 LUGGAGE LOOM LAMP .................................. 171 Removal and Installation ...................................... 171 MAP LAMP, PERSONAL LAMP ........................ 171 LUGGAGE ROOM LAMP .................................. 172 ILLUMINATION ....................................................... 173 System Description ............................................... 173 ILLUMINATION OPERATION BY LIGHTING SWITCH ............................................................. 173 EXTERIORLAMPBATTERYSAVERCONTROL.174 CAN Communication System Description ............ 174 CAN Communication Unit ..................................... 174 Schematic ............................................................. 175 Wiring Diagram — ILL — ...................................... 176 BULB SPECIFICATIONS ........................................ 183 Headlamp .............................................................. 183 Exterior Lamp ........................................................ 183 Interior Lamp/Illumination ...................................... 183 LT-4 PRECAUTIONS PRECAUTIONS PFP:00011 Precautions for Supplemental Restraint System (SRS) “AIR BAG” and “SEAT BELT PRE-TENSIONER” A BKS001CE The Supplemental Restraint System such as “AIR BAG” and “SEAT BELT PRE-TENSIONER”, used along with a front seat belt, helps to reduce the risk or severity of injury to the driver and front passenger for certain types of collision. Information necessary to service the system safely is included in the SRS and SB section of this Service Manual. WARNING: ● To avoid rendering the SRS inoperative, which could increase the risk of personal injury or death in the event of a collision which would result in air bag inflation, all maintenance must be performed by an authorized NISSAN/INFINITI dealer. ● Improper maintenance, including incorrect removal and installation of the SRS, can lead to personal injury caused by unintentional activation of the system. For removal of Spiral Cable and Air Bag Module, see the SRS section. ● Do not use electrical test equipment on any circuit related to the SRS unless instructed to in this Service Manual. SRS wiring harnesses can be identified by yellow and/or orange harnesses or harness connectors. Maintenance Information B C D E F BKS0028K If any of following part is replaced, always replace with new* one. If it's not (or fail to do so), the electrical system may not be operated properly. *: New one means a virgin control unit that has never been energized on-board. G RHD MODELS H ● ● ● ● ● ● BCM (Models without Intelligent Key system) Intelligent Key unit (Models with Intelligent Key system) ECM IPDM E/R Combination meter EPS control unit I J LHD MODELS ● ● ● BCM (Models without Intelligent Key system) Intelligent Key unit (Models with Intelligent Key system) ECM General Precautions for Service Operations ● ● ● ● ● ● LT L BKS001CF Never work with wet hands. Xenon headlamp includes high voltage generating part. Be sure to disconnect battery negative cable (negative terminal) or power fuse before removing, installing, or touching the xenon headlamp (including lamp bulb). Turn the lighting switch OFF before disconnecting and connecting the connector. When turning the xenon headlamp on and while it is illuminated, never touch the harness, bulb, and socket of the headlamp. When checking the headlamp on/off operation, check it on vehiPKIA0183E cle and with the power connected to the vehicle-side connector. Do not touch the headlamp bulb glass surface with bare hands or allow oil or grease to get on it. Do not touch the headlamp bulb just after the headlamp is turned off, because it is very hot. LT-5 M PRECAUTIONS ● ● ● ● ● Install the xenon headlamp bulb socket correctly. If it is installed improperly, high-voltage leak or corona discharge may occur that can melt the bulb, connector, and housing. Do not illuminate the xenon headlamp bulb out of the headlamp housing. Doing so can cause fire and harm your eyes. When the bulb has burned out, wrap it in a thick vinyl bag and discard. Do not break the bulb. Leaving the bulb removed from the headlamp housing for a long period of time can deteriorate the performance of the lens and reflector (dirt, clouding). Always prepare a new bulb and have it EL-3422D on hand when replacing the bulb. When adjusting the headlamp aiming, turn the aiming adjustment screw only in the tightening direction. (If it is necessary to loosen the screw, first fully loosen the screw, and then turn it in the tightening direction.) Do not use organic solvent (paint thinner or gasoline) to clean lamps and to remove old sealant. LT-6 HEADLAMP -CONVENTIONAL TYPEHEADLAMP -CONVENTIONAL TYPEComponent Parts and Harness Connector Location PFP:26010 A BKS001CH B C D E F G MKIB2268E 1. IPDM E/R E8,E11,E12 4. Combination meter M27 2. BCM M57,M59 (View with instrument upper panel removed) 3. Combination switch M38 System Description H BKS001CI The control of the headlamp system operation is dependent upon the position of the combination switch (lighting switch). When the lighting switch is placed in the 2ND position, the BCM (body control module) receives input signal requesting the headlamps (and tail lamps) illuminate. This input signal is communicated to the IPDM E/R (intelligent power distribution module engine room) via the CAN communication. The CPU (central processing unit) located in the IPDM E/R controls the headlamp high and headlamp low relay coils. These relays, when energized, direct power to the respective headlamps, which then illuminate. I J LT OUTLINE Power is supplied at all times ● to ignition relay (located in IPDM E/R), ● to headlamp high RH and LH relay (located in IPDM E/R) ● to headlamp low relay (located in IPDM E/R) from battery directly, ● through 20A fuse (No. 61, located in IPDM E/R), ● through 20A fuse (No. 62, located in IPDM E/R), ● through 40A fusible link (letter J, located in fuse, fusible link and relay box) ● to BCM terminals 74 and 79, ● through 10A fuse [No. 7, located in fuse block (J/B)] ● to combination meter terminal 27. With the ignition switch in the ON or START position, power is supplied ● to ignition relay (located in IPDM E/R) from battery directly, ● through 10A fuse [No. 5, located in fuse block (J/B)] ● to BCM terminal 24, ● through 10A fuse [No. 4, located in fuse block (J/B)] ● to combination meter terminal 28. Ground is supplied ● to BCM terminals 2 and 70 ● to combination meter terminals 21, 22 and 23 LT-7 L M HEADLAMP -CONVENTIONAL TYPE● ● ● through grounds M21 and M66, to IPDM E/R terminals 3 and 54 through grounds E45 (CR and HR engine models),E28 and E44. HEADLAMP OPERATION Low Beam Operation With the lighting switch in 2ND position, the BCM receives input signal requesting the headlamps to illuminate. This input signal is communicated to the IPDM E/R via the CAN communication. The CPU located in the IPDM E/R controls the headlamp low relay coil, which when energized, directs power ● through 15A fuse (No. 50, located in IPDM E/R) ● through IPDM E/R terminal 48 ● to headlamp RH terminal 1, ● through 15A fuse (No. 49, located in IPDM E/R) ● through IPDM E/R terminal 50 ● to headlamp LH terminal 1. Ground is supplied ● to headlamp RH and LH terminals 3 ● through grounds E45 (CR and HR engine models),E28 and E44. With power and ground supplied, low beam headlamps illuminate. High Beam Operation/Flash-to-Pass Operation With the lighting switch in 2ND position and placed in HIGH or PASS position, the BCM receives input signal requesting the headlamp high beams to illuminate. This input signal is communicated to the IPDM E/R via the CAN communication. The CPU located in the IPDM E/R controls the headlamp high relay coil, which when energized, directs power ● through 10A fuse (No. 43, located in IPDM E/R) ● through IPDM E/R terminal 46 ● to headlamp RH terminal 2, ● through 10A fuse (No. 44, located in IPDM E/R) ● through IPDM E/R terminal 47 ● to headlamp LH terminal 2. Ground is supplied ● to headlamp RH and LH terminals 3 ● through grounds E45 (CR and HR engine models),E28 and E44. With power and ground supplied, the high beam headlamps illuminate. The combination meter that received the high beam request signal by BCM via the CAN communication makes a high beam indicator lamp turn ON in combination meter. LT-8 HEADLAMP -CONVENTIONAL TYPECOMBINATION SWITCH READING FUNCTION A Refer to LT-114, "COMBINATION SWITCH READING FUNCTION" . AUTO LIGHT OPERATION Refer to LT-52, "System Description" . B FRIENDRY LIGHTING FUNCTION Low beam headlamps will illuminate for 30 seconds when, ● ignition switch is in OFF position, ● lighting switch is placed in OFF position, and ● lighting switch is placed in PASS position. Each activation of the switch adds 30 seconds to a maximum of 2 minutes. C D EXTERIOR LAMP BATTERY SAVER CONTROL To avoid flat battery caused by user leaving exterior lamps ON. When ignition is OFF and the driver side door is opened, all exterior lamps will be turned OFF. If the user wants some lamps to remain ON then they must switch these lamps OFF then ON again with the combination switch once the driver side door has been opened. A buzzer will sound if any exterior lamps are ON with the driver side door opened and ignition OFF. *:This setting can be changed by CONSULT-II. Refer to LT-19, "WORK SUPPORT" . E F FAIL-SAFE FUNCTION When CAN communication with other control units is impossible, IPDM E/R performs fail-safe control. If the fail-safe system is operating, headlamps illuminate when the ignition switch is turned from OFF to ON and headlamps are turned off when the ignition switch is turn from ON to OFF. If the fail-safe system is operating, headlamps does not operate when the combination switch is in any position. After CAN communication recovers normally, it also returns to normal control. (Refer to PG-18, "Fail-safe Control" .) CAN Communication System Description H BKS001CJ CAN (Controller Area Network) is a serial communication line for real time application. It is an on-vehicle multiplex communication line with high data communication speed and excellent error detection ability. Many electronic control units are equipped onto a vehicle, and each control unit shares information and links with other control units during operation (not independent). In CAN communication, control units are connected with 2 communication lines (CAN H line, CAN L line) allowing a high rate of information transmission with less wiring. Each control unit transmits/receives data but selectively reads required data only. CAN Communication Unit G BKS001CK I J LT Refer to LAN-27, "CAN Communication Unit" . L M LT-9 HEADLAMP -CONVENTIONAL TYPESchematic BKS001CL MKWA4318E LT-10 HEADLAMP -CONVENTIONAL TYPEWiring Diagram — H/LAMP — BKS001CM A B C D E F G H I J LT L M MKWA4319E LT-11 HEADLAMP -CONVENTIONAL TYPE- MKWA4320E LT-12 HEADLAMP -CONVENTIONAL TYPEA B C D E F G H I J LT L M MKWA4321E LT-13 HEADLAMP -CONVENTIONAL TYPE- MKWA4322E LT-14 HEADLAMP -CONVENTIONAL TYPETerminals and Reference Values for BCM BKS001CN CAUTION: ● Check combination switch system terminal waveform under the loaded condition with lighting switch, turn signal switch and wiper switch OFF not to be fluctuated by overloaded. ● Turn wiper dial position to 4 except when checking waveform or voltage of wiper dial position. Wiper dial position can be confirmed on CONSULT-II. Refer to LT-19, "DATA MONITOR" . Terminal No. Wire color 2 B Signal name Ground Ignition switch Operation or condition — ON — B C Measuring condition Signal input/ output A Reference value D Approx. 0V E OFF 8 L Combination switch output 3 Output ON Lighting, turn, wiper switch (Wiper intermittent dial position 4) F PKIB4958J Approx. 1.2V G Any of the conditions below ● Lighting switch 2ND ● Lighting switch HI beam (Operates only HI beam switch) H PKIB4959J I Approx. 1.0V J OFF LT PKIB4956J L Approx. 0.9V 15 W Combination switch input 5 Input ON Lighting, turn, wiper switch (Wiper intermittent dial position 4) M Lighting switch 2ND PKIB8639J Approx. 2.5 - 3.0V Lighting switch HIGH beam (Operates only HIGH beam switch) PKIB8644J Approx. 1.5 - 2.0V 19 L CAN − H Input/ Output ON — LT-15 Approx. 2.6V HEADLAMP -CONVENTIONAL TYPETerminal No. Wire color Signal name 24 O Ignition switch (ON) Measuring condition Signal input/ output Ignition switch Operation or condition Input ON — Reference value Battery voltage OFF 28 G Combination switch output 2 Output ON Lighting, turn, wiper switch (Wiper intermittent dial position 4) PKIB4958J Approx. 1.2V Any of the conditions below ● Lighting switch 2ND ● Lighting switch PASSING (Operates only PASSING switch) PKIB4959J Approx. 1.0V OFF PKIB4958J Approx. 1.0V 34 Y Combination switch input 4 Input ON Lighting, turn, wiper switch (Wiper intermittent dial position 4) Lighting switch 2ND PKIB8628J Approx. 1.5 - 2.0V Lighting switch PASSING (Operates only PASSING switch) PKIB8629J Approx. 2.0V 39 Y CAN − L Input/ Output ON — Approx. 2.4V 70 B Ground — ON — Approx. 0V 74 79 Y Battery power supply Input OFF — Battery voltage LT-16 HEADLAMP -CONVENTIONAL TYPETerminals and Reference Values for IPDM E/R BKS001CO A Measuring condition Signal input/ output Terminal No. Wire color 3 B Ground 46 Y Headlamp HIGH RH ON Headlamp HIGH LH ON 47 G Signal name — Ignition switch Operation or condition ON — Output Reference value B Approx. 0V Lighting switch HIGH beam or PASSING position OFF Approx. 0V ON Battery voltage Lighting switch HIGH beam or PASSING position OFF Approx. 0V ON Battery voltage Approx. 0V P Headlamp LOW RH ON Lighting switch 2ND position OFF 48 ON Battery voltage Approx. 0V L Headlamp LOW LH ON Lighting switch 2ND position OFF 50 ON Battery voltage 52 L CAN − H Input/ Output 54 B Ground — ON — Approx. 0V 58 Y CAN − L Input/ Output — — — — — — D E F G H How to Perform Trouble Diagnoses 1. 2. 3. 4. 5. 6. C BKS001CP Confirm the symptom or customer complaint. Understand operation description and function description. Refer to LT-7, "System Description" . Perform the Preliminary Check. Refer to LT-18, "Preliminary Check" . Check symptom and repair or replace the cause of malfunction. Does the headlamp operate normally? If YES, GO TO 6. If NO, GO TO 4. INSPECTION END I J LT L M LT-17 HEADLAMP -CONVENTIONAL TYPEPreliminary Check BKS001CQ CHECK POWER SUPPLY AND GROUND CIRCUIT 1. CHECK FUSE Check for blown fuses. Unit Power source Fuse and fusible link No. Battery J Ignition switch ON or START position 5 BCM 43 44 IPDM E/R 49 Battery 50 61 62 Refer to LT-11, "Wiring Diagram — H/LAMP —" . OK or NG OK >> GO TO 2. NG >> If fuse or fusible link is blown, be sure to eliminate cause of malfunction before installing new fuse or fusible link. Refer to PG-4, "POWER SUPPLY ROUTING CIRCUIT" . 2. CHECK POWER SUPPLY CIRCUIT 1. 2. 3. Turn ignition switch OFF. Disconnect BCM connector. Check voltage between BCM harness connector and ground. Terminal Ignition switch position (+) BCM Connector Terminal M57 24 74 (−) Ground M59 OFF ACC ON Approx. 0V Approx. 0V Battery voltage Battery voltage Battery voltage Battery voltage Battery voltage Battery voltage Battery voltage MKIB0352E 79 OK or NG OK >> GO TO 3. NG >> Repair harness or connector. 3. CHECK GROUND CIRCUIT Check continuity between BCM harness connector and ground. BCM connector Terminal M57 2 M59 70 Continuity Ground Yes OK or NG OK >> INSPECTION END NG >> Repair harness or connector. MKIB0353E LT-18 HEADLAMP -CONVENTIONAL TYPECONSULT-II Functions (BCM) BKS001CR A CONSULT-II can display each diagnostic item using the diagnostic test mode shown following. BCM diagnosis part Diagnosis mode Changes the setting for each function. DATA MONITOR Displays BCM input data in real time. HEADLAMP ACTIVE TEST SELF-DIAG RESULTS BCM Description WORK SUPPORT CAN DIAG SUPPORT MNTR B Operation of electrical loads can be checked by sending drive signal to them. C BCM performs self-diagnosis of CAN communication. The result of transmit/receive diagnosis of CAN communication can be read. D CONSULT-II INSPECTION PROCEDURE Refer to GI-36, "CONSULT-II Start Procedure" . CONSULT-II Application Items (BCM) BKS001LZ E WORK SUPPORT Operation Procedure 1. 2. 3. 4. 5. 6. 7. F Touch “HEAD LAMP” on “SELECT TEST ITEM” screen. Touch “WORK SUPPORT” on “SELECT DIAG MODE” screen. Touch “BATTERY SAVER SET” on “SELECT WORK ITEM” screen. Touch “START”. Touch “CHANGE SET”. The setting will be changed and “CUSTOMIZING COMPLETED” will be displayed. Touch “END”. G H Display Item List Item BATTERY SAVER SET Description CONSULT-II Factory setting Exterior lamp battery saver control mode can be changed in this mode. Select exterior lamp battery saver control mode between ON and OFF. ON × OFF — I J DATA MONITOR Monitor item UNIT. Display content IGN ON SW [ON/OFF] Displays status (Ignition switch ON: ON/Others OFF, ACC: OFF) as judged from the ignition switch signal. HI BEAM SW [ON/OFF] Displays status (High beam switch: ON/Others: OFF) as judged from lighting switch signal. H/L SW POS [ON/OFF] Displays status (Headlamp switch: ON/Others: OFF) as judged from lighting switch signal. LIGHT SW 1ST [ON/OFF] Displays status (Lighting switch 1st position: ON/Others: OFF) as judged from lighting switch signal. PASSING SW [ON/OFF] Displays status (Flash-to-pass switch: ON/Others: OFF) as judged from lighting switch signal. FR FOG SW [ON/OFF] Displays status (Front fog lamp switch: ON/Others: OFF) as judged from lighting switch signal. RR FOG SW [ON/OFF] Displays status (Rear fog lamp switch: ON/Others: OFF) as judged from lighting switch signal. DOOR SW-DR [ON/OFF] Displays status (Door open: ON/door closed: OFF) as judged from the door switch DR signal. H/L WASH SW [ON/OFF] Displays status (Headlamp washer switch: ON/Others: OFF) as judged from headlamp washer switch signal. ENGINE STATUS [STOP/ STALL/ RUN/ CRA] Displays status (Engine stop: STOP/engine stall: STALL/engine running: RUN/engine cranking: CRA) as judged from the engine status. LT-19 LT L M HEADLAMP -CONVENTIONAL TYPEACTIVE TEST Test item CONSULT-II screen display Description Tail lamp relay output TAIL LAMP Tail lamp relay can be operated by any ON–OFF operation. Headlamp relay output HEAD LAMP Headlamp relay can be operated by any ON–OFF operation. Front fog lamp relay output FR FOG LAMP Front fog lamp relay can be operated by any ON–OFF operation. Rear fog lamp relay output RR FOG LAMP Rear fog lamp relay can be operated by any ON–OFF operation. CONSULT-II Functions (IPDM E/R) BKS001LC CONSULT-II can display each diagnostic item using the diagnostic test mode shown following. Diagnosis Mode SELF-DIAGNOSTIC RESULTS Description Refer to PG-20, "SELF-DIAG RESULTS" . DATA MONITOR The input/output data of IPDM E/R is displayed in real time. CAN DIAG SUPPORT MNTR The result of transmit/receive diagnosis of CAN communication can be read. ACTIVE TEST IPDM E/R sends a drive signal to electronic components to check their operation. CONSULT-II INSPECTION PROCEDURE Refer to GI-36, "CONSULT-II Start Procedure" . CONSULT-II Application Items (IPDM E/R) BKS001M0 DATA MONITOR All Signals, Main Signals, Selection From Menu Monitor item selection Monitor item name Display and unit All signals Main signals selection from menu Display content TAIL & CLR REQ ON/OFF × × × Signal status input from BCM HL LO REQ ON/OFF × × × Signal status input from BCM HL HI REQ ON/OFF × × × Signal status input from BCM FR FOG REQ ON/OFF × × × Signal status input from BCM IGN RLY ON/OFF × × × Status of ignition relay being monitored by IPDM E/R ACTIVE TEST Test item CONSULT-II screen display Description Headlamp relay (HI, LO) output HEAD LAMP Headlamp relay (LO, HI) can be operated using random operation (OFF, HI ON, LO ON). Front fog lamp relay output FRONT FOG LAMP Fog lamp relay can be operated by any ON–OFF operation. Tail lamp relay output TAIL LAMP Tail lamp relay can be operated by any ON–OFF operation. LT-20 HEADLAMP -CONVENTIONAL TYPEHeadlamp High Beam Does Not Illuminate (Both Sides) BKS001CT 1. CHECK COMBINATION SWITCH INPUT SIGNAL A With CONSULT-II 1. Select “BCM” on CONSULT-II. Select “HEAD LAMP” on “SELECT TEST ITEM” screen. 2. Select “DATA MONITOR” on “SELECT DIAG MODE” screen. Make sure that “HI BEAM SW” turns ON-OFF linked with operation of lighting switch. When lighting switch is high position B C : HI BEAM SW ON D Without CONSULT-II Refer to LT-125, "Combination Switch Inspection" . PKIA7585E OK or NG OK >> GO TO 2. NG >> Check combination switch (lighting switch). Refer to LT-125, "Combination Switch Inspection" . E F 2. HEADLAMP ACTIVE TEST G With CONSULT-II 1. Select “IPDM E/R” on CONSULT-II. Select “ACTIVE TEST” on “SELECT DIAG MODE” screen. 2. Select “HEADLAMP” on “SELECT TEST ITEM” screen. 3. Touch “HI” screen. 4. Make sure headlamp high beam operates. H I Headlamp high beam should operate Without CONSULT-II 1. Start auto active test. Refer to PG-22, "Auto Active Test" . 2. Make sure headlamp high beam operates. J SKIA2339E LT Headlamp high beam should operate. OK or NG OK >> GO TO 3. NG >> GO TO 4. L 3. CHECK IPDM E/R M 1. 2. Select “IPDM E/R” on CONSULT-II. Select “DATA MONITOR” on “SELECT DIAG MODE” screen. Make sure “HL HI REQ” turns ON when lighting switch is in high position. When lighting switch is high position : HL HI REQ ON OK or NG OK >> Replace IPDM E/R. Refer to PG-37, "Removal and Installation of IPDM E/R" . NG >> Replace BCM. Refer to BCS-17, "Removal and Installation of BCM" . LT-21 PKIB8696E HEADLAMP -CONVENTIONAL TYPE- 4. CHECK HEADLAMP INPUT SIGNAL 1. 2. 3. 4. 5. 6. With CONSULT-II Turn ignition switch OFF. Disconnect headlamp RH and LH connector. Select “IPDM E/R” on CONSULT-II. Select “ACTIVE TEST” on “SELECT DIAG MODE” screen. Select “HEADLAMP” on “SELECT TEST ITEM” screen. Touch “HI” screen. When headlamp high beam is operating, check voltage between headlamp RH and LH harness connector and ground. Terminal (+) Headlamp connector 1. 2. 3. 4. RH E26 LH E46 (−) Voltage Terminal 2 Ground Battery voltage Without CONSULT-II MKIB2273E Turn ignition switch OFF. Disconnect headlamp RH and LH connector. Start auto active test. Refer to PG-22, "Auto Active Test" . When headlamp high beam is operating, check voltage between headlamp RH and LH harness connector and ground. Terminal (+) Headlamp connector RH E26 LH E46 (−) Voltage Terminal 2 Ground Battery voltage OK or NG OK >> GO TO 5. NG >> GO TO 6. 5. CHECK HEADLAMP GROUND CIRCUIT 1. 2. Turn ignition switch OFF. Check continuity between headlamp RH and LH harness connector and ground. Headlamp connector RH E26 LH E46 Terminal 3 Continuity Ground Yes OK or NG OK >> Check headlamp bulb. NG >> Repair harness or connector. MKIB2274E LT-22 HEADLAMP -CONVENTIONAL TYPE- 6. CHECK HEADLAMP CIRCUIT 1. 2. 3. A Turn ignition switch OFF. Disconnect IPDM E/R connector. Check continuity between IPDM E/R harness connector (A) and headlamp RH and LH harness connector (B). A Circuit B Connector RH LH 4. B E8 Terminal Connector 46 E26 47 E46 Terminal C Continuity 2 Yes D Check continuity between IPDM E/R harness connector (A) and ground. MKIB2275E A Circuit Connector LH Continuity Terminal RH Ground 46 E8 E F No 47 OK or NG OK >> Replace IPDM E/R. Refer to PG-37, "Removal and Installation of IPDM E/R" . NG >> Repair harness or connector. Headlamp High Beam Does Not Illuminate (One Side) G BKS001CU H 1. CHECK BULB Check headlamp bulb which does not illuminate. OK or NG OK >> GO TO 2. NG >> Replace bulb. I J 2. CHECK HEADLAMP INPUT SIGNAL 1. 2. 3. 4. 5. LT Turn ignition switch OFF. Disconnect headlamp RH or LH connector. Turn ignition switch ON. Lighting switch is turned to HIGH position. Check voltage between headlamp RH or LH harness connector and ground. L M Terminal (+) Headlamp connector RH E26 LH E46 Voltage Terminal 2 (−) Ground Battery voltage OK or NG OK >> GO TO 3. NG >> GO TO 4. MKIB2273E LT-23 HEADLAMP -CONVENTIONAL TYPE- 3. CHECK HEADLAMP GROUND CIRCUIT 1. 2. Turn ignition switch OFF. Check continuity between headlamp RH or LH harness connector and ground. Headlamp connector RH E26 LH E46 Terminal Continuity Ground 3 Yes OK or NG OK >> Check connecting condition headlamp harness connector. NG >> Repair harness or connector. MKIB2274E 4. CHECK HEADLAMP CIRCUIT 1. 2. 3. Turn ignition switch OFF. Disconnect IPDM E/R connector. Check continuity between IPDM E/R harness connector (A) and headlamp RH or LH harness connector (B). A Circuit Connector RH LH 4. E8 B Terminal Connector 46 E26 47 E46 Terminal Continuity 2 Yes Check continuity between IPDM E/R harness connector (A) and ground. MKIB2275E A Circuit Connector RH LH 46 E8 Continuity Terminal Ground No 47 OK or NG OK >> Replace IPDM E/R. Refer to PG-37, "Removal and Installation of IPDM E/R" . NG >> Repair harness or connector. LT-24 HEADLAMP -CONVENTIONAL TYPEHeadlamp Low Beam Does Not Illuminate (Both Sides) BKS001CV 1. CHECK COMBINATION SWITCH INPUT SIGNAL A With CONSULT-II 1. Select “BCM” on CONSULT-II. Select “HEAD LAMP” on “SELECT TEST ITEM” screen. 2. Select “DATA MONITOR” on “SELECT DIAG MODE” screen. Make sure that “H/L SW POS” turns ON-OFF linked with operation of lighting switch. When lighting switch is 2nd position When lighting switch is OFF position B C : H/L SW POS ON D : H/L SW POS OFF E MKIB2276E Without CONSULT-II Refer to LT-125, "Combination Switch Inspection" . OK or NG OK >> GO TO 2. NG >> Check combination switch (lighting switch). Refer to LT-125, "Combination Switch Inspection" . F G 2. CHECK HEADLAMP ACTIVE TEST With CONSULT-II 1. Select “IPDM E/R” on CONSULT-II. Select “ACTIVE TEST” on “SELECT DIAG MODE” screen. 2. Select “HEADLAMP” on “SELECT TEST ITEM” screen. 3. Touch “LO” screen. 4. Make sure headlamp low beam operates. H I J Headlamp low beam should operate. Without CONSULT-II 1. Start auto active test. Refer to PG-22, "Auto Active Test" . 2. Make sure headlamp low beam operates. LT SKIA2339E Headlamp low beam should operate. L OK or NG OK >> GO TO 3. NG >> GO TO 4. M 3. CHECK IPDM E/R 1. 2. Select “IPDM E/R” on CONSULT-II. Select “DATA MONITOR” on “SELECT DIAG MODE” screen. Make sure “HL LO REQ” turns ON when lighting switch is in 2ND position. When lighting switch is 2ND position : HL LO REQ ON OK or NG OK >> Replace IPDM E/R. Refer to PG-37, "Removal and Installation of IPDM E/R" . NG >> Replace BCM. Refer to BCS-17, "Removal and Installation of BCM" . LT-25 PKIA7644E HEADLAMP -CONVENTIONAL TYPE- 4. CHECK HEADLAMP INPUT SIGNAL 1. 2. 3. 4. 5. 6. With CONSULT-II Turn ignition switch OFF. Disconnect headlamp RH and LH connector. Select “IPDM E/R” on CONSULT-II. Select “ACTIVE TEST” on “SELECT DIAG MODE” screen. Select “HEADLAMP” on “SELECT TEST ITEM” screen. Touch “LO” screen. When headlamp low beam is operating, check voltage between headlamp RH and LH harness connector and ground. Terminal (+) Headlamp connector 1. 2. 3. 4. RH E26 LH E46 (−) Voltage Terminal 1 Ground Battery voltage Without CONSULT-II MKIB2277E Turn ignition switch OFF. Disconnect headlamp RH and LH connector. Start auto active test. Refer to PG-22, "Auto Active Test" . When headlamp low beam is operating, check voltage between headlamp RH and LH harness connector and ground. Terminal (+) Headlamp connector RH E26 LH E46 (−) Voltage Terminal 1 Ground Battery voltage OK or NG OK >> GO TO 5. NG >> GO TO 6. 5. CHECK HEADLAMP GROUND CIRCUIT 1. 2. Turn ignition switch OFF. Check continuity between headlamp RH and LH harness connector and ground. Headlamp connector RH E26 LH E46 Terminal 3 Continuity Ground Yes OK or NG OK >> Check headlamp bulbs. NG >> Repair harness or connector. MKIB2274E LT-26 HEADLAMP -CONVENTIONAL TYPE- 6. CHECK HEADLAMP CIRCUIT 1. 2. 3. A Turn ignition switch OFF. Disconnect IPDM E/R connector. Check continuity between IPDM E/R harness connector (A) and headlamp RH or LH harness connector (B). A Circuit Connector RH LH 4. E8 B B Terminal Connector 48 E26 50 E46 Terminal C Continuity 1 Yes D Check continuity between IPDM E/R harness connector (A) and ground. MKIB2278E A Circuit Connector RH LH Continuity Terminal Ground 48 E8 E F No 50 OK or NG OK >> Replace IPDM E/R. Refer to PG-37, "Removal and Installation of IPDM E/R" . NG >> Repair harness or connector. Headlamp Low Beam Does Not Illuminate (One Side) G BKS001CW H 1. CHECK BULB Check bulb of headlamp which does not illuminate. OK or NG OK >> GO TO 2. NG >> Replace bulb. I J 2. CHECK HEADLAMP INPUT SIGNAL 1. 2. 3. 4. 5. LT Turn ignition switch OFF. Disconnect headlamp RH or LH connector. Turn ignition switch ON. Lighting switch is turned to 2ND position. Check voltage between headlamp RH or LH harness connector and ground. L M Terminal (+) Headlamp connector RH E26 LH E46 Voltage Terminal 1 (−) Ground Battery voltage OK or NG OK >> GO TO 3. NG >> GO TO 4. MKIB2277E LT-27 HEADLAMP -CONVENTIONAL TYPE- 3. CHECK HEADLAMP GROUND CIRCUIT 1. 2. Turn ignition switch OFF. Check continuity between headlamp RH or LH harness connector and ground. Headlamp connector RH E26 LH E46 Terminal Continuity Ground 3 Yes OK or NG OK >> Check connecting condition headlamp harness connector. NG >> Repair harness or connector. MKIB2274E 4. CHECK HEADLAMP CIRCUIT 1. 2. 3. Turn ignition switch OFF. Disconnect IPDM E/R connector. Check continuity between IPDM E/R harness connector (A) and headlamp RH or LH harness connector (B). A Circuit Connector B Terminal Connector 48 E26 50 E46 RH LH 4. E8 Terminal Continuity 1 Yes Check continuity between IPDM E/R harness connector (A) and ground. MKIB2278E A Circuit Connector RH LH 48 E8 Continuity Terminal Ground No 50 OK or NG OK >> Replace IPDM E/R. Refer to PG-37, "Removal and Installation of IPDM E/R" . NG >> Repair harness or connector. LT-28 HEADLAMP -CONVENTIONAL TYPEHeadlamps Do Not Turn OFF BKS001CX 1. CHECK HEADLAMP TURN OFF A Make sure that lighting switch is OFF. And make sure headlamp turns off when ignition switch is turned OFF. OK or NG OK >> GO TO 3. NG >> GO TO 2. C 2. CHECK COMBINATION SWITCH INPUT SIGNAL 1. 2. Select “BCM” on CONSULT-II. Select “HEAD LAMP” on “SELECT TEST ITEM” screen. Select “DATA MONITOR” on “SELECT DIAG MODE” screen. Make sure that “H/L SW POS” and “HEAD LAMP SW 2” turns ON-OFF linked with operation of lighting switch. When lighting switch is OFF position B D E : H/L SW POS OFF F OK or NG OK >> Replace IPDM E/R. Refer to PG-37, "Removal and Installation of IPDM E/R" . NG >> Check combination switch (lighting switch). Refer to LT125, "Combination Switch Inspection" . MKIB2279E 3. CHECKING CAN COMMUNICATIONS BETWEEN BCM AND IPDM E/R G H Select “BCM” on CONSULT-II, and perform self-diagnosis for “BCM”. Display of self-diagnosis results NO DTC>> Replace IPDM E/R. Refer to PG-37, "Removal and Installation of IPDM E/R" . CAN COMM CIRCUIT>> Refer to BCS-17, "CAN Communication Inspection With CONSULT-II (Self-Diagnosis)" . I J LT PKIA7627E L M LT-29 HEADLAMP -CONVENTIONAL TYPEAiming Adjustment BKS001M7 MKIB2306E Turn the aiming adjusting screw to adjust. ● For positions of the adjustment screws, refer to the figures. CAUTION: Adjustment with the aiming adjusting screw must be done in the tightening direction. (When adjusting in the loosening direction, first loosen the screw, then tighten again.) ● PREPARATION BEFORE ADJUSTING For details, refer to the regulations in your own country. Before performing aiming adjustment, check the following. 1. Keep all tires inflated to correct pressures. 2. Place vehicle on flat surface. 3. Set that there is no-load in vehicle other than the driver (or equivalent weight placed in driver's position). Coolant, engine oil filled up to correct level and full fuel tank. LOW BEAM AND HIGH BEAM NOTE: Aim each headlamp individually and ensure other headlamp beam pattern is blocked from screen. 1. Turn headlamp low beam ON. 2. Use adjusting screws to perform aiming adjustment. ● First tighten the adjusting screw all the way and then make adjustment by loosening the screw. If the vehicle front body has been repaired and/or the headlamp assembly has been replaced, check aiming. Use the aiming chart shown in the figure. LT-30 HEADLAMP -CONVENTIONAL TYPE● ● ● Adjust headlamps so that main axis of light is parallel to center line of body and is aligned with point P shown in illustration. Figure shows headlamp aiming pattern for driving on right side of road; for driving on left side of road, aiming pattern is reversed. Dotted lines to point P in illustration show center of headlamp. “H” “WL ” “L” “C” A B C : Horizontal center line of headlamps : Distance between each headlamp center : 25,000 mm (984.25 in) : 250 mm (9.84 in) – 310 mm (12.20 in) Elbow point for LHD models must be in 300 mm (11.81 in) to the right form point P. Elbow point for RHD models must be in 300 mm (11.81 in) to the left form point P. ● Basic illuminating area for adjustment should be within the range shown in the figure. Adjust headlamps accordingly. CAUTION: Be sure aiming switch is set to “0” when preforming aiming adjustment. D E ● F G PKIA3537E H I J LT L M LT-31 HEADLAMP -CONVENTIONAL TYPEBulb Replacement BKS001CZ CAUTION: After installing bulb, be sure to install plastic cap and bulb socket securely to ensure watertightness. HEADLAMP (HIGH/LOW) 1. 2. 3. 4. Turn lighting switch OFF. Remove the socket connected to the bulb. Remove back cover. Unlock retaining spring and remove bulb from headlamp. Headlamp (High/Low) : 12V - 60/55W (H4) PARKING (CLEARANCE) LAMP 1. 2. 3. Turn lighting switch OFF. Turn bulb socket counterclockwise and unlock it. Remove bulb from its socket. Parking (Clearance) lamp : 12V - 5W FRONT TURN SIGNAL LAMP 1. 2. 3. Turn lighting switch OFF. Turn bulb socket counterclockwise and unlock it. Remove bulb from its socket. Front turn signal lamp : 12V - 21W (amber) Removal and Installation BKS001D0 SKIB3797J 1. Bolt 2. Headlamp REMOVAL 1. 2. 3. 4. Disconnect the battery cable from the negative terminal. Remove front bumper. Refer to EI-4, "FRONT BUMPER" . Remove headlamp mounting bolts. Pull headlamp toward the vehicle front, disconnect connector, and remove headlamp. CAUTION: When removing headlamps, put a shop cloth or something similar between headlamps and bumper to protect bumper. LT-32 HEADLAMP -CONVENTIONAL TYPEINSTALLATION A Installation is the reverse order of removal. Headlamp mounting bolt : 5.5 N·m (0.56 kg-m, 49 in-lb) NOTE: After installation, perform aiming adjustment. Refer to LT-30, "Aiming Adjustment" . B C D E F G H I J LT L M LT-33 HEADLAMP -CONVENTIONAL TYPEDisassembly and Assembly BKS001D1 MKIB2292E 1. Retaining spring 2. Parking (clearance) lamp bulb 3. Parking (clearance) lamp bulb socket 4. Halogen bulb (High/Low) 5. Back cover 6. Front turn signal lamp bulb 7. Front turn signal lamp bulb socket 8. Headlamp housing assembly DISASSEMBLY 1. 2. 3. 4. 5. 6. 7. Disconnect the socket connected to the bulb (High/low). Remove back cover. Unlock retaining spring and remove bulb (High/Low). Turn parking (clearance) lamp bulb socket counterclockwise and unlock it. Remove parking (clearance) lamp bulb from its socket. Turn front turn signal lamp bulb socket counterclockwise and unlock it. Remove front turn signal lamp bulb from its socket. ASSEMBLY Assembly is the reverse order of disassembly. CAUTION: ● After installing bulb, be sure to install plastic cap and bulb socket securely to insure watertightness. LT-34 HEADLAMP - DAYTIME LIGHT SYSTEM HEADLAMP - DAYTIME LIGHT SYSTEM Component Parts and Harness Connector Location PFP:26010 A BKS001D2 B C D E F G MKIB2271E 1. IPDM E/R E8,E11,E12 2. BCM M57,M59 (View with instrument upper panel removed) 4. Combination meter M27 5. Daytime light relay E54 3. System Description Combination switch M38 H BKS001D3 DAYTIME LIGHT SYSTEM turns on daytime light lamps while engine is running. Engine run or stop signal are sent to BCM (body control module) by CAN communication line, and control daytime light system. I J OUTLINE Power is supplied at all times ● to ignition relay (located in IPDM E/R), ● to headlamp high RH and LH relay (located in IPDM E/R) ● to headlamp low relay (located in IPDM E/R) from battery directly, ● through 20A fuse (No. 61, located in IPDM E/R), ● through 20A fuse (No. 62, located in IPDM E/R), ● through 40A fusible link (letter J, located in fuse and fusible link block) ● to BCM terminals 74 and 79, ● through 10A fuse [No. 7, located in fuse block (J/B)] ● to combination meter terminal 27, ● through 10A fuse (No. 37, located in fuse and fusible link block) ● to daytime light relay terminals 1 and 5. When the ignition switch is in ON or START position, power is supplied ● to ignition relay (located in IPDM E/R), ● through 10A fuse [No. 5, located in fuse block (J/B)] ● to BCM terminal 24, ● through 10A fuse [No. 4, located in fuse block (J/B)] ● to combination meter terminal 28. Ground is supplied ● to BCM terminals 2 and 70 ● to combination meter terminals 21, 22, and 23 ● through grounds E21 and M66, LT-35 LT L M HEADLAMP - DAYTIME LIGHT SYSTEM ● ● to IPDM E/R terminals 3 and 54 through grounds E45 (CR and HR engine models), E28 and E44. HEADLAMP OPERATION Low Beam Operation With the lighting switch in 2ND position, the BCM receives input signal requesting the headlamps to illuminate. This input signal is communicated to IPDM E/R across the CAN communication lines. The CPU located in the IPDM E/R controls the headlamp low relay coil, which when energized, directs power ● through 15A fuse (No. 50, located in IPDM E/R) ● through IPDM E/R terminal 48 ● to headlamp RH terminal 1, ● through 15A fuse (No. 49, located in IPDM E/R) ● through IPDM E/R terminal 50 ● to headlamp LH terminal 1. Ground is supplied ● to headlamp RH terminals 3 ● through daytime light relay terminal 3 and 4, ● to headlamp LH terminal 3 ● through grounds E45 (CR and HR engine models), E28 and E44. With power and ground supplied, low beam headlamps illuminate. High Beam Operation (When Daytime Light Does Not Operate)/Flash-to-Pass Operation With the lighting switch in 2ND position and placed in HIGH BEAM or PASSING position, the BCM receives input signal requesting headlamp high beams to illuminate. High beam request signal is communicated to the IPDM E/R across the CAN communication lines. The CPU located in the IPDM E/R controls headlamp high relay coil and low relay coil, which when energized, directs power ● through 10A fuse (No. 43, located in IPDM E/R) ● through IPDM E/R terminal 46 ● through headlamp RH terminals 2 ● through 10A fuse (No. 44, located in IPDM E/R) ● through IPDM E/R terminal 47 ● to headlamp LH terminal 2, ● through 15A fuse (No. 50, located in IPDM E/R) ● through IPDM E/R terminal 48 ● to headlamp RH terminal 1, ● through 15A fuse (No. 49, located in IPDM E/R) ● through IPDM E/R terminal 50 ● to headlamp LH terminal 1. Ground is supplied ● to headlamp RH terminal 3 ● to daytime light relay terminals 3and 4 ● to headlamp LH terminal 3 ● through grounds E45 (CR and HR engine models), E28 and E44. With the power and ground supplied, the headlamp high beam and low headlamp illuminate. High beam indicator illuminates when combination meter receives input signal requesting high beam indicator to illuminate. This is communicated to BCM across the CAN communication lines. LT-36 HEADLAMP - DAYTIME LIGHT SYSTEM DAYTIME LIGHT OPERATION With the engine running, the lighting switch in the OFF or AUTO position (headlamp is not illuminate) and parking brake released, the IPDM E/R receives input request signal from BCM to turn on daytime light. This input is communicated across the CAN communication lines. The CPU of the IPDM E/R controls the daytime light relay coil. When energized, this relay directs power ● through 10A fuse (No. 37, located in fuse and fusible link block) ● through daytime light relay terminals 5 and 3 ● through headlamp RH terminals 3 and 1 ● through IPDM E/R terminal 48 ● through 15A fuse (No. 50, located in IPDM E/R) ● through 15A fuse (No. 49, located in IPDM E/R) ● through IPDM E/R terminal 50 ● to headlamp LH terminal 1. Ground is supplied ● to headlamp LH terminal 3 ● through grounds E45 (CR and HR engine models), E28 and E44. Because the low beam headlamps are now wired in series, they operate at half illumination. If the lighting switch is in the 1st and 2nd position, daytime light operation is canceled. A B C D E F G COMBINATION SWITCH READING FUNCTION Refer to LT-114, "COMBINATION SWITCH READING FUNCTION" . AUTO LIGHT OPERATION H Refer to LT-52, "System Description" . FRIENDRY LIGHTING FUNCTION I Low beam headlamps will illuminate for 30 seconds when, ● ignition switch is in OFF position, ● lighting switch is placed in OFF position, and ● lighting switch is placed in PASS position. Each activation of the switch adds 30 seconds to a maximum of 2 minutes. J EXTERIOR LAMP BATTERY SAVER CONTROL LT To avoid flat battery caused by user leaving exterior lamps ON. When ignition is OFF and the driver side door is opened, all exterior lamps will be turned OFF. If the user wants some lamps to remain ON then they must switch these lamps OFF then ON again with the combination switch once the driver side door has been opened. A buzzer will sound if any exterior lamps are ON with the driver side door opened and ignition OFF. *:This setting can be changed by CONSULT-II. Refer to LT-45, "WORK SUPPORT" . L FAIL-SAFE FUNCTION M When CAN communication with other control units is impossible, IPDM E/R performs fail-safe control. If the fail-safe system is operating, headlamps illuminate when the ignition switch is turned from OFF to ON and headlamps are turned off when the ignition switch is turn from ON to OFF. If the fail-safe system is operating, headlamps does not operate when the combination switch is in any position. After CAN communication recovers normally, it also returns to normal control. (Refer to PG-18, "Fail-safe Control" .) CAN Communication System Description BKS001M4 CAN (Controller Area Network) is a serial communication line for real time application. It is an on-vehicle multiplex communication line with high data communication speed and excellent error detection ability. Many electronic control units are equipped onto a vehicle, and each control unit shares information and links with other control units during operation (not independent). In CAN communication, control units are connected with 2 communication lines (CAN H line, CAN L line) allowing a high rate of information transmission with less wiring. Each control unit transmits/receives data but selectively reads required data only. CAN Communication Unit BKS001M5 Refer to LAN-27, "CAN Communication Unit" . LT-37 HEADLAMP - DAYTIME LIGHT SYSTEM Schematic BKS001D5 MKWA4323E LT-38 HEADLAMP - DAYTIME LIGHT SYSTEM Wiring Diagram — DTRL — BKS001D6 A B C D E F G H I J LT L M MKWA4324E LT-39 HEADLAMP - DAYTIME LIGHT SYSTEM - MKWA4325E LT-40 HEADLAMP - DAYTIME LIGHT SYSTEM A B C D E F G H I J LT L M MKWA4326E LT-41 HEADLAMP - DAYTIME LIGHT SYSTEM Terminals and Reference Values for BCM BKS001D7 CAUTION: ● Check combination switch system terminal waveform under the loaded condition with lighting switch, turn signal switch and wiper switch OFF not to be fluctuated by overloaded. ● Turn wiper dial position to 4 except when checking waveform or voltage of wiper dial position. Wiper dial position can be confirmed on CONSULT-II. Refer to LT-45, "DATA MONITOR" . Terminal No. Wire color 2 B 13 SB Combination switch input 1 14 P Combination switch input 3 15 W Combination switch input 5 33 R Combination switch input 2 34 Y Combination switch input 4 7 BR Combination switch output 5 8 L Combination switch output 3 9 V Combination switch output 1 27 28 GR G Signal designation Ground Combination switch output 4 Measuring condition Signal input/ output Ignition switch Operation or condition Voltage [V] (Approx.) — ON — 0 Input ON Headlamps, turn signal, wipers OFF SKIA2167J Headlamps, turn signal, wipers OFF (wiper volume is 1 or 7) SKIA2166J Output ON Headlamps, turn signal, wipers OFF (wiper volume is other than 1 or 7) Combination switch output 2 SKIA2167J Input/ Output ON — Approx. 2.6V Input ON — Battery voltage 19 L CAN- H 24 O Ignition power supply 39 Y CAN- L Input/ Output ON — Approx. 2.4V 70 B Ground — ON — 0 74 79 Y Battery power supply Input OFF — Battery voltage LT-42 HEADLAMP - DAYTIME LIGHT SYSTEM Terminals and Reference Values for IPDM E/R BKS001D8 A Terminal No. Wire color 3 B Ground 46 Y Headlamp HI (RH) 47 G Headlamp HI (LH) Signal designation 48 P Headlamp LO (RH) 50 L Headlamp LO (LH) Measuring condition Signal input/ output Ignition switch Operation or condition Voltage [V] (Approx.) — ON — 0 ON ON Output ON ON Lighting switch (high beam) ON Battery voltage OFF 0 Lighting switch (low beam) ON Battery voltage OFF 0 52 L CAN- H Input/ Output 54 B Ground — ON — 0 58 Y CAH- L Input/ Output — — — 65 L Daytime light relay Input ON — — — Engine status (Lighting switch OFF) RUNNING STOP C D E F 0 Battery voltage How to Perform Trouble Diagnosis 1. 2. 3. 4. 5. 6. B BKS001D9 Confirm the symptom or customer complaint. Understand operation description and function description. Refer to LT-35, "System Description" . Perform the Preliminary Check. Refer to LT-44, "Preliminary Check" . Check symptom and repair or replace the cause of malfunction. Does the headlamp operate normally? If YES: GO TO 6. If NO: GO TO 4. INSPECTION END G H I J LT L M LT-43 HEADLAMP - DAYTIME LIGHT SYSTEM Preliminary Check BKS001DA INSPECTION FOR POWER SUPPLY AND GROUND CIRCUIT 1. CHECK FUSES Check for blown fuses or fusible link. Unit Power source Fuse No. Battery J Ignition switch ON or START position 5 BCM 43 44 IPDM E/R 49 Battery 50 61 62 Refer to LT-39, "Wiring Diagram — DTRL —" . OK or NG OK >> GO TO 2. NG >> If fuse is blown, be sure to eliminate cause of malfunction before installing new fuse. Refer to PG4, "POWER SUPPLY ROUTING CIRCUIT" . 2. CHECK POWER SUPPLY CIRCUIT 1. 2. 3. Turn ignition switch OFF. Disconnect BCM connector. Check voltage between BCM harness connector and ground. Terminal Ignition switch position (+) BCM Connector Terminal M57 24 74 (−) Ground M59 OFF ACC ON Approx. 0V Approx. 0V Battery voltage Battery voltage Battery voltage Battery voltage Battery voltage Battery voltage Battery voltage MKIB0352E 79 OK or NG OK >> GO TO 3. NG >> Repair harness or connector. 3. CHECK GROUND CIRCUIT Check continuity between BCM harness connector and ground. BCM connector Terminal M57 2 M59 70 Continuity Ground Yes OK or NG OK >> INSPECTION END NG >> Repair harness or connector. MKIB0353E LT-44 HEADLAMP - DAYTIME LIGHT SYSTEM CONSULT-II Functions (BCM) BKS001DB A CONSULT-II can display each diagnostic item using the diagnostic test mode shown following. BCM diagnosis part Diagnosis mode Changes the setting for each function. DATA MONITOR Displays BCM input data in real time. HEADLAMP ACTIVE TEST SELF-DIAG RESULTS BCM Description WORK SUPPORT CAN DIAG SUPPORT MNTR B Operation of electrical loads can be checked by sending drive signal to them. C BCM performs self-diagnosis of CAN communication. The result of transmit/receive diagnosis of CAN communication can be read. D CONSULT-II INSPECTION PROCEDURE Refer toGI-36, "CONSULT-II Start Procedure" . CONSULT-II Application Items (BCM) BKS001M1 E WORK SUPPORT Operation Procedure 1. 2. 3. 4. 5. 6. 7. F Touch “HEAD LAMP” on “SELECT TEST ITEM” screen. Touch “WORK SUPPORT” on “SELECT DIAG MODE” screen. Touch “BATTERY SAVER SET” on “SELECT WORK ITEM” screen. Touch “START”. Touch “CHANGE SET”. The setting will be changed and “CUSTOMIZING COMPLETED” will be displayed. Touch “END”. G H Display Item List Item BATTERY SAVER SET Description CONSULT-II Factory setting Exterior lamp battery saver control mode can be changed in this mode. Select exterior lamp battery saver control mode between ON and OFF. ON × OFF — I J DATA MONITOR Monitor item UNIT. Display content IGN ON SW [ON/OFF] Displays status (Ignition switch ON: ON/Others OFF, ACC: OFF) as judged from the ignition switch signal. HI BEAM SW [ON/OFF] Displays status (High beam switch: ON/Others: OFF) as judged from lighting switch signal. H/L SW POS [ON/OFF] Displays status (Headlamp switch: ON/Others: OFF) as judged from lighting switch signal. LIGHT SW 1ST [ON/OFF] Displays status (Lighting switch 1st position: ON/Others: OFF) as judged from lighting switch signal. PASSING SW [ON/OFF] Displays status (Flash-to-pass switch: ON/Others: OFF) as judged from lighting switch signal. FR FOG SW [ON/OFF] Displays status (Front fog lamp switch: ON/Others: OFF) as judged from lighting switch signal. RR FOG SW [ON/OFF] Displays status (Rear fog lamp switch: ON/Others: OFF) as judged from lighting switch signal. DOOR SW-DR [ON/OFF] Displays status (Door open: ON/door closed: OFF) as judged from the door switch DR signal. H/L WASH SW [ON/OFF] Displays status (Headlamp washer switch: ON/Others: OFF) as judged from headlamp washer switch signal. ENGINE STATUS [STOP/ STALL/ RUN/ CRA] Displays status (Engine stop: STOP/engine stall: STALL/engine running: RUN/engine cranking: CRA) as judged from the engine status. LT-45 LT L M HEADLAMP - DAYTIME LIGHT SYSTEM ACTIVE TEST Test item CONSULT-II screen display Description Tail lamp relay output TAIL LAMP Tail lamp relay can be operated by any ON–OFF operation. Headlamp relay output HEADLAMP Headlamp relay can be operated by any ON–OFF operation. Front fog lamp relay output FR FOG LAMP Front fog lamp relay can be operated by any ON–OFF operation. Rear fog lamp relay output RR FOG LAMP Rear fog lamp relay can be operated by any ON–OFF operation. CONSULT-II Functions (IPDM E/R) BKS001DC CONSULT-II can display each diagnostic item using the diagnostic test mode shown following. Diagnosis Mode SELF-DIAGNOSTIC RESULTS Description Refer to PG-20, "SELF-DIAG RESULTS" . DATA MONITOR The input/output data of IPDM E/R is displayed in real time. CAN DIAG SUPPORT MNTR The result of transmit/receive diagnosis of CAN communication can be read. ACTIVE TEST IPDM E/R sends a drive signal to electronic components to check their operation. CONSULT-II INSPECTION PROCEDURE Refer to GI-36, "CONSULT-II Start Procedure" . CONSULT-II Application Items (IPDM E/R) BKS001M2 DATA MONITOR All Signals, Main Signals, Selection From Menu Monitor item selection Monitor item name Display and unit All signals Main signals selection from menu Display content TAIL & CLR REQ ON/OFF × × × Signal status input from BCM HL LO REQ ON/OFF × × × Signal status input from BCM HL HI REQ ON/OFF × × × Signal status input from BCM FR FOG REQ ON/OFF × × × Signal status input from BCM IGN RLY ON/OFF × × × Status of ignition relay being monitored by IPDM E/R ACTIVE TEST Test item CONSULT-II screen display Description Headlamp relay (HI, LO) output HEAD LAMP Headlamp relay (LO, HI) can be operated using random operation (OFF, HI ON, LO ON). Front fog lamp relay output FRONT FOG LAMP Fog lamp relay can be operated by any ON–OFF operation. Tail lamp relay output TAIL LAMP Tail lamp relay can be operated by any ON–OFF operation. LT-46 HEADLAMP - DAYTIME LIGHT SYSTEM Daytime Light Control Does Not Operate Properly BKS001LO 1. CHECK HEADLAMP OPERATION A Lighting switch is turned to 2nd position. Does headlamp operate normally? Yes >> GO TO 2. No >> Check the following. ● Headlamp does not illuminate (both sides). GO TO LT-25, "Headlamp Low Beam Does Not Illuminate (Both Sides)" . ● Headlamp does not illuminate (one side). GO TO LT-27, "Headlamp Low Beam Does Not Illuminate (One Side)" . B C D 2. CHECK DAYTIME LIGHT RELAY 1. 2. 3. E Turn ignition switch OFF. Disconnect daytime light relay connector. Check voltage between daytime light relay harness connector and ground. F Terminals (+) Connector (–) Voltage [V] (Approx.) Ground Battery voltage G Terminal E54 1 H 5 OK or NG OK >> GO TO 3. NG >> Check the following. ● 10A fuse (No. 37, located in fuse and fusible link box). ● Harness for open or short between daytime relay and fuse. MKIB0408E I J 3. CHECK IPDM E/R OUTPUT SIGNAL 1. 2. 3. LT Connect daytime light relay. Disconnect IPDM E/R connector. Check voltage between IPDM E/R harness connector E5 terminal 65 and ground. 65 - Ground L : Battery voltage M OK or NG OK >> GO TO 4. NG >> GO TO 5. MKIB0745E LT-47 HEADLAMP - DAYTIME LIGHT SYSTEM - 4. CHECK IPDM E/R OUTPUT SIGNAL 1. 2. Connect IPDM E/R connector. Check voltage between IPDM and ground. Terminals (+) Connector Terminal E5 65 Ground Voltage [V] (Approx.) Condition (–) Engine stop Battery voltage Engine running 0 OK or NG OK >> Replace daytime relay. NG >> Replace IPDM E/R. MKIB0551E 5. CHECK IPDM E/R OUTPUT SIGNAL CIRCUIT 1. 2. Disconnect daytime light relay connector. Check continuity between daytime light relay harness connector E54 terminal 2 and IPDM E/R harness connector E5 terminal 65. 2 - 65 : Continuity should exist. OK or NG OK >> Replace daytime light relay. NG >> Repair or replace harness or connector. MKIB0409E RH High beam Does Not Illuminate BKS001LQ 1. CHECK BULB Check bulb of headlamp RH. OK or NG OK >> GO TO 2. NG >> Replace bulb of headlamp. 2. CHECK POWER SUPPLY CIRCUIT 1. 2. 3. Turn ignition switch OFF. Disconnect headlamp RH connector. Check voltage between headlamp RH harness connector E26 terminal 2 and ground. Terminals (+) Condition Connector Terminal E26 2 (–) Ground Lighting switch high beam ON Voltage [V] (Approx.) Battery voltage OK or NG OK >> GO TO 5. NG >> GO TO 3. MKIB1921E LT-48 HEADLAMP - DAYTIME LIGHT SYSTEM - 3. CHECK IPDM E/R CIRCUIT 1. 2. A Disconnect IPDM E/R connector. Check continuity between IPDM E/R harness connector (A) and headlamp RH harness connector (B). A 3. B B Continuity Connector Terminal Connector Terminal E8 46 E26 2 C Yes Check continuity between IPDM E/R harness connector (A) and ground. A Continuity Connector Terminal E8 46 Ground D MKIB2287E E No OK or NG OK >> GO TO 4. NG >> Repair or replace harness or connector. F 4. CHECK FUSE G Check 10A fuse [No. 43, located in IPDM E/R]. OK or NG OK >> Replace IPDM E/R. NG >> Replace fuse. If fuse is blown, be sure to eliminate cause of malfunction before installing new fuse. 5. CHECK HEADLAMP RH GROUND CIRCUIT Check continuity between daytime light relay harness connector E54 terminal 3 and headlamp RH harness connector E26 terminal 3. 3- 3 H I J : Continuity should exist. LT OK or NG OK >> GO TO 6. NG >> Repair or replace harness or connector. L MKIB2015E 6. CHECK DAYTIME LIGHT GROUND CIRCUIT Check continuity daytime light relay harness connector E54 terminal 4 and ground. 4 - Ground : Continuity should exist. OK or NG OK >> Replace daytime light relay. NG >> Repair or replace harness or connector. MKIB0420E LT-49 M HEADLAMP - DAYTIME LIGHT SYSTEM RH Low Beam Does Not Illuminate BKS001LT 1. CHECK BULB Check bulb of headlamp RH. OK or NG OK >> GO TO 2. NG >> Replace bulb of lamp. 2. CHECK POWER SUPPLY CIRCUIT 1. 2. 3. Turn ignition switch OFF. Disconnect headlamp RH connector. Check voltage between headlamp RH harness connector E26 terminal 1 and ground. Terminals (+) Voltage [V] (Approx.) Condition Connector Terminal E26 1 (–) Ground Lighting switch low beam ON Battery voltage OK or NG OK >> GO TO 5. NG >> GO TO 3. MKIB2019E 3. CHECK IPDM E/R CIRCUIT 1. 2. Disconnect IPDM E/R connector. Check continuity between IPDM E/R harness connector (A) and headlamp RH harness connector (B). A 3. B Continuity Connector Terminal Connector Terminal E8 48 E26 1 Yes Check continuity between IPDM E/R harness connector (A) and ground. A Continuity Connector Terminal E8 48 Ground MKIB2288E No OK or NG OK >> GO TO 4. NG >> Repair or replace harness or connector. 4. CHECK FUSE Check 15A fuse (No. 50 located in IPDM E/R). Refer to PG-34, "IPDM E/R Terminal Inspection" . OK or NG OK >> Replace IPDM E/R. NG >> Replace fuse. If fuse is blown, be sure to eliminate cause of malfunction before installing new fuse. LT-50 HEADLAMP - DAYTIME LIGHT SYSTEM - 5. CHECK HEADLAMP RH GROUND CIRCUIT A Check continuity between daytime light relay harness connector E54 terminal 3 and headlamp RH harness connector E26 terminal 3. 3-3 B : Continuity should exist. OK or NG OK >> GO TO 6. NG >> Repair or replace harness or connector. C D MKIB2015E 6. CHECK DAYTIME LIGHT GROUND CIRCUIT E Check continuity daytime light relay harness connector E54 terminal 4 and ground. 4 - Ground F : Continuity should exist. OK or NG OK >> Replace daytime light relay. NG >> Repair or replace harness connector. G H MKIB0420E Headlamp High Beam Does Not Illuminate (Both Sides) BKS001LP I BKS001LX J BKS001LY LT Refer to LT-21, "Headlamp High Beam Does Not Illuminate (Both Sides)" . Headlamp Low Beam Does Not Illuminate (Both Sides) Refer to LT-25, "Headlamp Low Beam Does Not Illuminate (Both Sides)" . Headlamp LH High Beam Does Not Illuminate Refer to LT-23, "Headlamp High Beam Does Not Illuminate (One Side)" . Headlamp LH Low Beam Does Not Illuminate BKS001LU Refer toLT-27, "Headlamp Low Beam Does Not Illuminate (One Side)" . Headlamps Do Not Turn OFF L BKS001LW M Refer toLT-29, "Headlamps Do Not Turn OFF" . Aiming Adjustment BKS001DN Refer to LT-30, "Aiming Adjustment" . Bulb Replacement BKS001DO Refer toLT-32, "Bulb Replacement" . Removal and Installation BKS001DP Refer to LT-32, "Removal and Installation" . Disassembly and Assembly BKS001DQ Refer to LT-34, "Disassembly and Assembly" . LT-51 AUTO LIGHT SYSTEM AUTO LIGHT SYSTEM Component Parts and Harness Connector Location PFP:28491 BKS001DR MKIB2270E 1. IPDM E/R E8,E12 2. BCM M57,M59 (View with instrument upper panel removed) 4. Combination switch M38 5. Front door switch driver side [B14 (LHD models)] [B29 (RHD models)] 3. Light and rain sensor R2 System Description BKS001DS Automatically turns ON/OFF the parking lamps and the headlamps in accordance with ambient light. OUTLINE The auto light control system has an light and rain sensor inside it that detects outside brightness. When the lighting switch is in AUTO position, it automatically turns ON/OFF the parking lamps and the headlamps in accordance with ambient light. Light and rain sensor, power is supplied ● through BCM terminal 73 ● to light and rain sensor terminal 1. Light and rain sensor, ground is supplied ● to light and rain sensor terminal 3 ● through grounds M21 and M66. When ignition switch is turn to ON position and When outside brightness is darker than prescribed level, input is supplied ● to light and rain sensor terminal 2 ● through BCM terminal 63. The headlamps will then illuminate. For a description of headlamp operation, Refer to LT-52, "System Description" . LT-52 AUTO LIGHT SYSTEM COMBINATION SWITCH READING FUNCTION A Refer to LT-114, "COMBINATION SWITCH READING FUNCTION" . FRIENDRY LIGHTING FUNCTION Low beam headlamps will illuminate for 30 seconds when, ● ignition switch is in OFF position, ● lighting switch is placed in OFF position, and ● lighting switch is placed in PASS position. Each activation of the switch adds 30 seconds to a maximum of 2 minutes. B C EXTERIOR LAMP BATTERY SAVER CONTROL To avoid flat battery caused by user leaving exterior lamps ON. When ignition is OFF and the driver side door is opened, all exterior lamps will be turned OFF. If the user wants some lamps to remain ON then they must switch these lamps OFF then ON again with the combination switch once the driver side door has been opened. A buzzer will sound if any exterior lamps are ON with the driver side door opened and ignition OFF. *:This setting can be changed by CONSULT-II. Refer to LT-63, "WORK SUPPORT" . CAN Communication System Description BKS001DT CAN (Controller Area Network) is a serial communication line for real time application. It is an on-vehicle multiplex communication line with high data communication speed and excellent error detection ability. Many electronic control units are equipped onto a vehicle, and each control unit shares information and links with other control units during operation (not independent). In CAN communication, control units are connected with 2 communication lines (CAN H line, CAN L line) allowing a high rate of information transmission with less wiring. Each control unit transmits/receives data but selectively reads required data only. D E F G H CAN Communication Unit BKS001DU Refer to LAN-27, "CAN Communication Unit" . Major Components and Functions BKS001DV Components BCM Light and rain sensor I Functions ● Turns ON/OFF circuits of tail light and headlamp according to signals from light sensor, lighting switch (AUTO), driver’s door switch, passenger’s door switch and ignition switch (ON, OFF). ● Converts outside brightness (lux) to voltage, and sends it to BCM. (Detects brightness of 50 to 1,300 lux) J LT L M LT-53 AUTO LIGHT SYSTEM Schematic BKS001DW MKWA4333E LT-54 AUTO LIGHT SYSTEM Wiring Diagram — AUTO/L — BKS001DX A B C D E F G H I J LT L M MKWA4334E LT-55 AUTO LIGHT SYSTEM MKWA4335E LT-56 AUTO LIGHT SYSTEM A B C D E F G H I J LT L M MKWA4336E LT-57 AUTO LIGHT SYSTEM MKWA4337E LT-58 AUTO LIGHT SYSTEM Terminals and Reference Values for BCM BKS001DY CAUTION: ● Check combination switch system terminal waveform under the loaded condition with lighting switch, turn signal switch and wiper switch OFF not to be fluctuated by overloaded. ● Turn wiper dial position to 4 except when checking waveform or voltage of wiper dial position. Wiper dial position can be confirmed on CONSULT-II. Refer to LT-64, "DATA MONITOR" . Terminal No. Wire color 2 B Signal name Ground Ignition switch Operation or condition — ON — B C Measuring condition Signal input/ output A Reference value D Approx. 0V E OFF F 14 P Combination switch input 3 Input ON Lighting, turn, wiper switch (Wiper intermittent dial position 4) PKIB4958J Approx. 1.0V G H Lighting switch AUTO PKIB8631J I Approx. 2.0V 19 L CAN − H Input/ Output 24 O Ignition switch (ON) Input ON — Approx. 2.6V ON — Battery voltage J LT L OFF 27 GR Combination switch output 4 Output ON Lighting, turn, wiper switch (Wiper intermittent dial position 4) PKIB4958J Approx. 1.2V Lighting switch AUTO PKIB4959J Approx. 1.0V LT-59 M AUTO LIGHT SYSTEM Terminal No. Wire color Signal name Signal input/ output Measuring condition Ignition switch Reference value Operation or condition ON (open) 29 LG*1 BR*2 Front door switch (driver side) signal Input OFF Front door switch (driver side) Approx. 0V OFF (closed) PKIB4950J Approx. 11.0V CAN − L Input/ Output ON — Approx. 2.4V Light and rain sensor signal Input ON When light and rain sensor is illuminated. Approx. 8.9VNOTE — ON — Approx. 0V Light and rain sensor power supply Output ON — Approx. 5V Battery power supply Input OFF — Battery voltage 39 Y 63 BR 70 B Ground 73 V 74 79 Y *1:LHD models *2:RHD models NOTE: Light and rain sensor must be securely subjected to work lamp light. If the light and rain sensor is insufficiently illuminated, the measured value may not satisfy standard. LT-60 AUTO LIGHT SYSTEM Terminals and Reference Values for IPDM E/R BKS001DZ A Terminal No. Wire color 3 B 15 GR 16 45 46 V BR Y Signal name Ground Measuring condition Signal input/ output Ignition switch Operation or condition — ON — Rear combination lamp LH (Tail) ON Rear combination lamp RH (Tail) and license plate lamp RH and LH ON Parking lamp RH Headlamp HIGH RH 48 49 50 G P O L Headlamp HIGH LH Headlamp LOW RH Lighting switch 1ST position OFF Approx. 0V ON Battery voltage OFF Approx. 0V ON Battery voltage Approx. 0V Lighting switch 1ST position ON Battery voltage OFF Approx. 0V ON Lighting switch HIGH beam or PASSING position ON Battery voltage Lighting switch HIGH beam or PASSING position OFF Approx. 0V ON ON Battery voltage Lighting switch 2ND position OFF Approx. 0V ON Battery voltage Lighting switch 1ST position OFF Approx. 0V ON Battery voltage Lighting switch 2ND position OFF Approx. 0V ON Battery voltage ON Headlamp LOW LH Lighting switch 1ST position ON ON Parking lamp LH B Approx. 0V OFF Output 47 Reference value ON 52 L CAN − H Input/ Output 54 B Ground — ON — Approx. 0V 58 Y CAN − L Input/ Output — — — — — — How to Proceed With Trouble Diagnosis 1. 2. 3. 4. 5. 6. Confirm the symptom or customer complaint. Understand operation description and function description. Refer to LT-52, "System Description" . Perform the preliminary check. Refer to LT-62, "Preliminary Check" . Check symptom and repair or replace the cause of malfunction. Does the auto light system operate normally? If YES, GO TO 6. If NO, GO TO 4. INSPECTION END LT-61 C D E F G H I J BKS001E0 LT L M AUTO LIGHT SYSTEM Preliminary Check BKS001E1 CHECK POWER SUPPLY AND GROUND CIRCUIT 1. CHECK FUSES Check for blown fuses. Unit Power source Fuse and fusible link No. Battery J Ignition switch ON or START position 5 BCM 43 44 45 IPDM E/R 46 Battery 49 50 61 62 Refer to LT-55, "Wiring Diagram — AUTO/L —" . OK or NG OK >> GO TO 2. NG >> If fuse or fusible link is blown, be sure to eliminate cause of malfunction before installing new fuse or fusible link. Refer to PG-4, "POWER SUPPLY ROUTING CIRCUIT" . 2. CHECK POWER SUPPLY CIRCUIT 1. 2. 3. Turn ignition switch OFF. Disconnect BCM connector. Check voltage between BCM harness connector and ground. Terminal Ignition switch position (+) BCM Connector Terminal M57 24 74 M59 (−) Ground OFF ACC ON Approx. 0V Approx. 0V Battery voltage Battery voltage Battery voltage Battery voltage Battery voltage Battery voltage Battery voltage MKIB0352E 79 OK or NG OK >> GO TO 3. NG >> Repair harness or connector. LT-62 AUTO LIGHT SYSTEM 3. CHECK GROUND CIRCUIT A Check continuity between BCM harness connector and ground. BCM connector Terminal M57 2 M59 70 Continuity Ground B Yes C OK or NG OK >> INSPECTION END NG >> Repair harness or connector. D MKIB0353E CONSULT-II Functions (BCM) BKS001E2 E CONSULT-II can display each diagnostic item using the diagnostic test modes shown following. BCM diagnosis part Diagnosis mode Changes the setting for each function. DATA MONITOR Displays BCM input data in real time. HEADLAMP ACTIVE TEST SELF-DIAG RESULTS BCM Description WORK SUPPORT CAN DIAG SUPPORT MNTR F Operation of electrical loads can be checked by sending drive signal to them. G BCM performs self-diagnosis of CAN communication. The result of transmit/receive diagnosis of CAN communication can be read. H CONSULT-II INSPECTION PROCEDURE Refer to GI-36, "CONSULT-II Start Procedure" . I CONSULT-II Application Items BKS001L1 WORK SUPPORT Operation Procedure 1. 2. 3. 4. 5. 6. 7. J Touch “HEAD LAMP” on “SELECT TEST ITEM” screen. Touch “WORK SUPPORT” on “SELECT DIAG MODE” screen. Touch “BATTERY SAVER SET” on “SELECT WORK ITEM” screen. Touch “START”. Touch “CHANGE SET”. The setting will be changed and “CUSTOMIZING COMPLETED” will be displayed. Touch “END”. LT L Display Item List Item BATTERY SAVER SET M Description CONSULT-II Factory setting Exterior lamp battery saver control mode can be changed in this mode. Select exterior lamp battery saver control mode between ON and OFF. ON × OFF — LT-63 AUTO LIGHT SYSTEM DATA MONITOR Monitor item UNIT. Display content IGN ON SW [ON/OFF] Displays status (Ignition switch ON: ON/Others OFF, ACC: OFF) as judged from the ignition switch signal. HI BEAM SW [ON/OFF] Displays status (High beam switch: ON/Others: OFF) as judged from lighting switch signal. H/L SW POS [ON/OFF] Displays status (Headlamp switch: ON/Others: OFF) as judged from lighting switch signal. LIGHT SW 1ST [ON/OFF] Displays status (Lighting switch 1st position: ON/Others: OFF) as judged from lighting switch signal. PASSING SW [ON/OFF] Displays status (Flash-to-pass switch: ON/Others: OFF) as judged from lighting switch signal. FR FOG SW [ON/OFF] Displays status (Front fog lamp switch: ON/Others: OFF) as judged from lighting switch signal. RR FOG SW [ON/OFF] Displays status (Rear fog lamp switch: ON/Others: OFF) as judged from lighting switch signal. DOOR SW-DR [ON/OFF] Displays status (Door open: ON/door closed: OFF) as judged from the door switch DR signal. H/L WASH SW [ON/OFF] Displays status (Headlamp washer switch: ON/Others: OFF) as judged from headlamp washer switch signal. ENGINE STATUS [STOP/ STALL/ RUN/ CRA] Displays status (Engine stop: STOP/engine stall: STALL/engine running: RUN/engine cranking: CRA) as judged from the engine status. ACTIVE TEST Test item CONSULT-II screen display Description Tail lamp relay output TAIL LAMP Tail lamp relay can be operated by any ON–OFF operation. Headlamp relay output HEAD LAMP Headlamp relay can be operated by any ON–OFF operation. Front fog lamp relay output FR FOG LAMP Front fog lamp relay can be operated by any ON–OFF operation. Rear fog lamp relay output RR FOG LAMP Rear fog lamp relay can be operated by any ON–OFF operation. LT-64 AUTO LIGHT SYSTEM Light and rain sensor System Inspection BKS001E5 1. CHECK LIGHT AND RAIN SENSOR INPUT SIGNAL 1. 2. A Turn ignition switch ON. Check voltage between BCM harness connector M58 terminal 63 and ground. Illuminated LIGHT AND RAIN SENSOR B C : Approx. 8.9V D MKIB2282E CAUTION: Light and rain sensor must be securely subjected to work lamp light. If light and rain sensor is insufficiently illuminated, the measured value may not satisfy the standard. OK or NG OK >> INSPECTION END NG >> GO TO 2. 2. CHECK LIGHT AND RAIN SENSOR VOLTAGE 1. 2. E F G H Turn ignition switch ON. Check voltage between BCM harness connector and ground. I Terminals (+) Voltage Connector Terminal M59 73 (–) Ground J Approx. 5 V OK or NG OK >> GO TO 3. NG >> Replace BCM. Refer to BCS-17, "Removal and Installation of BCM" . LT MKIB2286E L M LT-65 AUTO LIGHT SYSTEM 3. CHECK LIGHT AND RAIN SENSOR POWER SUPPLY CIRCUIT 1. 2. 3. Turn ignition switch OFF. Disconnect BCM connector and light and rain sensor connector. Check continuity between BCM harness connector (A) and light and rain sensor harness connector (B). A 4. B Continuity Connector Terminal Connector Terminal M59 73 R2 1 Yes Check continuity between BCM harness connector (A) and ground. A Continuity Connector Terminal M59 MKIB2283E Ground No 73 OK or NG OK >> GO TO 4. NG >> Repair harness or connector. 4. CHECK LIGHT AND RAIN SENSOR SIGNAL CIRCUIT 1. Check continuity between BCM harness connector (A) and light and rain sensor harness connector (B). A 2. B Continuity Connector Terminal Connector Terminal M58 63 R2 2 Yes Check continuity between BCM harness connector (A) and ground. A Continuity Connector Terminal M58 63 Ground MKIB2284E No OK or NG OK >> GO TO 5. NG >> Repair harness or connector. 5. CHECK LIGHT AND RAIN SENSOR GROUND CIRCUIT Check continuity between light and rain sensor harness connector R2 terminal 3 and ground. Light and rain sensor Connector Terminal R2 3 Ground Continuity Yes OK or NG OK >> Replace light and rain sensor. NG >> Repair harness or connector. MKIB2285E LT-66 AUTO LIGHT SYSTEM Removal and Installation of Light and Rain Sensor BKS001E6 A REMOVAL 1. Remove inside mirror. Refer to GW-104, "INSIDE MIRROR" . 2. Remove clip and pawl. 3. Pull out the light and rain sensor. 4. Remove light and rain sensor harness connector. CAUTION: Do not touch the electronic circuit board on rain sensor. B C D MKIB2028E INSTALLATION OF LIGHT AND RAIN SENSOR E Install in the reverse order of removal. INSTALLATION OF LIGHT AND RAIN SENSOR HOUSING F CAUTION: When windshield is replaced, always replace rain sensor housing. 1. Clean the surface of bonded area on the windshield. 2. Fix rain sensor housing against light and rain sensor bracket from the top, then press it in a downward motion until it is completely attach together. CAUTION: Do not touch the adhesive. G H I MKIB2029E J LT L M LT-67 HEADLAMP AIMING CONTROL HEADLAMP AIMING CONTROL Schematic PFP:26010 BKS001E7 MKWA4342E LT-68 HEADLAMP AIMING CONTROL Wiring Diagram—H/AIM— BKS001H8 A B C D E F G H I J LT L M MKWA4343E LT-69 HEADLAMP AIMING CONTROL MKWA4344E LT-70 HEADLAMP AIMING CONTROL A B C D E F G H I J LT L M MKWA4345E LT-71 HEADLAMP AIMING CONTROL Removal and Installation BKS001E8 REMOVAL 1. 2. Remove the switch panel assembly. Refer to IP-4, "INSTRUMENT PANEL ASSEMBLY" . Spread pawls (A) of switch panel assembly to remove headlamp aiming switch(1). MKIB2310E INSTALLATION Installation is the reverse order of removal. Switch Circuit Inspection BKS001E9 Using a circuit tester, check resistance between the headlamp aiming switch connector terminals in each operation status of the aiming switch. MKIB0746E LT-72 FRONT FOG LAMP FRONT FOG LAMP Component Parts and Harness Connector Location PFP:26150 A BKS001EA B C D E F G MKIB2268E 1. IPDM E/R E8,E11,E12 4. Combination meter M27 2. BCM M57,M59 (View with instrument upper panel removed) 3. Combination switch M38 System Description H BKS001EB I The control of the front fog lamps is dependent upon the position of the lighting switch. The lighting switch must be in the 1ST/ 2ND position or AUTO position (headlamp is ON) for front fog lamp operation. When the lighting switch is placed in front fog lamp switch ON position the BCM (body control module) receives input signal requesting the front fog lamps to illuminate. When the headlamps are illuminated, this input signal is J communicated to the IPDM E/R (intelligent power distribution module engine room) via the CAN communication. The CPU (central processing unit) located in the IPDM E/R controls the front fog lamp relay coil. When activated, this relay directs power to the front fog lamps. LT OUTLINE Power is supplied at all times ● to front fog lamp relay, located in IPDM E/R, and ● to ignition relay, located in IPDM E/R, from battery directly, ● through 20A fuse (No. 61, located in IPDM E/R), ● through 20A fuse (No. 62, located in IPDM E/R), ● through 40A fusible link (letter J, located in fuse, fusible link and relay box) ● to BCM terminals 74 and 79, ● through 10A fuse [No. 7, located in fuse block (J/B)] ● to combination meter terminal 27. With the ignition switch in the ON or START position, power is supplied ● to ignition relay, located in IPDM E/R, from battery directly, ● through 10A fuse [No. 5, located in fuse block (J/B)] ● to BCM terminal 24, ● through 10A fuse [No. 4, located in fuse block (J/B)] ● to combination meter terminal 28. Ground is supplied ● to BCM terminal 2 and 70 ● to combination meter terminals 21, 22 and 23 ● through grounds M21 and M66, LT-73 L M FRONT FOG LAMP ● ● to IPDM E/R terminals 3 and 54 through grounds E45 (CR and HR engine models),E28 and E44. FOG LAMP OPERATION The front fog lamp switch is built in lighting switch. The lighting switch must be in 1ST/2ND position or AUTO position (headlamp is ON) and front fog lamp switch must be ON position for front fog lamp operation. With the front fog lamp switch in the ON position, the CPU located in the IPDM E/R grounds coil side of the front fog lamp relay. Front fog lamp relay then directs power ● through 20A fuse (No. 65, located in IPDM E/R), ● through IPDM E/R terminal 44 ● to front fog lamp LH terminal 1, ● through IPDM E/R terminal 43 ● to front fog lamp RH terminal 1. Ground is supplied ● to front fog lamp LH and RH terminals 2 ● through grounds E45 (CR and HR engine models),E28 and E44. With power and grounds supplied, front fog lamps illuminate. COMBINATION SWITCH READING FUNCTION Refer to LT-114, "COMBINATION SWITCH READING FUNCTION" . EXTERIOR LAMP BATTERY SAVER CONTROL Refer to LT-9, "EXTERIOR LAMP BATTERY SAVER CONTROL" . FAIL-SAFE FUNCTION When CAN communication with other control units is impossible, IPDM E/R performs fail-safe control. If the fail-safe system is operating, front fog lamps does not operate when the combination switch is in any position. After CAN communication recovers normally, it also returns to normal control. (Refer to PG-18, "Fail-safe Control" .) CAN Communication System Description BKS001EC CAN (Controller Area Network) is a serial communication line for real time application. It is an on-vehicle multiplex communication line with high data communication speed and excellent error detection ability. Many electronic control units are equipped onto a vehicle, and each control unit shares information and links with other control units during operation (not independent). In CAN communication, control units are connected with 2 communication lines (CAN H line, CAN L line) allowing a high rate of information transmission with less wiring. Each control unit transmits/receives data but selectively reads required data only. CAN Communication Unit BKS001ED Refer to LAN-27, "CAN Communication Unit" . LT-74 FRONT FOG LAMP Schematic BKS001EE A B C D E F G H I J LT L M MKWA4349E LT-75 FRONT FOG LAMP Wiring Diagram — F/FOG — BKS001EF MKWA4350E LT-76 FRONT FOG LAMP A B C D E F G H I J LT L M MKWA4351E LT-77 FRONT FOG LAMP MKWA4352E LT-78 FRONT FOG LAMP Terminals and Reference Values for BCM BKS001EG CAUTION: ● Check combination switch system terminal waveform under the loaded condition with lighting switch, turn signal switch and wiper switch OFF not to be fluctuated by overloaded. ● Turn wiper dial position to 4 except when checking waveform or voltage of wiper dial position. Wiper dial position can be confirmed on CONSULT-II. Refer to LT-19, "DATA MONITOR" . Terminal No. Wire color 2 B Signal name Ground Ignition switch Operation or condition — ON — B C Measuring condition Signal input/ output A Reference value D Approx. 0V E OFF 7 BR Combination switch output 5 Output ON F Lighting, turn, wiper switch (Wiper intermittent dial position 4) PKIB8643J Approx. 1.2V G Front fog lamp switch ON (Operates only front fog lamp switch) H PKIB4956J I Approx. 1.0V 19 L CAN − H Input/ Output 24 O Ignition switch (ON) Input ON — Approx. 2.6V ON — Battery voltage J LT L OFF 34 Y Combination switch input 4 Input ON Lighting, turn, wiper switch (Wiper intermittent dial position 4) PKIB4958J Approx. 1.0V Front fog lamp switch ON (Operates only front fog lamp switch) PKIB8627J Approx. 1.5 - 2.0V CAN − L 39 Y 70 B Ground Y Battery power supply 74 79 Input/ Output ON — Approx. 2.4V — ON — Approx. 0V Input OFF — Battery voltage LT-79 M FRONT FOG LAMP Terminals and Reference Values for IPDM E/R BKS001EH Measuring condition Signal input/ output Ignition switch Operation or condition — ON — Front fog lamp RH Output ON Terminal No. Wire color 3 B Ground 43 W Signal name Reference value Approx. 0V Lighting switch must be in the 2ND position or AUTO position (headlamp is ON) Front fog lamp switch: OFF Approx. 0V Front fog lamp switch: ON Battery voltage Lighting switch must be in the 2ND position or AUTO position (headlamp is ON) Front fog lamp switch: OFF Approx. 0V Front fog lamp switch: ON Battery voltage 44 V Front fog lamp LH Output 52 L CAN − H Input/ Output — — — 54 B Ground — ON — Approx. 0V 58 Y CAN − L Input/ Output — — — ON How to Proceed With Trouble Diagnosis 1. 2. 3. 4. 5. 6. Confirm the symptom or customer complaint. Understand operation description and function description. Refer to LT-73, "System Description" . Perform the Preliminary Check. Refer to LT-81, "Preliminary Check" . Check symptom and repair or replace the malfunctioning parts. Does the front fog lamp operate normally? If YES, GO TO 6. If NO, GO TO 4. INSPECTION END LT-80 BKS001EI FRONT FOG LAMP Preliminary Check BKS001EJ A CHECK POWER SUPPLY AND GROUND CIRCUIT 1. CHECK FUSES B Check for blown fuses. Unit Power source Fuse and fusible link No. Battery J Ignition switch ON or START position 5 BCM C 61 IPDM E/R Battery D 62 65 Refer to LT-76, "Wiring Diagram — F/FOG —" . OK or NG OK >> GO TO 2. NG >> If fuse or fusible link is blown, be sure to eliminate cause of malfunction before installing new fuse or fusible link. Refer to PG-4, "POWER SUPPLY ROUTING CIRCUIT" . 2. CHECK POWER SUPPLY CIRCUIT 1. 2. 3. F G Turn ignition switch OFF. Disconnect BCM connector. Check voltage between BCM harness connector and ground. Terminal E H Ignition switch position I (+) BCM Connector Terminal M57 24 (−) 74 Ground M59 OFF ACC ON Approx. 0V Approx. 0V Battery voltage Battery voltage Battery voltage Battery voltage J LT MKIB0352E Battery voltage 79 Battery voltage Battery voltage OK or NG OK >> GO TO 3. NG >> Repair harness or connector. L 3. CHECK GROUND CIRCUIT M Check continuity between BCM harness connector and ground. BCM Connector Terminal M57 2 M59 70 Continuity Ground Yes OK or NG OK >> INSPECTION END NG >> Repair harness or connector. MKIB0353E LT-81 FRONT FOG LAMP CONSULT-II Functions (BCM) BKS001EK Refer to LT-19, "CONSULT-II Functions (BCM)" in “HEADLAMP - CONVENTIONAL TYPE -”. CONSULT-II Functions (IPDM E/R) BKS001EL Refer to LT-20, "CONSULT-II Functions (IPDM E/R)" in “HEADLAMP - CONVENTIONAL TYPE -”. Front Fog lamps Do Not Illuminate (Both Sides) BKS001EM 1. CHECK COMBINATION SWITCH INPUT SIGNAL With CONSULT-II 1. Select “BCM” on CONSULT-II. Select “HEAD LAMP” on “SELECT TEST ITEM” screen. 2. Select “DATA MONITOR” on “SELECT DIAG MODE” screen. Make sure that “FR FOG SW” turns ON-OFF linked with operation of fog lamp switch. When fog lamp switch is ON : FR FOG SW ON Without CONSULT-II Refer to LT-125, "Combination Switch Inspection" . OK or NG PKIA7598E OK >> GO TO 2. NG >> Check combination switch (lighting switch). Refer to LT-125, "Combination Switch Inspection" . 2. FOG LAMP ACTIVE TEST With CONSULT-II 1. Select “IPDM E/R” on CONSULT-II. Select “ACTIVE TEST” on “SELECT DIAG MODE” screen. 2. Select “FR FOG LAMP” on “SELECT TEST ITEM” screen. 3. Touch “ON” screen. 4. Make sure front fog lamp operates. Front fog lamp should operate. Without CONSULT-II 1. Start auto active test. Refer to PG-22, "Auto Active Test" . 2. Make sure front fog lamp operates. MKIB0552E Front fog lamp should operate. OK or NG OK >> GO TO 3. NG >> GO TO 4. 3. CHECK IPDM E/R 1. 2. Select “IPDM E/R” on CONSULT-II. Select “DATA MONITOR” on “SELECT DIAG MODE” screen. Make sure “FR FOG REQ” turns ON when front fog lamp switch is in ON position. When front fog lamp switch is ON position : FR FOG REQ ON OK or NG OK >> Replace IPDM E/R. Refer to PG-37, "Removal and Installation of IPDM E/R" . NG >> Replace BCM. Refer to BCS-17, "Removal and Installation of BCM" . LT-82 SKIA5898E FRONT FOG LAMP 4. CHECK FOG LAMP INPUT SIGNAL 1. 2. 3. 4. 5. 6. With CONSULT-II Turn ignition switch OFF. Disconnect front fog lamp RH and LH connector. Select “IPDM E/R” on CONSULT-II, and select “ACTIVE TEST” on “SELECT DIAG MODE” screen. Select “FR FOG LAMP” on “SELECT TEST ITEM” screen. Touch “ON” screen. When front fog lamp relay is operating, check voltage between front fog lamp RH and LH harness connector and ground. (+) (−) Front fog lamp connector 1. 2. 3. 4. A RH E23 LH E14 Ground (+) E23 LH E14 Battery voltage (−) Voltage Ground Battery voltage LT A Connector E8 LH 4. M B Terminal Connector 43 E23 44 E14 L Continuity Terminal 1 Yes Check continuity between IPDM E/R harness connector (A) and ground. Connector RH LH MKIB2266E A Circuit E8 H J Turn ignition switch OFF. Disconnect IPDM E/R connector. Check continuity between IPDM E/R harness connector (A) and front fog lamp RH and LH harness connector (B). RH G I 1 5. CHECK FOG LAMP CIRCUIT Circuit F Terminal OK or NG OK >> GO TO 6. NG >> GO TO 5. 1. 2. 3. D E Without CONSULT-II Turn ignition switch OFF. SKIB6284E Disconnect front fog lamp RH and LH connector. Start auto active test. Refer to PG-22, "Auto Active Test" . When front fog lamp relay is operating, check voltage between front fog lamp (RH and LH) harness connector and ground. RH C Voltage Terminal 1 Front fog lamp connector B Continuity Terminal Ground 43 No 44 OK or NG OK >> Replace IPDM E/R. Refer to PG-37, "Removal and Installation of IPDM E/R" . NG >> Repair harness or connector. LT-83 FRONT FOG LAMP 6. CHECK FOG LAMP GROUND 1. Check continuity between front fog lamp RH and LH harness connector and ground. Front fog lamp connector RH E23 LH E14 Terminal 2 Continuity Ground Yes OK or NG OK >> Check front fog lamp bulbs. NG >> Repair harness or connector. SKIB6285E LT-84 FRONT FOG LAMP Front Fog Lamp Does Not Illuminate (One Side) 1. BKS001EN A CHECK BULB Check bulb of lamp with does not illuminate which does not illuminate. OK or NG OK >> GO TO 2. NG >> Replace front fog lamp bulb. B C 2. CHECK FOG LAMP CIRCUIT 1. 2. 3. Turn ignition switch OFF. Disconnect IPDM E/R connector and front fog lamp RH or LH connector. Check continuity between IPDM E/R harness connector (A) and front fog lamp RH or LH harness connector (B). A Circuit Connector 4. E B Terminal Connector 43 E23 RH E8 LH D 44 Terminal Continuity F 1 E14 Yes Check continuity between IPDM E/R harness connector (A) and ground. MKIB2266E A Circuit Connector Continuity Terminal RH LH G Ground 43 E8 H No 44 I OK or NG OK >> GO TO 3. NG >> Repair harness or connector. J 3. CHECK FOG LAMP GROUND 1. LT Check continuity between front fog lamp RH or LH harness connector and ground. Front fog lamp connector RH E23 LH E14 Terminal 2 Continuity Ground L Yes OK or NG OK >> Replace IPDM E/R. Refer to PG-37, "Removal and Installation of IPDM E/R" . NG >> Repair harness or connector. LT-85 M SKIB6285E FRONT FOG LAMP Aiming Adjustment BKS001EO The front fog lamp is a semi-sealed beam type which uses a replaceable halogen bulb. Before performing aiming adjustment, make sure of the following. ● Keep all tires inflated to correct pressure. ● Place vehicle on level surface. ● Set that there is no-load in vehicle other than the driver (or equivalent weight placed in driver’s position). Coolant, engine oil filled up to correct level and full fuel tank. Adjust aiming in the vertical direction by turning the adjusting screw (A). MKIB2313E 1. 2. 3. Set the distance between the screen and the center of front fog lamp lens as shown. Turn front fog lamps ON. Adjust front fog lamps using adjusting screws so that the top edge of the high intensity zone is in the figure. When performing adjustment, if necessary, cover the headlamps and opposite front fog lamp. MKIB2314E Bulb Replacement 1. 2. 3. 4. 5. BKS001EP Turn lighting switch OFF. Turn off the fender protector (front) to obtain work space between the fender protector and fender. Disconnect front fog lamp connector (1). Turn bulb socket (2) counterclockwise unlock and remove it. Remove bulb from its socket. Front fog lamp : 12V-35W (H8) SKIB3270J LT-86 FRONT FOG LAMP Removal and Installation BKS001EQ A REMOVAL 1. 2. 3. 4. 5. Turn front fog lamp switch OFF. Turn over the fender protector and undercover to obtain work space between the fender protector and fender. Remove pawl (A), and front bumper finisher (1) from front bumper. Disconnect front fog lamp connector. Remove screw (3) and remove front fog lamp (2) from bracket. B C D E SKIB3804J INSTALLATION ● F Installation is the reverse order of removal. Tightening torque : 5.5 N·m (0.56 kg-m, 49 in-lb) G H I J LT L M LT-87 REAR FOG LAMP REAR FOG LAMP Component Parts and Harness Connector Location PFP:26550 BKS001ER MKIB2267E 1. BCM M57,M59 (View with instrument upper panel removed) 2. Combination switch M38 3. Combination meter M27 System Description BKS001ES The control of the rear fog lamps is dependent upon the position of the lighting switch. The lighting switch must be in the 1ST/2ND position for rear fog lamp operation. When the lighting switch is placed in the rear fog lamp position* the BCM (body control module) receives input signal requesting the rear fog lamps to illuminate. *:Rear fog lamp switch is an auto return switch. BCM reads a change when rear fog lamp switch is operated. It switches between ON and OFF every time when rear fog lamp switch is operated. OUTLINE Power is also supplied at all times ● through 40A fusible link (letter J, located in the fuse and fusible link block), ● to BCM terminals 74 and79, ● through 10A fuse [No. 7, located in the fuse block (J/B)] ● to combination meter terminal 27. With the ignition switch in the ON or START position, power is supplied ● through 10A fuse [No. 5 located in the fuse block (J/B)] ● to BCM terminal 24, ● through 10A fuse [No. 4, located in the fuse block (J/B)] ● to combination meter terminal 28. Ground is supplied ● to BCM terminals 2 and 70 ● to combination meter terminals 21, 22 and 23 ● through grounds M21 and M66. REAR FOG LAMP OPERATION The lighting switch must be in the 1ST or 2ND position for rear fog lamp operation. With the rear fog lamp switch in the ON position, the BCM directs power ● through BCM terminal 69 ● to rear combination lamp RH (rear fog lamp) terminal 2. Ground is supplied ● to rear combination lamp RH (rear fog lamp) terminal 1 ● through grounds B13,B28,B38 and B48. With power and grounds supplied, the rear fog lamp illuminate. The unified meter control unit that received the rear fog lamp request signal by BCM via the CAN communication makes a rear fog lamp indicator lamp turn on in combination meter. LT-88 REAR FOG LAMP COMBINATION SWITCH READING FUNCTION A Refer to LT-114, "COMBINATION SWITCH READING FUNCTION" . CAN Communication System Description BKS001ET CAN (Controller Area Network) is a serial communication line for real time application. It is an on-vehicle multiplex communication line with high data communication speed and excellent error detection ability. Many electronic control units are equipped onto a vehicle, and each control unit shares information and links with other control units during operation (not independent). In CAN communication, control units are connected with 2 communication lines (CAN H line, CAN L line) allowing a high rate of information transmission with less wiring. Each control unit transmits/receives data but selectively reads required data only. CAN Communication Unit BKS001EU B C D Refer to LAN-27, "CAN Communication Unit" . E F G H I J LT L M LT-89 REAR FOG LAMP Wiring Diagram — R/FOG — BKS001EW MKWA4353E LT-90 REAR FOG LAMP A B C D E F G H I J LT L M MKWA4354E LT-91 REAR FOG LAMP Terminals and Reference Values for BCM BKS001EX CAUTION: ● Check combination switch system terminal waveform under the loaded condition with lighting switch, turn signal switch and wiper switch OFF not to be fluctuated by overloaded. ● Turn wiper dial position to 4 except when checking waveform or voltage of wiper dial position. Wiper dial position can be confirmed on CONSULT-II. Refer to LT-19, "DATA MONITOR" . Terminal No. Wire color 2 B Signal name Ground Measuring condition Signal input/ output Ignition switch Operation or condition — ON — Reference value Approx. 0V OFF 7 BR Combination switch output 5 Output ON Lighting, turn, wiper switch (Wiper intermittent dial position 4) PKIB8643J Approx. 1.2V Rear fog lamp switch ON (Operates only rear fog lamp switch) PKIB4956J Approx. 1.0V OFF 14 P Combination switch input 3 Input ON Lighting, turn, wiper switch (Wiper intermittent dial position 4) PKIB4958J Approx. 1.0V Rear fog lamp switch ON (Operates only rear fog lamp switch) PKIC1030E Approx. 1.5V 19 L CAN − H Input/ Output ON — Approx. 2.6V 24 O Ignition switch (ON) Input ON — Battery voltage 39 Y CAN − L Input/ Output ON — Approx.2.4V 69 R Rear fog lamp Output ON Rear fog lamp switch LT-92 ON Battery voltage OFF Approx. 0V REAR FOG LAMP Terminal No. Wire color 70 B Ground 74 79 Y Battery power supply Signal name Measuring condition Signal input/ output Ignition switch Operation or condition — ON — Approx. 0V Input OFF — Battery voltage How to Proceed With Trouble Diagnosis 1. 2. 3. 4. 5. 6. A Reference value Confirm the symptom or customer complaint. Understand operation description and function description. Refer to LT-88, "System Description" . Perform the Preliminary Check. Refer to LT-94, "Preliminary Check" . Check symptom and repair or replace the cause of malfunction. Does the rear fog lamp operate normally? If YES, GO TO 6. If NO, GO TO 4. INSPECTION END B BKS001EY C D E F G H I J LT L M LT-93 REAR FOG LAMP Preliminary Check BKS001EZ CHECK POWER SUPPLY AND GROUND CIRCUIT 1. CHECK FUSES Check for blown fuses. Unit Power source Fuse and fusible link No. Battery J Ignition switch ON or START position 5 BCM Refer to LT-90, "Wiring Diagram — R/FOG —" . OK or NG OK >> GO TO 2. NO >> If fuse or fusible link is blown, be sure to eliminate cause of malfunction before installing new fuse or fusible link. Refer to PG-4, "POWER SUPPLY ROUTING CIRCUIT" . 2. CHECK POWER SUPPLY CIRCUIT 1. 2. 3. Turn ignition switch OFF. Disconnect BCM connector. Check voltage between BCM harness connector and ground. Terminal Ignition switch position (+) BCM Connector Terminal M57 24 (−) 74 Ground M59 OFF ACC ON Approx. 0V Approx. 0V Battery voltage Battery voltage Battery voltage Battery voltage Battery voltage Battery voltage Battery voltage MKIB0352E 79 OK or NG OK >> GO TO 3. NG >> Repair harness or connector. 3. CHECK GROUND CIRCUIT Check continuity between BCM harness connector and ground. BCM Connector Terminal M57 2 M59 70 Continuity Ground Yes OK or NG OK >> INSPECTION END NG >> Repair harness or connector. MKIB0353E CONSULT-II Functions (BCM) BKS001F0 Refer to LT-19, "CONSULT-II Functions (BCM)" in “HEADLAMP - CONVENTIONAL TYPE -.” LT-94 REAR FOG LAMP Rear Fog Lamp Does Not Operate BKS001F1 1. CHECK BULB A Check bulb of lamp which does not illuminate. OK or NG OK >> GO TO 2. NG >> Replace rear fog lamp bulb. B C 2. CHECK COMBINATION SWITCH INPUT SIGNAL 1. 2. Select “BCM” on CONSULT-II. Select “HEAD LAMP” on “SELECT TEST ITEM” screen. Select “DATA MONITOR” on “SELECT DIAG MODE” screen. Make sure “RR FOG SW” turns ON-OFF linked with operation of rear fog lamp switch. When lighting switch 1ST or 2ND position and rear fog lamp switch ON position D E : RR FOG SW ON F OK or NG OK >> GO TO 3. NG >> Replace combination switch (lighting switch). PKIB7212E 3. ACTIVE TEST 1. 2. 3. 4. G H Select “BCM” on CONSULT-II. Select “HEAD LAMP” on “SELECT TEST ITEM” screen. Select “ACTIVE TEST” on “SELECT DIAG MODE” screen. Touch “RR FOG LAMP” screen. Make sure rear fog lamp operates. I J Rear fog lamp should operate. OK or NG OK >> Replace BCM. Refer to BCS-17, "Removal and Installation of BCM" . NG >> GO TO 4. LT PKIB7213E L 4. CHECK REAR FOG LAMP CIRCUIT 1. 2. 3. Turn ignition switch OFF. Disconnect BCM connector and rear combination lamp RH (rear fog lamp) connector. Check continuity between BCM harness connector (A) and rear combination lamp RH (rear fog lamp) harness connector (B). A B M Continuity Connector Terminal Connector Terminal M59 69 B44 2 Yes OK or NG OK >> GO TO 5. NG >> Repair harness or connector. MKIB2258E LT-95 REAR FOG LAMP 5. CHECK REAR FOG LAMP GROUND Check continuity between rear combination lamp RH (rear fog lamp) harness connector and ground. connector Terminal B44 1 Ground Continuity Yes OK or NG OK >> GO TO 6. NG >> Repair harness or connector. MKIB2259E 6. CHECK SHORT CIRCUIT Check continuity between BCM harness connector and ground. BCM connector Terminal M59 69 Ground Continuity No OK or NG OK >> Replace BCM. Refer to BCS-17, "Removal and Installation of BCM" . NG >> After repairing harness be sure to disconnect battery negative cable, and then reconnect it. MKIB2260E LT-96 REAR FOG LAMP Bulb Replacement 1. 2. 3. 4. BKS001F2 A Remove rear bumper fascia. Refer to EI-8, "REAR BUMPER" . Disconnect rear fog lamp connector. Turn bulb socket (2) counterclockwise and unlock it. Remove bulb (1) from its socket. Rear fog lamp B : 12V - 21W C D MKIB2311E Removal and Installation BKS001F3 REMOVAL E 1. 2. 3. F Remove rear bumper fascia. Refer to EI-8, "REAR BUMPER" . Disconnect rear fog lamp connector. While pressing metal clip (A) on the revers side of the bumper fascia. G H MKIB2312E INSTALLATION I Installation is the reverse order of removal. J LT L M LT-97 TURN SIGNAL AND HAZARD WARNING LAMPS TURN SIGNAL AND HAZARD WARNING LAMPS Component Parts and Harness Connector Location PFP:26120 BKS001F4 MKIB2253E 1. BCM M57,M59 (View with instrument upper panel removed) 4. Combination meter M27 2. Combination switch M38 System Description 3. Hazard switch M63 BKS001F5 TURN SIGNAL OPERATION With the ignition switch in the ON or START position, power is supplied ● through 10A fuse [No. 5, located in fuse block (J/B)] ● to BCM terminal 24, ● through 10A fuse [No. 4, located in fuse block (J/B)] ● to combination meter terminal 28. Ground is supplied ● to BCM terminals 2 and 70 ● to combination meter terminals 21, 22 and 23 ● through grounds M21 and M66. LH Turn Signal Lamp When turn signal switch is moved to left position, BCM receives input signal requesting left turn signals to flash. BCM then supplies power ● through BCM terminal 65 ● to front combination lamp LH (turn signal) terminal 1 ● to side turn signal lamp LH terminal 1 ● to rear combination lamp LH (turn signal) terminal 3. Ground is supplied ● to front combination lamp LH (turn signal) terminal 2 ● to side turn signal lamp LH terminal 2 ● through grounds E45 (CR and HR engine models),E28 and E44, ● to rear combination lamp LH (turn signal) terminal 2 ● through grounds B13,B28,B38 and B48. The BCM also supplies input to combination meter terminals 1 and 2 via the CAN communication. This input is processed by unified meter control unit in combination meter, which in turn supplies ground to the left turn signal indicator lamp. LT-98 TURN SIGNAL AND HAZARD WARNING LAMPS With power and input supplied, BCM controls flashing of LH turn signal lamps. A RH Turn Signal Lamp When turn signal switch is moved to right position, BCM receives input signal requesting right turn signals to flash. BCM then supplies power ● through BCM terminal 66 ● to front combination lamp RH (turn signal) terminal 1 ● to side turn signal lamp RH terminal 1 ● to rear combination lamp RH (turn signal) terminal 3. Ground is supplied ● to front combination lamp RH (turn signal) terminal 2 ● to side turn signal lamp RH terminal 2 ● through grounds E45 (CR and HR engine models),E28 and E44, ● to rear combination lamp RH (turn signal) terminal 2 ● through grounds B13,B28,B38 and B48. The BCM also supplies input to combination meter terminals 1 and 2 via the CAN communication. This input is processed by unified meter control unit in combination meter, which in turn supplies ground to the right turn signal indicator lamp. With power and input supplied, BCM controls flashing of RH turn signal lamps. B C D E F G HAZARD LAMP OPERATION Power is supplied at all times ● through 40A fusible link (letter J, located in fuse, fusible link and relay box) ● to BCM terminals 74 and 79, ● through 10A fuse [No. 7, located in fuse block (J/B)] ● to BCM terminal 27. Ground is supplied ● to hazard switch terminal 1 ● to BCM terminals 2 and 70 ● to combination meter terminals 21, 22 and 23 ● through grounds M21 and M66. When hazard switch is depressed, ground is supplied ● to BCM terminal 26 ● through hazard switch terminal 2. BCM then supplies power ● through BCM terminal 65 ● to front combination lamp LH (turn signal) terminal 1 ● to side turn signal lamp LH terminal 1 ● to rear combination lamp LH (turn signal) terminal 3, ● through BCM terminal 66 ● to front combination lamp RH (turn signal) terminal 1 ● to side turn signal lamp RH terminal 1 ● to rear combination lamp RH (turn signal) terminal 3. Ground is supplied ● to front combination lamp LH and RH (turn signal) terminal 2 ● to side turn signal lamp LH and RH terminals 2 ● through grounds E45 (CR and HR engine models),E28 and E44, ● to rear combination lamp LH and RH (turn signal) terminal 2 ● through grounds B13,B28,B38 and B48. LT-99 H I J LT L M TURN SIGNAL AND HAZARD WARNING LAMPS The BCM also supplies input to combination meter terminals 1 and 2 across CAN communication lines. This input is processed by unified meter control unit in combination meter, which in turn supplies ground to the left and right turn signal indicator lamps. With power and input supplied, BCM controls flashing of hazard warning lamps. COMBINATION SWITCH READING FUNCTION Refer to LT-114, "COMBINATION SWITCH READING FUNCTION" . CAN Communication System Description BKS001F6 CAN (Controller Area Network) is a serial communication line for real time application. It is an on-vehicle multiplex communication line with high data communication speed and excellent error detection ability. Many electronic control units are equipped onto a vehicle, and each control unit shares information and links with other control units during operation (not independent). In CAN communication, control units are connected with 2 communication lines (CAN H line, CAN L line) allowing a high rate of information transmission with less wiring. Each control unit transmits/receives data but selectively reads required data only. CAN Communication Unit BKS001F7 Refer to LAN-27, "CAN Communication Unit" . LT-100 TURN SIGNAL AND HAZARD WARNING LAMPS Wiring Diagram — TURN — BKS001F9 A B C D E F G H I J LT L M MKWA4355E LT-101 TURN SIGNAL AND HAZARD WARNING LAMPS MKWA4356E LT-102 TURN SIGNAL AND HAZARD WARNING LAMPS Terminals and Reference Values for BCM BKS001FA CAUTION: ● Check combination switch system terminal waveform under the loaded condition with lighting switch, turn signal switch and wiper switch OFF not to be fluctuated by overloaded. ● Turn wiper dial position to 4 except when checking waveform or voltage of wiper dial position. Wiper dial position can be confirmed on CONSULT-II. Refer to LT-106, "DATA MONITOR" . Terminal No. Wire color 2 B Signal name Ground Ignition switch Operation or condition — ON — B C Measuring condition Signal input/ output A Reference value D Approx. 0V E OFF F 9 V Combination switch output 1 Output ON Lighting, turn, wiper switch (Wiper intermittent dial position 4) PKIB4958J Approx. 1.2V G Any of the conditions below ● Turn signal switch to right ● Turn signal switch to left H PKIB4959J I Approx. 1.0V J OFF 15 W Combination switch input 5 Input ON Lighting, turn, wiper switch (Wiper intermittent dial position 4) LT PKIB4956J L Approx. 0.9V M Turn signal switch to right PKIB8625J Approx. 1.5 - 2.0V 19 L CAN − H Input/ Output ON — Approx. 2.6V 24 O Ignition switch (ON) Input ON — Battery voltage 26 L Hazard switch signal Input OFF Hazard switch LT-103 ON Approx. 0V OFF Battery voltage TURN SIGNAL AND HAZARD WARNING LAMPS Terminal No. Wire color Signal name Signal input/ output Measuring condition Ignition switch Reference value Operation or condition OFF 34 Y Combination switch input 4 Input ON Lighting, turn, wiper switch (Wiper intermittent dial position 4) PKIB4958J Approx. 1.0V Turn signal switch to left PKIB8630J Approx. 2.0V 39 Y CAN − L Input/ Output ON — OFF 65 LG Flasher output (Left) Output ON Turn signal switch Approx. 2.4V Approx. 0V To left SKIA3009J OFF 66 W Flasher output (Right) Output ON Turn signal switch Approx. 0V To right SKIA3009J 70 B Ground 74 79 Y Battery power supply — ON — Approx. 0V Input OFF — Battery voltage How to Proceed With Trouble Diagnosis 1. 2. 3. 4. 5. 6. Confirm the symptom or customer complaint. Understand operation description and function description. Refer to LT-98, "System Description" . Perform the preliminary check. Refer to LT-105, "Preliminary Check" . Check symptom and repair or replace the malfunctioning parts. Do turn signal and hazard warning lamps operate normally? If YES, GO TO 6. If NO, GO TO 4. INSPECTION END LT-104 BKS001FB TURN SIGNAL AND HAZARD WARNING LAMPS Preliminary Check BKS001FC A CHECK POWER SUPPLY AND GROUND CIRCUIT 1. CHECK FUSES B Check for blown fuses. Unit Power source Fuse and fusible link No. Battery J Ignition switch ON or START position 5 BCM C Refer to LT-101, "Wiring Diagram — TURN —" . OK or NG OK >> GO TO 2. NG >> If fuse or fusible link is blown, be sure to eliminate cause of malfunction before installing new fuse or fusible link. Refer to PG-4, "POWER SUPPLY ROUTING CIRCUIT" . D E 2. CHECK POWER SUPPLY CIRCUIT 1. 2. 3. F Turn ignition switch OFF. Disconnect BCM connector. Check voltage between BCM harness connector and ground. Terminal G Ignition switch position (+) BCM Connector Terminal M57 24 74 (−) Ground M59 OFF ACC ON Approx. 0V Approx. 0V Battery voltage Battery voltage Battery voltage Battery voltage Battery voltage Battery voltage Battery voltage H I MKIB0352E 79 OK or NG OK >> GO TO 3. NG >> Repair harness or connector. J LT 3. CHECK GROUND CIRCUIT L Check continuity between BCM harness connector and ground. M BCM Connector Terminal M57 2 M59 70 Continuity Ground Yes OK or NG OK >> INSPECTION END NG >> Repair harness or connector. MKIB0353E LT-105 TURN SIGNAL AND HAZARD WARNING LAMPS CONSULT-II Functions (BCM) BKS001FD CONSULT-II can display each diagnostic item using the diagnostic test modes shown following. BCM diagnosis part Diagnosis mode FLASHER Description Work Support Changes the setting for each function. DATA MONITOR Displays BCM input data in real time. ACTIVE TEST Operation of electrical loads can be checked by sending driving signal to them. CONSULT-II INSPECTION PROCEDURE Refer to GI-36, "CONSULT-II Start Procedure" . CONSULT-II Application Items BKS001KZ WORK SUPPORT Supported Item All items will be monitored. HAZARD LAMP SET hazard reminder function mode can be changed in this mode. Hazard Lamp Set MODE1 MODE2 MODE3 MODE4 Remote controller operation Lock Unlock Lock Unlock Lock Unlock Lock Unlock Hazard warning lamp flash - - - Twice Once - Once Twice DATA MONITOR Monitor item Contents IGN ON SW “ON/OFF” Displays status (ignition switch IGN position: ON/other: OFF) of ignition switch judged from the ignition switch signal. HAZARD SW “ON/OFF” Displays status (hazard switch ON position: ON/other: OFF) of hazard switch judged from the hazard switch signal. TURN SIGNAL R “ON/OFF” Displays status (turn signal switch right position: ON/other: OFF) of turn RH switch judged from the turn signal switch signal. TURN SIGNAL L “ON/OFF” Displays status (turn signal switch left position: ON/other: OFF) of turn LH switch judged from the turn signal switch signal. TURN/L MNTR “ON/OFF” Displays status (One bulb blown: ON/Others: OFF) as judged from bulb signal. ACTIVE TEST Test Item FLASHER Description This test is able to check left or right turn signal lamp operation. The turn signal lamp turned ON when “LH” or “RH” on CONSULT-II screen is touched. LT-106 TURN SIGNAL AND HAZARD WARNING LAMPS Turn Signal Lamp Does Not Operate BKS001FE 1. CHECK BULB A Check bulb standard of each turn signal lamp is correct. OK or NG OK >> GO TO 2. NG >> Replace turn signal lamp bulb. B C 2. CHECK COMBINATION SWITCH INPUT SIGNAL With CONSULT-II 1. Select “BCM” on CONSULT-II. Select “FLASHER” on “SELECT TEST ITEM” screen. 2. Select “DATA MONITOR” on “SELECT DIAG MODE” screen. Make sure that “TURN SIGNAL R” and “TURN SIGNAL L” turns ON-OFF linked with operation of lighting switch. When turn signal switch is right position When turn signal switch is left position D E : TURN SIGNAL R ON F : TURN SIGNAL L ON G Without CONSULT-II Refer to LT-125, "Combination Switch Inspection" . OK or NG OK >> GO TO 3. NG >> Check combination switch. Refer to LT-125, "Combination Switch Inspection" . PKIA7600E H I 3. ACTIVE TEST With CONSULT-II 1. Select “BCM” on CONSULT-II. Select “FLASHER” on “SELECT TEST ITEM” screen. 2. Select “ACTIVE TEST” on “SELECT DIAG MODE” screen. Select “FLASHER” on “SELECT TEST ITEM” screen. 3. Make sure turn signal lamp operates. J LT L Turn signal lamp should operate. Without CONSULT-II GO TO 4. OK or NG OK >> Replace BCM. Refer to BCS-17, "Removal and Installation of BCM" . NG >> GO TO 4. LT-107 M PKIA7749E TURN SIGNAL AND HAZARD WARNING LAMPS 4. CHECK TURN SIGNAL LAMP CIRCUIT 1. 2. Turn ignition switch OFF. Disconnect BCM connector and all turn signal lamp connectors. 3. Check continuity between BCM harness connector (A) and front combination lamp LH and RH (turn signal) harness connector (B). A Circuit connector LH M59 RH B Terminal connector 65 E13 66 E22 Continuity Terminal 1 Yes MKIB2254E 4. Check continuity between BCM harness connector (A) and side turn signal lamp LH and RH harness connector (B). A Circuit connector LH M59 RH B Terminal connector 65 E41 66 E31 Terminal Continuity 1 Yes MKIB2255E 5. Check continuity between BCM harness connector (A) and rear combination lamp LH and RH (turn signal) harness connector (B). A Circuit connector LH M59 RH OK NG B Terminal connector 65 B17 66 B39 Terminal Continuity 3 Yes >> GO TO 5. >> Repair harness or connector. MKIB2256E 5. CHECK SIGNAL LAMP CIRCUIT (SHORT CIRCUIT) Check continuity between BCM harness connector and ground. BCM connector LH RH M59 Terminal 65 Continuity Ground No 66 OK or NG OK >> Replace BCM if turn signal lamps does not work after setting the connector again. Refer to BCS-17, "Removal and Installation of BCM" . NG >> Repair harness or connector. LT-108 MKIB2257E TURN SIGNAL AND HAZARD WARNING LAMPS Hazard Warning Lamp Does Not Operate But Turn Signal Lamp Operates BKS001FF 1. CHECK BULB A Make sure bulb standard of each turn signal lamp is correct. OK or NG OK >> GO TO 2. NG >> Replace bulb. B C 2. CHECK HAZARD SWITCH INPUT SIGNAL With CONSULT-II 1. Select “BCM” on CONSULT-II. Select “FLASHER” on “SELECT TEST ITEM” screen. 2. Select “DATA MONITOR” on “SELECT DIAG MODE” screen. Make sure that “HAZARD SW” turns ON-OFF linked with operation of malfunction switch (hazard switch). When hazard switch is ON position D E : HAZARD SW ON F G PKIA7601E Without CONSULT-II Check voltage between BCM harness connector and ground. H Terminal I (+) (−) BCM connector Terminal M57 26 Ground Condition Voltage Hazard switch is ON Approx. 0V Hazard switch is OFF Battery voltage OK or NG OK >> Replace BCM. Refer to BCS-17, "Removal and Installation of BCM" . NG >> GO TO 3. J LT MKIB1922E L 3. CHECK HAZARD SWITCH CIRCUIT 1. 2. 3. M Turn ignition switch OFF. Disconnect BCM connector and hazard switch connector. Check continuity between BCM harness connector M57 terminal 26 and hazard switch harness connector M63 terminal 2. 26 - 2 : Continuity should exist. OK or NG OK >> GO TO 4. NG >> Repair or replace harness or connector. MKIB0359E LT-109 TURN SIGNAL AND HAZARD WARNING LAMPS 4. CHECK GROUND Check continuity hazard switch harness connector M63 terminal 1 and ground. 1 – Ground : Continuity should exist. OK or NG OK >> GO TO 5. NG >> Repair harness or connector. PKIC1016E 5. CHECK HAZARD SWITCH 1. 2. Disconnect hazard switch connector. Check continuity hazard switch terminal. Terminal Condition Continuity Hazard switch is ON Yes Hazard switch is OFF No Hazard switch 1 2 OK or NG OK >> Replace BCM if turn signal lamps does not work after setting the connector again. Refer to BCS-17, "Removal and Installation of BCM" . NG >> Replace hazard switch. LT-110 PKIC1017E TURN SIGNAL AND HAZARD WARNING LAMPS Bulb Replacement (Front Turn Signal Lamp) BKS001FG A Refer to LT-32, "Bulb Replacement" in “HEADLAMP - CONVENTIONAL TYPE -”. Bulb Replacement (Rear Turn Signal Lamp) BKS001FH B Refer to LT-149, "Bulb Replacement" . Bulb Replacement (Side Turn Signal Lamp) 1. 2. 3. BKS001FI Remove side turn signal lamp (2). Refer to LT-111, "Removal and Installation of Side Turn Signal Lamp" . Turn bulb socket (1) counterclockwise and unlock it. Remove the bulb (3) from the socket. Side turn signal lamp C D : 12V - 5W E SKIB3806J Removal and Installation of Front Turn Signal Lamp BKS001FJ Refer to LT-32, "Removal and Installation" in “HEADLAMP - CONVENTIONAL TYPE -”. Removal and Installation of Rear Turn Signal Lamp F G BKS001FK Refer to LT-149, "Removal and Installation" . H Removal and Installation of Side Turn Signal Lamp BKS001FL REMOVAL 1. 2. Insert a spatula or the similar tool under the side turn signal lamp (1). While pushing the pawl (A) of the lamp, pull off the lamp from the vehicle. Disconnect side turn signal lamp. NOTE: Support side turn signal lamp harness with tape so that it won't fall into the front fender. CAUTION: Install the lamp housing with the bead facing up. I J LT SKIB3805J L INSTALLATION Installation is the reverse order of removal. M LT-111 LIGHTING AND TURN SIGNAL SWITCH LIGHTING AND TURN SIGNAL SWITCH Removal and Installation PFP:25540 BKS001FM REMOVAL 1. 2. Remove steering column cover. Refer to IP-4, "INSTRUMENT PANEL ASSEMBLY" . While pressing pawls (A) in direction as shown in the figure, pull lighting and turn signal switch (1) toward driver door and disconnect from the base. MKIB2297E INSTALLATION Installation is the reverse order of removal. LT-112 HAZARD SWITCH HAZARD SWITCH Removal and Installation PFP:25290 A BKS001FN REMOVAL 1. 2. 3. Remove controller (1). Refer to ATC-112, "CONTROLLER" . Disconnect hazard switch connector. Press pawl (A) on reverse side and remove the hazard switch (2). B C D E SKIB3816J F INSTALLATION Installation is the reverse order of removal. G H I J LT L M LT-113 COMBINATION SWITCH COMBINATION SWITCH System Description PFP:25567 BKS0027I COMBINATION SWITCH READING FUNCTION Description ● ● BCM reads combination switch (wiper) status, and controls related systems such as headlamps and wipers, according to the results. BCM reads information for a maximum of 20 switches by combining 5 output terminals (OUTPUT 1-5) and 5 input terminals (INPUT 1-5). Operation Description ● ● ● BCM activates transistors of output terminals (OUTPUT 1-5) periodically, and allows current to flow in turn. If any (1 or more) switches are turned ON, the circuit of output terminals (OUTPUT 1-5) and input terminals (INPUT 1-5) becomes active. At this time, transistors of output terminals (OUTPUT 1-5) are activated to allow current to flow. When voltage of the input terminal (INPUT 1-5) corresponding to that switch changes, the interface in the BCM detects a voltage change, and the BCM determines that the switch is ON. MKIB2223E LT-114 COMBINATION SWITCH BCM - Operation Table of Combination Switches ● BCM reads operation status of the combination switch using combinations shown in the table below. A B C D E F PKIC0420E G Sample Operation: (When Lighting Switch 1st Position Turned ON) ● ● ● When lighting switch 1st position is turned ON, contact in combination switch turns ON. At this time if OUTPUT 4 transistor is activated, BCM detects that voltage changes in INPUT 5. When OUTPUT 4 transistor is ON, BCM detects that voltage changes in INPUT 5, and judges lighting switch 1st position is ON. Then BCM sends tail lamp ON signal to IPDM E/R using CAN communication. When OUTPUT 4 transistor is activated again, BCM detects that voltage changes in INPUT 5 and recognizes that lighting switch 1st position is continuously ON. H I J LT L M MKIB2289E NOTE: Each output terminal transistor operates at 20 ms intervals. Therefore, after a switch is turned ON, the electrical loads are activate with a time delay, However, this delay is too small to be detected. LT-115 COMBINATION SWITCH Operation Mode Combination switch reading function has operation modes shown below. 1. Normal status ● When BCM is not in sleep status, output terminals (OUTPUT 1-5) send out ON signal every 10 ms. 2. Sleep status ● When BCM is in sleep status, BCM enters low power mode. Mean while out put terminals (OUTPUT 15) send out ON signal every 60ms, and accept only input from light switch system. PKIC0832E LT-116 COMBINATION SWITCH Wiring Diagram — COMBSW — BKS001FO A B C D E F G H I J LT L M MKWA4364E LT-117 COMBINATION SWITCH Terminals and Reference Values for BCM BKS001FQ CAUTION: ● Check combination switch system terminal waveform under the loaded condition with lighting switch, turn signal switch and wiper switch OFF not to be fluctuated by overloaded. ● Turn wiper dial position to 4 except when checking waveform or voltage of wiper dial position. Wiper dial position can be confirmed on CONSULT-II. Refer to LT-124, "DATA MONITOR" . Measuring condition Terminal No. Wire color Signal name Signal input/ output Ignition switch Operation or condition 2 B Ground — ON — Reference value Approx. 0V OFF (Wiper intermittent dial position 4) PKIB8643J Approx. 1.2V 7 BR Combination switch output 5 Output ON Lighting, turn, wiper switch Any of several conditions below ● Front fog lamp switch (Operates only front fog lamp switch) (Wiper intermittent dial position 4) ● Rear fog lamp switch (Wiper intermittent dial position 4) ● Rear wiper ON (Wiper intermittent dial position 4) ● Wiper intermittent dial position 1 ● Wiper intermittent dial position 2 ● Wiper intermittent dial position 6 ● Wiper intermittent dial position 7 PKIB4956J Approx. 1.0V OFF (Wiper dial position 4) PKIB4958J 8 L Combination switch output 3 Output ON Lighting, turn, wiper switch Approx. 1.2V Any of several conditions below ● Lighting switch 2ND (Wiper intermittent dial position 4) ● Lighting switch HI beam (Operates only HI beam switch) (Wiper intermittent dial position 4) ● Wiper intermittent dial position 1 ● Wiper intermittent dial position 2 ● Wiper intermittent dial position 3 LT-118 PKIB4959J Approx. 1.0V COMBINATION SWITCH Terminal No. Wire color Signal name Signal input/ output Measuring condition Reference value Ignition switch A Operation or condition B OFF 9 V Combination switch output 1 Output ON Lighting, turn, wiper switch (Wiper intermittent dial position 4) C PKIB4958J Approx. 1.2V D Any of several conditions below ● Turn signal switch to right ● Turn signal switch to left ● Front wiper switch MIST ● Front wiper switch LO ● Front washer switch E F PKIB4959J Approx. 1.0V 13 14 15 SB P W Combination switch input 1 Combination switch input 3 Combination switch input 5 Input Input Input ON ON ON Lighting, turn, wiper switch Lighting, turn, wiper switch (Wiper intermittent dial position 4) Lighting, turn, wiper switch (Wiper intermittent dial position 4) G ● OFF ● Front wiper switch HI (Wiper intermittent dial position 4) ● Wiper intermittent dial position 1 ● Wiper intermittent dial position 2 ● Wiper intermittent dial position 3 ● Wiper intermittent dial position 6 ● Wiper intermittent dial position 7 ● OFF ● Lighting switch AUTO ● Rear fog lamp switch ● Front wiper switch MIST ● Front wiper switch INT ● Front wiper switch LO ● OFF ● Lighting switch 1ST ● Lighting switch 2ND ● Lighting switch HIGH beam (Operates only HIGH beam switch) ● Turn signal switch to right Refer to LT-121, "Reference Values for BCM (Input)" . H I J Refer to LT-121, "Reference Values for BCM (Input)" . L M Refer to LT-121, "Reference Values for BCM (Input)" . 19 L CAN − H Input/ Output ON — Approx. 2.6V 22 Y Battery safety line Input OFF — — 24 O Ignition switch (ON) Input ON — Battery voltage LT-119 LT COMBINATION SWITCH Terminal No. Wire color Signal name Signal input/ output Measuring condition Reference value Ignition switch Operation or condition OFF (Wiper intermittent dial position 4) PKIB4958J 27 GR Combination switch output 4 Output ON Lighting, turn, wiper switch Approx. 1.2V Any of several conditions below ● Lighting switch AUTO (Wiper intermittent dial position 4) ● Lighting switch 1ST (The same result with lighting switch 2ND) (Wiper intermittent dial position 4) ● Wiper intermittent dial position 1 ● Wiper intermittent dial position 5 ● Wiper intermittent dial position 6 PKIB4959J Approx. 1.0V OFF 28 G Combination switch output 2 Output ON Lighting, turn, wiper switch (Wiper intermittent dial position 4) PKIB4958J Approx. 1.2V Any of several conditions below ● Lighting switch 2ND ● Lighting switch PASSING (Operates only PASSING switch) ● Front wiper switch INT ● Front wiper switch HI PKIB4959J Approx. 1.0V 33 34 39 R Y Y Combination switch input 2 Combination switch input 4 CAN − L Input Input Input/ Output ON ON ON Lighting, turn, wiper switch Lighting, turn, wiper switch (Wiper intermittent dial position 4) ● OFF ● Front washer switch (Wiper intermittent dial position 4) ● Wiper intermittent dial position 1 ● Wiper intermittent dial position 5 ● Wiper intermittent dial position 6 ● OFF ● Front fog lamp switch ON ● Lighting switch 2ND ● Lighting switch PASSING (Operates only PASSING switch) ● Turn signal switch to left — LT-120 Refer to LT-121, "Reference Values for BCM (Input)" . Refer to LT-121, "Reference Values for BCM (Input)" . Approx. 2.4V COMBINATION SWITCH Measuring condition Terminal No. Wire color Signal name Signal input/ output Ignition switch Operation or condition 70 B Ground — ON — Approx. 0V Input OFF — Battery voltage 74 79 Y Battery power supply A Reference value B C Reference Values for BCM (Input) BKS001FR CAUTION: ● Check combination switch system terminal waveform under the loaded condition with lighting switch, turn signal switch and wiper switch OFF not to be fluctuated by overloaded. ● Turn wiper dial position to 4 except when checking waveform or voltage of wiper dial position. Wiper dial position can be confirmed on CONSULT-II. Refer to LT-124, "DATA MONITOR" . INPUT D E Condition and reference value OFF Lighting switch 1ST Lighting switch 2ND F G PKIB4956J INPUT 5 (Wiper intermittent dial position 4) PKIB8624J Approx. 0.9V Approx. 1.5 - 2.0V Lighting switch HI beam (Operates only HI beam switch) Turn signal switch to right PKIB8639J Approx. 2.5 - 3.0V H I — J PKIB8625J PKIB8644J Approx. 1.5 - 2.0V OFF Approx. 1.5 - 2.0V Lighting switch 2ND LT Turn signal switch to left L M PKIB4958J INPUT 4 (Wiper intermittent dial position 4) PKIB8628J Approx. 1.0V Approx. 1.5 - 2.0V Front fog lamp switch (Operates only front fog lamp switch) Lighting switch PASSING (Operates only PASSING switch) PKIB8630J Approx. 2.0V — PKIB8629J PKIB8627J Approx. 1.5 - 2.0V Approx. 2.0V LT-121 COMBINATION SWITCH INPUT Condition and reference value OFF Lighting switch AUTO PKIB4958J PKIB8631J Approx. 1.0V INPUT 3 (Wiper intermittent dial position 4) Front wiper switch INT Approx. 2.0V PKIB8632J Approx. 2.0V Any of several conditions below ● Front ● Front wiper switch LO Rear fog lamp switch wiper switch MIST — PKIC1030E Approx. 1.5V PKIB8629J Approx. 2.0V OFF (Wiper intermittent dial position 4) Front washer switch (Wiper intermittent dial position 4) PKIB4958J Rear washer switch (Wiper intermittent dial position 4) PKIB8632J Approx. 1.0V Approx. 2.0V PKIB8631J Approx. 2.0V Any of the conditions below INPUT 2 Rear wiper switch ON (Wiper intermittent dial position 4) ● Wiper intermittent dial position 1 ● Wiper intermittent dial position 5 ● Wiper intermittent dial position 6 — PKIB8634J Approx. 1.5 - 2.0V PKIB8633J Approx. 2.0V LT-122 COMBINATION SWITCH INPUT Condition and reference value Any of the conditions below OFF (Wiper intermittent dial position 4) Front wiper switch HI (Wiper intermittent dial position 4) A ● Rear wiper switch INT (Wiper intermittent dial position 4) ● Wiper intermittent dial position 3 B C PKIB4958J PKIB8635J Approx. 1.0V Approx. 2.0V PKIB8636J D Approx. 2.0V INPUT 1 Any of the conditions below Any of the conditions below ● Wiper intermittent dial position 1 ● Wiper intermittent dial position 2 ● Wiper intermittent dial position 6 ● Wiper intermittent dial position 7 E F — G PKIB8637J Approx. 2.5 - 3.0V PKIB8638J H Approx. 2.0V I J LT L M LT-123 COMBINATION SWITCH CONSULT-II Function (BCM) BKS001FS CONSULT-II can display each diagnostic item using the diagnostic test modes shown following. BCM diagnosis part Diagnosis mode Description COMB SW DATA MONITOR Displays BCM input data in real time. CONSULT-II INSPECTION PROCEDURE Refer to GI-36, "CONSULT-II Start Procedure" . CONSULT-II Application Items BKS001KX DATA MONITOR Monitor item “UNIT” Display content TURN SIGNAL R [ON/OFF] Displays status (Turn right: ON/Others: OFF) as judged from lighting switch signal. TURN SIGNAL L [ON/OFF] Displays status (Turn left: ON/Others: OFF) as judged from lighting switch signal. HI BEAM SW [ON/OFF] Displays status (High beam switch: ON/Others: OFF) as judged from lighting switch signal. H/L SW POS [ON/OFF] Displays status (Headlamp switch 1: ON/Others: OFF) as judged from lighting switch signal. LIGHT SW 1ST [ON/OFF] Displays status (Lighting switch 1st position: ON/Others: OFF) as judged from lighting switch signal. PASSING SW [ON/OFF] Displays status (Flash-to-pass switch: ON/Others: OFF) as judged from lighting switch signal. FR FOG SW [ON/OFF] Displays status (Front fog lamp switch: ON/Others: OFF) as judged from lighting switch signal. (ON is also displayed when rear fog lamp switch is on.) RR FOG SW [ON/OFF] Displays status (Rear fog lamp switch: ON/Others: OFF) as judged from lighting switch signal. FR WIPER HI [ON/OFF] Displays status (Front Wiper HI: ON/Others: OFF) as judged from wiper switch signal. FR WIPER LOW [ON/OFF] Displays status (Front Wiper LOW: ON/Others: OFF) as judged from wiper switch signal. FR WIPER INT [ON/OFF] Displays status (Front Wiper INT: ON/Others: OFF) as judged from wiper switch signal. FR WASHER SW [ON/OFF] Displays status (Front Washer Switch: ON/Others: OFF) as judged from wiper switch signal. [1 - 7] Displays intermittent operation dial position setting (1 - 7) as judged from wiper switch signal. RR WIPER ON [ON/OFF] Displays status (Rear Wiper ON: ON/Others: OFF) as judged from wiper switch signal. RR WIPER INT [ON/OFF] Displays status (Rear Wiper INT: ON/Others: OFF) as judged from wiper switch signal. RR WASHER SW [ON/OFF] Displays status (Rear Washer Switch: ON/Others: OFF) as judged from wiper switch signal. INT VOLUME LT-124 COMBINATION SWITCH Combination Switch Inspection BKS001FT 1. SYSTEM CHECK 1 A Check which systems (INPUT and OUTPUT) the malfunctioning switch belongs to. Refer to the table below. OUTPUT1 INPUT1 INPUT2 INPUT3 INPUT4 INPUT5 — FRONT WASHER FRONT WIPER LO TURN LH TURN RH 1 PASSING HEAD LAMP 1 OUTPUT2 FRONT WIPER HI — * OUTPUT3 INT VOLUME 1 RR WASHER — HEAD LAMP 2 HI BEAM OUTPUT4 REAR WIPER INT INT VOLUME 3 AUTO LIGHT — LIGHT SW 1ST OUTPUT5 INT VOLUME 2 RR WIPER REAR FOG FRONT FOG — B C D *1: FRONT WIPER INT (without light and rain sensor), AUTO WIPER (with light and rain sensor) E >> GO TO 2. 2. SYSTEM CHECK 2 1. 2. 3. F Connect CONSULT-II and select “COMB SW” on “SELECT TEST ITEM” screen. Select “DATA MONITOR”. Select “START”. G H I PKIA7602E 4. Confirm that other switches in malfunctioning system operate normally. J Example: When “TURN RH” is malfunctioning, confirm other switches in malfunctioning system operate properly as described below. LT – INPUT5 Confirm that “HEAD LAMP1”, “HI BEAM” and “LIGHT SW 1ST” can be turned ON and OFF properly. – OUTPUT1 L Confirm that “TURN LH”, “FRONT WIPER LO” and “FRONT WASHER” can be turned ON and OFF properly. OK or NG M OK >> Replace malfunctioning lighting switch or wiper switch. Refer to LT-112, "LIGHTING AND TURN SIGNAL SWITCH" or WW-46, "Removal and Installation of Front Wiper and Washer Switch" . NG >> GO TO 3. LT-125 COMBINATION SWITCH 3. HARNESS INSPECTION 1. 2. 3. Turn ignition switch OFF. Disconnect BCM connector and combination switch connector. Check for continuity between BCM harness connector of the suspected system and the corresponding combination switch harness connector. BCM Connector M57 4. Combination switch Terminal Connector Terminal INPUT1 13 6 INPUT2 33 7 INPUT3 14 10 INPUT4 34 9 INPUT5 15 Continuity 8 M38 OUTPUT1 9 OUTPUT2 28 2 OUTPUT3 8 3 OUTPUT4 27 4 OUTPUT5 7 5 Yes 1 Check for continuity between BCM harness connector of the suspected system and ground. BCM Connector M57 MKIB0753E Continuity Terminal INPUT1 13 INPUT2 33 INPUT3 14 INPUT4 34 INPUT5 15 OUTPUT1 9 OUTPUT2 28 OUTPUT3 8 OUTPUT4 27 OUTPUT5 7 Ground No OK or NG OK >> GO TO4. NG >> Repair or replace harness connector. 4. SELECTION MALFUNCTION SYSTEM Which system does malfunction system belong to? INPUT or OUTPUT INPUT >> GO TO 5. OUTPUT >>GO TO 6. LT-126 COMBINATION SWITCH 5. CHECK BCM INPUT TERMINAL 1. 2. 3. 4. 5. A Connect BCM and combination switch connectors. Turn ignition switch ON. Turn “lighting”, “wiper” and “turn” switch OFF. Set wiper intermittent dial to position 4. Check BCM input terminal voltage waveform of the suspected malfunctioning system. BCM INPUT Connector B C Voltage Terminal 1 13 2 33 3 14 4 34 D E PKIB4958J Ground Approx. 1.2V F M57 G 5 15 H PKIB8643J Approx. 1.2V OK or NG OK >> Replace BCM.Refer to BCS-17, "Removal and Installation of BCM" . NG (0V) >>GO TO 7. NG (Other than 0V) >>Replace BCM.Refer to BCS-17, "Removal and Installation of BCM" . I J LT L M LT-127 COMBINATION SWITCH 6. CHECK BCM OUTPUT TERMINAL 1. 2. 3. 4. 5. Connect BCM and combination switch connectors. Turn ignition switch ON. Turn “lighting”, “wiper” and “turn” switch OFF. Set wiper intermittent dial to position 4. Check BCM input terminal voltage waveform of the suspected malfunctioning system. BCM OUTPUT Connector Voltage Terminal 1 9 2 28 3 8 4 27 PKIB4958J Ground Approx. 1.0V M57 5 7 PKIB4956J Approx. 0.9V OK or NG OK >> GO TO 7. NG >> Replace BCM. Refer to BCS-17, "Removal and Installation of BCM" . 7. COMBINATION SWITCH INSPECTION Perform combination switch inspection. Refer to the table below. Procedure 1 Replace lighting switch 2 Confirm check results 3 OK INSPECTION END NG Replace wiper switch 4 Confirm check results 5 OK INSPECTION END NG Replace switch base 6 Confirm check results 7 OK INSPECTION END NG Confirm symptom again >> INSPECTION END Removal and Installation BKS001FU Refer to LT-112, "LIGHTING AND TURN SIGNAL SWITCH" . LT-128 STOP LAMP STOP LAMP Wiring Diagram — STOP/L — PFP:26550 A BKS001FV B C D E F G H I J LT L M MKWA4361E LT-129 STOP LAMP Bulb Replacement of High-Mounted Stop Lamp 1. 2. 3. BKS001FW Remove high-mounted stop lamp (1). Refer to LT-130, "Removal and Installation of High-Mounted Stop Lamp" . Turn bulb socket (2) counter clock and unlock it. Remove the bulb (3) from the socket. High-mounted stop lamp : 12V - 16W SKIB3809J Bulb Replacement of Rear Combination Lamp (Stop Lamp) BKS001FX Refer to LT-149, "Bulb Replacement" . Removal and Installation of High-Mounted Stop Lamp BKS001FY REMOVAL 1. 2. Open the back door and remove seal cover (1). Remove nuts (A). SKIB3808J 3. 4. Pull the high-mounted stop lamp toward rear of the vehicle and remove from the back door. Disconnect high-mounted stop lamp connector. INSTALLATION Installation is the reverse order of removal. Removal and Installation of Rear Combination Lamp (Stop Lamp) Refer to LT-149, "Removal and Installation" . LT-130 BKS001FZ BACK-UP LAMP BACK-UP LAMP Wiring Diagram — BACK/L — PFP:26550 A BKS001G0 B C D E F G H I J LT L M MKWA4362E LT-131 BACK-UP LAMP MKWA4363E LT-132 BACK-UP LAMP Bulb Replacement BKS001G1 A Refer to LT-149, "Bulb Replacement" . Removal and Installation BKS001G2 B Refer to LT-149, "Removal and Installation" . C D E F G H I J LT L M LT-133 PARKING, LICENSE PLATE AND TAIL LAMPS PARKING, LICENSE PLATE AND TAIL LAMPS Component Parts and Harness Connector Location PFP:26550 BKS001G3 MKIB2252E 1. IPDM E/R E8,E10,E11,E12 2. BCM M57,M59 (View with instrument upper panel removed) System Description 3. Combination switch M38 BKS001G4 The control of the parking, license plate and tail lamp operation is dependent upon the position of lighting switch. When the lighting switch is placed in the 1ST position, the BCM (body control module) receives input signal requesting the parking, license plate and tail lamps to illuminate. This input signal is communicated to the IPDM E/R (intelligent power distribution module engine room) via the CAN communication. The CPU (central processing unit) located in the IPDM E/R controls the tail lamp relay coil. This relay, when energized, directs power to parking, license plate and tail lamps, which then illuminate. Power is supplied at all times ● to ignition relay located in IPDM E/R and ● to tail lamp relay located in IPDM E/R from battery directly, ● through 20A fuse (No. 61, located in IPDM E/R), ● through 20A fuse (No. 62, located in IPDM E/R), ● through 40A fusible link (letter J, located in fuse, fusible link and relay box) ● to BCM terminals 74 and 79. With the ignition switch in the ON or START position, power is supplied ● to ignition relay located in IPDM E/R, from battery directly and ● through 10A fuse [No. 5, located in fuse block (J/B)] ● to BCM terminal 24. Ground is supplied ● to BCM terminals 2 and 70, ● through grounds M21 and M66, ● to IPDM E/R terminals 3 and 54 ● through grounds E45 (CR and HR engine models), E28 and E44. OPERATION BY LIGHTING SWITCH With the lighting switch in the 1ST or 2ND position (or if auto light system is activated), the BCM receives input signal requesting parking, license plate and tail lamps to illuminate. This input signal is communicated to the IPDM E/R via CAN communication. The CPU located in the IPDM E/R controls tail lamp relay coil, which when energized, directs power ● through 10A fuse (No. 45, located in IPDM E/R), ● through IPDM E/R terminal 45 ● to parking lamp RH terminal 1, ● through IPDM E/R terminal 16 ● to rear combination lamp RH (tail) terminal 5 and ● to license plate lamp LH and RH terminals 1, ● through 10A fuse (No. 46, located in IPDM E/R), ● through IPDM E/R terminal 49 LT-134 PARKING, LICENSE PLATE AND TAIL LAMPS to parking lamp LH terminal 1 and through IPDM E/R terminal 15 ● to rear combination lamp LH (tail) terminal 5. Ground is supplied ● to parking lamp LH and RH terminals 2 ● through grounds E45 (CR and HR engine models), E28 and E44, ● to rear combination lamp LH (tail) and RH (tail) terminal 2, ● to license plate lamp LH and RH terminals 2 ● through grounds B13,B28,B38 and B48. With power and ground supplied, parking, license plate and tail lamps illuminate. ● A ● B C D COMBINATION SWITCH READING FUNCTION Refer to LT-114, "COMBINATION SWITCH READING FUNCTION" . E EXTERIOR LAMP BATTERY SAVER CONTROL Refer to LT-135, "EXTERIOR LAMP BATTERY SAVER CONTROL" . F FAIL-SAFE FUNCTION When CAN communication with other control units is impossible, IPDM E/R performs fail-safe control. If the fail-safe system is operating, parking, license plate and tail lamps illuminate when the ignition switch is turned from OFF to ON and parking, license plate and tail lamps are turned off when the ignition switch is turn from ON to OFF. If the fail-safe system is operating, parking, license plate and tail lamps does not operate when the combination switch is in any position. After CAN communication recovers normally, it also returns to normal control. (Refer to PG-18, "Fail-safe Control" .) CAN Communication System Description H BKS001G5 CAN (Controller Area Network) is a serial communication line for real time application. It is an on-vehicle multiplex communication line with high data communication speed and excellent error detection ability. Many electronic control units are equipped onto a vehicle, and each control unit shares information and links with other control units during operation (not independent). In CAN communication, control units are connected with 2 communication lines (CAN H line, CAN L line) allowing a high rate of information transmission with less wiring. Each control unit transmits/receives data but selectively reads required data only. CAN Communication Unit G I J BKS001G6 LT Refer to LAN-27, "CAN Communication Unit" . L M LT-135 PARKING, LICENSE PLATE AND TAIL LAMPS Schematic BKS001G7 MKWA4357E LT-136 PARKING, LICENSE PLATE AND TAIL LAMPS Wiring Diagram — TAIL/L — BKS001G8 A B C D E F G H I J LT L M MKWA4358E LT-137 PARKING, LICENSE PLATE AND TAIL LAMPS MKWA4359E LT-138 PARKING, LICENSE PLATE AND TAIL LAMPS A B C D E F G H I J LT L M MKWA4360E LT-139 PARKING, LICENSE PLATE AND TAIL LAMPS Terminals and Reference Values for BCM BKS001G9 CAUTION: ● Check combination switch system terminal waveform under the loaded condition with lighting switch, turn signal switch and wiper switch OFF not to be fluctuated by overloaded. ● Turn wiper dial position to 4 except when checking waveform or voltage of wiper dial position. Wiper dial position can be confirmed on CONSULT-II. Refer to LT-19, "DATA MONITOR" . Measuring condition Terminal No. Wire color Signal name 2 B Ground Signal input/ output Ignition switch Operation or condition — ON — Reference value Approx. 0V OFF 15 W Combination switch input 5 Input ON Lighting, turn, wiper switch (Wiper intermittent dial position 4) PKIB4956J Approx. 0.9V Lighting switch 1ST PKIB8624J Approx. 1.5 - 2.0V 19 L CAN − H 24 O Ignition switch (ON) Input/ Output — — — Input ON — Battery voltage OFF 27 GR Combination switch output 4 Output ON Lighting, turn, wiper switch (Wiper intermittent dial position 4) PKIB4958J Approx. 1.2V Lighting switch 1ST (The same result with lighting switch 2ND) PKIB4959J Approx. 1.0V 39 Y CAN − L Input/ Output — — — 70 B Ground — ON — Approx. 0V 74 79 Y Battery power supply Input OFF — Battery voltage LT-140 PARKING, LICENSE PLATE AND TAIL LAMPS Terminals and Reference Values for IPDM E/R BKS001GA A Measuring condition Terminal No. Wire color 3 B 15 GR 16 V 45 BR Signal name Ground Signal input/ output Reference value Operation or condition — — Rear combination lamp LH Output Rear combination lamp RH, license plate lamp RH and LH Output Parking lamp RH Ignition switch ON Output Lighting switch 1ST position B Approx. 0V OFF Approx. 0V ON Battery voltage OFF Approx. 0V ON Battery voltage OFF Approx. 0V ON Battery voltage OFF Approx. 0V ON Battery voltage 49 O Parking lamp LH Output 52 L CAN − H Input/ Output — — — 54 B Ground — ON — Approx. 0V 58 Y CAN − L Input/ Output — — — How to Proceed With Trouble Diagnosis 1. 2. 3. 4. 5. 6. Confirm the symptom or customer complaint. Understand operation description and function description. Refer to LT-134, "System Description" . Perform the preliminary check. Refer to LT-142, "Preliminary Check" . Check symptom and repair or replace the malfunctioning parts. Do the parking, license plate and tail lamps operate normally? If YES, GO TO 6. If NO, GO TO 4. INSPECTION END C D E F G BKS001GB H I J LT L M LT-141 PARKING, LICENSE PLATE AND TAIL LAMPS Preliminary Check BKS001GC CHECK POWER SUPPLY AND GROUND CIRCUIT 1. CHECK FUSES Check for blown fuses. Unit Power source Fuse and fusible link No. Battery J Ignition switch ON or START position 5 BCM 45 IPDM E/R 46 Battery 61 62 Refer to LT-137, "Wiring Diagram — TAIL/L —" . OK or NG OK >> GO TO 2. NG >> If fuse or fusible link is blown, be sure to eliminate cause of malfunction before installing new fuse or fusible link. Refer to PG-4, "POWER SUPPLY ROUTING CIRCUIT" . 2. CHECK POWER SUPPLY CIRCUIT 1. 2. 3. Turn ignition switch OFF. Disconnect BCM connector. Check voltage between BCM harness connector and ground. Terminal Ignition switch position (+) OFF ACC ON 24 Approx. 0V Approx. 0V Battery voltage 74 Battery voltage Battery voltage Battery voltage Battery voltage Battery voltage Battery voltage BCM Connector Terminal M57 (−) Ground M59 79 MKIB0352E OK or NG OK >> GO TO 3. NG >> Repair harness or connector. 3. CHECK GROUND CIRCUIT Check continuity between BCM harness connector and ground. BCM Connector Terminal M57 2 M59 70 Continuity Ground Yes OK or NG OK >> INSPECTION END NG >> Repair harness or connector. MKIB0353E LT-142 PARKING, LICENSE PLATE AND TAIL LAMPS CONSULT-II Functions (BCM) BKS001GD A Refer to LT-19, "CONSULT-II Functions (BCM)" in “HEADLAMP - CONVENTIONAL TYPE -”. CONSULT-II Functions (IPDM E/R) BKS001GE B Refer to LT-20, "CONSULT-II Functions (IPDM E/R)" in “HEADLAMP - CONVENTIONAL TYPE -”. Parking, License Plate and Tail Lamps Do Not Illuminate BKS001GF 1. CHECK COMBINATION SWITCH INPUT SIGNAL C With CONSULT-II 1. Select “BCM” on CONSULT-II. Select “HEAD LAMP” on “SELECT TEST ITEM” screen. 2. Select “DATA MONITOR” on “SELECT DIAG MODE” screen. Make sure “LIGHT SW 1ST” turns ON-OFF linked with operation of lighting switch. When lighting switch is 1ST position D E : LIGHT SW 1ST ON F Without CONSULT-II Refer to LT-125, "Combination Switch Inspection" . PKIA7607E OK or NG OK >> GO TO 2. NG >> Check combination switch (lighting switch). Refer to LT-125, "Combination Switch Inspection" . 2. ACTIVE TEST With CONSULT-II Select “IPDM E/R” on CONSULT-II, and select “ACTIVE TEST” on “SELECT DIAG MODE” screen. 2. Select “TAIL LAMP” on “SELECT TEST ITEM” screen. 3. Touch “ON” screen. 4. Make sure parking, license plate and tail lamp operates. G H I 1. J LT Parking, license plate and tail lamp should operate. 1. 2. Without CONSULT-II Start auto active test. Refer to PG-22, "Auto Active Test" . Make sure parking, license plate and tail lamp operates. Parking, license plate and tail lamp should operate. OK or NG OK >> GO TO 3. NG >> GO TO 4. LT-143 L SKIA2348E M PARKING, LICENSE PLATE AND TAIL LAMPS 3. CHECK IPDM E/R 1. 2. Select “IPDM E/R” on CONSULT-II, and select “DATA MONITOR” on “SELECT DIAG MODE” screen. Make sure “TAIL&CLR REQ” turns ON when lighting switch is in 1ST position. When lighting switch is 1ST position : TAIL&CLR REQ ON OK or NG OK >> Replace IPDM E/R. Refer to PG-37, "Removal and Installation of IPDM E/R" . NG >> Replace BCM. Refer to BCS-17, "Removal and Installation of BCM" . LT-144 SKIA5958E PARKING, LICENSE PLATE AND TAIL LAMPS 4. CHECK INPUT SIGNAL A With CONSULT-II Turn ignition switch OFF. Disconnect parking lamp RH and LH, license plate lamp RH and LH, and rear combination lamp RH and LH connectors. 3. Select “IPDM E/R” on CONSULT-II, and select “ACTIVE TEST” on “SELECT DIAG MODE” screen. 4. Select “TAIL LAMP” on “SELECT TEST ITEM” screen. 5. Touch “ON” screen. 6. When tail lamp relay is operating, check voltage between parking lamp, license plate lamp and rear combination lamp harness connector and ground. 1. 2. Without CONSULT-II 1. Turn ignition switch OFF. 2. Disconnect parking lamp RH and LH, license plate lamp RH and LH, and rear combination lamp RH and LH connectors. 3. Start auto active test. Refer to PG-22, "Auto Active Test" . 4. When tail lamp relay is operating, check voltage between parking lamp, license plate lamp and rear combination lamp harness connector and ground. (−) Parking lamp connector RH E30 LH E43 D E F Voltage Terminal 1 C G Terminal (+) B H Ground Battery voltage I MKIB2241E J Terminal LT (+) (−) License plate lamp connector RH D103 LH D105 Voltage Terminal L 1 Ground Battery voltage M MKIB2242E Terminal (+) Rear combination lamp connector (tail) RH B39 LH B17 (−) Voltage Terminal 5 Ground Battery voltage OK or NG OK >> GO TO 6. NG >> GO TO 5. MKIB2243E LT-145 PARKING, LICENSE PLATE AND TAIL LAMPS 5. CHECK PARKING, LICENSE PLATE AND TAIL LAMP CIRCUIT 1. 2. 3. Turn ignition switch OFF. Disconnect IPDM E/R connector. Check continuity between IPDM E/R harness connector (A) and parking lamp harness connector (B). A Circuit Connector RH LH E8 B Terminal Connector 45 E30 49 E43 Terminal Continuity 1 Yes MKIB2244E 4. Check continuity between IPDM E/R harness connector (A) and license plate lamp harness connector (B). A Circuit RH B Connector Terminal E10 16 LH Connector Continuity Terminal D103 1 Yes D105 MKIB2245E 5. Check continuity between IPDM E/R harness connector (A) and rear combination lamp harness connector (B). A Circuit Connector RH LH E10 B Terminal Connector 16 B39 15 B17 Terminal Continuity 5 Yes OK or NG OK >> Replace IPDM E/R. Refer to PG-37, "Removal and Installation of IPDM E/R" . NG >> Repair harness or connector. LT-146 MKIB2246E PARKING, LICENSE PLATE AND TAIL LAMPS 6. CHECK PARKING, LICENSE PLATE AND TAIL LAMPS GROUND CIRCUIT 1. A Check continuity between parking harness connector and ground. Parking lamp connector RH E30 LH E43 Terminal 2 B Continuity Ground Yes C D MKIB2247E 2. Check continuity between license plate lamp harness connector and ground. License plate lamp connector RH D103 LH D105 Terminal E Continuity F Ground 2 Yes G MKIB2248E 3. Check continuity between rear combination lamp harness connector and ground. Rear combination lamp connector RH B39 LH B17 Terminal H I Continuity Ground 2 J Yes OK or NG OK >> Check bulbs. NG >> Repair harness or connector. LT MKIB2249E Parking, License Plate and Tail Lamps Do Not Turn OFF (After Approx. 10 Minutes) L BKS001GG ● ● This symptom indicates the malfunction of ignition relay in IPDM E/R. Refer to PG-19, "Function of Detecting Ignition Relay Malfunction" . Select “BCM” on CONSULT-II. Select “HEADLAMP” on “SELECT TEST ITEM” screen and select “DATA MONITOR” on “SELECT DIAG MODE” screen. If “LIGHT SW 1ST” is OFF when lighting switch is OFF, replace IPDM E/R. LT-147 M PARKING, LICENSE PLATE AND TAIL LAMPS Bulb Replacement BKS001GH PARKING LAMP Refer to LT-149, "Bulb Replacement" . LICENSE PLATE LAMP 1. Insert a screwdriver A or the like wrapped in a cloth into the lens (1) notch. MKIB2308E 2. Remove bulb (1) from license plate lamp bulb socket. License plate lamp : 12V - 5W MKIB2309E TAIL LAMP Refer to LT-149, "Bulb Replacement" . Removal and Installation BKS001GI PARKING LAMP Refer to LT-149, "Removal and Installation" . LICENSE PLATE LAMP Removal 1. 2. 3. Remove license plate finisher. Refer to EI-24, "Removal and Installation" . Disconnect the license plate lamp connector. While pressing pawl on the reverse side of the back door finisher. MKIB2307E Installation Installation is the reverse order of removal. TAIL LAMP Removal Refer to LT-149, "Removal and Installation" . LT-148 REAR COMBINATION LAMP REAR COMBINATION LAMP Bulb Replacement 1. 2. 3. PFP:26554 A BKS001GJ Remove rear combination lamp. Refer to LT-149, "Removal and Installation" . Turn bulb socket (1), (2), (3) counterclockwise and unlock it. Remove bulb (4), (5), (6). Stop/tail lamp (5) Rear turn signal lamp (4) Back-up lamp (6) B C : 12V - 21/5W : 12V - 16W (amber) : 12V - 16W D SKIB3812J Removal and Installation BKS001GK E REMOVAL 1. 2. 3. 4. Remove rear pillar garnish. Refer to EI-26, "BODY SIDE TRIM" . Disconnect rear combination lamp connector. Remove rear combination lamp mounting bolts (A). Pull the rear combination lamp (1) toward rear of the vehicle and remove from the vehicle. F G H I SKIB3813J 5. While pressing pawls (A) in direction as shown in the figure, remove the rear combination lamp finisher (2) from the rear combination lamp body (1). J LT L SKIB3975J INSTALLATION Installation is the reverse order of removal. Rear combination lamp mounting nut : 5.5 N·m (0.56 kg-m, 49 in-lb) LT-149 M INTERIOR ROOM LAMP INTERIOR ROOM LAMP Component Parts and Harness Connector Location PFP:26410 BKS001GO MKIB2269E 1. BCM M57,M59 (View with instrument upper panel removed) 2. Key switch M33 3. (without Intelligent Key system) Key switch and ignition knob switch M34 (with Intelligent Key system) 4. Front door switch driver side [B14 (LHD models)] [B29 (RHD models)] Front door switch passenger side [B29 (LHD models)] [B14 (RHD models)] 5. Rear door switch LH B19 Rear door switch RH B42 Door lock/unlock switch M54 6. System Description BKS001GP When interior room lamp switch is in DOOR position, interior room lamp ON/OFF is controlled by timer according to signals from switches including key switch, front door switch driver side, unlock signal from key fob, door lock and unlock switch, key cylinder lock and unlock switch, ignition switch. When interior room lamp turns ON, there is a gradual brightening over 1 second. When interior room lamp turns OFF, there is a gradual dimming over 1 second. Interior room lamp timer is controlled by BCM. POWER SUPPLY AND GROUND Power is supplied at all times: ● through 40A fusible link (letter J, located in the fuse and fusible link box) ● to BCM terminals 74 and 79, ● through 10A fuse [No. 9, located in the fuse block (J/B)] ● to luggage room lamp terminal 1, ● to BCM terminal 72, ● to key switch terminal 2 (without Intelligent Key system) or ● through 10A fuse [No. 13, located in the fuse block (J/B)] ● to key switch and ignition knob switch terminal 2 and 4 (with Intelligent Key system). When the key is removed from ignition key cylinder, power is interrupted ● through key switch terminal 1 (without Intelligent Key system) or ● through key switch and ignition knob switch terminal 1 (with Intelligent Key system) ● to BCM terminal 3. With the ignition key switch in the ON or START position, power is supplied: ● through 10A fuse [No. 5, located in the fuse block (J/B)] ● to BCM terminal 24. LT-150 INTERIOR ROOM LAMP Ground is supplied: ● to BCM terminals 2 and 70. ● through grounds M21 and M66. When any door is opened, ground is supplied: ● to BCM terminal 29 ● to front door switch (driver side) terminal 1 ● through case ground of front door switch (driver side), ● to BCM terminal 30 ● to front door switch (passenger side) terminal 1 ● through case ground of front door switch (passenger side), ● to BCM terminal 59 ● to rear door switch LH terminal 1 ● through case ground of rear door switch LH, ● to BCM terminal 60 ● to rear door switch RH terminal 1 ● through case ground of rear door switch RH, ● to BCM terminal 10 ● to back door switch terminal 2 ● to back door switch terminal 1 ● through grounds B13,B28,B38 and B48. A B C D E F G H SWITCH OPERATION When map lamp switch is ON, power is supplied: ● through BCM terminal 73 ● to map lamp terminal 4. Ground is supplied: ● to map lamp terminal 3 ● through grounds M21 and M66. With power and ground are supplied, the map lamp illuminates. When map lamp switch is DOOR, power is supplied: ● through BCM terminal 73 ● to map lamp terminal 4. Ground is supplied: ● through map lamp terminal 2 ● to BCM terminal 21. With power and ground are supplied, the map lamp illuminates. When back door is opened, ground supplied: ● to luggage room lamp terminal 2 ● through back door switch terminals 2 and 1 ● through grounds B13,B28,B38 and B48. With power and ground are supplied, the luggage room lamp illuminates. LT-151 I J LT L M INTERIOR ROOM LAMP Models With Personal Lamp When personal lamp switch is ON, power is supplied: ● through BCM terminal 73 ● to personal lamp terminal 4. Ground is supplied: ● to personal lamp terminal 3 ● through grounds M21 and M66. With power and ground are supplied, the personal lamp illuminates. When personal lamp switch is DOOR, power is supplied: ● through BCM terminal 73 ● to personal lamp terminal 4. Ground is supplied: ● through personal lamp terminal 2 ● to BCM terminal 21. With power and ground are supplied, the personal lamp illuminates. INTERIOR ROOM LAMP TIMER OPERATION When interior room lamp switch is in the “DOOR” position, the BCM keeps the interior room lamp illuminated for Approx. 28 seconds when: ● unlock signal is received from Intelligent Key, while all doors are closed and key is out of the ignition key cylinder (with Intelligent Key system). ● unlock signal is received from key fob while all doors are closed and key is out of the ignition key cylinder (without Intelligent Key system). ● key is removed from ignition key cylinder while all doors are closed (without Intelligent Key system) ● any door is opened and then closed while key is out of the ignition key cylinder. The timer is canceled when: ● ignition switch is turned ON. ● lock signal is received from Intelligent Key, while all doors are closed and key is out of the ignition key cylinder (with Intelligent Key system). ● lock signal is received from remote controller while all doors are closed and key is out of the ignition key cylinder (without Intelligent Key system). INTERIOR ROOM LAMP BATTERY SAVER CONTROL If interior room lamp is left ON, it will not be turned off even when door is closed. BCM turns off interior room lamp automatically to save battery 15 minutes after ignition switch is turned off. BCM controls interior room lamps listed below: ● Interior room lamp After lamps turn OFF by the battery saver system, the lamps illuminate again when ● door lock switch is operated, ● Intelligent Key lock or unlock, ● door is opened, ● key is removed from ignition key cylinder. LT-152 INTERIOR ROOM LAMP Schematic BKS001GQ A —MODELS WITHOUT PERSONAL LAMP— B C D E F G H I J LT L M MKWA4365E LT-153 INTERIOR ROOM LAMP —MODELS WITH PERSONAL LAMP— MKWA4448E LT-154 INTERIOR ROOM LAMP Wiring Diagram — ROOM/L — BKS001GR A —MODELS WITHOUT PERSONAL LAMP— B C D E F G H I J LT L M MKWA4366E LT-155 INTERIOR ROOM LAMP MKWA4367E LT-156 INTERIOR ROOM LAMP A B C D E F G H I J LT L M MKWA4368E LT-157 INTERIOR ROOM LAMP MKWA4369E LT-158 INTERIOR ROOM LAMP —MODELS WITH PERSONAL LAMP— A B C D E F G H I J LT L M MKWA4449E LT-159 INTERIOR ROOM LAMP MKWA4450E LT-160 INTERIOR ROOM LAMP A B C D E F G H I J LT L M MKWA4451E LT-161 INTERIOR ROOM LAMP MKWA4452E LT-162 INTERIOR ROOM LAMP Terminals and Reference Values for BCM BKS001GS A Terminal No. Wire color 2 B 3 Signal designation Ground GR*1 Measuring condition Signal input/ output Ignition switch Operation or condition Voltage [V] (Approx.) — ON — 0 Input OFF Remove key. Key switch signal O*2 6 LG B 0 Key is inserted. Door lock / unlock switch (Lock signal) 10 P Back door switch signal 19 L CAN- H Input OFF Battery voltage Lock operation (ON) 0 Other than above (OFF) 5 ON (open) Input OFF Input/ Output — Back door switch signal 21 Y Input Battery voltage E — OFF Interior room lamp switch: DOOR position — Any door switch ON (Open) 0 OFF (Close) Battery voltage Key is removed from key cylinder Close all doors Turn ignition switch ON Key is removed Interior room lamp timer 24 O Ignition power supply 25 BR Door lock/unlock switch (Unlock signal) Input Driver door switch signal Input Passenger door switch signal Input 29 LG*3 4 BR* BR*3 30 LG*4 39 59 60 Input ON OFF Input/ Output Input Rear door switch RH signal Input Ground 72 Y Power source (Fuse) ON 0 Unlock operation (ON) 0 Other than above (OFF) 5 0 Driver door switch signal — H I — J LT Battery voltage 0 Passenger door switch signal OFF (close) G B OFF G Battery voltage ON (open) Rear door switch LH signal 70 Battery voltage — F Battery voltage OFF OFF (closed) CAN- L L OFF 0 0 ON (open) Y D 0 OFF (close) Key is inserted Logical lighting control C L Battery voltage — M OFF ON (open) Rear door switch LH signal OFF (close) OFF Rear door switch RH signal ON (open) OFF (close) 0 Battery voltage 0 Battery voltage — ON — 0 Input OFF — Battery voltage LT-163 INTERIOR ROOM LAMP Terminal No. Wire color Signal designation Signal input/ output Measuring condition Ignition switch Operation or condition Key is inserted. OFF 73 V Interior room lamp signal Y Power supply (Fusible link) Input OFF ON (open) OFF (closed) Key is removed after being fully inserted. Close all doors. — 74 79 Any door switch Interior room lamp switch: DOOR position Output Voltage [V] (Approx.) Turn ignition switch ON. — 0 Battery voltage 0 Battery voltage Battery voltage *1: With Intelligent Key system *2: Without Intelligent Key system *3: LHD models *4: RHD models How to Proceed With Trouble Diagnosis 1. 2. 3. 4. 5. 6. Confirm the symptom or customer complaint. Understand operation description and function description. Refer to LT-150, "System Description" . Perform the preliminary check. Refer to LT-165, "Preliminary Check" . Check symptom and repair or replace the malfunctioning parts. Does the interior room lamp operate normally? If YES, GO TO 6. If NO, GO TO 4. INSPECTION END LT-164 BKS001GT INTERIOR ROOM LAMP Preliminary Check BKS001GU A CHECK POWER SUPPLY AND GROUND CIRCUIT 1. CHECK FUSES B Check for blown fuses. Unit Power source Fuse and fusible link No. Battery J Ignition switch ON or START position 5 BCM C Refer to LT-155, "Wiring Diagram — ROOM/L —" . OK or NG OK >> GO TO 2. NG >> If fuse or fusible link is blown, be sure to eliminate cause of malfunction before installing new fuse or fusible link. Refer to PG-4, "POWER SUPPLY ROUTING CIRCUIT" . D E 2. CHECK POWER SUPPLY CIRCUIT 1. 2. 3. F Turn ignition switch OFF. Disconnect BCM connector. Check voltage between BCM harness connector and ground. Terminal G Ignition switch position (+) H BCM Connector Terminal M57 24 74 (−) Ground M59 79 OFF ACC ON Approx. 0V Approx. 0V Battery voltage Battery voltage Battery voltage Battery voltage Battery voltage Battery voltage Battery voltage I MKIB0352E J OK or NG OK >> GO TO 3. NG >> Repair harness or connector. LT L 3. CHECK GROUND CIRCUIT Check continuity between BCM harness connector and ground. M BCM Connector Terminal M57 2 M59 70 Continuity Ground Yes OK or NG OK >> INSPECTION END NG >> Repair harness or connector. MKIB0353E LT-165 INTERIOR ROOM LAMP CONSULT-II Functions (BCM) ● BKS001GV CONSULT-II can display each diagnostic item using the diagnostic test modes shown following. BCM diagnosis part INT LAMP Diagnosis mode Description DATA MONITOR Displays BCM input data in real time. ACTIVE TEST BCM Operation of electrical loads can be checked by sending driving signal to them. SELFDIAG RESULTS BCM performs self-diagnosis of CAN communication. CAN DIAG SUPPORT MNTR The result of transmit/receive diagnosis of CAN communication can be read. CONSULT-II INSPECTION PROCEDURE Refer to GI-36, "CONSULT-II Start Procedure" . CONSULT-II Application Items BKS001KV DATA MONITOR Monitor item “UNIT” Display content IGN ON SW [ON/OFF] Displays status (Ignition switch ON: ON/Others OFF, ACC: OFF) as judged from the ignition switch signal. PUSH SW (*1) [ON/OFF] Displays status (Ignition knob is pushed: ON/ released: OFF) as judged from the ignition knob switch signal. KEY IN SW (*2) [ON/OFF] Displays status (Key inserted: ON/Key removed: OFF) as judged from the key switch signal. DOOR SW-DR [ON/OFF] Displays status (Door open: ON/door closed: OFF) as judged from the front door switch RH signal. DOOR SW-AS [ON/OFF] Displays status (Door open: ON/Door closed: OFF) as judged from the front door switch LH signal. DOOR SW-RR [ON/OFF] Displays status (Door open: ON/door closed: OFF) as judged from the rear door switch RH signal. DOOR SW-RL [ON/OFF] Displays status (Door open: ON/Door closed: OFF) as judged from the rear door switch LH signal. BACK DOOR SW [ON/OFF] Displays status (Door open: ON/Door closed: OFF) as judged from the back door switch signal. CDL LOCK SW [ON/OFF] Displays status (Locked: ON/Others: OFF) as judged from lock signal. CDL UNLOCK SW [ON/OFF] Displays status (Unlocked: ON/Others: OFF) as judged from unlock signal. KEYLESS LOCK (*2) [ON/OFF] Displays status (Locked: ON/Others: OFF) as judged from lock signal. (Locked by Multi-Remote control system) KEYLESS UNLOCK(*2) [ON/OFF] Displays status (Unlocked: ON/Others: OFF) as judged from unlock signal. (Unlocked by Multi-Remote control system) I-KEY LOCK (*1) [ON/OFF] Displays status (Locked: ON/Others: OFF) as judged from lock signal. (Locked by Intelligent Key system) I-KEY UNLOCK (*1) [ON/OFF] Displays status (Unlocked: ON/Others: OFF) as judged from unlock signal. (Unlocked by Intelligent Key system) I-KEY ALL UNL (*1) [ON/OFF] Displays status (Unlocked: ON/Others: OFF) as judged from unlock signal. (Unlocked by Intelligent Key system) *1: Displayed for models with Intelligent Key system. *2: Displayed for models without Intelligent Key system. ACTIVE TEST Test item INT LAMP Description Interior room lamp can be operated by any ON-OFF operations. LT-166 INTERIOR ROOM LAMP Map Lamp Control Does Not Operate BKS001GW 1. CHECK EACH SWITCH A 1. Select “BCM” on CONSULT-II. Select “INT LAMP” on “SELECT TEST ITEM” screen. 2. Select “DATA MONITOR” on “SELECT DIAG MODE” screen. Make sure switches listed in display item list turn ON-OFF linked with switch operation. OK or NG OK >> GO TO 2. NG >> Inspect malfunctioning switch system. B C D PKIB0263E E 2. ACTIVE TEST 1. 2. 3. Select “BCM” on CONSULT-II. Select “INT LAMP” on “SELECT TEST ITEM” screen. Select “ACTIVE TEST” on “SELECT DIAG MODE” screen. Select “INT LAMP” on “SELECT TEST ITEM” screen. When map lamp switch is in DOOR position, make sure map lamp operates. F G Map lamp should operate. H OK or NG OK >> Replace BCM. Refer to BCS-17, "Removal and Installation of BCM" . NG >> GO TO 3. PKIA6881E 3. CHECK MAP LAMP INPUT VOLTAGE 1. 2. 3. J Turn ignition switch OFF. Disconnect map lamp connector. Check voltage between map lamp harness connector R3 terminal 4 and ground. 4 - Ground I LT : Battery voltage. L OK or NG OK >> GO TO 5. NG >> GO TO 4. M MKIB2250E LT-167 INTERIOR ROOM LAMP 4. CHECK MAP LAMP INPUT CIRCUIT 1. 2. Disconnect BCM connector. Check continuity between BCM harness connector (A) terminal and map lamp harness connector (B). A 3. B Continuity Connector Terminal Connector Terminal M59 73 R3 4 Yes Check continuity between BCM harness connector (A) and ground. A Continuity Connector Terminal M59 73 Ground MKIB2280E No OK or NG OK >> Replace BCM. Refer to BCS-17, "Removal and Installation of BCM" . NG >> Repair harness or connector. 5. CHECK MAP LAMP 1. Check continuity between map lamp terminals. Terminal Condition Map lamp 2 4 Continuity Map lamp switch is DOOR Yes Other than above No OK or NG OK >> GO TO 6. NG >> Replace map lamp or check bulb. MKIB2251E 6. CHECK CIRCUIT BETWEEN MAP LAMP AND BCM 1. 2. Disconnect BCM connector. Check continuity between BCM harness connector (A) and map lamp harness connector (B). A 3. B Continuity Connector Terminal Connector Terminal M57 21 R3 2 Yes Check continuity between BCM harness connector (A) and ground. A Continuity Connector Terminal M57 21 Ground MKIB2281E No OK or NG OK >> Replace BCM if map lamp does not work after setting the connector again. Refer to BCS-17, "Removal and Installation of BCM" . NG >> Repair harness or connector. LT-168 INTERIOR ROOM LAMP Personal Lamp Control Does Not Operate (Models With Personal Lamp) BKS0026H 1. CHECK EACH SWITCH A 1. Select “BCM” on CONSULT-II. Select “INT LAMP” on “SELECT TEST ITEM” screen. 2. Select “DATA MONITOR” on “SELECT DIAG MODE” screen. Make sure switches listed in display item list turn ON-OFF linked with switch operation. OK or NG OK >> GO TO 2. NG >> Inspect malfunctioning switch system. B C D PKIB0263E E 2. ACTIVE TEST 1. 2. 3. Select “BCM” on CONSULT-II. Select “INT LAMP” on “SELECT TEST ITEM” screen. Select “ACTIVE TEST” on “SELECT DIAG MODE” screen. Select “INT LAMP” on “SELECT TEST ITEM” screen. When personal lamp switch is in DOOR position, make sure personal lamp operates. F G Personal lamp should operate. H OK or NG OK >> Replace BCM. Refer to BCS-17, "Removal and Installation of BCM" . NG >> GO TO 3. PKIA6881E 3. CHECK PERSONAL LAMP INPUT VOLTAGE 1. 2. 3. J Turn ignition switch OFF. Disconnect personal lamp connector. Check voltage between personal lamp harness connector R4 terminal 4 and ground. 4 - Ground I LT : Battery voltage. L OK or NG OK >> GO TO 5. NG >> GO TO 4. M MKIB2250E LT-169 INTERIOR ROOM LAMP 4. CHECK PERSONAL LAMP INPUT CIRCUIT 1. 2. Disconnect BCM connector. Check continuity between BCM harness connector (A) terminal and personal lamp harness connector (B). A 3. B Continuity Connector Terminal Connector Terminal M59 73 R4 4 Yes Check continuity between BCM harness connector (A) and ground. A Continuity Connector Terminal M59 73 Ground MKIB2280E No OK or NG OK >> Replace BCM. Refer to BCS-17, "Removal and Installation of BCM" . NG >> Repair harness or connector. 5. CHECK PERSONAL LAMP 1. Check continuity between personal lamp terminals. Terminal Condition Personal lamp 2 4 Continuity Personal lamp switch is DOOR Yes Other than above No OK or NG OK >> GO TO 6. NG >> Replace personal lamp or check bulb. MKIB2251E 6. CHECK CIRCUIT BETWEEN PERSONAL LAMP AND BCM 1. 2. Disconnect BCM connector. Check continuity between BCM harness connector (A) and personal lamp harness connector (B). A 3. B Continuity Connector Terminal Connector Terminal M57 21 R4 2 Yes Check continuity between BCM harness connector (A) and ground. A Continuity Connector Terminal M57 21 Ground MKIB2281E No OK or NG OK >> Replace BCM if personal lamp does not work after setting the connector again. Refer to BCS-17, "Removal and Installation of BCM" . NG >> Repair harness or connector. LT-170 INTERIOR ROOM LAMP Bulb Replacement BKS001GX A MAP LAMP, PERSONAL LAMP 1. 2. Remove lamp lens. Refer to LT-171, "MAP LAMP, PERSONAL LAMP" . Remove bulb. Map lamp : 12V - 5W Personal lamp : 12V - 5W B C D MKIB2296E E LUGGAGE LOOM LAMP 1. 2. Remove luggage room lamp lens. Refer to LT-172, "LUGGAGE ROOM LAMP" . Remove bulb. Luggage room lamp F : 12V - 10W G H MKIB2299E Removal and Installation BKS001GY MAP LAMP, PERSONAL LAMP Removal 1. I J Insert a screwdriver A or the like wrapped in a cloth into the lens notch and remove lamp lens (1). LT L M MKIB2202E 2. 3. Pull the lamp (1) out forward while shifting the tabs with a screwdriver A or similar tool. Disconnect lamp connector. MKIB2295E Installation Installation is the reverse order of removal. LT-171 INTERIOR ROOM LAMP LUGGAGE ROOM LAMP Removal 1. 2. Pull the luggage room lamp. Disconnect luggage room lamp connector. MKIB2298E Installation Installation is the reverse order of removal. LT-172 ILLUMINATION ILLUMINATION System Description PFP:27545 A BKS001GZ The control of the illumination lamps operation is dependent upon the position of the lighting switch. When the lighting switch is placed in the 1ST or 2ND position (or if the auto light system is activated) BCM (body control B module) receives input signal requesting the illumination lamps to illuminate. This input signal is communicated to IPDM E/R (intelligent power distribution module engine room) across CAN communication lines. CPU (central processing unit) located in the IPDM E/R controls the tail lamp relay coil. This relay, when energized, C directs power to the illumination lamps, which then illuminate. Power is supplied at all times ● to ignition relay, located in IPDM E/R and D ● to tail lamp relay, located in IPDM E/R, from battery directly, ● through 20A fuse (No. 61, located in IPDM E/R), ● through 20A fuse (No. 62, located in IPDM E/R), E ● through 40A fusible link (letter J, located in fuse, fusible link and relay box) ● to BCM terminals 74 and 79 ● to power window main switch (illumination) terminal F 5 [with front power window (LHD models)], 6 [with front power window (RHD models)] or 19 (with front & rear power window), G ● through 10A fuse [No. 9, located in fuse block (J/B)] ● to BCM terminal 72, ● through 10A fuse [No. 7, located in fuse block (J/B)] H ● to combination meter terminal 27. With the ignition switch in the ON or START position, power is supplied I ● to ignition relay, located in IPDM E/R, ● through 10A fuse [No. 5, located in fuse block (J/B)] ● to BCM terminal 24 and J ● through 10A fuse [No. 4, located in fuse block (J/B)] ● to combination meter terminal 28. Ground is supplied LT ● to BCM terminals 2 and 70 ● to combination meter terminals 21, 22 and 23 ● to power window main switch (illumination) terminal L 12 (with front power window) or 17 (with front & rear power window) ● through grounds M21 and M66, M ● to IPDM E/R terminals 3 and 54 ● through grounds E45 (CR and HR engine models), E28 and E44. ILLUMINATION OPERATION BY LIGHTING SWITCH With the lighting switch in the 1ST or 2ND position (or if the auto light system is activated), BCM receives input signal requesting the illumination lamps to illuminate. This input signal is communicated to IPDM E/R across CAN communication lines. CPU located in the IPDM E/R controls the tail lamp relay coil, which, when energized, directs power ● through 10A fuse (No. 46, located in IPDM E/R), ● through IPDM E/R terminal 15 ● to door lock/unlock switch (illumination) terminal 4 ● to heated seat switch RH and LH (illumination) terminal 5 (with heated seat) ● through 10A fuse (No. 45, located in IPDM E/R), ● through IPDM E/R terminal 16 ● to audio unit (illumination) terminal 36 (with audio) ● to heater control panel (illumination) terminal 5 (without auto A/C) LT-173 ILLUMINATION to A/C auto amplifier (illumination) terminal 16 (with auto A/C) to mirror control switch (illumination) terminal 10 (with retract) ● to hazard switch (illumination) terminal 3 ● to power socket for cigarette lighter (illumination) terminal 3 ● to headlamp aiming switch (illumination) terminal 3 ● to A/T device (illumination) terminal 3 (with A/T) ● to ESP OFF switch (illumination) terminal 3 (with ESP) ● to headlamp washer switch (illumination) terminal 3 (with headlamp washer). Ground is supplied ● to door lock/unlock switch (illumination) terminal 3 ● to audio unit (illumination) terminal 4 (with audio) ● to heater control panel (illumination) terminal 6 (without auto A/C) ● to A/C auto amplifier (illumination) terminal 5 (with auto A/C) ● to mirror control switch (illumination) terminal 3 (with retract) ● to hazard switch (illumination) terminal 4 ● to power socket for cigarette lighter (illumination) terminal 2 ● to headlamp aiming switch (illumination) terminal 4 ● to A/T device (illumination) terminal 4 (with AT) ● to ESP OFF switch (illumination) terminal 4 (with ESP) ● to headlamp washer switch (illumination) terminal 4 (with headlamp washer) ● through grounds M21and M66, ● to heated seat switch RH and LH (illumination) terminal 6 (with heated seat) ● through grounds B13,B28,B38 and B48 With power and ground supplied, illumination lamps illuminate. ● ● EXTERIOR LAMP BATTERY SAVER CONTROL Refer to LT-9, "EXTERIOR LAMP BATTERY SAVER CONTROL" . CAN Communication System Description BKS001H0 CAN (Controller Area Network) is a serial communication line for real time application. It is an on-vehicle multiplex communication line with high data communication speed and excellent error detection ability. Many electronic control units are equipped onto a vehicle, and each control unit shares information and links with other control units during operation (not independent). In CAN communication, control units are connected with 2 communication lines (CAN H line, CAN L line) allowing a high rate of information transmission with less wiring. Each control unit transmits/receives data but selectively reads required data only. CAN Communication Unit BKS001H1 Refer to LAN-27, "CAN Communication Unit" . LT-174 ILLUMINATION Schematic BKS001H2 A B C D E F G H I J LT L M MKWA4370E LT-175 ILLUMINATION Wiring Diagram — ILL — BKS001H3 MKWA4371E LT-176 ILLUMINATION A B C D E F G H I J LT L M MKWA4372E LT-177 ILLUMINATION MKWA4373E LT-178 ILLUMINATION A B C D E F G H I J LT L M MKWA4374E LT-179 ILLUMINATION MKWA4375E LT-180 ILLUMINATION A B C D E F G H I J LT L M MKWA4376E LT-181 ILLUMINATION MKWA4377E LT-182 BULB SPECIFICATIONS BULB SPECIFICATIONS Headlamp PFP:26297 A BKS001H5 Item Wattage (W) High/Low (Halogen type) Exterior Lamp BKS001H6 Item Rear combination lamp C Wattage (W) Turn signal lamp Front combination lamp B 60/55 (H4) 21 (amber) Parking lamp 5 Stop/Tail lamp 21/5 Turn signal lamp D 16 (amber) Back-up lamp E 16 Front fog lamp 35 (H8) Side turn signal lamp 5 Rear fog lamp 21 License plate lamp 5 High-mounted stop lamp 16 Interior Lamp/Illumination F G BKS001H7 Item Wattage (W) Map lamp 5 Personal lamp 5 Luggage room lamp 10 H I J LT L M LT-183 BULB SPECIFICATIONS LT-184 ENGINE LUBRICATION SYSTEM B ENGINE SECTION LU ENGINE LUBRICATION SYSTEM A LU C D E CONTENTS CR HR PRECAUTIONS .......................................................... 3 Precautions For Liquid Gasket ................................. 3 REMOVAL OF LIQUID GASKET SEALING .......... 3 LIQUID GASKET APPLICATION PROCEDURE..... 3 PREPARATION ........................................................... 4 Special Service Tools ............................................... 4 Commercial Service Tool ......................................... 4 LUBRICATION SYSTEM ............................................ 5 Lubrication Circuit .................................................... 5 ENGINE OIL ............................................................... 6 Inspection ................................................................. 6 OIL LEVEL AND CONTAMINATION ..................... 6 OIL LEAK .............................................................. 6 OIL PRESSURE CHECK ...................................... 6 Changing Engine Oil ................................................ 7 OIL FILTER ................................................................. 9 Removal and Installation .......................................... 9 REMOVAL ............................................................. 9 INSTALLATION ..................................................... 9 INSPECTION AFTER INSTALLATION ................. 9 OIL PUMP ................................................................. 10 Removal and Installation ........................................ 10 REMOVAL ........................................................... 10 INSTALLATION ................................................... 10 Disassembly and Assembly ................................... 10 DISASSEMBLY ................................................... 10 INSPECTION AFTER DISASSEMBLY ............... 10 ASSEMBLY ..........................................................11 SERVICE DATA AND SPECIFICATIONS (SDS) ...... 12 Standard and Limit ................................................. 12 OIL PRESSURE .................................................. 12 OIL PUMP ........................................................... 12 OIL CAPACITY .................................................... 12 TIGHTENING TORQUE ...................................... 12 PRECAUTIONS ........................................................ 13 Precautions for Liquid Gasket ................................ 13 REMOVAL OF LIQUID GASKET SEALING ........ 13 LIQUID GASKET APPLICATION PROCEDURE... 13 PREPARATION ......................................................... 14 Special Service Tools ............................................. 14 Commercial Service Tool ........................................ 14 LUBRICATION SYSTEM .......................................... 15 Lubrication Circuit ................................................... 15 ENGINE OIL .............................................................. 16 Inspection ............................................................... 16 OIL LEVEL AND CONTAMINATION ................... 16 ENGINE OIL LEAKAGE ...................................... 16 OIL PRESSURE CHECK .................................... 16 Changing Engine Oil ............................................... 17 OIL FILTER ............................................................... 19 Removal and Installation ........................................ 19 REMOVAL ........................................................... 19 INSTALLATION ................................................... 19 INSPECTION AFTER INSTALLATION ................ 19 SERVICE DATA AND SPECIFICATIONS (SDS) ...... 20 Standard and Limit .................................................. 20 OIL PRESSURE .................................................. 20 OIL CAPACITY (APPROXIMATE) ....................... 20 TIGHTENING TORQUE ...................................... 20 K9K PRECAUTIONS ........................................................ 21 Precautions For Liquid Gasket ............................... 21 REMOVAL OF LIQUID GASKET ......................... 21 LIQUID GASKET APPLICATION PROCEDURE... 21 PREPARATION ......................................................... 22 Special Service Tools ............................................. 22 ENGINE OIL .............................................................. 23 Inspection ............................................................... 23 OIL LEVEL AND MUDDINESS ........................... 23 OIL LEAKAGE ..................................................... 23 LU-1 F G H I J K L M OIL PRESSURE CHECK .................................... 23 Changing Engine Oil ............................................... 24 OIL FILTER ............................................................... 25 Removal and Installation ........................................ 25 REMOVAL ........................................................... 25 INSTALLATION .................................................... 25 OIL PUMP ................................................................. 26 Removal and Installation ........................................ 26 REMOVAL ........................................................... 26 INSTALLATION .................................................... 26 OIL COOLER .............................................................27 Removal and Installation .........................................27 REMOVAL ............................................................27 INSPECTION .......................................................27 INSTALLATION ....................................................27 SERVICE DATA AND SPECIFICATIONS (SDS) ......29 Standard and Limit ..................................................29 OIL PRESSURE ..................................................29 OIL CAPACITY (APPROXIMATE) .......................29 TIGHTENING TORQUE ......................................29 LU-2 PRECAUTIONS [CR] PRECAUTIONS Precautions For Liquid Gasket [CR] PFP:00001 A BBS002R5 REMOVAL OF LIQUID GASKET SEALING After removing the mounting bolts and nuts, separate the mating surface using a seal cutter and remove the liquid gasket. CAUTION: Be careful not to damage the mating surfaces. ● In areas where the seal cutter is difficult to use, use a plastic hammer to lightly tap the gasket area. CAUTION: If for some unavoidable reason a tool such as a flat-bladed screwdriver is used, be careful not to damage the mating surfaces. ● LU C D PBIC0275E E LIQUID GASKET APPLICATION PROCEDURE 1. ● 2. 3. Using a scraper, remove the old liquid gasket adhering to the gasket application surface and the mating surface. Remove the liquid gasket completely from the groove of the gasket application surface, mounting bolts and bolt holes. Wipe the gasket application surface and the mating surface with white gasoline (lighting and heating use) to remove adhering moisture, grease and foreign materials. Attach the liquid gasket to the tube presser. Use Genuine Liquid Gasket or equivalent. F G H PBIC0003E I 4. ● Apply the gasket without breaks to the specified location with the specified dimensions. If there is a groove for the liquid gasket application, apply the gasket to the groove. J K L EMA0622D As for the bolt holes, normally apply the gasket inside the holes. Occasionally, it should be applied outside the holes. Make sure to read the instruction in this manual. ● Within five minutes of gasket application, install the mating component. ● If the liquid gasket protrudes, wipe it off immediately. ● Do not retighten after the installation. ● After 30 minutes or more have passed from the installation, fill the engine oil and coolant. CAUTION: If there are additional instructions in this manual, observe them. M ● LU-3 SEM164F PREPARATION [CR] PREPARATION Special Service Tools PFP:00002 BBS002R6 Tool number Tool name Description ST25051001 Oil pressure gauge Measuring oil pressure Maximum measuring range: 2,452 kPa (24.5 bar, 25 kg/cm2 , 356 psi) S-NT050 ST25052000 Hose Adapting oil pressure gauge to cylinder block S-NT559 KV10115801 Oil filter wrench Removing oil filter S-NT772 WS39930000 Tube presser Pressing the tube of liquid gasket S-NT052 Commercial Service Tool BBS002R7 Tool name Description Deep socket Removing and installing oil pressure switch a: 24 mm (0.94 in) PBIC2072E LU-4 LUBRICATION SYSTEM [CR] LUBRICATION SYSTEM Lubrication Circuit PFP:15010 A BBS002R8 LU C D E F G H I J K L M PBIC1465E LU-5 ENGINE OIL [CR] ENGINE OIL Inspection PFP:KLA92 BBS002R9 OIL LEVEL AND CONTAMINATION ● ● ● ● ● ● Before starting the engine, put vehicle horizontally and check the oil level. If the engine is already started, stop it and allow 10 minutes before checking. Check that the oil level is within the range shown in the figure. If oil level is outside the range, adjust level. Check the oil for white turbidity or remarkable contamination. If the oil becomes turbid and white, it is highly probable that it is contaminated with coolant. Find the cause and repair. When oil level gauge is inserted in guide, apply engine oil to rubber seal of grip. PBIC1466E OIL LEAK Check the following parts for engine oil leaks. ● Oil pan ● Oil pan drain plug ● Oil pressure switch ● Oil filter ● Front cover ● Cylinder head front cover ● Mating surfaces of cylinder block and cylinder head ● Mating surfaces of cylinder head and rocker cover ● Crankshaft oil seals (front and rear) OIL PRESSURE CHECK WARNING: ● Be careful not to burn yourself, as the engine oil is hot. ● Oil pressure check should be done in Neutral position. 1. Check the engine oil level. Refer to LU-6, "OIL LEVEL AND CONTAMINATION" 2. Remove oil filter. Refer to LU-9, "OIL FILTER" . 3. Remove oil pressure switch using a deep socket (commercial service tool). PBIC1467E LU-6 ENGINE OIL [CR] 4. 5. 6. Install oil pressure gauge and hose (SST). Install oil filter. Refer to LU-9, "OIL FILTER" . After warming up the engine, check that oil pressure corresponding to the engine speed is produced. NOTE: Low oil temperature creates high pressure. A LU C SLC926-A D Engine oil pressure [When oil temperature is 80 °C (176 °F)] Engine speed (rpm) Idle speed Engine oil pressure Approx. 44.1 (0.441, 0.45, 6.4) or more kPa (bar, kg/cm2 , psi) 2,000 Approx. 265 (2.65, 2.7, 38) or more 6,000 Approx. 373 (3.73, 3.8, 54) or more E If difference is extreme, check oil passage and oil pump for oil leaks. 7. a. b. F After checking the oil pressure, install oil pressure switch as follows: Remove old liquid gasket on the switch and engine. Apply liquid gasket and tighten oil pressure switch to specification. Use Genuine Liquid Gasket or equivalent. G : 18.7 - 20.5 N·m (1.9 - 2.0 kg-m, 14 - 15 ft-lb) H CAUTION: Be careful not to get burned when engine or engine oil is heated. Changing Engine Oil BBS002RA WARNING: ● Be careful not to burn yourself, as the engine oil is hot. ● Prolonged and repeated contact with used engine oil may cause skin cancer: try to avoid direct skin contact with used oil. If skin contact is made, wash thoroughly with soap or hand cleaner as soon as possible. 1. Warm up engine, and check for oil leakage from engine components. Refer to LU-6, "OIL LEAK" . 2. Stop engine and wait for 10 minutes. 3. Remove oil filler cap, and remove drain plug. 4. Drain engine oil. 5. Install drain plug with new washer. Refer to EM-26, "OIL PAN AND OIL STRAINER" . CAUTION: ● Be sure to clean drain plug and install with new washer. Oil pan drain plug: : 29.4 - 39.2 N·m (3.0 - 3.9 kg-m, 22 - 28 ft-lb) Engine oil specification and viscosity: Refer to MA-24, "RECOMMENDED FLUIDS AND LUBRICANTS". Refill with new engine oil. ● 6. LU-7 I J K L M ENGINE OIL [CR] Oil capacity (Approximate): Unit: Drain and refill With oil filter change (Imp qt) 3.4 (3) Without oil filter change 3.2 (2-7/8) Dry engine (engine overhaul) 3.9 (3-3/8) CAUTION: ● The refill capacity depends on the oil temperature and drain time. Use these specifications for reference only. ● Always use oil level gauge to determine the proper amount of oil is in the engine. 7. Warm up engine and check area around drain plug and oil filter for oil leakage. 8. Stop engine and wait for 10 minutes. 9. Check oil level. Refer to LU-6, "OIL LEVEL AND CONTAMINATION" . LU-8 OIL FILTER [CR] OIL FILTER Removal and Installation PFP:15208 A BBS002RB REMOVAL Using an oil filter wrench (special service tool), remove oil filter. CAUTION: ● Oil filter is provided with relief valve. Use genuine NISSAN oil filter or equivalent. ● Be careful not to get burned when the engine and engine oil are hot. ● When removing, prepare a shop cloth to absorb any oil leakage or spillage. ● Do not allow engine oil to adhere to the drive belts. ● Completely wipe off any oil that adheres to the engine and vehicle. LU C D PBIC1469E E INSTALLATION 1. 2. Remove foreign materials adhering to the oil filter installation surface. Apply engine oil to the oil seal circumference of the new oil filter. CAUTION: ● Use genuine NISSAN oil filter or the equivalent. F G H I SMA010 3. Screw the oil filter manually until it touches the installation surface, then tighten it by 2/3 turn. J Oil filter: K :11 - 14 N·m (1.2 - 1.4 kg-m, 9 - 10 ft-lb) L SMA229B INSPECTION AFTER INSTALLATION 1. 2. 3. 4. Check the engine oil level. Refer to LU-6, "OIL LEVEL AND CONTAMINATION" . After warming up the engine, check for engine oil leakage. Stop engine and wait for 10 minutes. Check the engine oil level. Refer to LU-6, "OIL LEVEL AND CONTAMINATION" LU-9 M OIL PUMP [CR] OIL PUMP Removal and Installation PFP:15010 BBS002RC REMOVAL ● Remove front cover. Refer to EM-50, "TIMING CHAIN" . INSTALLATION ● Install in the reverse order of removal. Disassembly and Assembly BBS002RD MBIB1233E 1. Front cover 4. Oil pump cover 2. Inner rotor 3. Outer rotor CAUTION: Prior to installation, apply new engine oil to the parts marked in figure. DISASSEMBLY 1. 2. Remove oil pump cover. Remove outer rotor and inner rotor from front cover. INSPECTION AFTER DISASSEMBLY Clearances of Oil Pump Parts ● Measure clearance with feeler gauge and straightedge. Side clearance between inner rotor and front cover (position 1). Standard : 0.025 - 0.075 mm (0.0010 - 0.0030 in) Side clearance between outer rotor and front cover (position 2). Standard : 0.025 - 0.075 mm (0.0010 - 0.0030 in) PBIC1472E ● Calculate the clearance from inner rotor to front cover socket with the following procedures. LU-10 OIL PUMP [CR] 1. Using a micrometer, measure the outer diameter of inner rotor protrusion (Position 3). A LU C PBIC1473E D 2. Using an inside micrometer, measure the inner diameter of front cover. (Position 4) (Clearance) = (Inner diameter of front cover) - (outer diameter of inner rotor protrusion) Standard E : 0.045 - 0.095 mm (0.0011 - 0.0037 in) F G PBIC1474E ASSEMBLY H Install in the reverse order of disassembly. I J K L M LU-11 SERVICE DATA AND SPECIFICATIONS (SDS) [CR] SERVICE DATA AND SPECIFICATIONS (SDS) Standard and Limit PFP:00030 BBS002RE OIL PRESSURE Engine speed rpm Approximate discharge pressure kPa (bar, kg/cm2 , psi) Idle speed 2,000 6,000 Approx. 44.1 (0.441, 0.45, 6.4) or more Approx. 265 (2.65, 2.7, 38) or more Approx. 373 (3.73, 3.8, 54) or more OIL PUMP Unit: mm (in) Body to inner rotor axial clearance 0.025 - 0.075 (0.0010 - 0.0030) Body to outer rotor axial clearance 0.025 - 0.075 (0.0010 - 0.0030) Inner rotor to brazed portion of housing clearance 0.045 - 0.095 (0.0018 - 0.0037) OIL CAPACITY Unit: With oil filter change (Imp qt) Approximately 3.4 (3) Without oil filter change Approximately 3.2 (2-7/8) Dry engine (engine overhaul) Approximately 3.9 (3-3/8) TIGHTENING TORQUE Oil pressure switch Unit: N·m (kg-m, ft-lb) Unit: N·m (kg-m, in-lb)* 18.7 - 20.5 (1.9 - 2.0, 14 - 15) Oil pan drain plug 29.4 - 39.2 (3.0 - 3.9, 22 - 28) Oil filter 11 - 14 (1.2 - 1.4, 9 - 10) Oil pump cover 6.3 - 8.3 (0.65 - 0.84, 56 - 73)* LU-12 PRECAUTIONS [HR] PRECAUTIONS Precautions for Liquid Gasket [HR] PFP:00001 A BBS002RF REMOVAL OF LIQUID GASKET SEALING After removing the mounting bolts and nuts, separate the mating surface using a seal cutter and remove the liquid gasket. CAUTION: Be careful not to damage the mating surfaces. ● In areas where the seal cutter is difficult to use, use a plastic hammer to lightly tap the gasket area. CAUTION: If for some unavoidable reason a tool such as a flat-bladed screwdriver is used, be careful not to damage the mating surfaces. ● LU C D PBIC0275E E LIQUID GASKET APPLICATION PROCEDURE 1. ● 2. 3. Using a scraper, remove the old liquid gasket adhering to the gasket application surface and the mating surface. Remove the liquid gasket completely from the groove of the gasket application surface, mounting bolts and bolt holes. Wipe the gasket application surface and the mating surface with white gasoline (lighting and heating use) to remove adhering moisture, grease and foreign materials. Attach the liquid gasket to the tube presser. Use Genuine Liquid Gasket or equivalent. F G H PBIC0003E I 4. ● Apply the gasket without breaks to the specified location with the specified dimensions. If there is a groove for the liquid gasket application, apply the gasket to the groove. J K L EMA0622D As for the bolt holes, normally apply the gasket inside the holes. Occasionally, it should be applied outside the holes. Make sure to read the instruction in this manual. ● Within five minutes of gasket application, install the mating component. ● If the liquid gasket protrudes, wipe it off immediately. ● Do not retighten after the installation. ● After 30 minutes or more have passed from the installation, fill the engine oil and coolant. CAUTION: If there are additional instructions in this manual, observe them. M ● LU-13 SEM164F PREPARATION [HR] PREPARATION Special Service Tools PFP:00002 BBS002RG Tool number Tool name Description ST25051001 Oil pressure gauge Measuring oil pressure Maximum measuring range: 2,452 kPa (24.52 bar, 25 kg/cm2 , 356 psi) S-NT050 ST25052000 Hose Adapting oil pressure gauge to cylinder block S-NT559 KV10115801 Oil filter wrench Removing and installing oil filter a: 64.3 mm (2.531 in) S-NT375 WS39930000 Tube presser Pressing the tube of liquid gasket S-NT052 Commercial Service Tool BBS002RH Tool name Description Deep socket Removing and installing oil pressure switch a: 27 mm (1.06 in) PBIC2072E LU-14 LUBRICATION SYSTEM [HR] LUBRICATION SYSTEM Lubrication Circuit PFP:15010 A BBS002RI LU C D E F G H I J K L M PBIC3819E LU-15 ENGINE OIL [HR] ENGINE OIL Inspection PFP:KLA92 BBS002RJ OIL LEVEL AND CONTAMINATION ● ● ● ● ● ● Before starting the engine, put vehicle horizontally and check the oil level. If the engine is already started, stop it and allow 10 minutes before checking. Check that the oil level is within the range shown in the figure. If oil level is outside the range, adjust level. Check the oil for white turbidity or remarkable contamination. If the oil becomes turbid and white, it is highly probable that it is contaminated with coolant. Find the cause and repair. When oil level gauge is inserted in guide, apply engine oil to rubber seal of grip. PBIC1466E ENGINE OIL LEAKAGE Check for engine oil leakage around the following area. ● Oil pan (upper and lower) ● Oil pan drain plug ● Oil pressure switch ● Oil filter ● Intake valve timing control solenoid valve ● Front cover ● Mating surface between cylinder block and cylinder head ● Mating surface between cylinder head and rocker cover ● Crankshaft oil seals (front and rear) ● Oil filter (for intake valve timing control) OIL PRESSURE CHECK WARNING: ● Be careful not to burn yourself, as engine oil may be hot. ● Engine oil pressure check should be in Neutral position and should apply parking brake securely. 1. Check oil level. Refer to LU-16, "OIL LEVEL AND CONTAMINATION" 2. Remove oil filter. Refer to LU-19, "OIL FILTER" . 3. Disconnect harness connector at oil pressure switch (2), and remove oil pressure switch using a deep socket (commercial service tool). 1 Cylinder block 3. Oil level sensor MBIB1356E LU-16 ENGINE OIL [HR] 4. Install oil pressure gauge and hose (SST). A LU C SLC926-A D 5. 6. 7. 8. Install oil filter. Refer to LU-19, "OIL FILTER" . Check engine oil level. Refer to LU-16, "OIL LEVEL AND CONTAMINATION" . Start engine and warm it up to normal operating temperature. Check oil pressure with engine running under no-load. NOTE: When engine oil temperature is low, engine oil pressure becomes high. E F Engine oil pressure [Engine oil temperature at 80°C (176°F)] 9. a. b. c. Engine speed rpm Approximate discharge pressure Idle speed More than 60 (0.60, 0.61, 9) 2,000 More than 275 (2.7, 2.8, 40) G kPa (bar, kg/cm2 , psi) H If difference is extreme, check oil passage and oil pump for oil leaks. After the inspections, install oil pressure switch as follows: Remove oil filter. Refer to LU-19, "OIL FILTER" . Remove old liquid gasket adhering to oil pressure switch and engine. Apply liquid gasket and tighten oil pressure switch to specification. Use Genuine Liquid Gasket or equivalent. I J : 19.6 N·m (2.0 kg-m, 14 ft-lb) d. e. f. K Install oil filter. Refer to LU-19, "OIL FILTER" . Check engine oil level. Refer to LU-16, "OIL LEVEL AND CONTAMINATION" . After warming up engine, make sure there is no leaks of engine oil with running engine. Changing Engine Oil L BBS002RK WARNING: ● Be careful not to burn yourself, as engine oil may be hot. ● Prolonged and repeated contact with used engine oil may cause skin cancer; try to avoid direct skin contact with used engine oil. If skin contact is made, wash thoroughly with soap or hand cleaner as soon as possible. 1. Warm up engine, put vehicle horizontally and check for engine oil leakage from engine components. Refer to LU-16, "ENGINE OIL LEAKAGE" . 2. Stop engine and wait for 10 minutes. 3. Loosen oil filler cap and then remove drain plug. 4. Drain engine oil. 5. Install drain plug with new washer. Refer to EM-127, "OIL PAN AND OIL STRAINER" . CAUTION: Be sure to clean drain plug and install with new washer. Oil pan drain plug: : 34.3 N·m (3.5 kg-m, 25 ft-lb) LU-17 M ENGINE OIL [HR] 6. Refill with new engine oil. Engine oil specification and viscosity: Refer to MA-24, "RECOMMENDED FLUIDS AND LUBRICANTS" . Engine oil capacity (Approximate): Unit: With oil filter change Drain and refill 4.6 (4) Without oil filter change 4.4 (3-7/8) Dry engine (Overhaul) 7. 8. 9. (lmp qt) 4.8 (4-1/4) CAUTION: ● The refill capacity depends on the engine oil temperature and drain time. Use these specifications for reference only. ● Always use oil level gauge to determine the proper amount of engine oil in the engine. Warm up engine and check area around drain plug and oil filter for engine oil leakage. Stop engine and wait for 10 minutes. Check the engine oil level. Refer to LU-16, "OIL LEVEL AND CONTAMINATION" . LU-18 OIL FILTER [HR] OIL FILTER Removal and Installation PFP:15208 A BBS002RL REMOVAL Using oil filter wrench (SST: KV10115801) (A), remove oil filter. LU : Vehicle font CAUTION: ● Oil filter is provided with relief valve. Use Genuine NISSAN oil filter or equivalent. ● Be careful not to get burned when engine and engine oil may be hot. ● When removing, prepare a shop cloth to absorb any engine oil leakage or spillage. ● Do not allow engine oil to adhere to drive belt. ● Completely wipe off any engine oil that adheres to engine and vehicle. C D MBIB1357E INSTALLATION 1. 2. E F Remove foreign materials adhering to the oil filter installation surface. Apply new engine oil to the oil seal contact surface of new oil filter. CAUTION: Use genuine NISSAN oil filter or the equivalent. G H I SMA010 3. J Screw oil filter manually until it touches the installation surface, then tighten it by 2/3 turn. Or tighten to specification. Oil filter: K : 17.7 N·m (1.8 kg-m, 13 ft-lb) L M SMA229B INSPECTION AFTER INSTALLATION 1. 2. 3. 4. Check the engine oil level. Refer to LU-16, "OIL LEVEL AND CONTAMINATION" . Start engine, and make sure there is no leaks of engine oil. Stop engine and wait for 10 minutes. Check the engine oil level. Refer to LU-16, "OIL LEVEL AND CONTAMINATION" . LU-19 SERVICE DATA AND SPECIFICATIONS (SDS) [HR] SERVICE DATA AND SPECIFICATIONS (SDS) Standard and Limit PFP:00030 BBS002RM OIL PRESSURE Engine speed rpm Approximate discharge pressure kPa (bar, kg/cm2 , psi) Idle speed 2,000 60 (0.60, 0.61, 9) 275 (2.7, 2.8, 40) OIL CAPACITY (APPROXIMATE) Unit: With oil filter change ·(Imp qt) 4.6 (4 Imp qt) Without oil filter change 4.4 (3-7/8 Imp qt) Dry engine (overhaul) 4.8 (4-1/4 Imp qt) TIGHTENING TORQUE Unit: N·m (kg-m, ft-lb) Oil pressure switch 19.6 (2.0, 14) Oil pan drain plug 34.3 (3.5, 25) Oil filter 17.7 (1.8, 13) LU-20 PRECAUTIONS [K9K] PRECAUTIONS Precautions For Liquid Gasket [K9K] PFP:00001 A BBS002RO REMOVAL OF LIQUID GASKET ● ● After removing the mounting bolts and nuts, separate the mating surface using a seal cutter and remove the liquid gasket. CAUTION: Be careful not to damage the mating surfaces. In areas where the cutter is difficult to use, use a plastic hammer to lightly tap the gasket applied area. CAUTION: If for some unavoidable reason a tool such as a flat-bladed screwdriver is used, be careful not to damage the mating surfaces. LU C D PBIC0275E E LIQUID GASKET APPLICATION PROCEDURE 1. 2. 3. Using a scraper, remove the old liquid gasket adhering to the gasket application surface and the mating surface. ● Remove the liquid gasket completely from the groove of the gasket application surface, mounting bolts and bolt holes. Wipe the gasket application surface and the mating surface with white gasoline (lighting and heating use) to remove adhering moisture, grease and foreign materials. Attach the liquid gasket to the tube presser. Use Genuine Liquid Gasket or equivalent. F G H PBIC0003E I 4. Apply the gasket without breaks to the specified location with the specified dimensions. ● If there is a groove for the liquid gasket application, apply the gasket to the groove. J K L EMA0622D As for the bolt holes, normally apply the gasket inside the holes. If specified, it should be applied outside the holes. Make sure to read the instruction in this manual. ● Within five minutes of gasket application, install the mating component. ● If the liquid gasket protrudes, wipe it off immediately. ● Do not retighten after the installation. ● After 30 minutes or more have passed from the installation, fill the engine oil and coolant. CAUTION: If there are instructions in this manual, observe them. ● LU-21 M SEM159F PREPARATION [K9K] PREPARATION Special Service Tools PFP:00002 BBS002RP NISSAN tool number (RENAULT tool number) Tool name Description KV113C0010 (Mot.1329) Oil filter wrench Removing and installing oil filter MBIB0369E KV113E0020 (Mot.836-05) Oil pressure gauge set Measuring oil pressure Use C, E, F. MBIB0663E WS39930000 ( — ) Tube presser Pressing the tube of liquid gasket S-NT052 LU-22 ENGINE OIL [K9K] ENGINE OIL Inspection PFP:KLA92 A BBS002RQ OIL LEVEL AND MUDDINESS ● ● ● ● ● Before starting the engine, check the oil level placing vehicle horizontally. If the engine is already started, stop it and allow 10 minutes before checking. Make sure the oil level is within the range shown in the figure. If it is out of range, adjust it. Check the oil for white turbidity or remarkable contamination. If the oil becomes turbid and white, it is highly probable that it is contaminated with coolant. Find the cause and repair. LU C D MBIB0548E E OIL LEAKAGE Check for oil leakage around the following area. ● Oil pan ● Oil pan drain plug ● Oil pressure switch ● Oil filter bracket ● Vacuum pump ● Oil pump housing ● Mating surface between cylinder block and cylinder head ● Mating surface between cylinder head and rocker cover ● Oil cooler ● Crankshaft oil seals F G H I OIL PRESSURE CHECK J WARNING: ● Be careful not to burn yourself, as the engine oil is hot. ● Oil pressure check should be done in Neutral “N” position. 1. Check the oil level. Refer to LU-23, "OIL LEVEL AND MUDDINESS" . 2. Remove engine undercover. 3. Remove the oil pressure switch to connect the oil pressure gauge (special service tool). 4. After warming up the engine, make sure oil pressure corresponding to the engine speed is produced. 5. a. b. Idle speed : Approx. 120 kPa (1.2 bar, 1.22 kg/cm2 , 17.4 psi) 3000 rpm : Approx. 350 kPa (3.5 bar, 3.57 kg/cm2 , 50.8 psi) After checking, install the oil pressure switch as follows. Remove old sealant adhering to the switch and engine. Apply thread sealant. Use Genuine Liquid Gasket or equivalent. Oil pressure switch: : 25 N·m (2.55 kg-m, 18.4 ft-lb) 6. Start engine and check for oil leakage. LU-23 K L M MBIB0549E ENGINE OIL [K9K] Changing Engine Oil BBS002RR WARNING: ● Be careful not to burn yourself, as the engine oil is hot. ● Prolonged and repeated contact with used engine oil may cause skin cancer: try to avoid direct skin contact with used oil. If skin contact is made, wash thoroughly with soap or hand cleaner as soon as possible. 1. Put vehicle horizontally. 2. Warm up engine, and check for oil leakage from engine components. 3. Stop engine and wait for 10 minutes. 4. Remove drain plug and oil filler cap. 5. Drain oil and refill with new engine oil. ● Refer to MA-24, "RECOMMENDED FLUIDS AND LUBRICANTS" . Oil capacity (Approximate): With oil filter change 4.40 (3-7/8 Imp qt) Without oil filter change 4.24 (3-3/4 Imp qt) Drain and refill Dry engine (overhaul) ● 6. 7. 8. 4.56 (4 Imp qt) The refill capacity depends on the oil temperature and drain MBIB0548E time. Use these specifications for reference only. Always use the dipstick to the determine when the proper amount of oil is in the engine. CAUTION: ● Be sure to clean drain plug and install with new washer. ● The refill capacity depends on the oil temperature and drain time. Use these specifications for reference only. Always use the dipstick to the determine when the proper amount of oil is in the engine. Warm up engine and check area around drain plug and oil filter for oil leakage. Stop engine and wait for 10 minutes. Check oil level. LU-24 OIL FILTER [K9K] OIL FILTER Removal and Installation PFP:15208 A BBS002RS LU C D E F MBIA0089E 1. Oil filter 4. Connecting bolt 2. O-ring 3. G Oil filter bracket H REMOVAL 1. Using an oil filter wrench (special service tool), remove oil filter. CAUTION: ● Be careful not to get burned when the engine and engine oil are hot. ● When removing, prepare a shop cloth to absorb any oil leakage or spillage. ● Do not allow engine oil to adhere to the drive belts. ● Completely wipe off any oil that adhere to the engine and the vehicle. I J K MBIB0551E L INSTALLATION 1. 2. 3. 4. 5. 6. 7. Remove foreign materials adhering to the oil filter installation surface. Install oil filter bracket to oil cooler. CAUTION: Install oil filter bracket, positioning lug in the hole of oil cooler. Apply engine oil to the oil seal contact surface of the new oil filter. Install the oil filter until it comes into contact with the oil seal on the engine bracket. Tighten the oil filter three-quarters of a turn by hand. After warming up the engine, check for engine oil leakage. Check oil level and add engine oil. Refer to LU-23, "ENGINE OIL" . M SMA010 LU-25 OIL PUMP [K9K] OIL PUMP Removal and Installation PFP:15010 BBS002RT MBIB0552E 1. Oil pump drive chain 2. Crankshaft sprocket 3. Oil pump assembly REMOVAL 1. 2. 3. 4. 5. 6. 7. Remove the following parts. ● Battery ground cable ● Undercover ● RH front wheel Remove right side splash cover. Remove drive belt. Refer to EM-242, "DRIVE BELTS" . Remove oil pan. Refer to EM-257, "OIL PAN" . Remove rear oil seal retainer. Refer to EM-272, "TIMING BELT" . Remove oil pump drive chain. Refer to EM-297, "Disassembly of The Bottom Engine" . Remove oil pump assembly. INSTALLATION Install in the reverse order of removal paying attention to the following. Rear Oil Seal Retainer and Oil Pump ● Refer to EM-310, "INSTALLATION OF REAR OIL SEAL RETAINER AND OIL PUMP" . LU-26 OIL COOLER [K9K] OIL COOLER Removal and Installation PFP:21305 A BBS002RU LU C D E F G H I MBIB9049E 1. Cylinder block 2. Water pipe 3. O-ring 4. Oil cooler 5. Connecting stud 6. O-ring 7. Oil filter Bracket 8. O-ring 9. Connecting bolt 11. Oil filter 12. O-ring 10. Oil pressure switch J K : To radiator lower hose : To water pump L CAUTION: ● Be careful not to get burned when the engine and engine oil are hot. ● When removing, prepare a shop cloth to absorb any oil leakage or spillage. ● Completely wipe off any oil that abhere to the engine and the vehicle. REMOVAL 1. 2. 3. 4. Drain engine coolant. Refer to CO-49, "DRAINING ENGINE COOLANT" . CAUTION: Perform when engine is cold. Remove oil filter and oil filter bracket. Refer to LU-25, "OIL FILTER" . Remove water hoses from oil cooler. Remove oil cooler. INSPECTION Oil Cooler Check oil cooler for cracks and clogging by blowing through coolant inlet. If necessary, replace oil cooler assembly. INSTALLATION Installation is in reverse order of removal. LU-27 M OIL COOLER [K9K] ● Replace the O-ring (A) of the oil cooler, positioning the lip (B) of the seal behind the lug (C) of the oil cooler. MBIB0458E ● Confirm that no foreign objects are adhering to the installation planes of the oil cooler and block. LU-28 SERVICE DATA AND SPECIFICATIONS (SDS) [K9K] SERVICE DATA AND SPECIFICATIONS (SDS) Standard and Limit PFP:00030 A BBS005AO OIL PRESSURE Engine speed rpm Approximate discharge pressure kPa (bar, kg/cm2 , psi) Idle speed 3,000 120 (1.2, 1.22, 17.4) 350 (3.5, 5.57, 50.8) LU C OIL CAPACITY (APPROXIMATE) Unit: With oil filter change 4.40 (3 - 7/8 lmp qt) Without oil filter change 4.24 (3 - 3/4 lmp qt) Dry engine (overhaul) ·(Imp qt) D 4.56 (4 Imp qt) E TIGHTENING TORQUE Unit: N·m (kg-m, ft-lb) Oil pressure switch 25 (2.55, 18.4) F G H I J K L M LU-29 SERVICE DATA AND SPECIFICATIONS (SDS) [K9K] LU-30 MAINTENANCE L MAINTENANCE SECTION MA MAINTENANCE A B C D CONTENTS PREPARATION ........................................................... 3 Special Service Tools ............................................... 3 Commercial Service Tool ......................................... 4 DESCRIPTION ............................................................ 5 Pre-delivery Inspection Items ................................... 5 GENERAL MAINTENANCE ....................................... 7 General Maintenance ............................................... 7 PERIODIC MAINTENANCE ....................................... 8 Periodic Maintenance ............................................... 8 ENGINE AND EMISSION CONTROL MAINTENANCE (CR ENGINE) .......................................... 8 CHASSIS AND BODY MAINTENANCE (CR ENGINE) ............................................................... 9 ENGINE AND EMISSION CONTROL MAINTENANCE (HR ENGINE) ........................................ 10 CHASSIS AND BODY MAINTENANCE (HR ENGINE) ..............................................................11 ENGINE AND EMISSION CONTROL MAINTENANCE (K9K ENGINE) ....................................... 12 CHASSIS AND BODY MAINTENANCE (K9K ENGINE) ............................................................. 13 MAINTENANCE UNDER SEVERE DRIVING CONDITIONS ...................................................... 14 ENGINE AND EMISSION CONTROL MAINTENANCE (CR ENGINE) ........................................ 16 CHASSIS AND BODY MAINTENANCE (CR ENGINE) ............................................................. 17 ENGINE AND EMISSION CONTROL MAINTENANCE (HR ENGINE) ........................................ 18 CHASSIS AND BODY MAINTENANCE (HR ENGINE) ............................................................. 19 ENGINE AND EMISSION CONTROL MAINTENANCE (K9K ENGINE) ....................................... 20 CHASSIS AND BODY MAINTENANCE (K9K ENGINE) ............................................................. 21 MAINTENANCE UNDER SEVERE DRIVING CONDITIONS ...................................................... 22 RECOMMENDED FLUIDS AND LUBRICANTS ...... 24 Fluids and Lubricants ............................................. 24 SAE Viscosity Number ........................................... 25 GASOLINE ENGINE ........................................... 25 DIESEL ENGINE ................................................. 25 Engine Coolant Mixture Ratio ................................. 26 ENGINE MAINTENANCE (CR) ................................. 27 Checking Drive Belts .............................................. 27 Tension Adjustment ................................................ 27 ALTERNATOR AND A/C COMPRESSOR BELT (WITH A/C MODELS) .......................................... 28 ALTERNATOR BELT (WITHOUT A/C MODELS)... 28 WATER PUMP BELT ........................................... 29 Changing Engine coolant ....................................... 29 DRAINING ENGINE COOLANT .......................... 29 REFILLING ENGINE COOLANT ......................... 29 FLUSHING COOLING SYSTEM ......................... 31 Checking Cooling System ...................................... 31 CHECKING COOLING SYSTEM HOSES ........... 31 CHECKING RADIATOR ...................................... 31 CHECKING COOLING SYSTEM FOR LEAKS ... 32 Checking Radiator Cap (Models without A/C) ........ 32 Checking Reservoir Tank Cap (Models with A/C)... 33 Checking Fuel Lines ............................................... 33 Changing Air Cleaner Filter .................................... 34 REMOVAL ........................................................... 34 INSTALLATION ................................................... 34 Changing Engine Oil ............................................... 34 Changing Oil Filter .................................................. 35 Changing Spark Plugs ............................................ 36 REMOVAL ........................................................... 36 INSPECTION AFTER REMOVAL ....................... 36 INSTALLATION ................................................... 37 Checking EVAP Vapor Lines .................................. 37 ENGINE MAINTENANCE (HR16DE) ........................ 38 Checking Drive Belts .............................................. 38 Tension Adjustment ................................................ 38 Changing Engine Coolant ....................................... 39 DRAINING ENGINE COOLANT .......................... 39 REFILLING ENGINE COOLANT ......................... 40 FLUSHING COOLING SYSTEM ......................... 41 Checking Cooling System ...................................... 41 CHECKING COOLING SYSTEM HOSES ........... 42 MA-1 E F G H I J K MA M CHECKING RADIATOR ...................................... 42 CHECKING COOLING SYSTEM FOR LEAKS ... 42 Checking Radiator Cap (M/T Models without A/C and A/T Models) ..................................................... 43 Checking Reservoir Tank Cap (M/T Models with A/ C) ............................................................................ 44 Checking Fuel Lines ............................................... 44 Changing Air Cleaner Filter .................................... 44 REMOVAL ........................................................... 44 INSPECTION AFTER REMOVAL ........................ 44 INSTALLATION .................................................... 45 Changing Engine Oil ............................................... 45 Changing Oil Filter .................................................. 46 REMOVAL ........................................................... 46 INSTALLATION .................................................... 46 INSPECTION AFTER INSTALLATION ................ 46 Changing Spark Plug (Platinum-Tipped Type) ....... 47 REMOVAL ........................................................... 47 INSPECTION AFTER REMOVAL ........................ 47 INSTALLATION .................................................... 48 Checking EVAP Vapor Lines .................................. 48 ENGINE MAINTENANCE (K9K) ............................... 49 Checking Drive Belts .............................................. 49 TENTION ADJUSTMENT .................................... 49 Changing Engine coolant ....................................... 49 DRAINING ENGINE COOLANT .......................... 49 REFILLING ENGINE COOLANT ......................... 50 FLUSHING COOLING SYSTEM ......................... 50 Checking Cooling System ...................................... 51 CHECKING COOLING SYSTEM HOSES ........... 51 CHECKING RADIATOR ...................................... 51 Checking Reservoir Tank Cap ................................ 51 Checking Radiator .................................................. 52 Checking Fuel Lines ............................................... 52 Changing Air Cleaner Filter .................................... 52 REMOVAL ........................................................... 52 INSTALLATION .................................................... 53 Changing Engine Oil ............................................... 53 Changing Oil Filter .................................................. 54 REMOVAL ........................................................... 54 INSTALLATION .................................................... 54 CHASSIS AND BODY MAINTENANCE ................... 55 Checking Exhaust System ......................................55 Checking Clutch Fluid Level and Leaks ..................55 Checking Clutch System .........................................55 Checking M/T Oil ....................................................55 Changing M/T Oil ....................................................56 Checking A/T Fluid ..................................................56 Changing A/T Fluid .................................................57 Rotation ...................................................................57 Checking Brake Fluid Level and Leaks ...................58 Checking Brake Lines and Cables ..........................58 Changing Brake Fluid .............................................58 Checking Disc Brake ...............................................58 ROTOR ................................................................58 CALIPER ..............................................................59 PAD ......................................................................59 Checking Drum Brake .............................................59 WHEEL CYLINDER .............................................59 DRUM ..................................................................59 LINING .................................................................59 Checking Steering Gear and Linkage .....................60 STEERING GEAR ...............................................60 STEERING LINKAGE ..........................................60 Axle and Suspension Parts .....................................60 Drive Shaft ..............................................................60 Lubricating Locks, Hinges and Hood Latches .........61 Checking Seat Belts, Buckles, Retractors, Anchors and Adjusters ..........................................................61 Checking Body Corrosion .......................................61 HEMMED PANELS ..............................................62 PANEL JOINT ......................................................62 PANEL EDGE ......................................................62 PARTS CONTACT ...............................................62 PROTECTORS ....................................................62 ANTI-CORROSION MATERIALS ........................62 DRAIN HOLES .....................................................62 SERVICE DATA AND SPECIFICATIONS (SDS) ......63 Standard and Limit ..................................................63 BELT DEFLECTION AND TENSION ...................63 ENGINE COOLANT CAPACITY ..........................64 ENGINE OIL CAPACITY ......................................64 SPARK PLUG ......................................................65 SPARK PLUG (PLATINUM-TIPPED TYPE) ........65 MA-2 PREPARATION PREPARATION Special Service Tools PFP:00002 A BLS0003G NISSAN tool number (RENAULT tool number) Tool name Description KV10115801 Oil filter wrench (For CR and HR engine) B Removing and installing oil filter C D S-NT772 KV113C0010 (Mot. 1329) Oil filter wrench (For K9K engine) Removing and installing oil filter E F MBIB0369E EG17650301 Radiator cap tester adapter Adapter radiator cap tester to radiator filler neck a: 28 (1.10) dia. b: 31.4 (1.236) dia. c: 41.3 (1.626) dia. Unit: mm (in) H I S-NT564 — (M.S. 554_07) Tester G Leak checking Checking reservoir tank and reservoir tank cap J K MLIA0012E — (M.S. 554_01) Reservoir tank tester adapter Adapting tester to reservoir tank MA M MLIA0013E — (M.S. 554_06) Reservoir tank cap tester adapter Adapting tester to reservoir tank cap MLIA0014E MA-3 PREPARATION Commercial Service Tool BLS0003H Tool name Description Radiator cap tester Checking radiator and radiator cap PBIC1982E Spark plug wrench Removing and installing spark plug NT047 MA-4 DESCRIPTION DESCRIPTION Pre-delivery Inspection Items PFP:00000 A BLS0003I Shown on next page are Pre-delivery Inspection Items required for the new vehicle. It is recommended that necessary items other than those listed here be added, paying due regard to the conditions in each country. Perform applicable items on each model. Consult text of this section for specifications. B C D E F G H I J K MA M MA-5 DESCRIPTION MLIB0002E MA-6 GENERAL MAINTENANCE GENERAL MAINTENANCE General Maintenance PFP:00000 A BLS0003K General maintenance includes those items which should be checked during the normal day-to-day operation of the vehicle. They are essential if the vehicle is to continue operating properly. The owners can perform the checks and inspections themselves or they can have their NISSAN dealers do them for a nominal charge. B OUTSIDE THE VEHICLE The maintenance items listed here should be performed from time to time, unless otherwise specified. Item Tyres Windshield wiper blades Doors and engine hood Tyre rotation C Reference page Check the pressure with a gauge periodically when at a service station, including the spare, and adjust to the specified pressure if necessary. Check carefully for damage, cuts or excessive wear. — Check for cracks or wear if not functioning correctly. — D E Check that all doors and the engine hood operate smoothly as well as the back door and glass hatch. Also ensure that all latches lock securely. Lubricate if necessary. Make sure that the secondary latch keeps the hood from opening when the primary latch is released. When driving in areas using road salt or other corrosive materials, check for lubrication frequently. Tyres should be rotated every 10,000 km (6,000 miles). BL-7, BL-195 F MA-57 G INSIDE THE VEHICLE The maintenance items listed here should be checked on a regular basis, such as when performing periodic maintenance, cleaning the vehicle, etc. Item Reference page Lamps Warning lamps and chimes Steering wheel Seat belts Make sure that the headlamps, stop lamps, tail lamps, turn signal lamps, and other lamps are all operating properly and installed securely. Also check headlamp aim. — Make sure that all warning lamps and buzzers/chimes are operating properly. — H I J Check that it has the specified play. Check for changes in the steering conditions, such as excessive free play, hard steering or strange noises. Free play: Less than 35 mm (1.38 in) — Check that all parts of the seat belt system (e.g. buckles, anchors, adjusters and retractors) operate properly and smoothly, and are installed securely. Check the belt webbing for cuts, fraying, wear or damage. SB-3 K MA UNDER THE HOOD AND VEHICLE The maintenance items listed here should be checked periodically. e.g. each time you check the engine oil or refuel. Item Reference page Windshield washer fluid Check that there is adequate fluid in the tank. Engine coolant level Check the coolant level when the engine is cold. Engine oil level Check the level after parking the vehicle (on level ground) and turning off the engine. LU-6, LU-16 , LU-23 Brake and clutch fluid levels Make sure that the brake and clutch fluid levels are between the “MAX” and “MIN” lines on the reservoir. MA-58, MA-55 Battery Check the fluid level in each cell. It should be between the “MAX” and “MIN” lines. — MA-7 — CO-8, CO-27 , CO-48 M PERIODIC MAINTENANCE PERIODIC MAINTENANCE Periodic Maintenance PFP:00026 BLS0003L The following tables show the normal maintenance schedule. Depending upon weather and atmospheric conditions, varying road surfaces, individual driving habits and vehicle usage, additional or more frequent maintenance may be required. Periodic maintenance beyond the last period shown on the tables requires similar maintenance. ENGINE AND EMISSION CONTROL MAINTENANCE (CR ENGINE) (Annual Mileage <30,000 Km/year) Abbreviations: I = Inspect and correct or replace as necessary, MAINTENANCE OPERATION R = Replace. MAINTENANCE INTERVAL Perform on a kilometer basis, but on an annual basis when driving less than 20,000 km (12,000 miles) per year km x 1,000 (Miles x 1,000) Months 20 (12) 12 40 (24) 24 60 (36) 36 80 (48) 48 100 (60) 60 120 (72) 72 Reference page Engine compartment and under vehicle Intake and exhaust valve clearance See NOTE (1) Drive belts See NOTE (2) Engine oil (Use recommended oil.) Engine oil filter (Use NISSAN genuine part or equivalent) Engine anti-freeze coolant (Use Nissan Genuine Coolant L250 or equivalent in its quality.) EM-47 I I I I I I EM-14 R R R R R R LU-6 R R R R R R LU-9 See NOTE (3) Cooling system I I Fuel lines I R I I I I Fuel filter (In-tank type) I CO-8 I FL-3 R EM-18 I R Air cleaner filter CO-8 See NOTE (4) FL-4 Spark plugs [Platinum-Tipped Type] (except for Russia and Ukraine) R Spark plugs [Platinum-Tipped Type] (for Russia and Ukraine) Replace every 30,000 km (18,000 miles) EVAP vapor lines (With carbon canister) Heated oxygen sensor 1 R I I See NOTE (5) MA-36 MA-36 I EC-40 or EC-469 EC-183 or EC-582 NOTE: ● Maintenance items with “ Conditions”. ” should be performed more frequently according to “Maintenance Under Severe Driving ● (1) Periodic maintenance is not required. However, if valve noise increases, check valve clearance. ● (2) Replace the drive belts if found damaged. ● (3) First replace at 100,000 Km (60,000 miles)/60 months, then every 60,000 km (36,000 miles)/36 months. Perform “I” (Checking the mixture ratio and correcting the mixture ratio if necessary) at the middle of replacement interval. ● (4) Fuel filter is maintenance-free item. For service procedures, refer to FL-4 . ● (5) Perform only according to “Maintenance Under Severe Driving conditions” for models without Euro-OBD system. For models with Euro-OBD system, periodic maintenance is not required. MA-8 PERIODIC MAINTENANCE CHASSIS AND BODY MAINTENANCE (CR ENGINE) A (Annual Mileage <30,000 Km/year) Abbreviations: I = Inspect and correct or replace as necessary, MAINTENANCE OPERATION R = Replace. MAINTENANCE INTERVAL Perform on a kilometer basis, but on an annual basis when driving less than 20,000 km (12,000 miles) per year km x 1,000 (Miles x 1,000) Months 20 (12) 12 40 (24) 24 60 (36) 36 80 (48) 48 100 (60) 60 120 (72) 72 Reference page B C Underhood and under vehicle Headlamp aiming I I I I I I LT-30 Brake & clutch, systems and fluid (For level & leaks) I I I I I I MA-58, MA-55 D Brake fluid R R R MA-58 Brake booster vacuum hoses, connections & check valve I I I BR-17 I MA-55 MA-60, MA-60 , MA-60 , MA55 F I G Manual transaxle gear oil (For leaks) I Steering gear & linkage, axle & suspension I I parts, front drive shafts & exhaust system Wheel alignment (If necessary, balance & rotate wheels) Brake pads, rotors, linings, drums & other brake components Foot brake, parking brake & clutch (For free play, stroke & operation) I I I I I I I I I FSU-15 I I I I I I MA-59, MA-59 , MA-58 I BR-6, PB-3 , CL-6 R ATC-129, MTC-75 I I R Air conditioner filter Body corrosion I See NOTE (1) I I R I Maintenance items with “ Conditions”. ● (1) Inspect once per year. H I MA-61 J NOTE: ● E ” should be performed more frequently according to “Maintenance Under Severe Driving K MA M MA-9 PERIODIC MAINTENANCE ENGINE AND EMISSION CONTROL MAINTENANCE (HR ENGINE) (Annual Mileage <30,000 Km/year) Abbreviations: I = Inspect and correct or replace as necessary, MAINTENANCE OPERATION R = Replace, [ ] = At the specified mileage only. MAINTENANCE INTERVAL Perform on a kilometer basis, but on an annual basis when driving less than 30,000 km (18,000 miles) per 2 years. km x 1,000 (Miles x 1,000) Months 30 (18) 24 60 (36) 48 90 (54) 72 120 (72) 96 Reference page Engine compartment and under vehicle Intake and exhaust valve clearance See NOTE (1) Drive belts See NOTE (2) EM-166 I I I I EM-114 R R R R LU-16 R R R R LU-19 I I R I CO-27 Cooling system I I I I CO-27 Fuel lines I I I I FL-14 R EM-118 Engine oil (Use recommended oil.) Engine oil filter (Use NISSAN genuine part or equivalent in its quality) Engine anti-freeze coolant (Use Nissan Genuine Coolant L250 or equivalent in its quality.) See NOTE (3) R Air cleaner filter Fuel filter (In-tank type) See NOTE (4) FL-15 Spark plugs [Platinum-Tipped Type] (except for Russia and Ukraine) [R] Spark plugs [Platinum-Tipped Type] (for Russia and Ukraine) EVAP vapor lines (With carbon canister) Heated oxygen sensor 1 EM-133 [R] [R] [R] [R] EM-133 I I I I EC-823 or EC1257 See NOTE (5) EC-959 or EC1373 NOTE: ● Maintenance items with “ Conditions”. ” should be performed more frequently according to “Maintenance Under Severe Driving ● (1) Periodic maintenance is not required. However, if valve noise increases, check valve clearance. ● (2) Replace the drive belts if found damaged. ● (3) First replace at 90,000 Km (54,000 miles)/60 months, then every 60,000 km (36,000 miles)/48 months. Perform “I” (Checking the mixture ratio and correcting the mixture ratio if necessary) at the middle of replacement interval. ● (4) Fuel filter is maintenance-free item. For service procedures, refer to FL-15 . ● (5) Perform only according to “Maintenance Under Severe Driving conditions” for models without Euro-OBD system. For models with Euro-OBD system, periodic maintenance is not required. MA-10 PERIODIC MAINTENANCE CHASSIS AND BODY MAINTENANCE (HR ENGINE) A (Annual Mileage <30,000 Km/year) Abbreviations: I = Inspect and correct or replace as necessary, MAINTENANCE OPERATION R = Replace. MAINTENANCE INTERVAL Perform on a kilometer basis, but on an annual basis when driving less than 15,000 km (9,000 miles) per year. km x 1,000 (Miles x 1,000) Months 15 (9) 12 30 (18) 24 45 (27) 36 60 (36) 48 75 (45) 60 90 (54) 72 105 (63) 84 120 (72) 96 Reference page Underhood and under vehicle C Headlamp aiming I I I I LT-30 Brake & clutch, systems and fluid (For level & leaks) I I I I MA-58, MA55 Brake fluid R R R R MA-58 Brake booster vacuum hoses, connections & check valve I I I I BR-17 I MA-56 Automatic transaxle fluid (For level & I leaks) I I I I I I D E F Manual transaxle gear oil (For leaks) I I I I MA-55 Steering gear & linkage, axle & suspension parts, front drive shafts & I I I I MA-60, MA60 , MA-60 , MA-55 I I I I FSU-15 exhaust system Wheel alignment (If necessary, balance & rotate wheels) G H Brake pads, rotors, linings, drums & I I I I MA-59, MA59 , MA-58 Foot brake, parking brake & clutch (For free play, stroke & operation) I I I I BR-6, PB-3 , CL-6 Air conditioner filter R R R R ATC-129, MTC-75 other brake components Body corrosion B See NOTE (1) I J MA-61 NOTE: ● Maintenance items with “ Conditions”. ● (1) Inspect once per year. ” should be performed more frequently according to “Maintenance Under Severe Driving K MA M MA-11 PERIODIC MAINTENANCE ENGINE AND EMISSION CONTROL MAINTENANCE (K9K ENGINE) (Annual Mileage <30,000 Km/year) Abbreviations: R = Replace, I = Inspect: Correct or replace if necessary, D = Check filter and drain water, [ ]= At the specified mileage only. MAINTENANCE OPERATION MAINTENANCE INTERVAL Perform on a kilometer basis, but on an annual basis when driving less than 20,000 km (12,000 miles) per year. km x 1,000 (Miles x 1,000) Months 20 (12) 12 40 (24) 24 60 (36) 36 80 (48) 48 100 (60) 60 120 (72) 72 Reference page Engine compartment and under vehicle See NOTE (1) Engine oil (Use recommended oil.) Engine oil filter (Use recommended oil filter) Timing belt See NOTE (2) Drive belt See NOTE (3) R R R R R R LU-23 R R R R R R LU-25 Replace every 120,000 km (72,000 miles)/60 months Cooling system Engine anti-freeze coolant (Use Nissan Genuine Coolant L250 or equivalent in its quality) I I I I I I EM-242 I I I I I I CO-48 See NOTE (4) I R R Air cleaner filter Intake & exhaust valve clearance See NOTE (5) CO-48 R Inspect every 100,000 km (60,000 miles) Fuel lines I D Fuel filter EM-272 [R] I D [R] D EM-245 EM-292 I FL-25 [R] FL-26 NOTE: ● Maintenance items with “ Conditions”. ” should be performed more frequently according to “Maintenance Under Severe Driving ● (1) Maximum 20,000 km (12,000 miles) with one refilling allowed between 2 oil changes or 1 year. ● (2) The replacement interval for the timing belt is the maximum lifespan which should not be exceeded. Replace the timing belt if it comes into contact with fuel. The frequency of replacement should be adapted depending on vehicle usage. See “Maintenance Under Severe Driving Conditions”. ● (3) Replace every 120,000 km (72,000 miles)/maximum 60 months. Replace drive belt if it comes into contact with fuel or damage is found during inspection. ● (4) First replace at 100,000 km (60,000 miles)/60 months, then every 60,000 km (36,000 miles)/36 months. After first replacement, perform “I” (Checking the mixture ratio and correcting the mixture ratio if necessary) at the middle of replacement interval. ● (5) If valve noise increases, check valve clearance. MA-12 PERIODIC MAINTENANCE CHASSIS AND BODY MAINTENANCE (K9K ENGINE) A (Annual Mileage <30,000 Km/year) Abbreviations: I = Inspect and correct or replace as necessary, MAINTENANCE OPERATION R = Replace. MAINTENANCE INTERVAL Perform on a kilometer basis, but on an annual basis when driving less than 20,000 km (12,000 miles) per year. km x 1,000 (Miles x 1,000) Months 20 (12) 12 40 (24) 24 60 (36) 36 80 (48) 48 100 (60) 60 120 (72) 72 Reference page B C Underhood and under vehicle Headlamp aiming I I I I I I LT-30 Brake & clutch, systems and fluid (For level & leaks) I I I I I I MA-58, MA-55 D Brake fluid R R R MA-58 Brake booster vacuum hoses, connections & check valve I I I BR-17 I MA-55 MA-60, MA-60 , MA-60 , MA55 F I G Manual transaxle gear oil (For leaks) I Steering gear & linkage, axle & suspension I I parts, front drive shafts & exhaust system Wheel alignment (If necessary, rotate & balance wheels) Brake pads, rotors, linings, drums & other brake components Foot brake, parking brake & clutch (For free play, stroke & operation) I I I I I I I I I FSU-15 I I I I I I MA-59, MA-59 , MA-58 I BR-6, PB-3 , CL-6 R ATC-129, MTC-75 I I R Air conditioner filter Body corrosion I See NOTE (1) I I R I Maintenance items with “ Conditions”. H I MA-61 J NOTE: ● (1) Inspect once per year. ● E ” should be performed more frequently according to “Maintenance Under Severe Driving K MA M MA-13 PERIODIC MAINTENANCE MAINTENANCE UNDER SEVERE DRIVING CONDITIONS (Annual Mileage <30,000 Km/year) The maintenance intervals shown on the preceding pages are for normal operating conditions. If the vehicle is mainly operated under severe driving conditions as shown below, more frequent maintenance must be performed on the following items as shown in the table. Severe driving conditions A — Driving in dusty conditions B — Repeatedly driving short distances C — Towing a trailer or caravan D — Extensive idling E — Driving in extremely adverse weather conditions or in areas where ambient temperatures are either extremely low or extremely high F — Driving in high humidity or mountainous areas G — Driving in areas using salt or other corrosive materials H — Driving on rough and/or muddy roads or in the desert I — Driving with frequent use of braking or in mountainous areas J — Frequent off road use or driving in water K —Sustained high speed driving L — For models without Euro-OBD system (For CR and HR petrol engine models) L — Repeated short journeys, cold engine at low temperature (For K9K diesel engine models) Maintenance operation: Check = Check and correct or replace as necessary. Driving condition Maintenance item Maintenance operation A . A . B . B . . . C D . . . . . D . . . . . . . . . . . . . . . H . . . . . . . . . . . L L Air cleaner filter Engine oil & engine oil filter Heated oxygen sensor 1 Timing belt MA-34 Every 30,000 km (18,000 miles) or 24 months MA-44 K9K engine models Every 30,000 km (18,000 miles) or 18 months MA-52 CR engine models Every 10,000 km (6,000 miles) or 6 months MA-34, MA-35 Every 15,000 km (9,000 miles) or 12 months MA-45, MA-46 K9K engine models Every 10,000 km (6,000 miles) or 6 months MA-53, MA-54 CR engine models Every 40,000 km (24,000 miles) or 24 months EC-178, EC577 , EC-756 Every 30,000 km (18,000 miles) or 24 months EC-959, EC1373 , EC-1549 HR engine models HR engine models Replace Replace Inspect HR engine models K9K engine models Replace . . . . F . . . . . . Brake fluid Replace HR and K9K engine models MA-14 More frequently EM-272 Every 20,000 km (12,000 miles) or 12 months CR engine models . Reference page Every 30,000 km (18,000 miles) or 18 months CR engine models A Maintenance interval Every 15,000 km (9,000 miles) or 12 months MA-58 PERIODIC MAINTENANCE Driving condition . . . A A . . . . . C C . . . . C . . . . . . . . . . . . . . . H H Maintenance item . . G H . G H I . . . . . . . . . . . . . . . . . . Automatic transaxle fluid Fuel filter Steering gear & linkage, axle & suspension parts, front drive shafts & exhaust system Brake pads, rotors, linings, drums & other brake components Air conditioner filter Maintenance operation Maintenance interval Replace Every 30,000 km (18,000 miles) or 24 months Check filter & drain water Every 10,000 km (6,000 miles) or 6 months Replace Every 20,000 km (12,000 miles) Inspect Every 20,000 km (12,000 miles) or 12 months HR and K9K engine models Inspect Every 15,000 km (9,000 miles) or 12 months CR engine models Inspect Every 10,000 km (6,000 miles) or 6 months Inspect Every 15,000 km (9,000 miles) or 12 months HR engine models K9K engine models CR engine models HR and K9K engine models Every 20,000 km (12,000 miles) or 12 months CR engine models Replace HR and K9K engine models Every 15,000 km (9,000 miles) or 12 months Reference page MA-57 A B C FL-26 D E MA-60, MA-60 , MA-60 , MA-55 F G MA-58, MA-59 H ATC-129, MTC75 I J K MA M MA-15 PERIODIC MAINTENANCE ENGINE AND EMISSION CONTROL MAINTENANCE (CR ENGINE) (Annual Mileage >30,000 Km/year) Abbreviations: I = Inspect and correct or replace as necessary, MAINTENANCE OPERATION MAINTENANCE INTERVAL Perform at number of kilometers (miles) basis only. km x 1,000 (Miles x 1,000) 20 (12) 40 (24) 60 (36) 80 (48) 100 (60) 120 (72) R = Replace,. Reference page Engine compartment and under vehicle Intake and exhaust valve clearance See NOTE (1) Drive belts See NOTE (2) Engine oil (Use recommended oil.) Engine oil filter (Use NISSAN genuine part or equivalent) Engine anti-freeze coolant (Use Nissan Genuine Coolant L250 or equivalent in its quality.) See NOTE (3) Cooling system EM-47 I I I I I I EM-14 R R R R R R MA-34 R R R R R R LU-9 I R I I CO-8 I CO-8 Fuel lines I I FL-3 Air cleaner filter R R EM-18 Fuel filter (In-tank type) See NOTE (4) FL-4 Spark plugs [Platinum-Tipped Type] (except for Russia and Ukraine) R Spark plugs [Platinum-Tipped Type] (for Russia and Ukraine) R MA-36 Replace every 30,000 km (18,000 miles) MA-36 EVAP vapor lines (With carbon canister) Heated oxygen sensor 1 I See NOTE (5) I EC-40 or EC469 EC-178, or EC-756 NOTE: ● Maintenance items with “ Conditions”. ” should be performed more frequently according to “Maintenance Under Severe Driving ● (1) Periodic maintenance is not required. However, if valve noise increases, check valve clearance. ● (2) Replace the drive belts if found damaged. ● (3) First replace at 100,000 km (60,000 miles), then every 60,000 km (36,000 miles). Perform “I” (Checking the mixture ratio and correcting the mixture ratio if necessary) at the middle of replacement interval. ● (4) Fuel filter is maintenance-free item. For service procedures, refer to FL-4 . ● (5) Perform only according to “Maintenance Under Severe Driving conditions” for models without Euro-OBD system. For models with Euro-OBD system, periodic maintenance is not required. MA-16 PERIODIC MAINTENANCE CHASSIS AND BODY MAINTENANCE (CR ENGINE) A (Annual Mileage >30,000 Km/year) Abbreviations: I = Inspect and correct or replace as necessary, R = Replace, MAINTENANCE OPERATION MAINTENANCE INTERVAL Perform at number of kilometers (miles) basis only. km x 1,000 (Miles x 1,000) 20 (12) 40 (24) 60 (36) 80 (48) 100 (60) 120 (72) L = Lubricate. Reference page B Underhood and under vehicle Headlamp aiming I Brake & clutch, systems and fluid (For level & leaks) I I I I I I I LT-30 I MA-58, MA-55 D Brake fluid R R MA-58 Brake booster vacuum hoses, connections & check valve I I BR-17 I MA-55 I MA-60, MA-60 , MA-60 , MA55 I FSU-6 Manual transaxle gear oil (For leaks) I I Steering gear & linkage, axle & suspension I I I I parts, front drive shafts & exhaust system Wheel alignment (If necessary, rotate & balance wheels) I I I I I E F G Brake pads, rotors, linings, drums & other brake components Foot brake, parking brake & clutch (For free play, stroke & operation) I I I I I I MA-59, MA-59 , MA-58 I I I I I I BR-6, PB-3 , CL-6 R ATC-129, MTC-75 R Air conditioner filter Body corrosion C See NOTE (1) R H I MA-61 NOTE: ● Maintenance items with “ Conditions”. ● (1) Inspect once per year. ” should be performed more frequently according to “Maintenance Under Severe Driving J K MA M MA-17 PERIODIC MAINTENANCE ENGINE AND EMISSION CONTROL MAINTENANCE (HR ENGINE) (Annual Mileage >30,000 Km/year) Abbreviations: I = Inspect and correct or replace as necessary, MAINTENANCE OPERATION MAINTENANCE INTERVAL Perform at number of kilometers (miles) basis only. km x 1,000 (Miles x 1,000) 30 (18) 60 (36) 90 (54) 120 (72) R = Replace,. Reference page Engine compartment and under vehicle Intake and exhaust valve clearance See NOTE (1) Drive belts See NOTE (2) Engine oil (Use recommended oil.) Engine oil filter (Use NISSAN genuine part or equivalent) Engine anti-freeze coolant (Use Nissan Genuine Coolant L250 or equivalent in its quality.) See NOTE (3) Cooling system EM-166 I I I I EM-114 R R R R LU-16 R R R R LU-19 I I R I CO-27 I I I I CO-27 Fuel lines I I FL-14 Air cleaner filter R R EM-118 Fuel filter (In-tank type) See NOTE (4) FL-15 Spark plugs [Platinum-Tipped Type] (except for Russia and Ukraine) R Spark plugs [Platinum-Tipped Type] (Russia and Ukraine) R EVAP vapor lines (With carbon canister) Heated oxygen sensor 1 R R I See NOTE (5) EM-133 R EM-133 I EC-823 or EC-1257 EC-959 or EC-1373 NOTE: ● Maintenance items with “ Conditions”. ” should be performed more frequently according to “Maintenance Under Severe Driving ● (1) Periodic maintenance is not required. However, if valve noise increases, check valve clearance. ● (2) Replace the drive belts if found damaged. ● (3) First replace at 90,000 Km (54,000 miles), then every 60,000 km (36,000 miles). Perform “I” (Checking the mixture ratio and correcting the mixture ratio if necessary) at the middle of replacement interval. ● (4) Fuel filter is maintenance-free item. For service procedures, refer to FL-15 . ● (5) Perform only according to “Maintenance Under Severe Driving conditions” for models without Euro-OBD system. For models with Euro-OBD system, periodic maintenance is not required. MA-18 PERIODIC MAINTENANCE CHASSIS AND BODY MAINTENANCE (HR ENGINE) A (Annual Mileage >30,000 Km/year) Abbreviations: I = Inspect and correct or replace as necessary, MAINTENANCE OPERATION MAINTENANCE INTERVAL Perform at number of kilometers (miles) basis only. km x 1,000 (Miles x 1,000) 15 (9) 30 (18) 45 (27) 60 (36) 75 (45) 90 (54) 105 (63) 120 (72) R = Replace. Reference page B Underhood and under vehicle Headlamp aiming I I I I LT-30 Brake & clutch, systems and fluid (For level & leaks) I I I I MA-58, MA55 Brake fluid R R MA-58 Brake booster vacuum hoses, connections & check valve I I BR-17 Automatic transaxle fluid (For level & leaks) I I I I MA-56 Manual transaxle gear oil (For leaks) I I I I MA-55 I MA-60, MA60 , MA-60 , MA-55 Steering gear & linkage, axle & suspension parts, I front drive shafts & exhaust system I I I I FSU-6 I I I I MA-59, MA59 , MA-58 Foot brake, parking brake & clutch (For free play, stroke & operation) I I I I BR-6, PB-3 , CL-6 Air conditioner filter R R R R ATC-129, MTC-75 Brake pads, rotors, linings, drums & other brake components See NOTE (1) MA-61 NOTE: ● Maintenance items with “ Conditions”. ● (1) Inspect once per year. D E F G Wheel alignment (If necessary, rotate & balance wheels) Body corrosion C H I J ” should be performed more frequently according to “Maintenance Under Severe Driving K MA M MA-19 PERIODIC MAINTENANCE ENGINE AND EMISSION CONTROL MAINTENANCE (K9K ENGINE) (Annual Mileage >30,000 Km/year) Abbreviations: R = Replace I = Inspect and correct or replace as necessary MAINTENANCE OPERATION D= Check filter and drain water. MAINTENANCE INTERVAL Perform at number of kilometers (miles) basis only. km x 1,000 (Miles x 1,000) 20 (12) 40 (24) 60 (36) 80 (48) 100 (60) 120 (72) Reference page Engine compartment and under vehicle See NOTE (1) Engine oil (Use recommended oil.) Engine oil filter (Use recommended oil filter) Timing belt See NOTE (2) Drive belt See NOTE (3) Cooling system Engine anti-freeze coolant (Use Nissan Genuine Coolant L250 or equivalent in its quality.) R R R R R R LU-23 R R R R R R LU-25 Replace every 120,000 km (72,000 miles) I I I I I I I I I I See NOTE (4) I Intake & exhaust valve clearance See NOTE (5) R I D R D R D CO-48 CO-48 Inspect every 100,000 km (60,000 miles) Fuel lines Fuel filter EM-242 I R R Air cleaner filter EM-272 EM-245 EM-292 I FL-25 R FL-26 NOTE: ● Maintenance items with “ Conditions”. ” should be performed more frequently according to “Maintenance Under Severe Driving ● (1) Maximum 20,000 km (12,000 miles) with one refilling allowed between 2 oil changes or 1 year. ● (2) The replacement interval for the timing belt is the maximum lifespan which should not be exceeded. Replace the timing belt if it comes into contact with fuel. The frequency of replacement should be adapted depending on vehicle usage. See “Maintenance Under Severe Driving Conditions”. ● (3) Replace every 120,000 km (72,000 miles). Replace drive belt if it comes into contact with fuel or damage is found during inspection. ● (4) First replace at 100,000 km (60,000 miles), then every 60,000 km (36,000 miles). After first replacement, Perform “I” (Checking the mixture ratio and correcting the mixture ratio if necessary) at the middle of replacement interval. ● (5) If valve noise increases, check valve clearance. MA-20 PERIODIC MAINTENANCE CHASSIS AND BODY MAINTENANCE (K9K ENGINE) A (Annual Mileage >30,000 Km/year) Abbreviations: I = Inspect and correct or replace as necessary, R = Replace, MAINTENANCE OPERATION MAINTENANCE INTERVAL Perform at number of kilometers (miles) basis only. km x 1,000 (Miles x 1,000) 20 (12) 40 (24) 60 (36) 80 (48) 100 (60) 120 (72) L = Lubricate. Reference page B Underhood and under vehicle Headlamp aiming I Brake & clutch, systems and fluid (For level & leaks) I I I I I I I LT-30 I MA-58, MA-55 D Brake fluid R R MA-58 Brake booster vacuum hoses, connections & check valve I I BR-17 I MA-55 I MA-60, MA-60 , MA-60 , MA55 I FSU-6 Manual transaxle gear oil (For leaks) I I Steering gear & linkage, axle & suspension I I I I parts, front drive shafts & exhaust system Wheel alignment (If necessary, rotate & balance wheels) I I I I I E F G Brake pads, rotors, linings, drums & other brake components Foot brake, parking brake & clutch (For free play, stroke & operation) I I I I I I MA-59, MA-59 , MA-58 I I I I I I BR-6, PB-3 , CL-6 R ATC-129, MTC-75 R Air conditioner filter Body corrosion C See NOTE (1) R H I MA-61 NOTE: ● Maintenance items with “ Conditions”. ● (1) Inspect once per year. ” should be performed more frequently according to “Maintenance Under Severe Driving J K MA M MA-21 PERIODIC MAINTENANCE MAINTENANCE UNDER SEVERE DRIVING CONDITIONS (Annual Mileage >30,000 Km/year) The maintenance intervals shown on the preceding pages are for normal operating conditions. If the vehicle is mainly operated under severe driving conditions as shown below, more frequent maintenance must be performed on the following items as shown in the table. Severe driving conditions A — Driving in dusty conditions B — Repeatedly driving short distances C — Towing a trailer or caravan D — Extensive idling E — Driving in extremely adverse weather conditions or in areas where ambient temperatures are either extremely low or extremely high F — Driving in high humidity or mountainous areas G — Driving in areas using salt or other corrosive materials H — Driving on rough and/or muddy roads or in the desert I — Driving with frequent use of braking or in mountainous areas J — Frequent off road use or driving in water K —Sustained high speed driving L — For models without Euro-OBD system (For CR and HR petrol engine models) L — Repeated short journeys, cold engine at low temperature (For K9K diesel engine models) Maintenance operation: Check = Check and correct or replace as necessary. Driving condition Maintenance item Maintenance operation Maintenance interval CR engine models A . . . . . . . . . . . Air cleaner filter HR engine models MA-34 Replace Every 30,000 km (18,000 miles) K9K engine models B C D . . . . . . . . Engine oil & engine oil filter HR engine models Every 10,000 km (6,000 miles) Replace K9K engine models Every 15,000 km (9,000 miles) . . . . . . . . . . L Heated oxygen sensor 1 MA-34, MA35 MA-45, MA46 MA-53, MA54 EC-178, EC577 , EC-756 CR engine models . MA-44 MA-52 CR engine models A Reference page Inspect Every 60,000 km (36,000 miles) HR engine models EC-959, EC1373 , EC1549 A B . D . . . H . . . L Timing belt K9K engine models Replace More frequently EM-272 . . . . . F . . . . . . Brake fluid All models Replace Every 30,000 km (18,000 miles) MA-58 . . C . . . . H . . . . Automatic transaxle fluid HR engine models Replace Every 60,000 km (36,000 miles) MA-57 Check filter & drain water Every 15,000 km (9,000 miles) Replace Every 30,000 km (18,000 miles) . . C . . . . H . . . . Fuel filter K9K engine models MA-22 FL-26 PERIODIC MAINTENANCE Driving condition . A A . . . . . C . . . . . . . . . Maintenance item G H . G H I . . . . . . . . . . . . Steering gear & linkage, axle & suspension parts, drive shafts & exhaust system Brake pads, rotors, linings, drums & other brake components Air conditioner filter Maintenance operation Maintenance interval Reference page A B All models Inspect CR engine models HR and K9K engine models CR engine models HR and K9K engine models Every 30,000 km (18,000 miles) Every 10,000 km (6,000 miles) Inspect Replace Every 15,000 km (9,000 miles) Every 20,000 km (12,000 miles) Every 15,000 km (9,000 miles) MA-60, MA60 , MA-60 , MA-55 MA-59, MA58 , MA-59 C D E ATC-129, MTC-75 F G H I J K MA M MA-23 RECOMMENDED FLUIDS AND LUBRICANTS RECOMMENDED FLUIDS AND LUBRICANTS Fluids and Lubricants PFP:00000 BLS0003M Capacity (Approximate) Engine oil Drain and refill With oil filter change Without oil filter change Dry engine (engine overhaul) CR engine Cooling system (with reservoir) HR engine Liter Imp measure CR engine 3.4 3 qt HR engine 4.6 4 qt K9K engine 4.40 3-7/8 qt CR engine 3.2 2-7/8 qt HR engine 4.4 3-7/8 qt K9K engine 4.24 3-3/4 qt CR engine 3.9 3-3/8 qt HR engine 4.8 4-1/4 qt K9K engine 4.56 4 qt Models with A/C 5.3 4-5/8 qt Models without A/C 4.9 4-3/8 qt M/T models without A/C 5.6 4-7/8 qt M/T models with A/C 6.0 5-1/4 qt A/T models 5.4 4-3/4 qt — 6.0 5-1/4 qt Models with A/C 1.2 1-1/8 qt Models without A/C 0.7 5/8 qt M/T models without A/C 0.7 5/8 qt M/T models with A/C 1.2 1-1/8 qt K9K engine CR engine Reservoir tank HR engine A/T models 0.7 5/8 qt 1.2 1-1/8 qt JH3 2.6 4-5/8 pt JR5 2.5 4-3/8 pt Automatic transaxle fluid 7.7 6-3/4 qt Brake and clutch fluid — — Multi-purpose grease — — K9K engine Manual transaxle gear oil — Recommended Fluids/Lubricants ● CR engine Nissan Genuine Oil or API SG, SH or SJ*1 ILSAC grade GF-I or GF-II*1 ACEA A2 ● HR engine Nissan Genuine Oil or API SL*1 ILSAC Grade GF-III*1 ● K9K engine Nissan Genuine Oil or ACEA B3, B4 ● Nissan Genuine Coolant L250 or equivalent in its quality*3 ● Nissan Genuine gear oil Passenger Car or API GL-4, Viscosity SAE 75W-80 ● Nissan Genuine ATF Matic D or equivalent*4 ● Nissan Genuine Brake Fluid or DOT 3 or DOT 4 (US FMVSS No. 116)*5 ● NLGI No. 2 (Lithium soap base) *1: For further details, see “SAE Viscosity Number”. *2: Never use API CG-4. *3: Use Nissan Genuine Coolant L250 or equivalent in its quality, in order to avoid possible aluminum corrosion within the engine cooling system caused by the use of non-genuine engine coolant. Note that any repairs for the incidents within the engine cooling system while using non-genuine engine coolant may not be covered by the warranty even if such incidents occurred during the warranty period. *4: Contact a Nissan dealership for more information regarding suitable fluids, including recommended brand(s) of DEXRONTM III/MERCONTM Automatic Transaxle Fluid. *5: Never mix different types of fluids (DOT 3 and DOT 4). MA-24 RECOMMENDED FLUIDS AND LUBRICANTS SAE Viscosity Number BLS0003N A GASOLINE ENGINE ● 5W-30 is preferable. If 5W-30 is not available, select the viscosity, from the chart, that is suitable for outside temperature range. B C D E F G H SMA203D DIESEL ENGINE ● I 5W-30 is preferable. If 5W-30 is not available, select the viscosity, from the chart, that is suitable for outside temperature range. J K MA M SMA204D MA-25 RECOMMENDED FLUIDS AND LUBRICANTS Engine Coolant Mixture Ratio BLS0003O The engine cooling system is filled at the factory with a high-quality, year-round and extended life engine coolant. The high quality engine coolant contains the specific solutions effective for the anti-corrosion and the anti-freeze function. Therefore, additional cooling system additives are not necessary. CAUTION: ● When adding or replacing coolant, be sure to use only Nissan Genuine Coolant L250 or equivalent. Because L250 is premixed type coolant. The use of other types of engine coolant may damage your SMA089D cooling system. ● When checking the engine coolant mixture ratio by the coolant hydrometer, use the chart below to correct your hydrometer reading (specific gravity) according to coolant temperature. Mixed coolant specific gravity Unit: specific gravity Coolant temperature °C (°F) Engine coolant mixture ratio 15 (59) 25 (77) 35 (95) 45 (113) 30% 1.046 - 1.050 1.042 - 1.046 1.038 - 1.042 1.033 - 1.038 50% 1.076 - 1.080 1.070 - 1.076 1.065 - 1.071 1.059 - 1.065 WARNING: Never remove the radiator cap when the engine is hot. Serious burns could be caused by high pressure fluid escaping from the radiator. Wait until the engine and radiator cool down. MA-26 ENGINE MAINTENANCE (CR) ENGINE MAINTENANCE (CR) Checking Drive Belts ● ● ● ● PFP:00000 A BLS0003P Inspection should be done only when engine is cold or over 30 minutes after the engine is stopped. Turn the clamp pulleys two times clockwise, and make sure tension on all pulleys is equal before doing the test. Visually check the belts for wear, damage, and cracks on inside and edges. B C When measuring deflection, apply 98,1 N (10 kg, 22lb) at the marked point. D PBIC1414E E F G H PBIC1415E CAUTION: When measuring belt tension immediately after the belt is installed, first set the tension to the standard, rotate the crankshaft for more than two turns in order to eliminate variance in the tension between pulleys, then measure and adjust tension to the standard again. Deflection [mm (in)] [When pressed by force of 98.1N (10 kg, 22lb)] Tension [N (kg, lb)] Location New Alternator and A/C compressor belt 603 - 691 (61.5 - 70.5, 135.6 - 155.3) 603 - 691 (61.5 - 70.5, 135.6 - 155.3) Alternator belt Water pump belt 446 - 534 (45.5 - 54.5, 100.3 - 120.0) At adjustment 495 - 583 (50.5 - 59.5, 111.3 - 131.1) 495 - 583 (50.5 - 59.5, 111.3 - 131.1) 348 - 436 (35.5 - 44.5, 78.2 - 98.0) Tension Adjustment Location Limit Measuring point New belt At adjustment Limit A 6.6 - 7.8 (0.260 0.307) 7.3 - 8.5 (0.287 0.335) 13.8 (0.543) B 5.6 - 6.6 (0.220 0.260) 7.1 - 8.3 (0.280 0.327) 11.9 (0.469) A 3.1 - 4.1 (0.122 0.161) 9.8 - 10.6 (0.386 0.417) 13.8 (0.543) C 6.7 - 7.3 (0.264 0.287) 7.6 - 8.6 (0.299 0.339) 12.4 (0.448) D 4.7 - 5.6 (0.185 0.220) 7.0 - 7.7 (0.276 0.303) 8.6 (0.339) 196 (20, 44.1) 196 (20, 44.1) 137 (14, 30.9) Alternator and A/C compressor drive belt Adjusting bolt on idler pulley Water pump belt Adjusting bolt on idler pulley MA-27 J K MA M BLS0003Q Location of adjuster and tightening method I ENGINE MAINTENANCE (CR) CAUTION: ● When the belt is replaced with new one, adjust the belt tension to the value for “New belt”, because new belt will not fully seat in the pulley groove. ● When tension of the belt being used exceeds “Limit”, adjust it to the value for “At adjustment”. ● When installing a belt, make sure that it is correctly engaged with the pulley groove. ● Do not allow oil or engine coolant to get on the belt. ● Do not twist or bend the belt strongly. ALTERNATOR AND A/C COMPRESSOR BELT (WITH A/C MODELS) 1. 2. 3. 4. 5. 6. Remove RH front fender protector. Loosen lock nut (1). Tighten lock nut (1) with fingers. Loosen lock nut (1) half a turn counter-clockwise. Adjust the belt tension by turning the adjuster bolt (2). For the specified belt tension, refer to MA-27, "Checking Drive Belts" . Tighten lock nut (1). Nut (1): : 24.5 - 31.4 N·m (2.5 - 3.2 kg-m, 18 - 23 ft-lb) 7. 8. Turn the crankshaft pulley two times clockwise. Check that the belt tension is within the standard. Refer to MA27, "Checking Drive Belts" . PBIC1290E ALTERNATOR BELT (WITHOUT A/C MODELS) 1. 2. 3. 4. 5. 6. Remove RH front fender protector. Loosen lock nut (1). Tighten lock nut (1) with fingers. Loosen lock nut (1) half a turn counter-clockwise. Adjust the belt tension by turning the adjuster bolt (2). For the specified belt tension, refer to MA-27, "Checking Drive Belts" . Tighten lock nut (1). Nut (1): : 24.5 - 31.4 N·m (2.5 - 3.2 kg-m, 18 - 23 ft-lb) 7. 8. Turn the crankshaft pulley two times clockwise. Check that the belt tension is within the standard. Refer to MA27, "Checking Drive Belts" . PBIC1416E MA-28 ENGINE MAINTENANCE (CR) WATER PUMP BELT 1. 2. 3. 4. 5. A Remove RH front fender protector. Loosen lock nut (3). Tighten lock nut (3) with fingers. Adjust the belt tension by turning the adjuster bolt (4). For the specified belt tension, refer to MA-27, "Checking Drive Belts" . Tighten lock nut (3). B C Nut (3) : : 24.5 - 31.4 N·m (2.5 - 3.2 kg-m, 18 - 23 ft-lb) 6. 7. D Turn the crankshaft pulley two times clockwise. Check that the belt tension is within the standard. Refer to MA-27, "Checking Drive Belts" . Changing Engine coolant BLS0003R E WARNING: ● To avoid being scalded, never change the coolant when the engine is hot. ● Wrap a thick cloth around radiator cap and carefully remove the cap. First, turn the cap a quarter of a turn to release built-up pressure. Then turn the cap all the way. F DRAINING ENGINE COOLANT Models without A/C G 1. 2. a. b. 3. Disconnect radiator lower hose and radiator cap. CAUTION: Make sure to drain when the engine coolant temperature is cold. H Remove reservoir tank and drain the engine coolant in the following procedures. Move relay case in front of the battery. Disconnect the reservoir tank from fan shroud to remove. With force applied in the left direction of vehicle, pull up reservoir tank. Check drain coolant for contaminants such as rust, corrosion or discoloration. If contaminated, flush engine cooling system. Refer to MA-31, "FLUSHING COOLING SYSTEM" . I J K PBIC1476E MA Models with A/C 1. 2. Disconnect radiator lower hose and reservoir tank cap. CAUTION: Make sure to drain when the engine coolant temperature is cold. M Remove reservoir tank and drain the engine coolant. : Vehicle front 3. Check drain coolant for contaminants such as rust, corrosion or discoloration. If contaminated, flush engine cooling system. Refer to MA-31, "FLUSHING COOLING SYSTEM" . MBIB1360E REFILLING ENGINE COOLANT 1. 2. Install reservoir tank. Connect radiator lower hose. MA-29 ENGINE MAINTENANCE (CR) 3. Disconnect heater hose (at heater hose outlet side: upper side) as shown in figure. Keep hose end at the same height as that of before removal. PBIC1477E 4. Fill radiator and reservoir tank to specified level. ● Pour coolant slowly of less than 2 (1-3/4 lmp qt) a minute to allow air in system to escape. ● When coolant from heater hose starts to drain, connect heater hose and continue to fill. ● Use Nissan Genuine Coolant L250 or equivalent mixed with water (distilled or demineralized). Refer to MA-24, "RECOMMENDED FLUIDS AND LUBRICANTS". SMA182B Engine coolant capacity Models without A/C With reservoir tank : Approx. 4.9 Reservoir tank : 0.7 (4-3/8 Imp qt) (5/8 lmp qt) SMA412B Models with A/C With reservoir tank : Approx. 5.3 Reservoir tank : 1.2 (4-5/8 Imp qt) (1-1/8 lmp qt) : Vehicle front MBIB1360E MA-30 ENGINE MAINTENANCE (CR) A B C MBIA0092E 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. Warm up engine to normal operating temperature with radiator cap installed. Warm up until thermostat opens. Keep warming at 3,000 rpm for approximately 10 minutes as guide. ● For thermostat opening, touch radiator upper hose by hand to insure that water flow is hot. CAUTION: Be careful not to overheat. Stop the engine. After cooling engine [approximately 50°C (122 °F) or lower], remove radiator cap and check coolant level. If the level is low, fill up to the radiator neck again and repeat from step 5. When the coolant level stabilizes, fill reservoir tank up to the “MAX” line. Check cooling system for leaks with engine running. Allow the engine to cool [approximately 50°C (122°F) or lower]. Start the engine. Perform the following cycle three times. Keep an engine speed of 1,000 rpm for approximately 30 seconds. Then increase it gradually to 3,000 rpm. During the above step 12, make sure water flow sound is not heard from heater core. ● Sound may be noticeable at heater unit. If water flow sound is heard, repeat from step 4 to 13. ● Clean excess coolant from engine. E F G H I J FLUSHING COOLING SYSTEM 1. 2. 3. 4. 5. 6. D Fill radiator and reservoir tank with water and reinstall radiator cap. Run engine and warm it up to normal operating temperature. Rev engine two or three times under no-load. Stop engine and wait until it cools down. Drain water. Repeat steps 1 through 5 until clear water begins to drain from radiator. Checking Cooling System K MA BLS0003S WARNING: Never remove the radiator cap when the engine is hot; serious burns could be caused by high pressure fluid escaping from the radiator. Wrap a thick cloth around the cap and carefully remove it by turning it a quarter turn to allow built-up pressure to escape and then turn the cap all the way off. CHECKING COOLING SYSTEM HOSES Check hoses for improper attachment, leaks, cracks, damage, loose connections, chafing and deterioration. CHECKING RADIATOR Check radiator for mud or clogging. If necessary, clean radiator as follows. ● Be careful not to bend or damage the radiator fins. ● When radiator is cleaned without removal, remove all surrounding parts such as cooling fan, radiator shroud and horns. Then tape the harness and connectors to prevent water from entering. 1. Apply water by hose to the back side of the radiator core vertically downward. 2. Apply water again to all radiator core surfaces once per minute. 3. Stop washing if any stains no longer flow out from the radiator. MA-31 M ENGINE MAINTENANCE (CR) 4. Blow air into the back side of radiator core vertically downward. 5. Use compressed air lower than 490 kPa (4.9 bar, 5 kg/cm2 , 71 psi) and keep distance more than 30 cm (11.8 in). Blow air again into all the radiator core surfaces once per minute until no water sprays out. ● CHECKING COOLING SYSTEM FOR LEAKS Models without A/C ● To check for leakage, apply pressure to the cooling system with a radiator cap tester (commercial service tool) and radiator cap tester adapter (SST). Testing pressure : 157 kPa (1.57 bar, 1.6 kg/cm2 , 23 psi) ● WARNING: Never remove the radiator cap when the engine is hot. Serious burns could occur from high pressure coolant escaping from the radiator. CAUTION: Higher pressure than specified may cause radiator damage. NOTE: In a case that engine coolant decreases, replenish radiator with engine coolant. If anything is found, repair or replace damaged parts. SLC134B Models with A/C ● To check for leakage, fit the adapter to the reservoir tank (1), and then connect it to the tester. MBIB1362E ● ● Warm up the engine and turn it off. Apply pressure to the cooling system and stop pumping. Testing pressure ● ● : 90 kpa (0.9 bar, 0.92 kg/cm2 , 13.1 psi) If the pressure drops, look for leakage. Unscrew slowly the adapter from the reservoir tank to reduce the pressure in cooling system, and install the reservoir tank cap. WARNING: Never remove the reservoir tank cap when the engine is hot. Serious burns could occur from high pressure engine coolant escaping from the radiator. CAUTION: Higher pressure than specified may cause radiator damage. Checking Radiator Cap (Models without A/C) 1. MBIA0094E BLS0003T Pull the negative-pressure valve to open it and check that it closes completely when released. ● Check that there is no dirt or damage on the valve seat of the radiator cap negative-pressure valve. MA-32 ENGINE MAINTENANCE (CR) ● Check that there are no unusual conditions in the opening and closing conditions of the negative-pressure valve. A B C SMA967B D 2. Check radiator cap relief pressure. Standard: 78 - 98 kPa (0.78 - 0.98 bar, 0.8 - 1.0 kg/cm2 , 11 - 14 psi) Limit: E F 59 kPa (0.59 bar, 0.6 kg/cm2 , 9 psi) When connecting the radiator cap to the tester, apply water or engine coolant to the cap seal part. SLC135B ● Replace the radiator cap if there is an unusual conditions in the negative-pressure valve, or if the open-valve pressure is outside of the standard values. CAUTION: When installing radiator cap, thoroughly wipe out the radiator filler neck to remove any waxy residue or foreign material. ● Checking Reservoir Tank Cap (Models with A/C) ● ● ● G H I BLS0003U Fit the adapter to the tester as shown. When connecting the reservoir tank cap to the tester, apply water or LLC to the cap seal part. Check reservoir tank cap relief pressure. J K 2 88 kPa (0.88 bar, 0.90 kg/cm , 12.8 psi) ● Replace the reservoir tank cap if the engine coolant passes through it, or if any fur signs is detected. MA MBIB1079E Checking Fuel Lines BLS0003V Inspect fuel lines, filler cap and tank for improper attachment, leaks, cracks, damage, loose connections, chafing or deterioration. If necessary, repair or replace malfunctioning parts. SMA803A CAUTION: Tighten high-pressure rubber hose clamp so that clamp end is 3 mm (0.12 in) from hose end. MA-33 M ENGINE MAINTENANCE (CR) Tightening torque specifications are the same for all rubber hose clamps. Ensure that screw does not contact adjacent parts. Changing Air Cleaner Filter BLS0003W REMOVAL 1. 2. 3. 4. Remove air duct. Refer to EM-18, "REMOVAL" . Remove clips (2) of air cleaner body (1). After moving the air cleaner body downward, remove it by pulling it forward. ● While pressing down the radiator upper hose, remove air cleaner body. Remove air cleaner filter from the air cleaner body. NOTE: In some cases the air cleaner filter might remain in the air cleaner case (upper). PBIC1296E INSTALLATION 1. 2. 3. Set the air cleaner filter on the air cleaner case (upper) (1). Insert the two projections (3) on the air cleaner body (2) into the two notch holes (4) on the rear of the air cleaner case (upper) (1), then lift up and fasten with the clip. Attach air duct. PBIC1297E Changing Engine Oil BLS0003X WARNING: ● Be careful not to burn yourself, as the engine oil is hot. ● Prolonged and repeated contact with used engine oil may cause skin cancer: try to avoid direct skin contact with used oil. If skin contact is made, wash thoroughly with soap or hand cleaner as soon as possible. 1. Warm up engine put vehicle horizontally, and check for oil leakage from engine components. 2. Stop engine and wait for 10 minutes. 3. Remove oil filler cap, and remove drain plug. 4. Drain engine oil. 5. Install drain plug. Refill with new engine oil. ● Install drain plug washer in the direction shown in figure. Oil specification and viscosity: Refer to MA-24, "RECOMMENDED FLUIDS AND LUBRICANTS". PBIC1468E MA-34 ENGINE MAINTENANCE (CR) Oil capacity (Approximate): Unit: Drain and refill With oil filter change A (Imp qt) 3.4 (3) Without oil filter change 3.2 (2-7/8) Dry engine (engine overhaul) B 3.9 (3-3/8) CAUTION: ● Be sure to clean drain plug and install with new washer. C Oil pan drain plug: : 29.4 - 39.2 N·m (3.0 - 3.9 kg-m, 22 - 28 ft-lb) ● 6. 7. 8. The refill capacity depends on the oil temperature and drain time. Use these specifications for reference only. Always use the dipstick to determine when the proper amount of oil is in the engine. Warm up engine and check area around drain plug and oil filter for oil leakage. Check oil level. Refer to LU-6, "Inspection" . Stop engine and wait for 10 minutes. Changing Oil Filter 1. 2. 3. D E F BLS0003Y Using an oil filter wrench (special service tool), remove oil filter. CAUTION: ● Be careful not to get burned when the engine and engine oil are hot. ● When removing, prepare a shop cloth to absorb any oil leakage or spillage. ● Do not allow engine oil to adhere to the drive belts. ● Completely wipe off any oil that adheres to the engine and the vehicle. Remove foreign materials adhering to the oil filter installation surface. Apply engine oil to the oil seal circumference of the new oil filter. CAUTION: ● Use genuine NISSAN oil filter or the equivalent. G H I PBIC1469E J K MA M SMA010 4. Screw the oil filter manually until it touches the installation surface, then tighten it by 2/3 turn. Oil filter: :14.7 - 20.5 N·m (1.5 - 2.1 kg-m, 11 - 15 ft-lb) 5. 6. After warming up the engine, check for engine oil leakage. Check oil level and add engine oil. Refer to LU-6, "ENGINE OIL" . SMA229B MA-35 ENGINE MAINTENANCE (CR) Changing Spark Plugs BLS0003Z REMOVAL 1. 2. Remove ignition coil. Refer to EM-29, "IGNITION COIL" . Remove spark plugs with a spark plug wrench. CAUTION: Handle spark plug with care. Avoid impacts. SMA581C INSPECTION AFTER REMOVAL ● ● – – ● – – Use standard type spark plug for normal condition. The hot type spark plug is suitable when fouling occurs with the standard type spark plug under conditions such as: Frequent engine starts Low ambient temperatures The cold type spark plug is suitable when spark plug knock occurs with the standard type spark plug under conditions such as: Extended highway driving Frequent high engine revolution Make NGK Champion Standard type LFR5AP-11 REC10PYC4 Hot type LFR4AP-11 — Cold type LFR6AP-11 — Gap (Nominal) : 1.1 mm (0.043 in) CAUTION: ● Do not use a wire brush for cleaning. ● If plug tip is covered with carbon, spark plug cleaner may be used. Cleaner air pressure: Less than 588 kPa (6 kg/cm2 , 85 psi) Cleaning time: Less than 20 seconds SMA773C ● Checking and adjusting plug gap is not required between change intervals. SMA806CA MA-36 ENGINE MAINTENANCE (CR) INSTALLATION A Install in the reverse order of removal. Spark plug : 19.6 - 29.4 N·m (2.0 - 3.0 kg-m, 15 - 21 ft-lb) Checking EVAP Vapor Lines B BLS00040 1. Visually inspect EVAP vapor lines for improper attachment and for cracks, damage, loose connections, chafing and deterioration. 2. Inspect fuel tank filler cap vacuum relief valve for clogging, sticking, etc. Refer to EC-40, "EVAPORATIVE EMISSION SYSTEM" (CR engine models with E-OBD), EC-469, "EVAPORATIVE EMISSION SYSTEM" (CR engine models without E-OBD). C D E F G H I J K MA M MA-37 ENGINE MAINTENANCE (HR16DE) ENGINE MAINTENANCE (HR16DE) Checking Drive Belts ● ● ● ● PFP:00100 BLS00041 Inspection should be done only when engine is cold or over 30 minutes after the engine is stopped. 1. Alternator 2. Water pump 3. Crankshaft pulley 4. A/C compressor 5. Idler pulley 6. Drive belt Visually check belts for wear, damage, and cracks on inside and PBIC3642E edges. Turn crankshaft pulley two time clockwise, and make sure tension on all pulleys is equal before doing the test. When measuring deflection, apply 98 N (10 kg, 22 lb) at the ( ) marked point. Measure the belt tension and frequency with acoustic tension gauge (commercial service tool) at the ( ) marked point. CAUTION: ● When the tension and frequency are measured, the acoustic tension gauge should be used. ● When checking immediately after installation, first adjust it to the specified value. Then, after turning crankshaft two turns or more, re-adjust to the specified value to avoid variation in deflection between pulleys. ● Belt Deflection: Deflection adjustment * Location Drive belt Unit: mm (in) Used belt New belt Limit After adjusted With A/C models 7.9 (0.31) 4.8 - 5.3 (0.19 - 0.21) 4.2 - 4.5 (0.17 - 0.18) Without A/C models 7.1 (0.28) 4.3 - 4.7 (0.17 - 0.19) 3.6 - 3.9 (0.14 - 0.15) Applied pushing force 98 N (10 kg, 22lb) *: When engine is cold. Tension Adjustment BLS00042 Location Location of adjuster and tightening method Drive belt Adjusting bolt on idler pulley CAUTION: ● When belt is replaced with new one, adjust belt tension to the value for “New belt”, because new belt will not fully seat in the pulley groove. ● When tension of the belt being used exceeds “Limit”, adjust it to the value for “After adjusted”. ● When installing a belt, make sure it is correctly engaged with the pulley groove. ● Do not allow oil or engine coolant to get on the belt. ● Do not twist or bend the belt strongly. 1. Remove front fender protector (RH). Refer to EI-14, "FENDER PROTECTOR" . MA-38 ENGINE MAINTENANCE (HR16DE) 2. 3. 4. Loosen the idler pulley lock nut (A) from the tightening position with the specified torque by 45 degrees. 1 : Alternator 2 : Water pump 3 : Crankshaft pulley 4 : A/C compressor (Models with A/C) Idler pulley (Models without A/C) 5 : Idler pulley 6 : Drive belt A B C PBIC3643E CAUTION: ● When the lock nut is loosened excessively, the idler pulley tilts and the correct tension adjustment cannot be performed. Do not loosen it excessively (more than 45 degrees). ● Put a matching mark on the lock nut (A), and check turning angle with a protractor. Do not visually check the tightening angle. Adjust the belt tension by turning the adjusting bolt (B). Refer to MA-38, "Checking Drive Belts" . CAUTION: ● When checking immediately after installation, first adjust it to the specified value. Then, after turning crankshaft two turns or more, re-adjust to the specified value to avoid variation in deflection between pulleys. ● When the tension adjustment is performed, the lock nut should be in the condition at step“ 2”. If the tension adjustment is performed when the lock nut is loosened more than the standard, the idler pulley tilts and the correct tension adjustment cannot be performed. Tighten the lock nut (A). D E F G H : 34.8 N·m (3.5 kg-m, 26 ft-lb) I Changing Engine Coolant BLS00043 WARNING: ● To avoid being scalded, never change the coolant when the engine is hot. ● Wrap a thick cloth around radiator cap and carefully remove the cap. First, turn the cap a quarter of a turn to release built-up pressure. Then turn the cap all the way. K DRAINING ENGINE COOLANT M/T Models without A/C and A/T models 1. 2. a. b. 3. Disconnect radiator lower hose and radiator cap. CAUTION: Make sure to drain when the engine coolant temperature is cold. Remove reservoir tank and drain the engine coolant in the following procedures. Move relay case in front of the battery. Disconnect the reservoir tank from fan shroud to remove. With force applied in the left direction of vehicle, pull up reservoir tank. Check drain coolant for contaminants such as rust, corrosion or discoloration. If contaminated, flush engine cooling system. Refer to MA-41, "FLUSHING COOLING SYSTEM" . MA M PBIC1476E M/T Models with A/C 1. 2. J Disconnect radiator lower hose and reservoir tank cap. CAUTION: Make sure to drain when the engine coolant temperature is cold. Remove reservoir tank and drain the engine coolant. MA-39 ENGINE MAINTENANCE (HR16DE) : Vehicle front 3. Check drain coolant for contaminants such as rust, corrosion or discoloration. If contaminated, flush engine cooling system. Refer to MA-41, "FLUSHING COOLING SYSTEM" . MBIB1360E REFILLING ENGINE COOLANT 1. 2. 3. Install reservoir tank. Connect radiator lower hose. Disconnect heater hose (1) (at heater hose outlet side: upper side) as shown in figure. Keep hose end at the same height as that of before removal. : Vehicle front : Disconnect MBIB1361E 4. Fill radiator and reservoir tank to specified level. ● Pour coolant slowly of less than 2 (1-3/4 lmp qt) a minute to allow air in system to escape. ● When coolant from heater hose starts to drain, connect heater hose and continue to fill. ● Use Nissan Genuine Coolant L250 or equivalent mixed with water (distilled or demineralized). Refer to MA-24, "RECOMMENDED FLUIDS AND LUBRICANTS". SMA182B Engine coolant capacity M/T models without A/C With reservoir tank : Approx. 5.6 Reservoir tank : 0.7 A/T models With reservoir tank : Approx. 5.4 Reservoir tank : 0.7 (4-7/8 Imp qt) (5/8 lmp qt) (4-3/4 Imp qt) (5/8 lmp qt) SMA412B MA-40 ENGINE MAINTENANCE (HR16DE) : Vehicle front A M/T models with A/C With reservoir tank : Approx. 6.0 (5-1/4 Imp qt) Reservoir tank : 1.2 (1-1/8 lmp qt) B C MBIB1360E D E F G MBIA0092E 5. 6. 7. 8. 9. 10. 11. 12. 13. ● 14. ● Warm up engine to normal operating temperature with radiator cap installed. Warm up until thermostat opens. Keep warming at 3,000 rpm for approximately 10 minutes as guide. H ● For thermostat opening, touch radiator upper hose by hand to insure that water flow is hot. CAUTION: Be careful not to overheat. I Stop the engine. After cooling engine [approximately 50°C (122 °F) or lower], remove radiator cap and check coolant level. If the level is low, fill up to the radiator neck again and repeat from step 5. J When the coolant level stabilizes, fill reservoir tank up to the “MAX” line. Check cooling system for leaks with engine running. K Allow the engine to cool [approximately 50°C (122°F) or lower]. Start the engine. Perform the following cycle three times. Keep an engine speed of 1,000 rpm for approximately 30 seconds. Then increase it gradually to 3,000 rpm. MA During the above step 12, make sure water flow sound is not heard from heater core. Sound may be noticeable at heater unit. If water flow sound is heard, repeat from step 4 to 13. M Clean excess coolant from engine. FLUSHING COOLING SYSTEM 1. 2. 3. 4. 5. 6. Fill radiator and reservoir tank with water and reinstall radiator cap. Run engine and warm it up to normal operating temperature. Rev engine two or three times under no-load. Stop engine and wait until it cools down. Drain water. Repeat steps 1 through 5 until clear water begins to drain from radiator. Checking Cooling System BLS00044 WARNING: Never remove the radiator cap when the engine is hot; serious burns could be caused by high pressure fluid escaping from the radiator. Wrap a thick cloth around the cap and carefully remove it by turning it a quarter turn to allow built-up pressure to escape and then turn the cap all the way off. MA-41 ENGINE MAINTENANCE (HR16DE) CHECKING COOLING SYSTEM HOSES Check hoses for improper attachment, leaks, cracks, damage, loose connections, chafing and deterioration. CHECKING RADIATOR Check radiator for mud or clogging. If necessary, clean radiator as follows. ● Be careful not to bend or damage the radiator fins. ● When radiator is cleaned without removal, remove all surrounding parts such as cooling fan, radiator shroud and horns. Then tape harness and electrical connectors to prevent water from entering. 1. Apply water by hose to the back side of radiator core vertically downward. 2. Apply water again to all radiator core surface once per minute. 3. Stop washing if any stains no longer flow out from radiator. 4. Blow air into the back side of radiator core vertically downward. Use compressed air lower than 490 kPa (4.9 bar, 5 kg/cm2 , 71 psi) and keep distance more than 30 cm (11.8 in). Blow air again into all the radiator core surfaces once per minute until no water sprays out. ● 5. CHECKING COOLING SYSTEM FOR LEAKS M/T Models without A/C and A/T Models ● To check for leakage, apply pressure to the cooling system with a radiator cap tester (commercial service tool) and radiator cap tester adapter (SST). Testing pressure : 157 kPa (1.57 bar, 1.6 kg/cm2 , 23 psi) ● WARNING: Never remove the radiator cap when the engine is hot. Serious burns could occur from high pressure coolant escaping from the radiator. CAUTION: Higher pressure than specified may cause radiator damage. NOTE: In a case that engine coolant decreases, replenish radiator with engine coolant. If anything is found, repair or replace damaged parts. SLC134B M/T Models with A/C ● To check for leakage, fit the adapter to the reservoir tank (1), and then connect it to the tester as shown. MBIB1362E ● Warm up the engine and turn it off. MA-42 ENGINE MAINTENANCE (HR16DE) ● Apply pressure to the cooling system and stop pumping. Testing pressure ● ● If the pressure drops, look for leakage. Unscrew slowly the adapter from the reservoir tank to reduce the pressure in cooling system, and install the reservoir tank cap. WARNING: Never remove the radiator cap when the engine is hot. Serious burns could occur from high pressure engine coolant escaping from the radiator. CAUTION: Higher pressure than specified may cause radiator damage. Checking Radiator Cap (M/T Models without A/C and A/T Models) 1. A : 90 kpa (0.9 bar, 0.92 kg/cm2 , 13.1 psi) B C MBIA0094E D E BLS00045 Pull the negative-pressure valve to open it and check that it closes completely when released. ● Check that there is no dirt or damage on the valve seat of the radiator cap negative-pressure valve. ● Check that there are no unusual conditions in the opening and closing conditions of the negative-pressure valve. F G H I SMA967B 2. J Check radiator cap relief pressure. Standard: 78 - 98 kPa (0.78 - 0.98 bar, 0.8 - 1.0 kg/cm2 , 11 - 14 psi) Limit: 59 kPa (0.59 bar, 0.6 kg/cm 2 K MA , 9 psi) When connecting the radiator cap to the tester, apply water or SLC135B engine coolant to the cap seal part. ● Replace the radiator cap if there is an unusual conditions in the negative-pressure valve, or if the openvalve pressure is outside of the standard values. CAUTION: When installing radiator cap, thoroughly wipe out the radiator filler neck to remove any waxy residue or foreign material. ● MA-43 M ENGINE MAINTENANCE (HR16DE) Checking Reservoir Tank Cap (M/T Models with A/C) ● ● ● BLS00046 Fit the adapter to the tester as shown. When connecting the reservoir tank cap to the tester, apply water or LLC to the cap seal part. Check reservoir tank cap relief pressure. 140 kPa (1.4 bar, 1.43 kg/cm2 , 20.3 psi) ● Replace the reservoir tank cap if the engine coolant passes through it, or if any fur signs is detected. MBIB1079E Checking Fuel Lines BLS00047 Inspect fuel lines, fuel filler cap and fuel tank for improper attachment, leaks, cracks, damage, loose connections, chafing or deterioration. If necessary, repair or replace damaged parts. SMA803A Changing Air Cleaner Filter BLS00048 REMOVAL 1. 2. Push the tabs (A) of both ends of the air cleaner cover (1) into the inside (B). Pull up the air cleaner cover forward (C) and remove it. PBIC3557J 3. 4. Remove the air cleaner filter (1) and holder (2) assembly from the air cleaner case. Remove the air cleaner filter from the holder. PBIC3558J INSPECTION AFTER REMOVAL It is necessary to clean air cleaner filter or replace it at the recommended intervals, more often under dusty driving conditions. Refer to MA-8, "PERIODIC MAINTENANCE" . MA-44 ENGINE MAINTENANCE (HR16DE) ● Blow air into the back side of air cleaner filter until no any object sprays out. A B C SMA384C D INSTALLATION Note the following, and install in the reverse order of removal. ● Install the air cleaner cover (1) in the direction shown in the figure. 2 : Air cleaner filter 3 : Holder E F G PBIC3559J Changing Engine Oil BLS00049 H WARNING: ● Be careful not to burn yourself, as engine oil may be hot. I ● Prolonged and repeated contact with used engine oil may cause skin cancer; try to avoid direct skin contact with used engine oil. If skin contact is made, wash thoroughly with soap or hand cleaner as soon as possible. 1. Warm up engine, put vehicle horizontally and check for engine oil leakage from engine components. Refer J to LU-16, "ENGINE OIL LEAKAGE" . 2. Stop engine and wait for 10 minutes. K 3. Loosen oil filler cap and then remove drain plug. 4. Drain engine oil. 5. Install drain plug with new washer. Refer to EM-127, "OIL PAN AND OIL STRAINER" . MA CAUTION: Be sure to clean drain plug and install with new washer. Oil pan drain plug: M : 34.3 N·m (3.5 kg-m, 25 ft-lb) 6. Refill with new engine oil. Engine oil specification and viscosity: Refer to MA-24, "RECOMMENDED FLUIDS AND LUBRICANTS" . Engine oil capacity (Approximate): Unit: Drain and refill With oil filter change (lmp qt) 4.6 (4) Without oil filter change Dry engine (Overhaul) 4.4 (3-7/8) 4.8 (4-1/4) CAUTION: ● The refill capacity depends on the engine oil temperature and drain time. Use these specifications for reference only. ● Always use oil level gauge to the determine when the proper amount of engine oil is in the engine. MA-45 ENGINE MAINTENANCE (HR16DE) 7. 8. 9. Warm up engine and check area around drain plug and oil filter for engine oil leakage. Stop engine and wait for 10 minutes. Check the engine oil level. PBIC0249E Changing Oil Filter BLS0004A REMOVAL 1. Using oil filter wrench (SST: KV10115801) (A), remove oil filter. : Vehicle font CAUTION: Oil filter is provided with relief valve. Use Genuine NISSAN Oil Filter or equivalent. ● Be careful not to get burned when engine and engine oil may be hot. ● When removing, prepare a shop cloth to absorb any engine oil leakage or spillage. ● Do not allow engine oil to adhere to drive belt. ● Completely wipe off any engine oil that adheres to engine and vehicle. ● MBIB1357E INSTALLATION 1. 2. Remove foreign materials adhering to the oil filter installation surface. Apply new engine oil to the oil seal contact surface of new oil filter. SMA010 3. Screw oil filter manually until it touches the installation surface, then tighten it by 2/3 turn. Or tighten to specification. Oil filter: : 17.7 N·m (1.8 kg-m, 13 ft-lb) SMA229B INSPECTION AFTER INSTALLATION 1. 2. Check the engine oil level. Refer to MA-45, "Changing Engine Oil" . Start engine, and check there is no leaks of engine oil. MA-46 ENGINE MAINTENANCE (HR16DE) 3. 4. Stop engine and wait for 10 minutes. Check the engine oil level and add engine oil. Refer to MA-45, "Changing Engine Oil" . Changing Spark Plug (Platinum-Tipped Type) A BLS0004B REMOVAL 1. 2. 3. B Remove intake manifold. Refer to EM-120, "INTAKE MANIFOLD" . Remove ignition coil. Refer to EM-132, "IGNITION COIL" . Remove spark plug using spark plug wrench (commercial service tool). CAUTION: Do not drop or shock it. C D E PBIC3871E F INSPECTION AFTER REMOVAL Use standard type spark plug for normal condition. Hot type spark plug is suitable when fouling occurs with standard type spark plug under conditions such as: ● Frequent engine starts ● Low ambient temperatures Cold type spark plug is suitable when spark plug knock occurs with standard type spark plug under conditions such as: ● Extended highway driving ● Frequent high engine revolution Make NGK Standard type PLZKAR6A-11 Hot type PLZKAR5A-11 Cold type PLZKAR7A-11 Gap (Nominal) G H I J K : 1.1 mm (0.043 in) CAUTION: Do not drop or shock spark plug. ● Do not use wire brush for cleaning. ● If plug tip is covered with carbon, spark plug cleaner may be used. MA ● M Cleaner air pressure: Less than 588 kPa (5.88 bar, 6 kg/cm2 , 85 psi) Cleaning time: Less than 20 seconds SMA773C MA-47 ENGINE MAINTENANCE (HR16DE) ● Checking and adjusting plug gap is not required between change intervals. SMA806CA INSTALLATION Install in the reverse order of removal. : 19.6 N·m (2.0 kg-m, 14 ft-lb) Checking EVAP Vapor Lines 1. 2. BLS0004C Visually inspect EVAP vapor lines for improper attachment and for cracks, damage, loose connections, chafing and deterioration. Inspect fuel tank filler cap vacuum relief valve for clogging, sticking, etc. Refer to EC-823, "EVAPORATIVE EMISSION SYSTEM" (with EURO-OBD) or EC-1257, "EVAPORATIVE EMISSION SYSTEM" (without EURO-OBD). MA-48 ENGINE MAINTENANCE (K9K) ENGINE MAINTENANCE (K9K) Checking Drive Belts PFP:00000 A BLS0004D WARNING: Be sure to perform when the engine is stopped. 1. Inspect belts for cracks, fraying, wear and oil. If necessary, replace. 2. Tighten auto-tensioner lock nut (models with A/C compressor) or idler pulley lock nut (models without A/C compressor) by hand and measure deflection or tension without looseness. B C D E MBIB0664E 3. When measuring deflection, apply 98 N (10 kg, 22 lb) at the marked point as shown (models without A/C compressor). F G H MBIB0556E I TENTION ADJUSTMENT Models With A/C Compressor J Belt tensioning is not necessary, as it is automatically adjusted by auto-tensioner. Models Without A/C Compressor Belt tightening method for adjustment K Adjusting bolt on idler pulley The tension value is 234±10 Hz. NOTE: MA The engine must be turned through two revolutions in order to position the belt correctly. CAUTION: ● When checking belt tension immediately after installation, first adjust it to the specified value. M Then, after turning the crankshaft two turns or more, re-adjust to the specified value to avoid variation in deflection between pulleys. ● When installing belt, make sure that it is correctly engaged with pulley groove. ● Keep oil and water away from belt. ● Do not twist or bend belt excessively. ● Changing Engine coolant BLS0004E WARNING: ● To avoid being scalded, never change the coolant when the engine is hot. ● Wrap a thick cloth around cap and carefully remove the cap. First, turn the cap a quarter of a turn to release built-up pressure. Then turn the cap all the way. DRAINING ENGINE COOLANT 1. Remove engine undercover. MA-49 ENGINE MAINTENANCE (K9K) 2. 3. 4. Disconnect lower radiator hose, and remove radiator cap. Remove reservoir tank, drain coolant, then clean reservoir tank. Check drained coolant for contaminants such as rust, corrosion or discoloration. If contaminated, flush engine cooling system. Refer to CO-50, "FLUSHING COOLING SYSTEM" . MBIB1056E REFILLING ENGINE COOLANT 1. 2. Install reservoir tank, radiator lower hose and air relief plug. Fill reservoir tank slowly with coolant until coolant spills from radiator cap holes. CAUTION: If the filling rate is too fast, this could lead to air being mixed in the coolant. Be sure to fill the coolant slowly according to the rate indicated above. ● Use Nissan Genuine Coolant L250 or equivalent mixed with water (distilled or demineralized). Refer to MA-24, "RECOMMENDED FLUIDS AND LUBRICANTS". Engine coolant capacity With reservoir tank : Approx. 6.0 Reservoir tank : 1.0 (5-1/4 Imp qt) (7/8 Imp qt) Pour coolant through coolant filler neck slowly of less than 2 (1-3/4 lmp qt) a minute to allow air in system to escape. 3. Fill reservoir tank to specified level. 4. Warm up engine to normal operating temperature without radiator cap installed. SMA412B ● If coolant overflows radiator filler hole, install filler cap. 5. Run engine at 3,000 rpm for 10 seconds and return to idle speed with radiator cap installed. ● Repeat two or three times. Watch coolant temperature gauge so as not to overheat the engine. 6. Stop engine and cool down to less than approximately 50°C (122°F). ● Cool down using a fan to reduce the time. ● If necessary, refill radiator up to filler neck with coolant. 7. Refill reservoir tank to MAX level line with coolant. 8. Repeat steps 5 through 7 two or more times with radiator cap installed until coolant level no longer drops. 9. Check cooling system for leaks with engine running. 10. Warm up engine, and check for sound of coolant flow while running engine from idle up to 3,000 rpm with heater temperature controller set at several position between COOL and WARM. ● Sound may be noticeable at heater unit. 11. If sound is heard, bleed air from cooling system by repeating steps 5 through 7 until coolant level no longer drops. ● Clean excess coolant from engine. ● FLUSHING COOLING SYSTEM 1. 2. 3. 4. 5. Fill radiator with water until water spills from the air relief hole, then close air relief plug. Fill radiator and reservoir tank with water and reinstall radiator cap. Run engine and warm it up to normal operating temperature. Rev engine two or three times under no-load. Stop engine and wait until it cools down. Drain water. MA-50 ENGINE MAINTENANCE (K9K) 6. 7. Repeat steps 1 through 5 until clear water begins to drain from radiator. Blow compressed air into cooling circuit through the reservoir tank valve hole to drain all the water. Checking Cooling System A BLS0004F WARNING: Never remove the radiator cap when the engine is hot; serious burns could be caused by high pressure fluid escaping from the radiator. Wrap a thick cloth around the cap and carefully remove it by turning it a quarter turn to allow built-up pressure to escape and then turn the cap all the way off. B C CHECKING COOLING SYSTEM HOSES Check hoses for improper attachment, leaks, cracks, damage, loose connections, chafing and deterioration. D CHECKING RADIATOR Check radiator for mud or clogging. If necessary, clean radiator as follows. ● Be careful not to bend or damage the radiator fins. ● When radiator is cleaned without removal, remove all surrounding parts such as cooling fan, radiator shroud and horns. Then tape the harness and connectors to prevent water from entering. 1. Apply water by hose to the back side of the radiator core vertically downward. 2. Apply water again to all radiator core surfaces once per minute. 3. Stop washing if any stains no longer flow out from the radiator. 4. Blow air into the back side of radiator core vertically downward. Use compressed air lower than 490 kPa (4.9 bar, 5 kg/cm2 , 71 psi) and keep distance more than 30 cm (11.8 in). Blow air again into all the radiator core surfaces once per minute until no water sprays out. E F G ● 5. Checking Reservoir Tank Cap ● ● ● ● BLS0004G Fit the adapter to the tester as shown. When connecting the reservoir tank cap to the tester, apply water or LLC to the cap seal part. Check reservoir tank cap relief operation. Replace the reservoir tank cap if the engine coolant passes through it, or if any fur signs is detected. H I J K MA MBIB1079E M MA-51 ENGINE MAINTENANCE (K9K) Checking Radiator BLS0004H Check radiator for mud or clogging. If necessary, clean radiator as follows. ● Be careful not to bend or damage the radiator fins. ● When radiator is cleaned without removal, remove all surrounding parts such as radiator fan, radiator shroud and horns. Then tape the harness and connectors to prevent water from entering. 1. Apply water by hose to the back side of the radiator core vertically downwards. 2. Apply water again to all radiator core surface once per minute. 3. Stop washing if any stains no longer flow out from the radiator. 4. Blow air into the back side of radiator core vertically downwards. ● 5. Use compressed air lower than 490 kPa (4.9 bar 5 kg/cm2 , 71psi) and keep distance more than 30 cm (11.8 in). Blow air again into all the radiator core surface once per minute until no water sprays out. Checking Fuel Lines BLS0004I Inspect fuel lines, filler cap and tank for improper attachment, leaks, cracks, damage, loose connections, chafing or deterioration. If necessary, repair or replace malfunctioning parts. SMA803A CAUTION: Tighten high-pressure rubber hose clamp so that clamp end is 3 mm (0.12 in) from hose end. Tightening torque specifications are the same for all rubber hose clamps. Ensure that screw does not contact adjacent parts. Changing Air Cleaner Filter BLS0004J REMOVAL 1. Open air cleaner case. MBIB1036E MA-52 ENGINE MAINTENANCE (K9K) 2. Remove air cleaner filter. A B C MBIB1036E D INSTALLATION Install in the reverse order of removal. Changing Engine Oil BLS0004K WARNING: ● Be careful not to burn yourself, as the engine oil is hot. ● Prolonged and repeated contact with used engine oil may cause skin cancer: try to avoid direct skin contact with used oil. If skin contact is made, wash thoroughly with soap or hand cleaner as soon as possible. 1. Put vehicle horizontally. 2. Warm up engine, and check for oil leakage from engine components. 3. Stop engine and wait for 10 minutes. 4. Remove drain plug and oil filler cap. 5. Drain oil and refill with new engine oil. ● Refer to MA-24, "RECOMMENDED FLUIDS AND LUBRICANTS" . Oil capacity (Approximate): With oil filter change 4.40 (3-7/8 Imp qt) Without oil filter change 4.24 (3-3/4 Imp qt) Drain and refill Dry engine (overhaul) 4.56 (4 Imp qt) E F G H I J K The refill capacity depends on the oil temperature and drain MBIB0548E time. Use these specifications for reference only. MA Always use the dipstick to the determine when the proper amount of oil is in the engine. CAUTION: ● Be sure to clean drain plug and install with new washer. ● The refill capacity depends on the oil temperature and drain time. Use these specifications for ref- M erence only. Always use the dipstick to the determine when the proper amount of oil is in the engine. 6. Warm up engine and check area around drain plug and oil filter for oil leakage. 7. Stop engine and wait for 10 minutes. 8. Check oil level. ● MA-53 ENGINE MAINTENANCE (K9K) Changing Oil Filter BLS0004L REMOVAL 1. Using an oil filter wrench (special service too), remove oil filter. CAUTION: ● Be careful not to get burned when the engine and engine oil are hot. ● When removing, prepare a shop cloth to absorb any oil leakage or spillage. ● Do not allow engine oil to adhere to the drive belts. ● Completely wipe off any oil that adhere to the engine and the vehicle. MBIB0551E INSTALLATION 1. 2. 3. Remove foreign materials adhering to the oil filter installation surface. Install oil filter bracket to oil cooler. CAUTION: Install oil filter bracket, positioning lug in the hole of oil cooler. Apply engine oil to the oil seal contact surface of the new oil filter. SMA010 4. 5. 6. Install the oil filter to oil filter bracket. After warming up the engine, check for engine oil leakage. Check oil level and add engine oil. Refer to LU-23, "ENGINE OIL" . MA-54 CHASSIS AND BODY MAINTENANCE CHASSIS AND BODY MAINTENANCE Checking Exhaust System PFP:00100 A BLS0004M Check exhaust pipes, muffler and mounting for improper attachment, leaks, cracks, damage, chafing or deterioration. B C D SMA211A Checking Clutch Fluid Level and Leaks E BLS0004N If fluid level is extremely low, check clutch system for leaks. F G H SFIA0066J Checking Clutch System BLS0004O Check fluid lines and operating cylinder for improper attachment, cracks, damage, loose connections, chafing and deterioration. I J K MA SMA859 Checking M/T Oil ● ● ● BLS0004P Check that oil is not leaking from transaxle or around it. Check oil level from filler plug mounting hole as shown in the figure. CAUTION: Never start engine while checking oil level. Set a new gasket on the filler plug and install it on the transaxle. Filler plug: : 2 N·m (0.2 kg-m, 1.8 in-lb) CAUTION: Do not reuse gasket. SMA066C MA-55 M CHASSIS AND BODY MAINTENANCE Changing M/T Oil 1. 2. BLS0004Q Drain oil from drain plug and refill with new gear oil. Check oil level. Oil grade and viscosity: Refer to MA-24, "RECOMMENDED FLUIDS AND LUBRICANTS" Oil capacity (Reference): JH3: Approx. 2.6 (4-5/8 lmp pt) JR5: Approx. 2.5 Drain plug: (4-3/8 lmp pt) : 22 N·m (2.2 kg-m, 1.5 - 1.7 ft-lb) CAUTION: Do not reuse gasket. Checking A/T Fluid 1. 2. BLS00059 Warm up engine. Check for A/T fluid leakage. SMA146B 3. a. b. c. Before driving, A/T fluid level can be checked at A/T fluid temperatures of 30 to 50°C (86 to 122°F) using “COLD” range on A/ T fluid level gauge. Park vehicle on level surface and set parking brake. Start engine and move selector lever through each gear position. Leave selector lever in “P” position. Check A/T fluid level with engine idling. SCIA3451E d. e. f. 4. Remove A/T fluid level gauge and wipe clean with lint-free cloth. CAUTION: When wiping away the A/T fluid level gauge, always use lint-free cloth, not a cloth one. Re-insert A/T fluid level gauge into A/T fluid charging pipe as far as it will go. CAUTION: Firmly fix the A/T fluid level gauge to the A/T fluid charging pipe using a stopper attached. Remove A/T fluid level gauge and note reading. If reading is at low side of range, add ATF to the A/T fluid charging pipe. CAUTION: Do not overfill. Drive vehicle for approximately 5 minutes in urban areas. MA-56 SMA051D CHASSIS AND BODY MAINTENANCE 5. 6. 7. Re-check A/T fluid level at A/T fluid temperatures of 50 to 80°C (122 to 176°F) using “HOT” range on A/T fluid level gauge. CAUTION: ● When wiping away the A/T fluid level gauge, always use lint-free cloth, not cloth one. ● Firmly fix the A/T fluid level gauge to the A/T fluid charging pipe using a stopper attached. Check A/T fluid condition: ● If ATF is very dark or smells burned, check operation of A/T and repair if necessary. Flush cooling system after repair of A/ T. ● If ATF contains frictional material (clutches, bands, etc.), replace radiator and flush cooler line using cleaning solvent and compressed air after repair of A/T. Refer to CO-31, "RADIATOR" . Install the removed A/T fluid level gauge into the A/T fluid charging pipe. SAT638A CAUTION: Firmly fix the A/T fluid level gauge to the A/T fluid charging pipe using a stopper attached. Changing A/T Fluid 1. 2. 3. B C D E F BLS0005A Warm up ATF. Stop engine. Drain ATF from drain hole and refill with new ATF. Always refill same volume with drained fluid. CAUTION: Do not reuse drain plug gasket. G H Fluid grade: Nissan Genuine ATF Matic D or equivalent. Refer to MA-24, "RECOMMENDED FLUIDS AND LUBRICANTS" . Fluid capacity: Approx. 7.7 A I J (6-3/4 lmp qt) Drain plug: K : 34.5 N·m (3.5 kg-m, 25 ft-lb) 4. 5. Run engine at idle speed for 5 minutes. MA Check A/T fluid level and condition. Refer to MA-56, "Checking A/T Fluid" . If ATF is still dirty, repeat steps 2 through 5. Rotation ● ● BLS0004T After rotating the tyres, adjust the tyre pressure. Retighten the wheel nuts when the vehicle has been driven for 1,000 km (600 miles) (also in cases of a flat tyre, etc.). CAUTION: When installing wheels, tighten them diagonally by dividing the work two to three times in order to prevent the wheels from developing any distortion. Tightening torque of wheel nut: 98 - 118N·m (10 - 12 kg·m, 72 - 87 ft·lb) SMA829C MA-57 M CHASSIS AND BODY MAINTENANCE Checking Brake Fluid Level and Leaks BLS0004U If fluid level is extremely low, check brake system for leaks. ● SFIA0066J Checking Brake Lines and Cables BLS0004V Check brake fluid lines and parking brake cables for improper attachment, leaks, chafing, abrasions, deterioration, etc. ● SBR389C Changing Brake Fluid 1. 2. BLS0004W Drain brake fluid from each air bleeder valve. Refill until new brake fluid comes out from each air bleeder valve. Use same procedure as in bleeding hydraulic system to refill brake fluid. Refer to BR-9, "BRAKE FLUID" . ● Refill with “Nissan Genuine Brake Fluid or DOT 3 or DOT 4 (US FMVSS No.116)”. Refer toMA-24, "RECOMMENDED FLUIDS AND LUBRICANTS" . ● Never reuse drained brake fluid. ● Be careful not to splash brake fluid on painted areas. Checking Disc Brake BLS0004X ROTOR Check condition, wear, and damage. Applied Front Brake model CL22 Standard thickness Maximum runout Minimum thickness (Wear limit) SBR419C 22.0 mm (0.87 in) 0.058 mm (0.0023 in) 20 mm (0.79 in) MA-58 CHASSIS AND BODY MAINTENANCE CALIPER ● A Check for leakage. B C SMA922A D PAD Check for wear or damage. Applied Brake model E Front CL22 Standard thickness 12.4 mm (0.488 in) Minimum thickness (Wear Limit) 2.0 mm (0.079 in) F G BRA0010D Checking Drum Brake H BLS0004Y WHEEL CYLINDER I Check for leakage. DRUM Check condition and inner surface. J Standard inner diameter 202 mm (7.95 in) Drum repair limit (Maximum inner diameter) 203.2 mm (8.0 in) K MA SMA848B LINING Check wear or damage. Standard thickness 4.5 mm (0.177 in) Lining Wear Limit (Minimum thickness) 1.5 mm (0.059 in) SMA849B MA-59 M CHASSIS AND BODY MAINTENANCE Checking Steering Gear and Linkage BLS0004Z STEERING GEAR ● ● Check gear housing and boots for looseness, damage and grease leakage. Check connection with steering column for looseness. SLIA0014E STEERING LINKAGE Check ball joint, dust cover and other component parts for looseness, wear, damage and grease leakage. Axle and Suspension Parts BLS00050 Check front and rear axle and suspension parts for excessive play, cracks, wear or other damage. ● Shake each wheel to check for excessive play. ● Check wheel bearings for smooth operation. ● Check axle and suspension nuts and bolts for looseness. ● Check strut (shock absorber) for oil leakage or other damage. ● Check suspension ball joint for grease leakage and ball joint dust cover for cracks or other damage. SMA525A SFA392B Drive Shaft ● BLS00051 Check boot and drive shaft for cracks, wear, damage and grease leakage. SFA108A MA-60 CHASSIS AND BODY MAINTENANCE Lubricating Locks, Hinges and Hood Latches BLS00052 A Front door Refer to BL-195, "DOOR" . Back door Refer to BL-207, "BACK DOOR" . Checking Seat Belts, Buckles, Retractors, Anchors and Adjusters B BLS00053 C D E F G H I J PIIB3436E CAUTION: K ● After any collision, inspect all seat belt assemblies, including retractors and other attached hardwares (I.e. anchor bolt, guide rail set). Nissan recommends to replace all seat belt assemblies in use during a collision, unless not damaged and properly operating after minor collision. Also inspect seat belt assemblies not in use during a collision, and replace if damaged or improp- MA erly operating. Seat belt pre-tensioner should be replaced even if the seat belts are not in use during a frontal collision where the driver and passenger air bags are deployed. M ● If any component of seat belt assembly is questionable, do not repair. Replace as seat belt assembly. ● If webbing is cut, frayed, or damaged, replace belt assembly. ● Never oil tongue and buckle. ● Use a genuine NISSAN seat belt assembly. For details, refer to SB-5, "Inspection" in SB section. ● Check anchors for loose mounting ● Check belts for damage ● Check retractor for smooth operation ● Check function of buckles and tongues when buckled and released Checking Body Corrosion BLS00054 Visually check body panels for collision damage (scratches, chipping, rubbing, etc.) or damage to the anti-corrosion materials. In particular, check the following locations. MA-61 CHASSIS AND BODY MAINTENANCE HEMMED PANELS Hood front end, door lower end, trunk lid rear end, etc. PANEL JOINT Side sill of rear fender and center pillar, rear wheel housing of rear fender, around strut tower in engine compartment, etc. PANEL EDGE Trunk lid opening, sunroof opening, fender wheel-arch flange, fuel filler lid flange, around holes in panel, etc. PARTS CONTACT Waist moulding, windshield moulding, bumper, etc. PROTECTORS Damage or condition of mudguard, fender protector, chipping protector, etc. ANTI-CORROSION MATERIALS Damage or separation of anti-corrosion materials under the body. DRAIN HOLES Condition of drain holes at door and side sill. When repairing corroded areas, refer to the Corrosion Repair Manual. MA-62 SERVICE DATA AND SPECIFICATIONS (SDS) SERVICE DATA AND SPECIFICATIONS (SDS) Standard and Limit PFP:00030 A BLS00055 BELT DEFLECTION AND TENSION CR Engine B Deflection [mm (in)] [When pressed by force of 98.1N (10 kg, 22lb)] Tension [N (kg, lb)] Location New Alternator and A/C compressor belt 603 - 691 (61.5 - 70.5, 135.6 - 155.3) 603 - 691 (61.5 - 70.5, 135.6 - 155.3) Alternator belt 446 - 534 (45.5 - 54.5, 100.3 - 120.0) Water pump belt At adjustment Limit 495 - 583 (50.5 - 59.5, 111.3 - 131.1) 495 - 583 (50.5 - 59.5, 111.3 - 131.1) 348 - 436 (35.5 - 44.5, 78.2 - 98.0) New belt At adjustment Limit A 6.6 - 7.8 (0.260 0.307) 7.3 - 8.5 (0.287 0.335) 13.8 (0.543) D B 5.6 - 6.6 (0.220 0.260) 7.1 - 8.3 (0.280 0.327) 11.9 (0.469) E A 3.1 - 4.1 (0.122 0.161) 9.8 - 10.6 (0.386 0.417) 13.8 (0.543) F C 6.7 - 7.3 (0.264 0.287) 7.6 - 8.6 (0.299 0.339) 12.4 (0.448) G D 4.7 - 5.6 (0.185 0.220) 7.0 - 7.7 (0.276 0.303) 8.6 (0.339) H 196 (20, 44.1) 196 (20, 44.1) C Measuring point 137 (14, 30.9) I J K PBIC1414E PBIC1415E MA HR Engine Deflection adjustment * Location Drive belt Unit: mm (in) Used belt New belt Limit After adjusted With A/C models 7.9 (0.31) 4.8 - 5.3 (0.19 - 0.21) 4.2 - 4.5 (0.17 - 0.18) Without A/C models 7.1 (0.28) 4.3 - 4.7 (0.17 - 0.19) 3.6 - 3.9 (0.14 - 0.15) Applied pushing force 98 N (10 kg, 22lb) *: When engine is cold. K9K Engine Refer to EM-242, "DRIVE BELTS" . MA-63 M SERVICE DATA AND SPECIFICATIONS (SDS) ENGINE COOLANT CAPACITY CR Engine Coolant capacity [With reservoir tank (MAX level)] Models with A/C Approximately 5.3 (4-5/8) Models without A/C Approximately 4.9 (4-3/8) Models with A/C Reservoir tank Unit: (Imp qt) Unit: (Imp qt) Unit: (Imp qt) Unit: (Imp qt) Unit: ·(Imp qt) Unit: (Imp qt) 1.2 (1-1/8) Models without A/C 0.7 (5/8) HR Engine M/T models without A/C Coolant capacity [With reservoir tank (MAX level)] M/T models with A/C Approximately 6.0 (5-1/4) A/T models Approximately 5.4 (4-3/4) M/T models without A/C Reservoir tank Approximately 5.6 (4-7/8) M/T models with A/C 0.7 (5/8) 1.2 (1-1/8) A/T models 0.7 (5/8) K9K Engine Coolant capacity [With reservoir tank (MAX level)] Approximately 6.0 (5-1/4) Reservoir tank 1.2 (1-1/8) ENGINE OIL CAPACITY CR Engine With oil filter change 3.4 (3) Without oil filter change 3.2 (2-7/8) Dry engine (engine overhaul) 3.9 (3-3/8) HR Engine With oil filter change 4.6 (4) Without oil filter change 4.4 (3-7/8) Dry engine (overhaul) 4.8 (4-1/4) K9K Engine With oil filter change 4.40 (3-7/8) Without oil filter change 4.24 (3-3/4) Dry engine (engine overhaul) 4.56 (4) MA-64 SERVICE DATA AND SPECIFICATIONS (SDS) SPARK PLUG CR Engine A Make NGK Champion Standard type LFR5AP-11 REC10PYC4 Hot type LFR4AP-11 — Cold type LFR6AP-11 — Gap (nominal) 1.1 mm (0.043 in) SPARK PLUG (PLATINUM-TIPPED TYPE) HR Engine B C D Make NGK Standard type PLZKAR6A-11 Hot type PLZKAR5A-11 Cold type PLZKAR7A-11 Gap (nominal) 1.1 mm (0.043 in) E F G H I J K MA M MA-65 SERVICE DATA AND SPECIFICATIONS (SDS) MA-66 MANUAL TRANSAXLE C TRANSMISSION/TRANSAXLE SECTION MT MANUAL TRANSAXLE A B MT D E CONTENTS PRECAUTIONS .......................................................... 3 Cautions ................................................................... 3 PREPARATION ........................................................... 4 Special Service Tools ............................................... 4 JH3 DESCRIPTION ............................................................ 6 Cross-sectional View ................................................ 6 REMOVAL AND INSTALLATION ............................... 7 Removal ................................................................... 7 Installation ................................................................ 7 TIGHTENING TORQUES ........................................... 8 Description ............................................................... 8 COMPONENTS .......................................................... 9 Gear Components .................................................... 9 Differential Gear ..................................................... 10 Shift Control Components ...................................... 10 Case Components ..................................................11 Clutch Housing ........................................................11 CONTROL LINKAGE ............................................... 12 Removal and Installation of Control Device and Cable ...................................................................... 12 REMOVAL ........................................................... 12 INSTALLATION ................................................... 12 RATIOS ..................................................................... 13 NISSAN Gearbox ................................................... 13 CONSUMABLES ...................................................... 14 Description ............................................................. 14 CAPACITIES - LUBRICANTS .................................. 15 Description ............................................................. 15 TROUBLE DIAGNOSIS ............................................ 16 Symptom Chart ...................................................... 16 Back-Up Lamp Switch ............................................ 16 Park/Neutral Position Switch .................................. 16 PRECAUTIONS ........................................................ 17 Precautions ............................................................ 17 PARTS TO BE REPLACED SYSTEMATICALLY ..... 18 Description ............................................................. 18 CHECKING ............................................................... 19 Bearings ................................................................. 19 Gearing ................................................................... 19 Synchronizer Ring .................................................. 19 Sliding Gear Hub .................................................... 19 SEPARATING THE HOUSINGS ............................... 20 Removal ................................................................. 20 REPAIRING THE GEARBOX ................................... 22 Removal ................................................................. 22 MAINSHAFT ............................................................. 24 Removal ................................................................. 24 Refitting .................................................................. 25 TRANSAXLE CASE BEARING ................................ 26 Removal ................................................................. 26 Refitting .................................................................. 26 CLUTCH HOUSING BEARING ................................ 27 Removal ................................................................. 27 Refitting .................................................................. 27 SELECTOR SHAFT RINGS ...................................... 28 Removal ................................................................. 28 Refitting .................................................................. 28 DIFFERENTIAL BEARINGS ..................................... 29 Removal and Installation ........................................ 29 SELECTOR SHAFT .................................................. 30 Removal ................................................................. 30 Refitting .................................................................. 30 ASSEMBLY ............................................................... 31 Refitting .................................................................. 31 HOUSING ASSEMBLY ............................................. 33 Assembly ................................................................ 33 JR5 DESCRIPTION .......................................................... 36 Cross-Sectional View ............................................. 36 REMOVAL AND INSTALLATION ............................. 37 Removal ................................................................. 37 Installation .............................................................. 37 TIGHTENING TORQUES .......................................... 38 Description .............................................................. 38 MT-1 F G H I J K L M COMPONENTS ......................................................... 39 Gear Components .................................................. 39 Differential Gear ...................................................... 40 Shift Control Components ....................................... 40 Case Components .................................................. 41 Clutch Housing ....................................................... 41 CONTROL LINKAGE ................................................ 42 Removal and Installation of Control Device and Cable ...................................................................... 42 REMOVAL ........................................................... 42 INSTALLATION .................................................... 42 RATIOS ..................................................................... 43 NISSAN Gearbox ................................................... 43 CONSUMABLES ....................................................... 44 Description .............................................................. 44 CAPACITIES - LUBRICANTS ................................... 45 Description .............................................................. 45 TROUBLE DIAGNOSIS ............................................ 46 Symptom Chart ....................................................... 46 Back-Up Lamp Switch ............................................ 46 Park/Neutral Position Switch .................................. 46 PRECAUTIONS ......................................................... 47 Precautions ............................................................. 47 PARTS TO BE REPLACED SYSTEMATICALLY ..... 48 Description .............................................................. 48 CHECKING ................................................................ 49 Bearings ................................................................. 49 Gearing ................................................................... 49 Synchronizer Ring ...................................................49 Sliding Gear Hub .....................................................49 SEPARATING THE HOUSINGS ................................50 Removal ..................................................................50 REPAIRING THE GEARBOX ....................................52 Removal ..................................................................52 Removing the Gearing ............................................53 Checking Parts ........................................................53 Refitting the Gearing ...............................................54 TRANSAXLE CASE BEARING ................................55 Removing the Bearing, Input Shaft Side .................55 Refitting ...................................................................55 CLUTCH HOUSING BEARING .................................56 Removal and Installation .........................................56 SELECTOR SHAFT RINGS ......................................57 Removal ..................................................................57 Refitting ...................................................................57 DIFFERENTIAL BEARINGS .....................................58 Removal and Installation .........................................58 SELECTOR SHAFT ...................................................59 Removal ..................................................................59 Refitting ...................................................................59 REPAIRING THE GEARBOX ....................................60 Setting the Pre-tensioning of the Output Shaft Bearings .........................................................................60 ASSEMBLY ...............................................................61 Refitting ...................................................................61 HOUSING ASSEMBLY ..............................................63 Assembly ................................................................63 MT-2 PRECAUTIONS PRECAUTIONS Cautions ● ● ● ● ● ● PFP:00001 A BCS000L0 Do not reuse transaxle oil, once it has been drained. B Check oil level or replace oil with vehicle on level ground. During removal or installation, keep inside of transaxle clear of dust or dirt. Check the correct installation status prior to removal or disassembly. If mating marks are required, make MT sure that they do not interfere with the function of the parts they are applied to. In principle, tighten nuts and bolts gradually in several steps working diagonally from inside to outside. If tightening sequence is specified, observe it. D Be careful not to damage sliding surfaces and mating surfaces. E F G H I J K L M MT-3 PREPARATION PREPARATION Special Service Tools Tool number Tool name PFP:00002 BCS000L1 Description B. Vi. 1581 Transmission stand Disassembly and assembly for transmission or transaxle YMT029 B. Vi. 31-01 Pin punch Removing and installing retaining pin YMT030 B. Vi. 1170 Puller Removing 5th synchronizer YMT031 B. Vi. 22-01 Puller Removing 5th gear B. Vi. 1000-01 Puller Removing 5th gear MCIB0026E B. Vi. 1576 Mandrel Removing input shaft bearing YMT032 B. Vi. 1601 Mandrel Installing bearing guide of mainshaft YMT033 MT-4 PREPARATION Tool number Tool name Description A B. Vi. 1554 Drift kit Installing bearing race B MT MCIA0151E B. Vi. 1175 Installer Installing 5th gear D E YMT035 B. Vi. 1666 Drift Installing differential oil seal F G YMT036 B. Vi. 1165 Extractor Removing mainshaft bearing H I MCIA0152E J K L M MT-5 DESCRIPTION [JH3] DESCRIPTION Cross-sectional View [JH3] PFP:zzzzz BCS000L2 MCIA0153E MT-6 REMOVAL AND INSTALLATION [JH3] REMOVAL AND INSTALLATION Removal PFP:00000 A BCS000L3 CAUTION: Remove the crankshaft position sensor (POS) from transaxle assembly before separating transaxle B from engine. Be careful not to damage sensor edge. 1. Remove battery. 2. Remove the air cleaner. Refer to EM-18, "AIR CLEANER AND AIR DUCT" (CR engine) or EM-245, "AIR MT CLEANER AND AIR DUCT" (K9K engine). 3. Disconnect the cable end ball of the select cable, and the cable end of the shift cable. Refer to MT-12, "CONTROL LINKAGE" . D 4. Disconnect the clutch tube. 5. Remove the engine harness clamp. 6. Remove the starter. Refer to SC-51, "Removal and Installation (CR Engine Models)" , “STARTING SYS- E TEM”. 7. Remove the engine mounting LH side installation bolt. Refer to EM-70, "ENGINE ASSEMBLY" (CR engine) or EM-279, "ENGINE ASSEMBLY" (K9K engine). F 8. Set the engine hanger. G H I MBIB0585E 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. Lift up the vehicle and remove the front fender protectors (RH & LH). Remove the undercover. Remove the front exhaust pipe. Refer to EX-3, "Removal and Installation" , “EXHAUST SYSTEM”. Remove the turbocharger outlet tube bracket from the transaxle. Remove the RH and LH drive shafts. Refer to FAX-13, "Removal and Installation" , “FRONT DRIVE SHAFT”. Disconnect the ground cable from the transaxle. Set the transmission jack. Remove the rear engine mounting bracket. Then, remove the rear torque link from the transaxle. Refer to EM-70, "ENGINE ASSEMBLY" (CR engine) or EM-279, "ENGINE ASSEMBLY" (K9K engine). CAUTION: Do not remove the rear torque link from the suspension member. Remove the engine mounting bracket LH. Disconnect the position switch connector. Remove the transaxle mounting nuts and bolts, and remove the transaxle. Installation BCS000L4 Install in the reverse order of removal. MT-7 J K L M TIGHTENING TORQUES [JH3] TIGHTENING TORQUES Description PFP:32010 BCS000L5 Tightening portion N·m (kg-m, ft-lb) Gearbox casing bolt 25 (2.6, 18) Mainshaft bolt 70 (7.1, 52) Input shaft nut 190 (19, 140) Rear cover bolt 25 (2.6, 18) Back-up lamp switch 25 (2.6, 18) Concentric slave cylinder 21 (2.1, 15) Selector shaft bolt 20 (2.0, 15) Gear shift catch bolt 10 (1.0, 7) Reverse gear fork support bolt 25 (2.6, 18) Drain bolt 25 (2.6, 18) Selector shaft balls 23 (2.3, 17) MT-8 COMPONENTS [JH3] COMPONENTS Gear Components PFP:32010 A BCS000L6 B MT D E F G H I MCIB0130E 1. Oil channel 2. Mainshaft front bearing 3. Mainshaft 4. 1st main gear 5. Baulk ring 6. 1st & 2nd synchronizer hub 7. Spring 8. Roller 9. Stop ring 10. Adapter plate 11. 2nd main gear 12. 3rd main gear 13. 3rd & 4th synchronizer hub 14. 4th main gear 15. Support washer 16. Retaining clip 17. Mainshaft rear bearing 18. 5th main gear 19. Bolt 20. Bearing guide 21. Input shaft 22. Retaining clip 23. Input shaft rear bearing 24. Support washer 25. 2nd & 3rd gear bushing 26. 5th main gear 27. Baulk ring 28. Spread spring 29. 5th synchronizer hub 30. Spread spring 31. Friction cone 32. Baulk ring 33. Washer 34. Nut MT-9 J K L M COMPONENTS [JH3] Differential Gear 1 Oil seal 2 Differential side bearing 3 Differential case 4 Pinion mate gear 5 Bevel side gear 6 Pinion mate shaft 7 Shaft retaining spring 8 Side gear thrust washer BCS000L7 MCIA0170E Shift Control Components 1 Control assembly 2 Gear shift catch 3 Reverse gear brake fork and shaft 4 Fork rod (For 5th) 5 Lock pin 6 Reverse idler gear assembly 7 Fork rod (For 3rd and 4th) 8 Ring 9 Lock pin 10 Fork rod (For 1st and 2nd) 11 Check ball cartridge BCS000L8 12 Selector shaft bolt [20 N·m (2.0 kg-m, 15 ft-lb)] 13 Reverse gear fork shaft bolt [25 N·m (2.6 kg-m, 18 ft-lb)] MCIA0155E MT-10 COMPONENTS [JH3] Case Components BCS000L9 A 1 Transaxle case 2 Filler plug 3 Dowel pin 4 Oil gutter 5 Breather pipe 6 Back-up lamp switch 7 O-ring 8 Transaxle case cover 9 Gearbox edge bolt [25 N·m (2.6 kg-m, 18 ft-lb)] 10 Fifth gear housing bolt [25 N·m (2.6 kg-m, 18 ft-lb)] B MT D E F G MCIB0013E Clutch Housing BCS000LA 1 Clutch housing 2 Drain bolt [25 N·m (2.6 kg-m, 18 ft-lb)] 3 Magnet 4 Concentric slave cylinder 5 Concentric slave cylinder bolt [21 N·m (2.1 kg-m, 15 ft-lb)] H I J K L M MCIB0014E MT-11 CONTROL LINKAGE [JH3] CONTROL LINKAGE Removal and Installation of Control Device and Cable PFP:34103 BCS000LB MCIB0167E 1. Shift knob 2. Shift lever 3. Control device 4. Selector lever 5. Shift cable 6. Clutch housing 7. Cable bracket 1 8. Cable bracket 2* A. Black color B. White color *: Only for HR16DE Refer to GI section to make sure icons (symbol marks) in the figure. Refer to GI-11 . REMOVAL 1. Remove center console and shift boot. Refer to IP-4, "INSTRUMENT PANEL ASSEMBLY" . 2. Remove control device mounting bolts. 3. Pressing release bottom of cable end, remove cable from either manual transmission shift lever. 4. Lift up cable and remove it from cable bracket 1. 5. Remove center muffler and heat plate. Refer to EX-3, "Removal and Installation" , “EXHAUST SYSTEM”. 6. Remove cable bracket 2 from the vehicle. (Only for HR16DE) 7. Remove front and rear claws of control device. Remove control device and cable from the vehicle. NOTE: If shift knob needs to be removed, pull it up to remove. INSTALLATION Note the following, and install in the reverse order of removal. ● When installing, make sure to insert cable end into either manual transmission shift lever. ● After assembly, make sure selector lever automatically returns to Neutral when it is moved to 1st, 2nd, or Reverse. ● After installation, make sure that the shift to each position works well. ● When installing shift knob, press it onto selector lever. MT-12 RATIOS [JH3] RATIOS NISSAN Gearbox PFP:32010 A BCS000LC Engine Suffix First Second Third Fourth Fifth Reverse gear Final drive K9K (50 kw) JH3-162 11:37 22:41 28:37 30:29 42:31 11:39 15:58 CR14DE JH3-103 11:41 21:43 28:39 34:35 39:32 11:39 15:61 HR16DE JH3-149 12:41 22:43 29:39 35:35 40:32 12:39 16:61 B MT D E F G H I J K L M MT-13 CONSUMABLES [JH3] CONSUMABLES Description Types PFP:32010 BCS000LD Packaging Parts Department No. Component RHODORSEAL 100 g tubes 77 01 404 452 Housing assembly LOCTITE 518 24 ml syringe 77 01 421 162 Back-up lamp switch threading Gearbox oil Cover all parts MT-14 CAPACITIES - LUBRICANTS [JH3] CAPACITIES - LUBRICANTS Description Capacity 2.6 (4-5/8 Imp pt) PFP:32010 A BCS000LE Grade B Nissan Genuine gear oil Passenger Car or API GL-4 Viscosity 75W-80 Fill to the level of the oil filler cap hole. MT D MCIB0015E E F G H I J K L M MT-15 TROUBLE DIAGNOSIS [JH3] TROUBLE DIAGNOSIS Symptom Chart PFP:00004 BCS000LF Symptoms (after checking the clutch) Possible causes Oil level or grade External control Synchronizer Gear grinding 1 2 3 One or more gears cannot be selected 1 2 3 Gear disengagement 2 4 One or more gears locked 1 Symptoms Noisy Gearing Sliding gear hub Fork and balls Bearings Engine mounting - housing 4 4 4 4 1 3 3 1 2 3 2 NOTE: The numbers indicate the order of priority for diagnostics. Back-Up Lamp Switch ● BCS000LG Check continuity between terminals 1 and 2. Gear position Continuity Reverse Yes Except reverse No MCIA0157E Park/Neutral Position Switch ● BCS000LH Check continuity between terminals 2 and 3. Gear position Continuity Neutral Yes Except neutral No MT-16 PRECAUTIONS [JH3] PRECAUTIONS Precautions PFP:00001 A BCS000LI Removing and handling the parts must be carried out on a workbench with a knockproof cover. (rubber or thick plastic) B Cover all turning and synchronizer points in oil. Observe the tightening torques. Carefully carry out the specific settings and adjustments. MT Be sure to properly refit parts in the same order and position after removal. Marking the position of the sliding rods in relation to the hubs before removal is recommended. During refitting, make sure the inside of the box remains free of dust or impurities. D E F G H I J K L M MT-17 PARTS TO BE REPLACED SYSTEMATICALLY [JH3] PARTS TO BE REPLACED SYSTEMATICALLY Description If they have been removed: ● the lip seals, ● the O-rings, ● the gear supporting rings, ● the roll pins, ● the input shaft and mainshaft bearing circlips, ● the sliding gear hub springs. MT-18 PFP:32010 BCS000LJ CHECKING [JH3] CHECKING Bearings PFP:32010 A BCS000LK Check that the bearings show no signs of damage and that they turn evenly. Replace them if necessary. B MT D MCIB0017E E Gearing BCS000LL NOTE: The inspection focuses mainly on the appearance of the teeth, especially in terms of claw chamfers. 1. Check that the teeth (A) are not broken or chipped. 2. Check that the claws (B) are not broken, chipped or worn. 3. Check that the friction cone (C) shows no scratches or blueness. F G H MCIB0018E Synchronizer Ring I BCS000LM Check that the grooves and ridges on the ring are not worn or damaged. 1. Check that the ring puts onto the gear cone. 2. Check that the ring rotates while applying force in the direction of the cone (D). 3. Check that the ring should lock against the cone. Otherwise, replace the synchronizer ring. J K L MCIB0019E Sliding Gear Hub BCS000LN Make sure the sliding gear turns smoothly in the hub. Check that the rollers or keys are in good condition. MCIB0020E MT-19 M SEPARATING THE HOUSINGS [JH3] SEPARATING THE HOUSINGS Removal PFP:32010 BCS000LO Fit the B. Vi. 1581 support plate on a Desvil stand. Fit the gearbox on the B. Vi. 1581 support. MCIB0021E 1. 2. Remove the concentric slave cylinder. Remove the bolts located inside the housing. MCIB0022E 3. Remove the rear housing. This must be removed along the horizontal axis of the gearbox because it has a lubrication spline which is located in the input shaft bore. MCIB0023E 4. 5. 6. 7. Remove the two reverse gear fork support mounting bolts (A). Drive in the 5th gear fork using B. Vi. 31-01. Shift the 3rd gear on the gear selector lever and the 5th gear by sliding the 5th gear fork on its shaft. Remove the mainshaft bolt (B). Remove the input shaft nut (C). Remove the reverse gear synchronizer. Remove the 5th gear fork and sliding gear. MCIB0024E MT-20 SEPARATING THE HOUSINGS [JH3] Remove the 5th gear hub using B. Vi. 1170. To do this, fit the sliding gear B. Vi. 1170 and rotate it so that the splines are opposite those of the input shaft hub. A B MT MCIB0025E D Remove the fixed 5th gear using B. Vi. 22-01 and B. Vi. 100001. Remove the gearbox edge bolts. E F G MCIB0026E H Remove the back-up lamp switch (B). Engage 3rd gear. Lift and remove the mechanism housing. I J K MCIB0027E L M MT-21 REPAIRING THE GEARBOX [JH3] REPAIRING THE GEARBOX Removal 1. PFP:32010 BCS000LP Remove the 4th-gear pinion. MCIB0028E 2. Remove the 3rd/4th gear shaft/fork and sliding gear assembly while gently lifting the mainshaft assembly. MCIB0029E 3. Remove input shaft assembly. MCIB0030E 4. Remove mainshaft assembly. MCIB0031E MT-22 REPAIRING THE GEARBOX [JH3] 5. Remove the 1st/2nd shaft and fork and the 5th gear shaft. A B MT MCIB0032E D 6. Remove the pin from the reverse gear and remove the reverse gear. E F G MCIB0033E H I J K L M MT-23 MAINSHAFT [JH3] MAINSHAFT Removal 1. 2. PFP:32241 BCS000LQ Put the mainshaft in a vice with soft jaws. Remove the 4th main gear and the 3rd/4th gear sliding gear hub. MCIA0158E 3. Remove the stop ring (systematically replace) and the grooved washer. MCIA0159E 4. Remove the 3rd main gear and the grooved washer. MCIA0160E 5. Remove the stop ring (systematically replace) and the grooved washer. MCIA0161E MT-24 MAINSHAFT [JH3] 6. Remove the 2nd main gear and the grooved washer. A B MT MCIA0162E D 7. Remove the stop ring and the 1st/2nd gear sliding gear hub. E F G MCIA0163E Refitting BCS000LR Proceed in the reverse order of removal. The retaining rings must be systematically replaced. Oil the synchronizer rings. WARNING: Make sure that the notches on the synchronizer double cones are correctly positioned. H I J K MCIA0164E L M MT-25 TRANSAXLE CASE BEARING [JH3] TRANSAXLE CASE BEARING Removal PFP:32010 BCS000LS Remove the circlips with circlip pliers and drive the bearing inside the housing using tool B. Vi. 1576. MCIA0165E Refitting BCS000LT Place the new circlips in their respective housings. Fit the bearings using tool B. Vi. 1576. Knock the tool with the bearing using a small hammer. MT-26 CLUTCH HOUSING BEARING [JH3] CLUTCH HOUSING BEARING Removal PFP:32010 A BCS000LU Cut the base of the plastic hollow needle located at the centre of the bearing. Fit tool B. Vi. 1165 and extract the bearing. B MT D MCIA0166E E Refitting 1. 2. BCS000LV Fit a new deflector, then the bearing on the press flush with the inner surface of the housing. Set the bearing with a mortise chisel. F G H MCIA0167E I 3. Remove the input shaft bearing guide using the press and a 38 mm (1.50 in) diameter tube. J K L MCIB0044E 4. Refit the bearing guide using the press and tool B. Vi. 1601. M MCIB0045E MT-27 SELECTOR SHAFT RINGS [JH3] SELECTOR SHAFT RINGS Removal PFP:32010 BCS000LW Remove the rings with an inertia puller. MCIB0046E Refitting BCS000LX Refit the rings using a 14.5 mm (0.57 in) tube down to the thrust bearing. MCIB0047E MT-28 DIFFERENTIAL BEARINGS [JH3] DIFFERENTIAL BEARINGS Removal and Installation 1. PFP:32010 A BCS000LY Remove the bearing using an antisticking pin. B MT D MCIB0048E 2. E Refit the bearings using a 40 mm (1.57 in) tube. F G H MCIB0049E 3. Remove the bearing races using a roll pin punch. I J K MCIB0050E 4. L Refit the bearing races using tools C-F from the B. Vi. 1554 kit. M MCIB0051E MT-29 SELECTOR SHAFT [JH3] SELECTOR SHAFT Removal PFP:32010 BCS000LZ After removing the pin from the selector finger (B), remove the mounting bolts (C) and remove the control shaft unit. MCIB0052E MCIB0053E Refitting BCS000M0 Proceed in the reverse order to removal. NOTE: Replace the O-ring (D). MCIB0054E MT-30 ASSEMBLY [JH3] ASSEMBLY Refitting 1. PFP:00000 A BCS000M1 Fit the mainshaft and 1st/2nd gear fork assembly. B MT D MCIB0055E 2. E Fit the input shaft. F G H MCIB0056E 3. Fit the reverse gear assembly. I J K MCIB0057E 4. L Fit the two locking shafts. M MCIB0058E MT-31 ASSEMBLY [JH3] 5. Fit the 5th gear shaft and the 3rd/4th gear shaft/fork and sliding gear assembly while gently lifting the input shaft assembly. Rotate the reverse gear assembly to position the 5th gear fork (A). MCIB0059E 6. Pin the reverse gear assembly. MCIB0060E 7. Shift to 3rd gear and insert the rollers and clawing springs. MCIB0061E 8. Refit the 4th main gear fitted with its synchronizer ring. MCIB0028E MT-32 HOUSING ASSEMBLY [JH3] HOUSING ASSEMBLY Assembly 1. 2. PFP:32010 A BCS000M2 Fit the 1st/2nd, 3rd/4th, and 5th gear shaft ball cartridges into the housing mechanism. Engage 3rd gear. B MT D MCIB0062E 3. 4. E Check the positioning of the centring dowels (A). Check the positioning of magnet (B). F G H MCIB0063E 5. 6. Apply a line of LOCTITE 518 to the gasket face. Offer up the housing while guiding the selector finger (C) into fork (D) of the 3rd gear. I J K MCIB0064E 7. 8. 9. Pretighten the peripheral bolts and rotate the input shaft to check that they make contact with the bearings. Tighten the bolts to a torque of [25 N·m (2.6 kg-m, 18 ft-lb)]. Put three drops of LOCTITE Frenbloc on the splines of the fixed 5th gear and fit it using tool B. Vi. 1175. M MCIB0065E MT-33 L HOUSING ASSEMBLY [JH3] 10. On the input shaft, fit the support washer (top side gear side). 11. On the input shaft, fit the sprocket bushing. 12. On the input shaft, fit the 5th main gear fitted with its synchronizer ring. 13. On the input shaft, fit the 5th gear hub fitted with its spring. MCIB0066E 14. Refit the 5th gear fork/sliding gear/reverse gear fork assembly. 15. Fit the reverse gear synchronizer. 16. Screw on the reverse gear fork support and tighten the bolts (A) to a torque of [25 N·m (2.6 kg-m, 18 ft-lb)]. 17. Slide the 5th gear fork on its shaft to engage 5th gear. MCIB0067E 18. Tighten the gear bolt and nut to torque of: output shaft bolt (B) input shaft nut (C) : [70 N·m (7.1 kg-m, 52 ft-lb)] : [190 N·m (19 kg-m, 140 ft-lb)] 19. Reset to neutral and pin the 5th gear fork. MCIB0024E 20. Fit a new O-ring, position the 5th gear cover and tighten the bolts to a torque of [25 N·m (2.6 kg-m, 18 ft-lb)]. 21. Fit the back-up lamp switch (A) and tighten to a torque of [25 N·m (2.6 kg-m, 18 ft-lb)]. MCIB0068E 22. Refit the new differential output seals using B. Vi. 1666. MCIB0069E MT-34 HOUSING ASSEMBLY [JH3] 23. Refit the concentric slave cylinder and tighten the bolts. A Tightening torque : 21 N·m (2.1 kg-m, 15 ft-lb) B MT MCIB0022E D E F G H I J K L M MT-35 DESCRIPTION [JR5] DESCRIPTION Cross-Sectional View [JR5] PFP:00000 BCS000M3 MCIA0168E MT-36 REMOVAL AND INSTALLATION [JR5] REMOVAL AND INSTALLATION Removal PFP:00000 A BCS000M4 CAUTION: Remove the crankshaft position sensor (POS) from transaxle assembly before separating transaxle B from engine. Be careful not to damage sensor edge. 1. Remove battery. 2. Remove the air cleaner. Refer to EM-245, "AIR CLEANER AND AIR DUCT" . MT 3. Disconnect the cable end ball of the select cable, and the cable end of the shift cable. Refer to MT-42, "CONTROL LINKAGE" . 4. Disconnect the clutch tube. D 5. Remove the engine harness clamp. 6. Remove the starter. Refer to SC-51, "Removal and Installation (CR Engine Models)" , “STARTING SYSE TEM”. 7. Remove the engine mounting LH side installation bolt. Refer to . 8. Set the engine hanger. F G H MBIB0585E I 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. Lift up the vehicle and remove the front fender protectors (RH & LH). Remove the undercover. Remove the front exhaust pipe. Refer to EX-3, "Removal and Installation" , “EXHAUST SYSTEM”. Remove the turbocharger outlet tube bracket from the transaxle. Remove the RH and LH drive shafts. Refer to FAX-13, "Removal and Installation" , “FRONT DRIVE SHAFT”. Disconnect the ground cable from the transaxle. Set the transmission jack. Remove the rear engine mounting bracket. Then, remove the rear torque link from the transaxle. Refer to EM-279, "ENGINE ASSEMBLY" . CAUTION: Do not remove the rear torque link from the suspension member. Remove the engine mounting bracket LH. Disconnect the position switch connector. Remove the transaxle mounting nuts and bolts, and remove the transaxle. Installation BCS000M5 Install in the reverse order of removal. MT-37 J K L M TIGHTENING TORQUES [JR5] TIGHTENING TORQUES Description PFP:32010 BCS000M6 Tightening portion N·m (kg-m, ft-lb) Gearbox casing bolt 25 (2.6, 18) Mainshaft bolt 70 (7.1, 52) Input shaft nut 190 (19, 140) Rear cover bolt 25 (2.6, 18) Back-up lamp switch 25 (2.6, 18) Concentric slave cylinder 21 (2.1, 15) Selector shaft bolt 20 (2.0, 15) Gear shift catch bolt 10 (1.0, 7) Reverse gear fork support bolt 25 (2.6, 18) Drain bolt 25 (2.6, 18) Selector shaft balls 23 (2.3, 17) MT-38 COMPONENTS [JR5] COMPONENTS Gear Components PFP:32010 A BCS000M7 B MT D E F G H I MCIB0131E 1. Oil channel 2. Mainshaft front bearing 3. Mainshaft 4. 1st main gear 5. Synchronizer ring 6. Spread spring 7. 1st & 2nd synchronizer hub 8. Synchronizer ring 9. Mainshaft bearing 10. 2nd main gear 11. Adapter plate 12. Mainshaft bearing 13. 3rd main gear 14. Baulk ring 15. 3rd & 4th synchronizer hub and reverse gear 16. Baulk ring 17. Mainshaft bearing 18. 4th main gear 19. Adapter plate 20. Mainshaft rear bearing 21. 5th main gear 22. Bolt 23. Bearing guide 24. Input shaft 25. Retaining clip 26. Input shaft rear bearing 27. Adapter plate 28. 2nd & 3rd gear bushing 29. 5th main gear 30. Baulk ring 31. Spread spring 32. 5th synchronizer hub 33. Spread spring 34. Friction cone 35. Baulk ring 36. Washer 37. Nut MT-39 J K L M COMPONENTS [JR5] Differential Gear 1 Oil seal 2 Differential side bearing 3 Differential case 4 Pinion mate gear 5 Bevel side gear 6 Pinion mate shaft 7 Shaft retaining spring 8 Side gear thrust washer BCS000M8 MCIA0170E Shift Control Components 1 Control assembly 2 Gear shift catch 3 Reverse gear brake fork and shaft 4 Fork rod (For 5th) 5 Lock pin 6 Reverse idler gear assembly 7 Fork rod (For 3rd and 4th) 8 Ring 9 Lock pin 10 Fork rod (For 1st and 2nd) 11 Check ball cartridge BCS000M9 12 Selector shaft bolt [20 N·m (2.0 kg-m, 15 ft-lb)] 13 Reverse gear fork shaft bolt [25 N·m (2.6 kg-m, 18 ft-lb)] MCIA0155E MT-40 COMPONENTS [JR5] Case Components BCS000MA A 1 Transaxle case 2 Filler plug 3 Dowel pin 4 Oil gutter 5 Breather pipe 6 Back-up lamp switch 7 O-ring 8 Transaxle case cover 9 Gearbox edge bolt [25 N·m (2.6 kg-m, 18 ft-lb)] 10 Fifth gear housing bolt [25 N·m (2.6 kg-m, 18 ft-lb)] B MT D E F G MCIB0013E Clutch Housing BCS000MB 1 Clutch housing 2 Drain bolt [25 N·m (2.6 kg-m, 18 ft-lb)] 3 Magnet 4 Concentric slave cylinder 5 Concentric slave cylinder bolt [21 N·m (2.1 kg-m, 15 ft-lb)] H I J K L M MCIB0014E MT-41 CONTROL LINKAGE [JR5] CONTROL LINKAGE Removal and Installation of Control Device and Cable PFP:34103 BCS000MC MCIB0168E 1. Shift knob 2. Shift lever 3. Control device 4. Selector lever 5. Shift cable 6. Clutch housing B. White color 7. Cable bracket 1 A. Black color Refer to GI section to make sure icons (symbol marks) in the figure. Refer to GI-11 . REMOVAL 1. Remove center console and shift boot. Refer to IP-4, "INSTRUMENT PANEL ASSEMBLY" . 2. Remove control device mounting bolts. 3. Pressing release bottom of cable end, remove cable from either manual transmission shift lever. 4. Lift up cable and remove it from cable bracket 1. 5. Remove center muffler and heat plate. Refer to EX-3, "Removal and Installation" , “EXHAUST SYSTEM”. 6. Remove front and rear claws of control device. Remove control device and cable from the vehicle. NOTE: If shift knob needs to be removed, pull it up to remove. INSTALLATION Note the following, and install in the reverse order of removal. ● When installing, make sure to insert cable end into either manual transmission shift lever. ● After assembly, make sure selector lever automatically returns to Neutral when it is moved to 1st, 2nd, or Reverse. ● After installation, make sure that the shift to each position works well. ● When installing shift knob, press it onto selector lever. MT-42 RATIOS [JR5] RATIOS NISSAN Gearbox PFP:32010 A BCS000MD Engine Suffix First Second Third Fourth Fifth Reverse gear Final drive K9K (63 kw) JH5-140 11:41 21:43 28:37 35:34 42:31 11:39 15:56 B MT D E F G H I J K L M MT-43 CONSUMABLES [JR5] CONSUMABLES Description Types PFP:32010 BCS000ME Packaging Parts Department No. Component RHODORSEAL 100 g tubes 77 01 404 452 Housing assembly LOCTITE 518 24 ml syringe 77 01 421 162 Back-up lamp switch threading Gearbox oil Cover all parts MT-44 CAPACITIES - LUBRICANTS [JR5] CAPACITIES - LUBRICANTS Description Capacity 2.6 (4-5/8 Imp pt) PFP:32010 A BCS000MF Grade B Nissan Genuine gear oil Passenger Car or API GL-4 Viscosity 75W-80 Fill to the level of the oil filler cap hole. MT D MCIB0015E E F G H I J K L M MT-45 TROUBLE DIAGNOSIS [JR5] TROUBLE DIAGNOSIS Symptom Chart PFP:00004 BCS000MG Symptoms (after checking the clutch) Possible causes Oil level or grade External control Synchronizer Gear grinding 1 2 3 One or more gears cannot be selected 1 2 3 Gear disengagement 2 4 One or more gears locked 1 Symptoms Noisy Gearing Sliding gear hub Fork and balls Bearings Engine mounting - housing 4 4 4 4 1 3 3 1 2 3 2 NOTE: The numbers indicate the order of priority for diagnostics. Back-Up Lamp Switch ● BCS000MH Check continuity between terminals 1 and 2. Gear position Continuity Reverse Yes Except reverse No MCIA0157E Park/Neutral Position Switch ● BCS000MI Check continuity between terminals 2 and 3. Gear position Continuity Neutral Yes Except neutral No MT-46 PRECAUTIONS [JR5] PRECAUTIONS Precautions PFP:00001 A BCS000MJ Removing and handling the parts must be carried out on a workbench with a knockproof cover. (rubber or thick plastic) B Cover all turning and synchronizer points in oil. Observe the tightening torques. Carefully carry out the specific settings and adjustments. MT Be sure to properly refit parts in the same order and position after removal. Marking the position of the sliding rods in relation to the hubs before removal is recommended. During refitting, make sure the inside of the box remains free of dust or impurities. D E F G H I J K L M MT-47 PARTS TO BE REPLACED SYSTEMATICALLY [JR5] PARTS TO BE REPLACED SYSTEMATICALLY Description If they have been removed: ● the lip seals, ● the O-rings, ● the gear supporting rings, ● the roll pins, ● the input shaft and mainshaft bearing circlips, ● the sliding gear hub springs. MT-48 PFP:32010 BCS000MK CHECKING [JR5] CHECKING Bearings PFP:32010 A BCS000ML Check that the bearings show no signs of damage and that they turn evenly. Replace them if necessary. B MT D MCIB0017E E Gearing BCS000MM NOTE: The inspection focuses mainly on the appearance of the teeth, especially in terms of claw chamfers. 1. Check that the teeth (A) are not broken or chipped. 2. Check that the claws (B) are not broken, chipped or worn. 3. Check that the friction cone (C) shows no scratches or blueness. F G H MCIB0018E Synchronizer Ring I BCS000MN Check that the grooves and ridges on the ring are not worn or damaged. 1. Check that the ring puts onto the gear cone. 2. Check that the ring rotates while applying force in the direction of the cone (D). 3. Check that the ring should lock against the cone. Otherwise, replace the synchronizer ring. J K L MCIB0019E Sliding Gear Hub BCS000MO Make sure the sliding gear turns smoothly in the hub. Check that the rollers or keys are in good condition. MCIB0020E MT-49 M SEPARATING THE HOUSINGS [JR5] SEPARATING THE HOUSINGS Removal PFP:32010 BCS000MP Fit the B. Vi. 1581 support plate on a Desvil stand. Fit the gearbox on the B. Vi. 1581 support. MCIB0021E 1. 2. Remove the concentric slave cylinder. Remove the bolts located inside the housing. MCIB0022E 3. Remove the rear housing. This must be removed along the horizontal axis of the gearbox because it has a lubrication spline which is located in the input shaft bore. MCIB0023E 4. 5. 6. 7. Remove the two reverse gear fork support mounting bolts (A). Drive in the 5th gear fork using B. Vi. 31-01. Shift the 3rd gear on the gear selector lever and the 5th gear by sliding the 5th gear fork on its shaft. Remove the mainshaft bolt (B). Remove the input shaft nut (C). Remove the reverse gear synchronizer. Remove the 5th gear fork and sliding gear. MCIB0024E MT-50 SEPARATING THE HOUSINGS [JR5] Remove the 5th gear hub using B. Vi. 1170. To do this, fit the sliding gear B. Vi. 1170 and rotate it so that the splines are opposite those of the input shaft hub. A B MT MCIB0025E D Remove the fixed 5th gear using B. Vi. 22-01 and B. Vi. 100001. Remove the gearbox edge bolts. E F G MCIB0026E H Remove the back-up lamp switch (B). Engage 3rd gear. Lift and remove the mechanism housing. I J K MCIB0027E L M MT-51 REPAIRING THE GEARBOX [JR5] REPAIRING THE GEARBOX Removal 1. PFP:32010 BCS000MQ Remove the 4th-gear pinion. MCIB0028E 2. Remove the 3rd/4th gear shaft/fork and sliding gear assembly while gently lifting the mainshaft assembly. MCIB0029E 3. Remove input shaft assembly. MCIB0030E 4. Remove mainshaft assembly. MCIB0031E MT-52 REPAIRING THE GEARBOX [JR5] 5. Remove the 1st/2nd shaft and fork and the 5th gear shaft. A B MT MCIB0032E D 6. Remove the pin from the reverse gear and remove the reverse gear. E F G MCIB0033E Removing the Gearing BCS000MR NOTE: The rings underneath the 2nd, 3rd and 4th gears are fitted tightened. They will be systematically replaced during refitting. 1. Remove the ring/hub/3rd gear assembly with the press, resting underneath the 3rd gear claw teeth. H I J K MCIB0072E 2. L Remove the rings/1st and 2nd gears/hub/sliding gear assembly with the press, resting underneath the 1st gear. M MCIB0073E Checking Parts BCS000MS The sprocket teeth and the claws should not be chipped or excessively worn. Also ensure that there are no signs of grating or abnormal wear on the surfaces of the shafts or the inner walls of the sprockets. It is advisable to mark the position of the sliding shafts in relation to the hub. MT-53 REPAIRING THE GEARBOX [JR5] Refitting the Gearing BCS000MT A hot plate with a setting of 150°C (302°F) should be used for refitting. Place the new rings on the cold hot plate. Heat them for 15 minutes with a thermostat setting of 150°C (302°F). MCIB0074E Proceed in the reverse order to removal. Refit the rings: Remove a ring from the heating plate, using pliers, and use a tube with an internal diameter of 33 mm (1.30 in) to fit it on the shaft until it is resting on the hub. NOTE: The 1st/2nd gear has double-cone synchronizer, bring the notches of the synchro rings together with those on the hubs and gears. MCIB0075E MT-54 TRANSAXLE CASE BEARING [JR5] TRANSAXLE CASE BEARING Removing the Bearing, Input Shaft Side PFP:32010 A BCS000MU Remove the circlips and drive the bearing inside the housing using tool B. Vi. 1576. B MT D MCIB0076E E Refitting 1. 2. 3. BCS000MV Fit a new circlip. Fit the bearing using tool B. Vi. 1576. Remove the bearing race, output shaft side using a tube with a diameter of 55 mm (2.17 in). F G H MCIB0077E I 4. Refit the race using a 60 mm (2.36 in) diameter tube. J K L MCIB0078E M MT-55 CLUTCH HOUSING BEARING [JR5] CLUTCH HOUSING BEARING Removal and Installation 1. PFP:32010 BCS000MW Cut the base of the deflector plastic hollow needle located at the centre of the bearing. Drive out the cup using a puller. MCIB0079E 2. Fit a new deflector, then the bearing race using a 55 mm (2.17 in) diameter tube. MCIB0080E 3. Remove the input shaft bearing guide using the press and a 38 mm (1.50 in) diameter tube. MCIB0044E 4. Refit the bearing guide using the press and tool B. Vi. 1601. MCIB0045E MT-56 SELECTOR SHAFT RINGS [JR5] SELECTOR SHAFT RINGS Removal PFP:32010 A BCS000MX Remove the rings with an inertia puller. B MT D MCIB0046E E Refitting BCS000MY Refit the rings using a 14.5 mm (0.57 in) tube down to the thrust bearing. F G H MCIB0047E I J K L M MT-57 DIFFERENTIAL BEARINGS [JR5] DIFFERENTIAL BEARINGS Removal and Installation 1. PFP:32010 BCS000MZ Remove the bearing using an antisticking pin. MCIB0048E 2. Refit the bearings using a 40 mm (1.57 in) tube. MCIB0049E 3. Remove the bearing races using a roll pin punch. MCIB0050E 4. Refit the bearing races using tools C-F from the B. Vi. 1554 kit. MCIB0051E MT-58 SELECTOR SHAFT [JR5] SELECTOR SHAFT Removal PFP:32010 A BCS000N0 After removing the pin from the selector finger (B), remove the mounting bolts (C) and remove the control shaft unit. B MT D MCIB0052E E F G H MCIB0053E Refitting BCS000N1 Proceed in the reverse order to removal. NOTE: Replace the O-ring (D). I J K L MCIB0054E M MT-59 REPAIRING THE GEARBOX [JR5] REPAIRING THE GEARBOX Setting the Pre-tensioning of the Output Shaft Bearings PFP:32010 BCS000N2 NOTE: This operation is carried out in the event of replacing the bearings, housings or mainshaft. Clutch housing without differential and without input shaft. Fit the mainshaft in the clutch housing with the bearings and the presetting washer B. Vi. 1161, or equivalent, of 1.60 mm (0.06 in) (large outer ý). Fit the transaxle case assembly. Fit and tighten to torque the box belt bolts. Fit the dial gauge support plate B. Vi. 1161, or equivalent, on the tripod basin mountings. MCIB0081E 1. 2. 3. Fit the B. Vi. 1527 special spacer (A). Fit the bolt (C). Fit the dial gauge with its magnetic holder. 1 Rotate the mainshaft several times to fit the bearings. 2 Set the dial gauge to zero. 3 Pull the mainshaft upwards by making a lever out of two screwdrivers. 4 Take a reading from the dial gauge. Repeat the operations several times (1 to 4). MCIB0082E Calculate the average of the readings. Calculation of the value of the pre-load washer. Prescribed value + value of the pre-setting washer + average of the readings on the dial gauge = value of the pre-tensioning dial gauge washer. Example: [Value in mm (in)] 0.26 + 0.49 + 1.60 = 2.35 ↓ ↓ ↓ ↓ Prescribed value Average reading Pre-setting washer value Pre-load washer value NOTE: A set of pre-load washers of 2.15 mm (0.08 in) to 2.43 mm (0.10 in) from 0.04 mm (0.002 in) to 0.04 mm (0.002 in) thickness is supplied as replacement parts. MT-60 ASSEMBLY [JR5] ASSEMBLY Refitting 1. PFP:00000 A BCS000N3 Fit the mainshaft and 1st/2nd gear fork assembly. B MT D MCIB0055E 2. E Fit the input shaft. F G H MCIB0056E 3. Fit the reverse gear assembly. I J K MCIB0057E 4. L Fit the two locking shafts. M MCIB0058E MT-61 ASSEMBLY [JR5] 5. Fit the 5th gear shaft and the 3rd/4th gear shaft/fork and sliding gear assembly while gently lifting the input shaft assembly. Rotate the reverse gear assembly to position the 5th gear fork (A). MCIB0059E 6. Pin the reverse gear assembly. MCIB0060E 7. Shift to 3rd gear and insert the rollers and clawing springs. MCIB0061E 8. Refit the 4th main gear fitted with its synchronizer ring. MCIB0028E MT-62 HOUSING ASSEMBLY [JR5] HOUSING ASSEMBLY Assembly 1. 2. PFP:32010 A BCS000N4 Fit the 1st/2nd, 3rd/4th, and 5th gear locking balls into the transaxle case. Engage 3rd gear. B MT D MCIB0062E 3. 4. E Check the positioning of the centring dowels (A). Check the positioning of magnet (B). F G H MCIB0063E 5. 6. Apply a line of LOCTITE 518 to the gasket face. Offer up the housing while guiding the selector finger (C) into fork (D) of the 3rd gear. I J K MCIB0064E 7. 8. 9. Pretighten the peripheral bolts and rotate the input shaft to check that they make contact with the bearings. Tighten the bolts to a torque of [25 N·m (2.6 kg-m, 18 ft-lb)]. Put three drops of LOCTITE Frenbloc on the splines of the fixed 5th gear and fit it using tool B. Vi. 1175. M MCIB0065E MT-63 L HOUSING ASSEMBLY [JR5] 10. On the input shaft, fit the support washer (top side gear side). 11. On the input shaft, fit the sprocket bushing. 12. On the input shaft, fit the 5th main gear fitted with its synchronizer ring. 13. On the input shaft, fit the 5th gear hub fitted with its spring. MCIB0066E 14. Refit the 5th gear fork/sliding gear/reverse gear fork assembly. 15. Fit the reverse gear synchronizer. 16. Screw on the reverse gear fork support and tighten the bolts (A) to a torque of [25 N·m (2.6 kg-m, 18 ft-lb)]. 17. Slide the 5th gear fork on its shaft to engage 5th gear. MCIB0067E 18. Tighten the gear bolt and nut to torque of: output shaft bolt (B) input shaft nut (C) : [70 N·m (7.1 kg-m, 52 ft-lb)] : [190 N·m (19 kg-m, 140 ft-lb)] 19. Reset to neutral and pin the 5th gear fork. MCIB0024E 20. Fit a new O-ring, position the 5th gear cover and tighten the bolts to a torque of [25 N·m (2.6 kg-m, 18 ft-lb)]. 21. Fit the back-up lamp switch (A) and tighten to a torque of [25 N·m (2.6 kg-m, 18 ft-lb)]. MCIB0068E 22. Refit the new differential output seals using B. Vi. 1666. MCIB0069E MT-64 HOUSING ASSEMBLY [JR5] 23. Refit the concentric slave cylinder and tighten the bolts. A Tightening torque : 21 N·m (2.1 kg-m, 15 ft-lb) B MT MCIB0022E D E F G H I J K L M MT-65 HOUSING ASSEMBLY [JR5] MT-66 MANUAL AIR CONDITIONER J AIR CONDITIONER SECTION MTC MANUAL AIR CONDITIONER A B C D CONTENTS PRECAUTIONS .......................................................... 4 Precautions for Supplemental Restraint System (SRS) “AIR BAG” and “SEAT BELT PRE-TENSIONER” .................................................................. 4 PrecautionsforProcedureswithoutCowlTopCover..... 4 Precautions for Working with HFC-134a (R-134a)..... 4 General Refrigerant Precautions .............................. 4 Lubricant Precautions .............................................. 5 Precautions for Refrigerant Connection ................... 5 FEATURES OF NEW TYPE REFRIGERANT CONNECTION ...................................................... 5 O-RING AND REFRIGERANT CONNECTION..... 6 Precautions for Servicing Compressor ..................... 8 Precautions for Service Equipment .......................... 8 RECOVERY/RECYCLING EQUIPMENT .............. 8 ELECTRONIC LEAK DETECTOR ........................ 8 VACUUM PUMP ................................................... 9 MANIFOLD GAUGE SET ...................................... 9 SERVICE HOSES ................................................. 9 SERVICE COUPLERS ........................................ 10 REFRIGERANT WEIGHT SCALE ...................... 10 CALIBRATING ACR4 WEIGHT SCALE .............. 10 CHARGING CYLINDER ...................................... 10 Precautions for Leak Detection Dye ........................11 IDENTIFICATION .................................................11 IDENTIFICATION LABEL FOR VEHICLE ............11 PREPARATION ......................................................... 12 HFC-134a (R-134a) Service Tools and Equipment... 12 Commercial Service Tools ...................................... 14 REFRIGERATION SYSTEM ..................................... 15 Refrigerant Cycle ................................................... 15 REFRIGERANT FLOW ....................................... 15 FREEZE PROTECTION ..................................... 15 Refrigerant System Protection ............................... 15 REFRIGERANT PRESSURE SENSOR ............. 15 PRESSURE RELIEF VALVE ............................... 15 Component Layout ................................................. 16 LUBRICANT .............................................................. 17 Maintenance of Lubricant Quantity in Compressor... 17 LUBRICANT ........................................................ 17 LUBRICANT RETURN OPERATION .................. 17 LUBRICANT ADJUSTING PROCEDURE FOR COMPONENTS REPLACEMENT EXCEPT COMPRESSOR .................................................. 18 LUBRICANT ADJUSTING PROCEDURE FOR COMPRESSOR REPLACEMENT ....................... 18 AIR CONDITIONER CONTROL ............................... 20 Control Operation ................................................... 20 FAN CONTROL DIAL .......................................... 20 TEMPERATURE CONTROL DIAL ...................... 20 MODE CONTROL DIAL ...................................... 20 INTAKE DOOR LEVER ....................................... 20 REAR WINDOW DEFOGGER SWITCH ............. 20 A/C SWITCH ....................................................... 20 Discharge Air Flow ................................................. 21 System Description ................................................. 22 SWITCHES AND THEIR CONTROL FUNCTION... 22 CAN Communication System Description .............. 22 TROUBLE DIAGNOSIS ............................................ 23 CONSULT-II Function (BCM) ................................. 23 CONSULT-II BASIC OPERATION ....................... 23 DATA MONITOR ................................................. 23 How to Perform Trouble Diagnosis for Quick and Accurate Repair ...................................................... 24 WORK FLOW ...................................................... 24 SYMPTOM TABLE .............................................. 24 Component Parts and Harness Connector Location... 25 Wiring Diagram — HEATER — .............................. 26 Wiring Diagram — A/C — CR Engine Models ........ 27 Wiring Diagram — A/C — HR Engine Models ........ 29 Wiring Diagram — A/C — K9K Engine Models ...... 31 Wiring Diagram — PTC/H — .................................. 33 Operational Check .................................................. 34 CHECKING BLOWER ......................................... 34 CHECKING DISCHARGE AIR ............................ 34 CHECKING RECIRCULATION ........................... 34 CHECKING TEMPERATURE DECREASE ......... 35 MTC-1 E F G H I MTC K L M CHECKING TEMPERATURE INCREASE .......... 35 CHECKING A/C SWITCH ................................... 35 Mode Door .............................................................. 36 INSPECTION FLOW ........................................... 36 Air Mix Door ............................................................ 37 INSPECTION FLOW ........................................... 37 Intake Door ............................................................. 38 INSPECTION FLOW ........................................... 38 Blower Motor Circuit ............................................... 39 INSPECTION FLOW ........................................... 39 DIAGNOSTIC PROCEDURE FOR BLOWER MOTOR ............................................................... 39 COMPONENT INSPECTION .............................. 42 Magnet Clutch Circuit ............................................. 43 INSPECTION FLOW ........................................... 43 SYSTEM DESCRIPTION .................................... 44 DIAGNOSTIC PROCEDURE FOR MAGNET CLUTCH .............................................................. 44 COMPONENT INSPECTION .............................. 51 Insufficient Cooling ................................................. 52 INSPECTION FLOW ........................................... 52 PERFORMANCE TEST DIAGNOSIS ................. 53 PERFORMANCE CHART ................................... 55 TROUBLE DIAGNOSIS FOR UNUSUAL PRESSURE ................................................................... 56 Insufficient Heating ................................................. 59 INSPECTION FLOW ........................................... 59 Noise ...................................................................... 60 INSPECTION FLOW ........................................... 60 CONTROLLER .......................................................... 62 Removal and Installation ........................................ 62 REMOVAL ........................................................... 62 INSTALLATION .................................................... 62 Disassembly and Assembly .................................... 63 THERMO CONTROL AMPLIFIER ............................ 64 Removal and Installation ........................................ 64 REMOVAL ........................................................... 64 INSTALLATION .................................................... 64 A/C UNIT ASSEMBLY .............................................. 65 Removal and Installation ........................................ 65 REMOVAL ........................................................... 65 INSTALLATION .................................................... 66 Disassembly and Assembly .................................... 67 BLOWER MOTOR .................................................... 69 Removal and Installation ........................................ 69 REMOVAL ........................................................... 69 INSTALLATION .................................................... 69 INTAKE DOOR .......................................................... 70 Intake Door Cable Adjustment ................................ 70 AIR MIX DOOR ......................................................... 71 Air Mix Door Cable Adjustment .............................. 71 MODE DOOR ............................................................ 72 Mode Door Cable Adjustment ................................ 72 BLOWER FAN RESISTOR ....................................... 73 Removal and Installation ........................................ 73 REMOVAL ........................................................... 73 INSTALLATION .................................................... 73 HEATER CORE .........................................................74 Removal and Installation .........................................74 REMOVAL ............................................................74 INSTALLATION ....................................................74 AIR CONDITIONER FILTER .....................................75 Removal and Installation .........................................75 FUNCTION ..........................................................75 REPLACEMENT TIMING ....................................75 REPLACEMENT PROCEDURES ........................75 DUCTS AND GRILLES .............................................76 Removal and Installation .........................................76 REMOVAL ............................................................76 INSTALLATION ....................................................80 REFRIGERANT LINES .............................................81 HFC-134a (R-134a) Service Procedure ..................81 SETTING OF SERVICE TOOLS AND EQUIPMENT ...................................................................81 Components ............................................................83 CR ENGINE MODELS .........................................83 HR ENGINE MODELS .........................................84 K9K ENGINE MODELS .......................................85 Removal and Installation of Compressor ................86 REMOVAL ............................................................86 INSTALLATION ....................................................86 CHECK DISC TO PULLEY CLEARANCE ...........87 Removal and Installation for Pipe and Hose ...........87 REMOVAL ............................................................87 INSTALLATION ....................................................87 Removal and Installation for Refrigerant Pressure Sensor .....................................................................88 REMOVAL AND INSTALLATION .........................88 Removal and Installation for Condenser (Models without Integrated Condenser) ................................88 REMOVAL ............................................................88 INSTALLATION ....................................................89 Removal and Installation for Condenser (Models with Integrated Condenser) .....................................89 REMOVAL ............................................................89 INSTALLATION ....................................................89 RemovalandInstallationforLiquidTank(HREngine with A/T Models) .....................................................90 REMOVAL ............................................................90 INSTALLATION ....................................................90 RemovalandInstallationforLiquidTank(ExceptHR Engine with A/T Models) .........................................90 REMOVAL ............................................................90 INSTALLATION ....................................................91 Removal and Installation for Evaporator .................91 REMOVAL ............................................................91 INSTALLATION ....................................................91 Removal and Installation for Expansion Valve ........91 REMOVAL ............................................................91 INSTALLATION ....................................................92 Checking for Refrigerant Leaks ..............................93 Checking System for Leaks Using the Fluorescent Leak Detector ..........................................................93 Dye Injection ...........................................................93 Electronic Refrigerant Leak Detector ......................94 PRECAUTIONS FOR HANDLING LEAK MTC-2 DETECTOR ........................................................ 94 CHECKING PROCEDURE ................................. 95 SERVICE DATA AND SPECIFICATIONS (SDS) ...... 97 COMPRESSOR ..................................................... 97 LUBRICANT ........................................................... 97 REFRIGERANT ...................................................... 97 ENGINE IDLING SPEED ........................................ 97 BELT TENSION ...................................................... 97 A B C D E F G H I MTC K L M MTC-3 PRECAUTIONS PFP:00001 PRECAUTIONS Precautions for Supplemental Restraint System (SRS) “AIR BAG” and “SEAT BELT PRE-TENSIONER” BJS000CW The Supplemental Restraint System such as “AIR BAG” and “SEAT BELT PRE-TENSIONER”, used along with a front seat belt, helps to reduce the risk or severity of injury to the driver and front passenger for certain types of collision. Information necessary to service the system safely is included in the SRS and SB section of this Service Manual. WARNING: ● To avoid rendering the SRS inoperative, which could increase the risk of personal injury or death in the event of a collision which would result in air bag inflation, all maintenance must be performed by an authorized NISSAN/INFINITI dealer. ● Improper maintenance, including incorrect removal and installation of the SRS, can lead to personal injury caused by unintentional activation of the system. For removal of Spiral Cable and Air Bag Module, see the SRS section. ● Do not use electrical test equipment on any circuit related to the SRS unless instructed to in this Service Manual. SRS wiring harnesses can be identified by yellow and/or orange harnesses or harness connectors. Precautions for Procedures without Cowl Top Cover BJS000CX When performing the procedure after removing cowl top cover, cover the lower end of windshield with urethane, etc. PIIB3706J Precautions for Working with HFC-134a (R-134a) BJS000CY WARNING: ● Use only specified lubricant for the HFC-134a (R-134a) A/C system and HFC-134a (R-134a) components. If lubricant other than that specified is used, compressor malfunction is likely to occur. ● The specified HFC-134a (R-134a) lubricant rapidly absorbs moisture from the atmosphere. The following handling precautions must be observed: – When removing refrigerant components from a vehicle, immediately cap (seal) the component to minimize the entry of moisture from the atmosphere. – When installing refrigerant components to a vehicle, do not remove the caps (unseal) until just before connecting the components. Connect all refrigerant loop components as quickly as possible to minimize the entry of moisture into system. – Only use the specified lubricant from a sealed container. Immediately reseal containers of lubricant. Without proper sealing, lubricant will become moisture saturated and should not be used. – Avoid breathing A/C refrigerant and lubricant vapor or mist. Exposure may irritate eyes, nose and throat. Use only approved recovery/recycling equipment to discharge HFC-134a (R-134a) refrigerant. If accidental system discharge occurs, ventilate work area before resuming service. Additional health and safety information may be obtained from refrigerant and lubricant manufacturers. – Do not allow lubricant (Nissan A/C System Oil Type R) to come in contact with styrofoam parts. Damage may result. General Refrigerant Precautions BJS000CZ WARNING: ● Do not release refrigerant into the air. Use approved recovery/recycling equipment to capture the refrigerant every time an air conditioning system is discharged. MTC-4 PRECAUTIONS ● ● ● ● ● ● ● Always wear eye and hand protection (goggles and gloves) when working with any refrigerant or air conditioning system. Do not store or heat refrigerant containers above 52°C. Do not heat a refrigerant container with an open flame; if container warming is required, place the bottom of the container in a warm pail of water. Do not intentionally drop, puncture, or incinerate refrigerant containers. Keep refrigerant away from open flames: poisonous gas will be produced if refrigerant burns. Refrigerant will displace oxygen, therefore be certain to work in well ventilated areas to prevent suffocation. Do not pressure test or leak test HFC-134a (R-134a) service equipment and/or vehicle air conditioning systems with compressed air during repair. Some mixtures of air and HFC-134a (R-134a) have been shown to be combustible at elevated pressures. These mixtures, if ignited, may cause injury or property damage. Additional health and safety information may be obtained from refrigerant manufacturers. Lubricant Precautions ● ● – – – ● ● B C D E BJS000D0 Use only specified lubricant for the HFC-134a (R-134a) A/C system and HFC-134a (R-134a) components. F If lubricant other than that specified is used, compressor malfunction is likely to occur. The specified HFC-134a (R-134a) lubricant rapidly absorbs moisture from the atmosphere. The following handling precautions must be observed: When removing refrigerant components from a vehicle, immediately cap (seal) the component to minimize G the entry of moisture from the atmosphere. When installing refrigerant components to a vehicle, do not remove the caps (unseal) until just before connecting the components. Connect all refrigerant loop components as quickly as possible to minimize the H entry of moisture into system. Only use the specified lubricant from a sealed container. Immediately reseal containers of lubricant. WithI out proper sealing, lubricant will become moisture saturated and should not be used. Avoid breathing A/C refrigerant and lubricant vapor or mist. Exposure may irritate eyes, nose and throat. Use only approved recovery/recycling equipment to discharge HFC-134a (R-134a) refrigerant. If accidental system discharge occurs, ventilate work area before resuming service. Additional health and safety MTC information may be obtained from refrigerant and lubricant manufacturers. Do not allow lubricant (Nissan A/C System Oil Type R) to come in contact with styrofoam parts. Damage may result. K Precautions for Refrigerant Connection BJS000D1 A new type refrigerant connection has been introduced to all refrigerant lines except the following location. ● Expansion valve to evaporator ● Refrigerant pressure sensor to condenser FEATURES OF NEW TYPE REFRIGERANT CONNECTION ● A The O-ring has been relocated. It has also been provided with a groove for proper installation. This eliminates the chance of the O-ring being caught in, or damaged by, the mating part. The sealing direction of the O-ring is now set vertically in relation to the contacting surface of the mating part to improve sealing characteristics. MTC-5 L M PRECAUTIONS ● The reaction force of the O-ring will not occur in the direction that causes the joint to pull out, thereby facilitating piping connections. SHA815E O-RING AND REFRIGERANT CONNECTION CAUTION: The new and former refrigerant connections use different O-ring configurations. Do not confuse Orings since they are not interchangeable. If a wrong O-ring is installed, refrigerant will leak at, or around, the connection. O-Ring Part Numbers and Specifications (CR Engine Models) Connection type New Piping connection point Part number Qty. Low-pressure flexible hose to heater & cooling unit 92473 BC700 1 High-pressure pipe to heater & cooling unit 92471 BC700 1 Condenser to high-pressure flexible hose 92472 BC700 1 Condenser to high-pressure pipe 92471 BC700 1 Compressor to low-pressure flexible hose 92474 BC700 1 Compressor to high-pressure flexible hose 92472 BC700 1 Liquid tank to condenser pipe 92471 N8210 1 — – Inlet 92477 AX000 1 Outlet 92477 AX005 1 Refrigerant pressure sensor Former Expansion valve to evaporator Remarks O-Ring Part Numbers and Specifications (HR Engine Models) Connection type New Part number Qty. Low-pressure flexible hose to heater & cooling unit Piping connection point 92473 N8210 1 High-pressure pipe to heater & cooling unit 92471 N8210 1 Condenser to high-pressure flexible hose 92472 N8210 1 Condenser to high-pressure pipe 92471 N8210 1 Compressor to low-pressure flexible hose 92474 N8210 1 Compressor to high-pressure flexible hose 92472 N8210 1 Liquid tank to condenser pipe 92471 N8210 1 — – Inlet 92477 AX000 1 Outlet 92477 AX005 1 Refrigerant pressure sensor Former Expansion valve to evaporator MTC-6 Remarks PRECAUTIONS O-Ring Part Numbers and Specifications (K9K Engine Models) Connection type New Piping connection point Part number Qty. Low-pressure flexible hose to heater & cooling unit 92473 N8210 1 Low-pressure flexible hose to Low-pressure pipe 92473 N8210 1 High-pressure pipe to heater & cooling unit 92471 N8210 1 Condenser to high-pressure flexible hose 92472 N8210 1 Condenser to high-pressure pipe 92471 N8210 1 Compressor to low-pressure flexible hose 92474 N8210 1 Compressor to high-pressure flexible hose 92472 N8210 1 Liquid tank to condenser pipe 92471 N8210 1 — – Inlet 92477 AX000 1 Outlet 92477 AX005 1 Refrigerant pressure sensor Former Expansion valve to evaporator Remarks A B C D E WARNING: Make sure all refrigerant is discharged into the recycling equipment and the pressure in the system is F less than atmospheric pressure. Then gradually loosen the discharge side hose fitting and remove it. CAUTION: G When replacing or cleaning refrigerant cycle components, observe the following. ● When the compressor is removed, store it in the same position as it is when mounted on the car. Malfunction to do so will cause lubricant to enter the low-pressure chamber. H ● When connecting tubes, always use a torque wrench and a back-up wrench. ● After disconnecting tubes, immediately plug all openings to prevent entry of dirt and moisture. ● When installing an air conditioner in the vehicle, connect the pipes as the final stage of the operaI tion. Do not remove the seal caps of pipes and other components until just before required for connection. ● Allow components stored in cool areas to warm to working area temperature before removing seal MTC caps. This prevents condensation from forming inside A/C components. ● Thoroughly remove moisture from the refrigeration system before charging the refrigerant. ● Always replace used O-rings. K ● When connecting tube, apply lubricant to circle of the O-rings shown in illustration. Be careful not to apply lubricant to threaded portion. Name Parts number ● ● ● Gasoline engine K9K engine Nissan A/C System Oil Type R Nissan A/C System Oil Type S KLH00 - PAGR0 KLH00 - PAGS0 O-ring must be closely attached to dented portion of tube. When replacing the O-ring, be careful not to damage O-ring and tube. Connect tube until you hear it click, then tighten the nut or bolt by hand until snug. Make sure that the O-ring is installed to tube correctly. MTC-7 L M PRECAUTIONS ● After connecting line, perform leak test and make sure that there is no leakage from connections. When the refrigerant leaking point is found, disconnect that line and replace the O-ring. Then tighten connections of seal seat to the specified torque. RHA861F Precautions for Servicing Compressor ● ● ● ● ● ● BJS000D2 Plug all openings to prevent moisture and foreign matter from entering. When the compressor is removed, store it in the same position as it is when mounted on the car. When replacing or repairing compressor, follow “Maintenance of Lubricant Quantity in Compressor” exactly. Refer to MTC-17, "Maintenance of Lubricant Quantity in Compressor" . Keep friction surfaces between clutch and pulley clean. If the surface is contaminated, with lubricant, wipe it off by using a clean waste cloth moistened with thinner. After compressor service operation, turn the compressor shaft by hand more than five turns in both directions. This will equally distribute lubricant inside the compressor. After the compressor is installed, let the engine idle and operate the compressor for one hour. After replacing the compressor magnet clutch, apply voltage to the new one and check for usual operation. Precautions for Service Equipment BJS000D3 RECOVERY/RECYCLING EQUIPMENT Be certain to follow the manufacturer’s instructions for machine operation and machine maintenance. Never introduce any refrigerant other than that specified into the machine. ELECTRONIC LEAK DETECTOR Be certain to follow the manufacturer’s instructions for tester operation and tester maintenance. MTC-8 PRECAUTIONS VACUUM PUMP A The lubricant contained inside the vacuum pump is not compatible with the specified lubricant for HFC-134a (R-134a) A/C systems. The vent side of the vacuum pump is exposed to atmospheric pressure. So the vacuum pump lubricant may migrate out of the pump into the service hose. This is possible when the pump is switched off after evacuation (vacuuming) and hose is connected to it. To prevent this migration, use a manual valve placed near the hoseto-pump connection, as follows. ● Usually vacuum pumps have a manual isolator valve as part of the pump. Close this valve to isolate the service hose from the pump. ● For pumps without an isolator, use a hose equipped with a manual shut-off valve near the pump end. Close the valve to isolate the hose from the pump. ● If the hose has an automatic shut-off valve, disconnect the hose from the pump. As long as the hose is connected, the valve is open and lubricating oil may migrate. Some one-way valves open when vacuum is applied and close under a no vacuum condition. Such valves may restrict the pump’s ability to pull a deep vacuum and are not recommended. B C D E F G RHA270DA H MANIFOLD GAUGE SET Be certain that the gauge face indicates HFC-134a or R-134a. Be sure the gauge set has 1/2″-16 ACME threaded connections for service hoses. Confirm the set has been used only with refrigerant HFC-134a (R-134a) and specified lubricants. I MTC K SHA533D SERVICE HOSES L Be certain that the service hoses display the markings described (colored hose with black stripe). All hoses must include positive shutoff devices (either manual or automatic) near the end of the hoses opposite the manifold gauge. M RHA272D MTC-9 PRECAUTIONS SERVICE COUPLERS Never attempt to connect HFC-134a (R-134a) service couplers to a CFC-12 (R-12) A/C system. The HFC-134a (R-134a) couplers will not properly connect to the CFC-12 (R-12) system. However, if an improper connection is attempted, discharging and contamination may occur. Shut-off valve rotation A/C service valve Clockwise Open Counterclockwise Close RHA273D REFRIGERANT WEIGHT SCALE Verify that no refrigerant other than HFC-134a (R-134a) and specified lubricants have been used with the scale. If the scale controls refrigerant flow electronically, the hose fitting must be 1/2″-16 ACME. RHA274D CALIBRATING ACR4 WEIGHT SCALE Calibrate the scale every three months. To calibrate the weight scale on the ACR4: 1. Press “Shift/Reset” and “Enter” at the same time. 2. Press “8787” . “A1” will be displayed. 3. Remove all weight from the scale. 4. Press “0” , then press “Enter” . “0.00” will be displayed and change to “A2” . 5. Place a known weight (dumbbell or similar weight), between 4.5 and 8.6 kg (10 and 19 lb) on the center of the weight scale. 6. Enter the known weight using four digits. (Example 10 lb = 10.00, 10.5 lb = 10.50) 7. Press “Enter” — the display returns to the vacuum mode. 8. Press “Shift/Reset” and “Enter” at the same time. 9. Press “6” — the known weight on the scale is displayed. 10. Remove the known weight from the scale. “0.00” will be displayed. 11. Press “Shift/Reset” to return the ACR4 to the program mode. CHARGING CYLINDER Using a charging cylinder is not recommended. Refrigerant may be vented into air from cylinder’s top valve when filling the cylinder with refrigerant. Also, the accuracy of the cylinder is generally less than that of an electronic scale or of quality recycle/recharge equipment. MTC-10 PRECAUTIONS Precautions for Leak Detection Dye ● ● ● ● ● ● ● ● ● ● ● BJS000D4 The A/C system contains a fluorescent leak detection dye used for locating refrigerant leaks. An ultraviolet (UV) lamp is required to illuminate the dye when inspecting for leaks. Always wear fluorescence enhancing UV safety goggles to protect your eyes and enhance the visibility of the fluorescent dye. The fluorescent dye leak detector is not a replacement for an electronic refrigerant leak detector. The fluorescent dye leak detector should be used in conjunction with an electronic refrigerant leak detector to pinpoint refrigerant leaks. For your safety and your customer’s satisfaction, read and follow all manufacture’s operating instructions and precautions prior to performing the work. A compressor shaft seal should not be repaired because of dye seepage. The compressor shaft seal should only be repaired after confirming the leak with an electronic refrigerant leak detector. Always remove any remaining dye from the leak area after repairs are complete to avoid a misdiagnosis during a future service. Do not allow dye to come into contact with painted body panels or interior components. If dye is spilled, clean immediately with the approved dye cleaner. Fluorescent dye left on a surface for an extended period of time cannot be removed. Do not spray the fluorescent dye cleaning agent on hot surfaces (engine exhaust manifold, etc.). Do not use more than one refrigerant dye bottle (1/4 ounce /7.4 cc) per A/C system. Leak detection dyes for HFC-134a (R-134a) and CFC-12 (R-12) A/C systems are different. Do not use HFC-134a (R-134a) leak detection dye in CFC-12 (R-12) A/C system or CFC-12 (R-12) leak detector dye in HFC-134a (R-134a) A/C system or A/C system damage may result. The fluorescent properties of the dye will remain for over three (3) years unless a compressor malfunction occurs. A B C D E F G H IDENTIFICATION I NOTE: Vehicles with factory installed fluorescent dye have a green label. Vehicles without factory installed fluorescent dye have a blue label. MTC IDENTIFICATION LABEL FOR VEHICLE Vehicles with factory installed fluorescent dye have this identification label on the front side of hood. K L M MJIB0432E MTC-11 PREPARATION PREPARATION HFC-134a (R-134a) Service Tools and Equipment PFP:00002 BJS000D6 Never mix HFC-134a (R-134a) refrigerant and/or its specified lubricant with CFC-12 (R-12) refrigerant and/or its lubricant. Separate and non-interchangeable service equipment must be used for handling each type of refrigerant/lubricant. Refrigerant container fittings, service hose fittings and service equipment fittings (equipment which handles refrigerant and/or lubricant) are different between CFC-12 (R-12) and HFC-134a (R-134a). This is to avoid mixed use of the refrigerants/lubricant. Adapters that convert one size fitting to another must never be used: refrigerant/lubricant contamination will occur and compressor malfunction will result. Tool number Tool name Description Container color: Light blue Container marking: HFC-134a (R134a) Fitting size: Thread size HFC-134a (R-134a) refrigerant ● Large container 1/2″ -16 ACME S-NT196 Type: Polyalkylene glycol oil (PAG), type R (DH-PR) Application: HFC-134a (R-134a) vane rotary compressors (Nissan only) Lubricity: 40 m (1.4 Imp fl oz.) KLH00-PAGR0 Nissan A/C System Oil Type R (DH-PR) S-NT197 Recovery/Recycling/ Recharging equipment (ACR4) Function: Refrigerant recovery and recycling and recharging RJIA0195E Power supply: DC 12V (Cigarette lighter) Electrical leak detector SHA705EB MTC-12 PREPARATION Tool number Tool name Description (J-43926) Refrigerant dye leak detection kit Kit includes: (J-42220) UV lamp and UV safety goggles (J-41459) HFC-134a (R-134a) dye injector Use with J-41447, 1/4 ounce bottle (J-41447) HFC-134a (R-134a) fluorescent leak detection dye (Box of 24, 1/4 ounce bottles) (J-43872) Refrigerant dye cleaner A B C Power supply: DC 12V (Battery terminal) D ZHA200H E Power supply: DC 12V (Battery terminal) For checking refrigerant leak when fluorescent dye is installed in A/C system Includes: UV lamp and UV safety goggles (J-42220) UV lamp and UV safety goggles SHA438F Application: For HFC-134a (R-134a) PAG oil Container: 1/4 ounce (7.4 cc) bottle (Includes self-adhesive dye identification labels for affixing to vehicle after charging system with dye.) (J-41447) HFC-134a (R-134a) fluorescent leak detection dye (Box of 24, 1/4 ounce bottles) SHA439F F G H I MTC (J-41459) HFC-134a (R-134a) dye injector Use with J-41447, 1/4 ounce bottle For injecting 1/4 ounce of fluorescent leak detection dye into A/C system K L SHA440F M (J-43872) Refrigerant dye cleaner For cleaning dye spills SHA441F Identification: ● Manifold gauge set (with hoses and couplers) The gauge face indicates HFC-134a (R-134a). Fitting size: Thread size ● RJIA0196E MTC-13 1/2″ -16 ACME PREPARATION Tool number Tool name Description Hose color: Service hoses ● High-pressure side hose ● Low-pressure side hose ● Utility hose Service couplers High-pressure side coupler ● Low-pressure side coupler Low hose: Blue with black stripe ● High hose: Red with black stripe ● Utility hose: Yellow with black stripe or green with black stripe Hose fitting to gauge: S-NT201 ● ● ● 1/2″ -16 ACME Hose fitting to service hose: ● M14 x 1.5 fitting is optional or permanently attached. S-NT202 For measuring of refrigerant Fitting size: Thread size Refrigerant weight scale ● 1/2″ -16 ACME S-NT200 Capacity: Vacuum pump (Including the isolator valve) ● Air displacement: 4 CFM ● Micron rating: 20 microns ● Oil capacity: 482 g (17 oz.) Fitting size: Thread size S-NT203 ● 1/2″ -16 ACME Commercial Service Tools BJS000D7 Tool name Description Power tool For loosening bolts and nuts PBIC0190E MTC-14 REFRIGERATION SYSTEM REFRIGERATION SYSTEM Refrigerant Cycle PFP:KA990 A BJS000D8 REFRIGERANT FLOW The refrigerant flows in the standard pattern, that is, through the compressor, the condenser with liquid tank, through the evaporator, and back to the compressor. The refrigerant evaporation through the evaporator is controlled by an externally equalized expansion valve, located inside the evaporator case. FREEZE PROTECTION B C Under usual operating conditions, when the A/C is switched ON, the compressor runs continuously, and the evaporator pressure, and therefore, temperature is controlled by the compressor to prevent freeze up. Refrigerant System Protection BJS000D9 D REFRIGERANT PRESSURE SENSOR The refrigerant system is protected against excessively high- or low-pressures by the refrigerant pressure sensor, located on the condenser. If the system pressure rises above, or falls below the specifications, the refrigerant pressure sensor detects the pressure inside the refrigerant line and sends the voltage signal to the ECM. ECM makes the A/C relay go OFF and stops the compressor when pressure on the high-pressure side detected by refrigerant pressure sensor is over about 2,746 kPa (27.46 bar, 28.0 kg/cm2 , 398 psi), or below about 134 kPa (1.34 bar, 1.4 kg/cm2 , 20 psi). PRESSURE RELIEF VALVE The refrigerant system is also protected by a pressure relief valve, located in the rear head of the compressor. When the pressure of refrigerant in the system increases to an unusual level [more than 3.8 MPa (38 bar, 38.76 kg/cm2 , 551 psi)], the release port on the pressure relief valve automatically opens and releases refrigerant into the atmosphere. E F G H I MTC K L M MJIB0355E MTC-15 REFRIGERATION SYSTEM Component Layout BJS000DA MJIB0368E 1. Defroster nozzle 2. Side defroster duct 3. Side ventilator duct 4. A/C unit 5. Center ventilator duct 6. Front floor duct 7. Rear floor duct MTC-16 LUBRICANT LUBRICANT Maintenance of Lubricant Quantity in Compressor PFP:KLG00 A BJS000DB The lubricant in the compressor circulates through the system with the refrigerant. Add lubricant to compressor when replacing any component or after a large refrigerant leakage occurred. It is important to maintain the specified amount. If lubricant quantity is not maintained properly, the following malfunctions may result: ● Lack of lubricant: May lead to a seized compressor. ● Excessive lubricant: Inadequate cooling (thermal exchange interference) B C LUBRICANT D Name Gasoline engine K9K engine Nissan A/C System Oil Type R Nissan A/C System Oil Type S KLH00 - PAGR0 KLH00 - PAGS0 Parts number E LUBRICANT RETURN OPERATION Adjust the lubricant quantity according to the test group shown below. F 1. CHECK LUBRICANT RETURN OPERATION Can lubricant return operation be performed? ● A/C system works properly. ● There is no evidence of a large amount of lubricant leakage. CAUTION: If excessive lubricant leakage is noted, do not perform the lubricant return operation. OK or NG OK >> GO TO 2. NG >> GO TO 3. 2. PERFORM LUBRICANT RETURN OPERATION, PROCEEDING AS FOLLOWS 1. – – – – – 2. 3. Start engine, and set the following conditions: Engine speed: Idling to 1,200 rpm A/C switch: ON Blower speed: Max. position Temp. control: Optional (Set so that intake air temperature is 25 to 30°C.) Intake position: Recirculation (REC) Perform lubricant return operation for about 10 minutes. Stop engine. >> GO TO 3. 3. CHECK REPLACEMENT PART Should the compressor be replaced? YES >> GO TO MTC-18, "LUBRICANT ADJUSTING PROCEDURE FOR COMPRESSOR REPLACEMENT" . NO >> GO TO MTC-18, "LUBRICANT ADJUSTING PROCEDURE FOR COMPONENTS REPLACEMENT EXCEPT COMPRESSOR" . MTC-17 G H I MTC K L M LUBRICANT LUBRICANT ADJUSTING PROCEDURE FOR COMPONENTS REPLACEMENT EXCEPT COMPRESSOR After replacing any of the following major components, add the correct amount of lubricant to the system. Amount of lubricant to be added Lubricant to be added to system Part replaced Amount of lubricant m (Imp fl oz.) Remarks Evaporator 35 (1.2) - Condenser 15 (0.5) - Liquid tank 5 (0.2) - 30 (1.1) Large leak - Small leak *1 In case of refrigerant leak *1: If refrigerant leak is small, no addition of lubricant is needed. LUBRICANT ADJUSTING PROCEDURE FOR COMPRESSOR REPLACEMENT 1. 2. 3. 4. 5. 6. 7. Before connecting ACR4 to vehicle, check ACR4 gauges. No refrigerant pressure should be displayed. If NG, recover refrigerant from equipment lines. Discharge refrigerant into the refrigerant recovery/recycling equipment. Measure lubricant discharged into the recovery/recycling equipment. Drain the lubricant from the old (removed) compressor into a graduated container and recover the amount of lubricant drained. Drain the lubricant from the new compressor into a separate, clean container. Measure an amount of new lubricant installed equal to amount drained from old compressor. Add this lubricant to new compressor through the suction port opening. Measure an amount of new lubricant equal to the amount recovered during discharging. Add this lubricant to new compressor through the suction port opening. If the liquid tank also needs to be replaced, add another 5 m (0.2 Imp fl oz.) of lubricant at this time. Do not add this 5 m (0.2 Imp fl oz.) of lubricant only when replaces the compressor. MTC-18 LUBRICANT A B C D E F G H I SJIA0596E MTC K L M MTC-19 AIR CONDITIONER CONTROL AIR CONDITIONER CONTROL Control Operation PFP:27500 BJS000DC SJIA0699E FAN CONTROL DIAL This dial turns the fan ON and OFF, and controls fan speed. TEMPERATURE CONTROL DIAL This dial allows you to adjust the temperature of the discharge air. MODE CONTROL DIAL This dial controls the outlet air flow. INTAKE DOOR LEVER ● ● Recirculation (REC) position: Interior air is recirculated inside the vehicle. Fresh (FRE) position: Outside air is drawn into the passenger compartment. REAR WINDOW DEFOGGER SWITCH When illumination is ON, rear window is defogged. A/C SWITCH The A/C switch controls the air conditioner system. When the switch is depressed with the fan ON, the compressor will turn ON. The indicator lamp also illuminates. MTC-20 AIR CONDITIONER CONTROL Discharge Air Flow BJS000JC A B C D E F G H I MTC K L M MJIB0512E MTC-21 AIR CONDITIONER CONTROL System Description BJS000DE SWITCHES AND THEIR CONTROL FUNCTION MJIB0507E SJIA0701E CAN Communication System Description BJS000DF CAN (Controller Area Network) is a serial communication line for real time application. It is an on-vehicle multiplex communication line with high data communication speed and excellent error detection ability. Many electronic control units are equipped onto a vehicle, and each control unit shares information and links with other control units during operation (not independent). In CAN communication, control units are connected with 2 communication lines (CAN-H line, CAN-L line) allowing a high rate of information transmission with less wiring. Each control unit transmits/receives data but selectively reads required data only. For details, refer to LAN-27, "CAN Communication Unit" . MTC-22 TROUBLE DIAGNOSIS TROUBLE DIAGNOSIS CONSULT-II Function (BCM) PFP:00004 A BJS000DG CONSULT-II can display diagnostic item using the diagnostic test modes shown following. System part Check item, diagnosis mode BCM Data monitor B Description Displays BCM input data in real time. C CONSULT-II BASIC OPERATION Refer to GI-36, "CONSULT-II Start Procedure" . DATA MONITOR Operation Procedure 1. D Touch “AIR CONDITIONER” on “SELECT TEST ITEM” screen. E F G MJIB0465E 2. H Touch “DATA MONITOR” on “SELECT DIAG MODE” screen. I MTC K MJIB0466E 3. Touch either “ALL SIGNALS” or “SELECTION FROM MENU” on “DATA MONITOR” screen. All signals Monitors all the items. Selection from menu Selects and monitors the individual item selected. 4. 5. 6. L M When “SELECTION FROM MENU” is selected, touch items to be monitored. When “ALL SIGNALS” is selected, all the items will be monitored. Touch “START”. Touch “RECORD” while monitoring, then the status of the monitored item can be recorded. To stop recording, touch “STOP”. RJIA1111E Display Item List Monitor item name “operation or unit” Contents IGN ON SW “ON/OFF” Displays “IGN Position (ON)/OFF, ACC Position (OFF)” status as judged from ignition switch signal. FAN ON SIG “ON/OFF” Displays “FAN (ON)/FAN (OFF)” status as judged from blower fan motor switch signal. AIR COND SW “ON/OFF” Displays “COMP (ON)/COMP (OFF)” status as judged from air conditioner switch signal. MTC-23 TROUBLE DIAGNOSIS How to Perform Trouble Diagnosis for Quick and Accurate Repair BJS000DH WORK FLOW SHA900E *1 MTC-34, "Operational Check" SYMPTOM TABLE Symptom Reference Page MTC-36, "Mode Door" Air outlet does not change. Go to Trouble Diagnosis Procedure for mode door. Discharge air temperature does not change. Go to Trouble Diagnosis Procedure for Air Mix Door. MTC-37, "Air Mix Door" Intake door does not change. Go to Trouble Diagnosis Procedure for Intake Door. MTC-38, "Intake Door" Blower motor operation is malfunctioning. Go to Trouble Diagnosis Procedure for Blower Motor. MTC-39, "Blower Motor Circuit" Magnet clutch does not engage. Go to Trouble Diagnosis Procedure for Magnet Clutch. MTC-43, "Magnet Clutch Circuit" Insufficient cooling Go to Trouble Diagnosis Procedure for Insufficient Cooling. MTC-52, "Insufficient Cooling" Insufficient heating Go to Trouble Diagnosis Procedure for Insufficient Heating. MTC-59, "Insufficient Heating" Noise Go to Trouble Diagnosis Procedure for Noise. MTC-24 MTC-60, "Noise" TROUBLE DIAGNOSIS Component Parts and Harness Connector Location BJS000DI A B C D E F G H I MTC K L M MJIB0491E 1. Compressor (CR & HR engine F28) (K9K engine F129) 2. Refrigerant pressure sensor (CR & HR engine E21) (K9K engine E65) 3. Heater control panel M62 4. Blower motor M56 5. Fan resistor M29 6. Thermo control amp. M44 MTC-25 TROUBLE DIAGNOSIS Wiring Diagram — HEATER — BJS000DK MJWA0265E MTC-26 TROUBLE DIAGNOSIS Wiring Diagram — A/C — CR Engine Models BJS000IM A B C D E F G H I MTC K L M MJWA0266E MTC-27 TROUBLE DIAGNOSIS MJWA0267E MTC-28 TROUBLE DIAGNOSIS Wiring Diagram — A/C — HR Engine Models BJS000IN A B C D E F G H I MTC K L M MJWA0268E MTC-29 TROUBLE DIAGNOSIS MJWA0269E MTC-30 TROUBLE DIAGNOSIS Wiring Diagram — A/C — K9K Engine Models BJS000IO A B C D E F G H I MTC K L M MJWA0270E MTC-31 TROUBLE DIAGNOSIS MJWA0271E MTC-32 TROUBLE DIAGNOSIS Wiring Diagram — PTC/H — BJS000IP A B C D E F G H I MTC K L M MJWA0272E PTC heater function is intended to improve the heating performance with CTP electrical system for air heating system which is broken down into several stages controlled by relays. MTC-33 TROUBLE DIAGNOSIS Operational Check BJS000DL The purpose of the operational check is to confirm that the system operates properly. Conditions : Engine running at usual operating temperature CHECKING BLOWER 1. Turn fan control dial to 1-speed. Blower should operate on low speed. 2. Then turn fan control dial to 2-speed, and continue checking blower speed until all speeds are checked. 3. Leave blower on Max. speed. If NG, go to trouble diagnosis procedure for MTC-39, "Blower Motor Circuit" . If OK, continue the check. SJIA0704E CHECKING DISCHARGE AIR 1. Turn mode control dial to each position. SJIA0705E 2. Confirm that discharge air comes out according to the air distribution table. Refer to MTC-21, "Discharge Air Flow" . If NG, go to trouble diagnosis procedure for MTC-36, "Mode Door" . If OK, continue the check. MJIB0374E CHECKING RECIRCULATION 1. 2. 3. Set intake door lever to REC position. Operate intake door lever to FRE position. Listen for intake door position change (you should hear blower sound change slightly). If NG, go to trouble diagnosis procedure for MTC-38, "Intake Door" . If OK, continue the check. SJIA0708E MTC-34 TROUBLE DIAGNOSIS CHECKING TEMPERATURE DECREASE A 1. Turn temperature control dial counterclockwise until full cold position. 2. Check for cold air at discharge air outlets. If NG, go to trouble diagnosis procedure for MTC-52, "Insufficient Cooling" . If OK, continue the check. B C SJIA0710E D CHECKING TEMPERATURE INCREASE 1. Turn temperature control dial clockwise until full hot position. 2. Check for hot air at discharge air outlets. If NG, go to trouble diagnosis procedure for MTC-59, "Insufficient Heating" . If OK, continue the check. E F G SJIA0711E H CHECKING A/C SWITCH 1. 2. 3. Turn fan control dial to the desired (1 to 4 speed) position. Press A/C switch. A/C switch indicator will turn ON. ● Confirm that the compressor clutch engages (sound or visual inspection). If NG, go to trouble diagnosis procedure for MTC-43, "Magnet Clutch Circuit" . If all operational checks are OK (symptom cannot be duplicated), go to Incident Simulation Tests in GI-25, "How to Perform Efficient Diagnosis for an Electrical Incident" and perform tests as outlined to simulate driving conditions environment. If symptom appears, refer to MTC-24, "SYMPTOM TABLE" and perform applicable trouble diagnosis procedures. I MTC K SJIA0713E L M MTC-35 TROUBLE DIAGNOSIS Mode Door BJS000DM SYMPTOM: Air outlet does not change. INSPECTION FLOW MJIB0493E *1 MTC-21, "Discharge Air Flow" *4 MTC-24, "SYMPTOM TABLE" *2 MTC-34, "Operational Check" MTC-36 *3 MTC-72, "Mode Door Cable Adjustment" TROUBLE DIAGNOSIS Air Mix Door BJS000DN A SYMPTOM: Air mix door does not change. INSPECTION FLOW B C D E F G H I MTC K L M SJIA0720E *1 MTC-34, "Operational Check" *2 MTC-71, "Air Mix Door Cable Adjust- *3 ment" MTC-37 MTC-24, "SYMPTOM TABLE" TROUBLE DIAGNOSIS Intake Door BJS000DO SYMPTOM: Intake door does not change. INSPECTION FLOW SJIA0722E *1 MTC-34, "Operational Check" *2 MTC-70, "Intake Door Cable Adjustment" MTC-38 *3 MTC-24, "SYMPTOM TABLE" TROUBLE DIAGNOSIS Blower Motor Circuit BJS000DP A SYMPTOM: Blower motor operation is malfunctioning. INSPECTION FLOW B C D E F G H I SJIA0723E *1 MTC-34, "Operational Check" *2 MTC-39, "DIAGNOSTIC PROCE- *3 DURE FOR BLOWER MOTOR" MTC MTC-24, "SYMPTOM TABLE" K DIAGNOSTIC PROCEDURE FOR BLOWER MOTOR SYMPTOM: Blower motor operation is malfunctioning. L M MJIB0521E 1. CHECK BLOWER MOTOR OPERATION 1. Turn ignition switch ON. 2. Check blower motor operation at each fan speed. OK or NG Blower motor does not operate at all speed.>>GO TO 2. Blower motor does not operate at one of speeds 1-4.>>GO TO 6. MTC-39 TROUBLE DIAGNOSIS 2. CHECK POWER SUPPLY FOR BLOWER MOTOR 1. 2. 3. 4. Turn ignition switch OFF. Disconnect blower motor connector. Turn ignition switch ON. Check voltage between blower motor harness connector and ground. Terminals (+) Voltage (Approx.) (−) Connector Terminal Blower motor: M56 1 Ground Battery voltage MJIB0516E OK or NG OK >> GO TO 3. NG >> Check power supply circuit and 15A fuses (Nos. 18 and 20, located in the fuse block). Refer to PG-95, "FUSE BLOCK" . ● If fuses are OK, check harness for open circuit. Repair or replace if necessary. ● If fuses are NG, replace fuse and check harness for short circuit. Repair or replace if necessary. 3. CHECK GROUND CIRCUIT FOR BLOWER MOTOR 1. 2. Turn ignition switch OFF. Check continuity between blower motor harness connector and ground. Connector Terminal Blower motor: M56 2 Continuity Ground Yes OK or NG OK >> GO TO 4. NG >> GO TO 5. MJIB0519E 4. CHECK BLOWER MOTOR Check continuity between blower motor harness connector terminal 1 and 2. Connector Blower motor: M56 Terminals 1 Continuity 2 Yes OK or NG OK >> GO TO 9. NG >> Replace blower motor. MJIB0517E MTC-40 TROUBLE DIAGNOSIS 5. CHECK CIRCUIT CONTINUITY BETWEEN BLOWER MOTOR AND BLOWER FAN RESISTOR 1. 2. A Disconnect fan resistor connector. Check continuity between blower motor harness connector (A) and fan resistor harness connector (B). A B B Continuity Connector Terminal Connector Terminal Blower motor: M56 2 Fan resistor: M29 4 C Yes D OK or NG OK >> GO TO 6. NG >> Repair harness or connector. MJIB0522E E 6. CHECK BLOWER FAN RESISTOR 1. 2. 3. F Turn ignition switch OFF. Disconnect fan resistor connector. Check resistance between fan resistor connector terminal 4 and 1, 2, 3. Connector Terminals Fan resistor: M29 4 G Resistance 1 Approx. 2.15Ω 2 Approx. 1.10Ω 3 Approx. 0.46Ω OK or NG OK >> GO TO 7. NG >> Replace fan resistor. H SJIA0730E I MTC 7. CHECK FAN SWITCH 1. 2. Disconnect heater control panel connector. Check continuity between heater control panel connector terminal 9 and 10, 11, 12, 13, 14. Connector Heater control panel: M62 Terminals 9 Condition 14 Fan control dial: OFF 10 Fan control dial: 1-speed 11 Fan control dial: 2-speed 12 Fan control dial: 3-speed 13 Fan control dial: 4-speed K L Continuity M Yes SJIA0732E OK or NG OK >> GO TO 8. NG >> Replace heater control panel. MTC-41 TROUBLE DIAGNOSIS 8. CHECK CIRCUIT CONTINUITY BETWEEN HEATER CONTROL PANEL AND BLOWER FAN RESISTOR Check continuity between heater control panel harness connector (A) and blower fan resistor harness connector (B). A Connector B Terminal Connector 10 Heater control panel: M62 11 12 Continuity Terminal 1 Fan resistor: M29 13 2 Yes. 3 4 OK or NG OK >> Check harness connector and connector for open circuit. NG >> Repair harness and connector. SJIA0733E 9. CHECK FAN SWITCH GROUND CIRCUIT 1. 2. Disconnect heater control panel connector. Check continuity between heater control panel harness connector and ground. Connector Terminal Heater control panel: M62 9 Continuity Ground Yes OK or NG OK >> INSPECTION END NG >> Repair harness and connector. SJIA0734E COMPONENT INSPECTION Blower Motor Confirm smooth rotation of the blower motor (1). ● Ensure that there are no foreign particles inside the A/C unit assembly. MJIB0494E MTC-42 TROUBLE DIAGNOSIS Magnet Clutch Circuit BJS000DQ A SYMPTOM: Magnet clutch does not engage. INSPECTION FLOW B C D E F G H I MTC K L M SJIA0740E *1 MTC-34, "Operational Check" *2 CR: EM-14, "Checking drive Belts" HR: EM-114, "Checking Drive Belts" K9K: EM-242, "Checking Drive Belts" *4 MTC-24, "SYMPTOM TABLE" *5 MTC-56, "TROUBLE DIAGNOSIS FOR UNUSUAL PRESSURE" MTC-43 *3 MTC-44, "DIAGNOSTIC PROCEDURE FOR MAGNET CLUTCH" TROUBLE DIAGNOSIS SYSTEM DESCRIPTION Thermo control amp. controls compressor operation by intake air temperature and signal from ECM. Low Temperature Protection Control When intake air temperatures are higher than 4°C (39°F), the compressor turns ON. The compressor turns OFF when intake air temperatures are lower than 2°C (36°F). SJIA0741E DIAGNOSTIC PROCEDURE FOR MAGNET CLUTCH SYMPTOM: Magnet clutch does not engage when A/C switch and fan switch are ON. MJIB0495E 1. PERFORM AUTO ACTIVE TEST Refer to PG-22, "Auto Active Test" . Does the magnet clutch operate? YES >> ● WITH CONSULT-II GO TO 6. ● WITHOUT CONSULT-II GO TO 7. NO >> GO TO 2. MTC-44 TROUBLE DIAGNOSIS 2. CHECK POWER SUPPLY FOR COMPRESSOR 1. 2. 3. 4. 5. A Turn ignition switch OFF. Disconnect compressor connector. Start the engine. Turn fan control dial and A/C switch ON. Check voltage between compressor harness connector and ground. B C Terminals (+) Engine Voltage (Approx.) (−) Connector Terminal CR and HR Compressor: F28 K9K Compressor: F129 D MJIB0405E Ground 1 E 12V OK or NG OK >> GO TO 4. NG >> Check 10A fuse (No. 51, located in the fuse block) ● If fuse is OK, GO TO 3. ● If fuse is NG, replace fuse and GO TO 3. F G 3. CHECK CIRCUIT CONTINUITY BETWEEN IPDM E/R AND COMPRESSOR 1. 2. 3. A Engine Connector CR and HR Compressor: F28 K9K Compressor: F129 4. H Turn ignition switch OFF. Disconnect IPDM E/R connector. Check continuity between compressor harness connector (A) and IPDM E/R harness connector (B). B Continuity Terminal Connector Terminal 1 IPDM E/R: E7 41 CR and HR Compressor: F28 K9K Compressor: F129 K MJIB0406E A Connector MTC Yes Check continuity between compressor harness connector (A) and ground. Engine I L Continuity Terminal 1 Ground NO. OK or NG OK >> GO TO 4. NG >> Repair harness and connector. MTC-45 M TROUBLE DIAGNOSIS 4. CHECK COMPRESSOR GROUND CIRCUIT Check continuity between compressor harness connector and ground. Connector Compressor: F129 Terminal Ground Continuity 2 Yes OK or NG OK >> GO TO 5. NG >> Repair harness and connector. MJIB0519E 5. CHECK COMPRESSOR Check for operation sound when applying battery voltage direct current to terminal. OK or NG OK >> 1. Check harness and connector for open circuit. 2. Repair or replace if necessary. NG >> 1. Replace magnet clutch. 2. Go to operational check. Refer to MTC-35, "CHECKING A/C SWITCH" . Confirm that magnet clutch operation is usual. MJIB0407E 6. CHECK BCM INPUT (COMPRESSOR ON) SIGNAL Check compressor ON/OFF signal. Refer to MTC-23, "CONSULT-II Function (BCM)" . A/C SW ON A/C SW OFF : AIR COND SW ON : AIR COND SW OFF OK or NG OK >> GO TO 8. NG >> GO TO 7. RJIA1111E MTC-46 TROUBLE DIAGNOSIS 7. CHECK CIRCUIT CONTINUITY BETWEEN HEATER CONTROL PANEL AND BCM 1. 2. 3. A Turn ignition switch OFF. Disconnect heater control panel and BCM connector. Check continuity between heater control panel harness connector (A) and BCM harness connector (B). A B B Connector Terminal Connector Terminal Heater control panel: M62 1 BCM: M58 61 Continuity C Yes D MJIB0492E OK or NG OK >> GO TO 8. NG >> Repair harness or connector. E 8. CHECK REFRIGERANT PRESSURE SENSOR 1. 2. 3. 1. 2. 3. F WITH CONSULT-II Reconnect heater control panel connector and BCM connector. Start the engine. Check voltage of refrigerant pressure sensor. CR (WITH EURO–OBD): Refer to EC-112, "CONSULT-II Reference Value in Data Monitor Mode" . CR (WITHOUT EURO–OBD): Refer to EC-527, "CONSULT-II Reference Value in Data Monitor Mode" . HR (WITH EURO–OBD): Refer to EC-902, "CONSULT-II Reference Value in Data Monitor" . HR (WITHOUT EURO–OBD): Refer to EC-1321, "CONSULT-II Reference Value in Data Monitor" . K9K: Refer to EC-1694, "CONSULT-II Reference Value in Data Monitor Mode" . *For further information refer to EC-21, "APPLICATION NOTICE" . WITHOUT CONSULT-II Reconnect heater control panel connector and BCM connector. Start the engine. Check voltage between ECM harness connector and ground. G H I MTC K Terminals (+) Engine Connector (−) ECM: F2 69 HR ECM: F51 41 K9K ECM: F134 89 ● NG >> ● ● ● ● ● Voltage (Approx.) L Terminal CR OK or NG OK >> ● Condition Ground A/C switch: ON (Blower motor operates.) 1 - 4V M WITH CONSULT-II GO TO 9. WITHOUT CONSULT-II GO TO 10. CR (WITH EURO–OBD): Refer to EC-443 ... CR (WITHOUT EURO–OBD): Refer to EC-794 . HR (WITH EURO–OBD): Refer to EC-1231 . HR (WITHOUT EURO–OBD): Refer to EC-1590 . K9K: Refer to EC-1811 . MJIB0410E MTC-47 TROUBLE DIAGNOSIS 9. CHECK BCM INPUT (FAN ON) SIGNAL Check FAN ON/OFF signal. Refer to MTC-23, "CONSULT-II Function (BCM)" . FAN CONTROL DIAL ON FAN CONTROL DIAL OFF : FAN ON SIG ON : FAN ON SIG OFF OK or NG OK >> Stop the engine and GO TO 14. NG >> GO TO 10. RJIA1111E 10. CHECK BCM INPUT (FAN ON) SIGNAL 1. 2. 3. Stop the engine and turn ignition switch ON. Turn fan control dial to 1-speed. Confirm fan on signal between heater control panel harness connector and ground using oscilloscope. Terminals Voltage (Approx.) (+) Connector Terminal (-) SJIA0750E Heater control panel: M62 14 Ground ZJIA0583J OK or NG OK >> Turn ignition switch OFF and disconnect heater control panel connector, GO TO 12. NG >> GO TO 11. 11. CHECK CIRCUIT CONTINUITY BETWEEN BCM AND HEATER CONTROL PANEL 1. 2. 3. Turn ignition switch OFF. Disconnect heater control panel connector and BCM connector. Check continuity between BCM harness connector (A) and heater control panel harness connector (B). A B Continuity Connector Terminal Connector Terminal BCM: M58 50 Heater control panel: M62 14 Yes MJIB0497E OK or NG OK >> GO TO 12. NG >> Repair harness or connector. MTC-48 TROUBLE DIAGNOSIS 12. CHECK FAN SWITCH CIRCUIT 1. 2. A Turn fan control dial to the OFF position. Check continuity between heater control panel connector terminal 9 and 14. Connector Terminals Heater control panel: M62 9 B Continuity 14 C Yes OK or NG OK >> GO TO 13. NG >> Replace heater control panel. D SJIA0753E 13. CHECK HEATER CONTROL PANEL GROUND CIRCUIT E Check continuity between heater control panel harness connector and ground. Connector Terminal Heater control panel: M62 9 F Continuity Ground Yes G OK or NG OK >> GO TO 14. NG >> Repair harness or connector. H SJIA0754E 14. CHECK BCM INPUT (COMPRESSOR ON) SIGNAL 1. 2. 3. I Reconnect BCM connector and heater control panel connector. Turn ignition switch ON. Confirm compressor on signal between heater control panel harness connector and ground using oscilloscope. MTC K Terminals (+) Connector Terminal (-) Voltage (Approx.) L SJIA0755E Heater control panel: M62 M 1 Ground ZJIA0584J OK or NG OK >> GO TO 15. NG >> GO TO 17. MTC-49 TROUBLE DIAGNOSIS 15. CHECK A/C SWITCH CIRCUIT 1. 2. 3. 4. Turn ignition switch OFF. Disconnect heater control panel connector. Pressing A/C switch. Check continuity between heater control panel connector terminal 1 and 8. Connector Terminals Heater control panel: M62 1 8 Condition Continuity Pressing A/C switch. Yes OK or NG OK >> GO TO 16. NG >> Replace heater control panel. SJIA0756E 16. CHECK HEATER CONTROL PANEL GROUND CIRCUIT Check continuity between heater control panel harness connector and ground. Connector Terminal Heater control panel: M62 8 Continuity Ground Yes OK or NG OK >> GO TO 19. NG >> Repair harness or connector. SJIA0758E 17. CHECK POWER SUPPLY THERMO CONTROL AMP. 1. 2. Turn ignition switch ON. Check voltage thermo control amp. harness connector and ground. Terminals (+) (−) Connector Terminal Thermo control amp.: M44 1 Ground Voltage (Approx.) Battery voltage MJIB0498E OK or NG OK >> GO TO 18. NG >> Check power supply circuit and 10A fuse (No. 19, located in the fuse block). Refer to PG-95, "FUSE BLOCK" . ● If fuse is OK, check harness for open circuit. Repair or replace if necessary. ● If fuse is NG, replace fuse and check harness for short circuit. Repair or replace if necessary. MTC-50 TROUBLE DIAGNOSIS 18. CHECK CIRCUIT CONTINUITY THERMO CONTROL AMP. AND BCM 1. 2. 3. A Turn ignition switch OFF. Disconnect BCM connector. Check continuity thermo control amp. harness connector (A) and BCM harness connector (B). A B B Connector Terminal Connector Terminal Thermo control amp.: M44 2 BCM: M57 35 C Continuity D Yes MJIB0499E OK or NG OK >> GO TO 19. NG >> Repair harness or connector. E 19. CHECK CAN COMMUNICATION F Check CAN communication. Refer to BCS-17, "CAN Communication Inspection With CONSULT-II (Self-Diagnosis)" . ● BCM – ECM ● ECM – IPDM E/R OK or NG OK >> Replace BCM. NG >> Repair or replace malfunction part(s). COMPONENT INSPECTION Refrigerant Pressure Sensor G H I MTC K L MJIB0457E 1. Refrigerant pressure sensor 4. Air guide 2. Condenser 3. M Liquid tank The refrigerant pressure sensor (1) is attached to the condenser. Make sure that the A/C refrigerant pressure and the sensor output voltage are within the specified range as shown in the A/C operating condition figure. CR (WITH EURO–OBD): Refer to EC-443 . CR (WITHOUT EURO–OBD): Refer to EC-794 . HR (WITH EURO–OBD): Refer to EC-1231 . HR (WITHOUT EURO–OBD): Refer to EC-1590 . K9K: Refer to EC-1811 . *For further information refer to EC-21, "APPLICATION NOTICE" . RJIA2954E MTC-51 TROUBLE DIAGNOSIS Insufficient Cooling BJS000DR SYMPTOM: Insufficient cooling INSPECTION FLOW SJIA0766E *1 MTC-34, "Operational Check" *2 CR: EM-14, "Checking drive Belts" HR: EM-114, "Checking Drive Belts" K9K: EM-242, "Checking Drive Belts" *3 MTC-71, "Air Mix Door Cable Adjustment" *4 MTC-55, "Test Reading" *5 MTC-24, "SYMPTOM TABLE" *6 CR (WITH EURO–OBD): EC-345 CR (WITHOUT EUROOBD): EC-662 HR (WITH EUROOBD): EC-1130 HR (WITHOUT EUROOBD): EC-1451 K9K: EC-1864 *7 MTC-53, "PERFORMANCE TEST DIAGNOSIS" *For further information refer to EC-21, "APPLICATION NOTICE" . MTC-52 TROUBLE DIAGNOSIS PERFORMANCE TEST DIAGNOSIS A B C D E F G H I MTC K L M RJIA1601E *1 MTC-55, "PERFORMANCE CHART" *2 *4 MTC-71, "Air Mix Door Cable Adjustment" MTC-55, "PERFORMANCE CHART" *3 MTC-53 MTC-56, "TROUBLE DIAGNOSIS FOR UNUSUAL PRESSURE" TROUBLE DIAGNOSIS RJIA3107E *1 MTC-87, "CHECK DISC TO PULLEY *2 CLEARANCE" MTC-39, "Blower Motor Circuit" MTC-54 *3 CR: EM-14, "Checking drive Belts" HR: EM-114, "Checking Drive Belts" K9K: EM-242, "Checking Drive Belts" TROUBLE DIAGNOSIS PERFORMANCE CHART Test Condition A Testing must be performed as follows: Vehicle condition Indoors or in the shade (in a well-ventilated place) Doors Closed Door window Open Hood Open TEMP. Max. COLD Mode control dial C (Ventilation) set Intake door lever B D (Recirculation) set Max. speed set Fan (blower) speed Engine speed E Idle speed Operate the air conditioning system for 10 minutes before taking measurements. Test Reading F Recirculating-to-discharge Air Temperature Table Inside air (Recirculating air) at blower assembly inlet Relative humidity % Discharge air temperature at center ventilator °C (°F) Air temperature °C (°F) 50 - 60 60 - 70 20 (68) 7.2 - 9.1 (45 - 48) 25 (77) 11.4 - 13.8 (53 - 57) 30 (86) 15.5 - 18.4 (60 - 65) 35 (95) 20.3 - 23.7 (69 - 75) 20 (68) 9.1 - 10.9 (48 - 52) 25 (77) 13.8 - 16.2 (57 - 61) 30 (86) 18.4 - 21.3 (65 - 70) 35 (95) 23.7 - 27.1 (75 - 81) Relative humidity % 50 - 70 High-pressure (Discharge side) Low-pressure (Suction side) Air temperature °C (°F) kPa (bar, kg/cm2 , psi) kPa (bar, kg/cm2 , psi) 20 (68) 843 - 1,036 *1 (11.08 - 13.63, 8.6 - 10.6, 122 - 150) 159.0 - 194.0 (1.59 - 1.94, 1.62 - 1.98, 23.1 - 28.1) 25 (77) 1,094 - 1,338 *1 (10.94 - 13.38, 11.2 - 13.6, 159 - 194) 196.3 - 240.0 (1.96 - 2.40, 2.00 - 2.45, 28.5 - 34.8) 30 (86) 1,298 - 1,590 *1 (12.98 - 15.90, 13.2 - 16.2, 188 - 231) 248.0 - 302.7 (2.48 - 3.03, 2.53 - 3.09, 36.0 - 43.9) 35 (95) 1,383 - 1,688 *2 (13.83 - 16.88, 14.1 - 17.2, 201 - 245) 308.8 - 377.4 (3.09 - 3.77, 3.15 - 3.85, 44.8 - 54.7) 40 (104) 1,628 - 1,988 *2 (16.28 - 19.88, 16.6 - 20.3, 236 - 288) 377.4 - 461.2 (3.77 - 4.61, 3.85 - 4.70, 54.7 - 66.8) *1: In the motor fan low-speed control *2: In the motor fan high-speed control MTC-55 H I MTC K Ambient Air Temperature-to-operating Pressure Table Ambient air G L M TROUBLE DIAGNOSIS TROUBLE DIAGNOSIS FOR UNUSUAL PRESSURE Whenever system’s high and/or low side pressure(s) is/are unusual, diagnose using a manifold gauge. The marker above the gauge scale in the following tables indicates the standard (usual) pressure range. Since the standard (usual) pressure, however, differs from vehicle to vehicle, refer to above table (Ambient air temperature-to-operating pressure table). Both High- and Low-pressure Sides are Too High Gauge indication Refrigerant cycle Probable cause Pressure is reduced soon after water is splashed on condenser. Air suction by cooling fan is insufficient. Excessive refrigerant charge in refrigeration cycle. Insufficient condenser cooling performance. ↓ 1. Condenser fins are clogged. Corrective action Reduce refrigerant until specified pressure is obtained. ● Clean condenser. ● Check and repair cooling fan if necessary. 2. Improper fan rotation of cooling fan. Both high- and low-pressure sides are too high. ● Low-pressure pipe is not cold. ● When compressor is stopped high-pressure value quickly drops by approximately 196 kPa (1.96 bar, 2 kg/cm2 , 28 psi). It then decreases gradually thereafter. AC359A Engine tends to overheat. ● ● An area of the low-pressure pipe is colder than areas near the evaporator outlet. Plates are sometimes covered with frost. Poor heat exchange in condenser (After compressor operation stops, high-pressure decreases too slowly.). ↓ Air in refrigeration cycle. Evacuate repeatedly and recharge system. Engine cooling systems malfunction. Check and repair each engine cooling system. ● Excessive liquid refrigerant on lowpressure side. ● Excessive refrigerant discharge flow. ● Expansion valve is open a little compared with the specification. Replace expansion valve. ↓ Improper expansion valve adjustment. High-pressure Side is Too High and Low-pressure Side is Too Low Gauge indication Refrigerant cycle Probable cause Upper side of condenser and high-pressure side are hot, however, liquid tank is not so hot. High-pressure tube or parts located between compressor and condenser are clogged or crushed. Corrective action High-pressure side is too high and low-pressure side is too low. AC360A MTC-56 ● Check and repair or replace malfunctioning parts. ● Check lubricant for contamination. TROUBLE DIAGNOSIS High-pressure Side is Too Low and Low-pressure Side is Too High Gauge indication High-pressure side is too low and low-pressure side is too high. Refrigerant cycle Probable cause High- and low-pressure sides become equal soon after compressor operation stops. Compressor pressure operation is improper. ↓ Damaged inside compressor packings. No temperature difference between high- and low-pressure sides. Compressor pressure operation is improper. ↓ Damaged inside compressor packings. AC356A Corrective action Replace compressor. A B C Replace compressor. D Both High- and Low-pressure Sides are Too Low Gauge indication Refrigerant cycle ● Liquid tank inlet and expansion valve are frosted. ● Temperature of expansion valve inlet is extremely low as compared with areas near liquid tank. ● AC353A There is a big temperature difference between liquid tank outlet and inlet. Outlet temperature is extremely low. ● ● Both high- and low-pressure sides are too low. Probable cause Expansion valve inlet may be frosted. Liquid tank inside is slightly clogged. Corrective action ● Replace liquid tank. ● Check lubricant for contamination. There is a big temperature difference between expansion valve inlet and outlet while the valve itself is frosted. High-pressure pipe located between liquid tank and expansion valve is clogged. ● Check and repair malfunctioning parts. ● Check lubricant for contamination. Low refrigerant charge. ↓ Leaking fittings or components Expansion valve closes a little compared with the specification. ↓ 1. Improper expansion valve adjustment. 2. Malfunctioning expansion valve. Check refrigerant for leaks. Refer to MTC-93, "Checking for Refrigerant Leaks" . Air flow volume is not enough or is too low. Low-pressure pipe is clogged or crushed. Evaporator is frozen. MTC-57 H I MTC K ● Remove foreign particles by using compressed air. ● Replace expansion valve. ● Check lubricant for contamination. 3. Outlet and inlet may be clogged. An area of the low-pressure pipe is colder than areas near the evaporator outlet. F G Temperature difference occurs somewhere in highpressure side. Expansion valve and liquid tank are warm or only cool when touched. E ● Check and repair malfunctioning parts. ● Check lubricant for contamination. ● Check thermo control amp. Refer to MTC-43, "Magnet Clutch Circuit" . ● Replace compressor. ● Repair evaporator fins. ● Replace evaporator. ● Refer to MTC-39, "Blower Motor Circuit" . L M TROUBLE DIAGNOSIS Low-pressure Side Sometimes Becomes Negative Gauge indication Low-pressure side sometimes becomes negative. Refrigerant cycle ● ● AC354A Air conditioning system does not function and does not cyclically cool the compartment air. The system constantly functions for a certain period of time after compressor is stopped and restarted. Probable cause Refrigerant does not discharge cyclically. ↓ Moisture is frozen at expansion valve outlet and inlet. ↓ Water is mixed with refrigerant. Corrective action ● Drain water from refrigerant or replace refrigerant. ● Replace liquid tank. Low-pressure Side Becomes Negative Gauge indication Refrigerant cycle Probable cause Corrective action Leave the system at rest until no frost is present. Start it again to check whether or not the malfunction is caused by water or foreign particles. ● If water is the cause, initially cooling is okay. Then the water freezes causing a blockage. Drain water from refrigerant or replace refrigerant. ● If due to foreign particles, remove expansion valve and remove the particles with dry and compressed air (not shop air). ● If either of the above methods cannot correct the malfunction, replace expansion valve. ● Replace liquid tank. ● Check lubricant for contamination. Low-pressure side becomes negative. Liquid tank or front/rear side of expansion valve’s pipe is frosted or dewed. High-pressure side is closed and refrigerant does not flow. ↓ Expansion valve or liquid tank is frosted. AC362A MTC-58 TROUBLE DIAGNOSIS Insufficient Heating BJS000DS A SYMPTOM: Insufficient heating INSPECTION FLOW B C D E F G H I MTC K L M SJIA0767E *1 MTC-34, "Operational Check" *2 CR: CO-9, "Changing Engine coolant" HR: CO-28, "Changing Engine coolant" K9K: CO-49, "Changing Engine Coolant" *3 CR: CO-15 or CO-16 HR: CO-34 or CO-35 K9K: CO-53 *4 CR (WITH EURO–OBD): EC-166 CR (WITHOUT EURO–OBD): EC-565 HR (WITH EURO–OBD): EC-947 HR: (WITHOUT EURO–OBD): EC-1361 K9K: EC-1727 *5 MTC-24, "SYMPTOM TABLE" *6 MTC-71, "Air Mix Door Cable Adjustment" *For further information refer to EC-21, "APPLICATION NOTICE" . MTC-59 TROUBLE DIAGNOSIS Noise BJS000DT SYMPTOM: Noise INSPECTION FLOW SJIA0843E MTC-60 TROUBLE DIAGNOSIS *1 MTC-34, "Operational Check" *4 CR: EM-14, "Checking drive Belts" HR: EM-114, "Checking Drive Belts" K9K: EM-242, "Checking Drive Belts" *2 MTC-87, "CHECK DISC TO PULLEY *3 CLEARANCE" MTC-17, "Maintenance of Lubricant Quantity in Compressor" A B C D E F G H I MTC K L M MTC-61 CONTROLLER CONTROLLER Removal and Installation PFP:28074 BJS000E2 REMOVAL 1. 2. 3. Remove intake door lever knob. Refer to MTC-63, "Disassembly and Assembly" . Remove controller mounting clips (A) using remover tool, and then remove controller finisher (1). Disconnect front passenger air bag OFF indicator harness connector. ZJIA0850J 4. Remove mounting screws, and then pull out controller. ZJIA0851J 5. 6. 7. Remove instrument panel & pad. Refer to IP-4, "INSTRUMENT PANEL ASSEMBLY" . Remove air mix door cable, mode door cable and intake door cable from A/C unit assembly. Disconnect connector, and then remove controller. INSTALLATION Installation is basically the reverse order of removal. CAUTION: Adjust the door cables during installation. Refer to MTC-70, "Intake Door Cable Adjustment" , MTC-71, "Air Mix Door Cable Adjustment" and MTC-72, "Mode Door Cable Adjustment" . MTC-62 CONTROLLER Disassembly and Assembly BJS000E3 A B C D E F ZJIA0106J 1. Air mix door cable 2. Intake door cable 3. Mode door cable 4. A/C controller assembly 5. Mode control dial 6. Rear DEF button 7. A/C button 8. Temperature control dial 9. Illumination bulb 10. Intake door lever knob G H 11. Fan control dial CAUTION: Install inner cable of each door cable to the corresponding lever, as shown in the figure. Press outer cable until it hooks on the tabs and becomes fixed. I MTC K MJIA0038E L M MTC-63 THERMO CONTROL AMPLIFIER THERMO CONTROL AMPLIFIER Removal and Installation PFP:27675 BJS000E4 REMOVAL 1. 2. Remove evaporator. Refer to MTC-91, "Removal and Installation for Evaporator" . CAUTION: Cap or wrap the joint of the pipe with suitable material such as vinyl tape to avoid the entry of air. Remove thermo control amp. (1) from evaporator (2). MJIB0459E INSTALLATION Installation is basically the reverse order of removal. CAUTION: ● Replace O-rings for A/C piping with new ones, and then apply compressor oil to it when installing it. ● Mark the mounting position of thermo control amp. ● When recharging refrigerant, check for leaks. MTC-64 A/C UNIT ASSEMBLY A/C UNIT ASSEMBLY Removal and Installation PFP:27110 A BJS000E5 REMOVAL 1. 2. 3. 4. 5. Use a refrigerant collecting equipment (for HFC-134a) to discharge refrigerant. Drain coolant from cooling system. CR: Refer to CO-9, "Changing Engine coolant" . HR: Refer to CO-28, "Changing Engine coolant" . K9K: Refer to CO-49, "Changing Engine Coolant" . Remove cowl top cover. Refer to EI-12, "Removal and Installation" . Remove lower dash insulator. Remove mounting bolt (A), and then disconnect low-pressure flexible hose (1) and high-pressure pipe (2) from evaporator. CAUTION: Cap or wrap the joint of the pipe with suitable material such as vinyl tape to avoid the entry of air. B C D E F G MJIB0471E 6. Remove clamps (A), and then disconnect heater hoses (1) from heater core. H I MTC MJIB0472E 7. 8. Remove console box assembly. Refer to IP-4, "INSTRUMENT PANEL ASSEMBLY" . Remove mounting nuts (A) and harness clamps (B), and then remove instrument stay (1). K L M MJIB0473E MTC-65 A/C UNIT ASSEMBLY 9. Disconnect thermo control amp. connector (1). MJIB0474E 10. 11. 12. 13. Remove instrument panel & pad. Refer to IP-4, "INSTRUMENT PANEL ASSEMBLY" . Remove side ventilator ducts. Refer to MTC-78, "Removal of Side Ventilator Ducts" . Remove center ventilator ducts. Refer to MTC-78, "Removal of Center Ventilator Ducts" . Remove A/C unit assembly mounting bolts (A), steering member mounting bolts (B), steering column mounting nuts (C) and harness clips. MJIB0435E 14. Remove steering member, and then remove A/C unit assembly. INSTALLATION Installation is basically the reverse order of removal. CAUTION: ● Replace O-rings for A/C piping with new ones, and then apply compressor oil to it when installing it. ● When recharging refrigerant, check for leaks. NOTE: ● When filling radiator with coolant. CR: Refer to CO-9, "Changing Engine coolant" . HR: Refer to CO-28, "Changing Engine coolant" . K9K: Refer to CO-49, "Changing Engine Coolant" . ● Recharge the refrigerant. A/C unit assembly mounting bolt Tightening torque : 6.9 N·m (0.7 kg-m, 61 in-lb) Steering member mounting bolt Tightening torque : 12 N·m (1.25 kg-m, 9 ft-lb) MTC-66 A/C UNIT ASSEMBLY Steering column mounting nut Tightening torque : 12 N·m (1.25 kg-m, 9 ft-lb) A Disassembly and Assembly BJS000E6 B C D E F G H I MTC K L M MJIB0506E 1. Center defroster duct 2. Seal 3. 4. Insulator 5. Nut 6. Blower unit 7. Air conditioner filter 8. Evaporator assembly 9. Foot duct assembly (RH) MTC-67 Intake case A/C UNIT ASSEMBLY 10. Ventilator-defroster door lever 11. Rod 12. Foot door lever 13. Air mix door link 14. Main link 15. Foot door link 16. A/C controller assembly 17. Clip 18. Heater cover 19. Lower blower case 20. Heater core assembly 21. PTC heater 22. Foot duct assembly (LH) 23. Heater hose cover 24. Air mix door lever 25. Blower fan resistor 26. Intake door link 27. Intake door lever 28. Heater pipe packing 29. Cover 30. Expansion valve assembly 31. O-ring 32. Evaporator valve block 33. Expansion valve cover 34. Thermal control amplifier 35. Drain hose 36. Blower case (RH) 37. Blower case (LH) 38. Ventilator-defroster door 39. Air mix door 1 40. Air mix door 2 41. Foot duct 42. Foot door link MTC-68 BLOWER MOTOR BLOWER MOTOR Removal and Installation PFP:27226 A BJS000E7 REMOVAL 1. 2. 3. 4. Remove instrument panel & pad. Refer to IP-4, "INSTRUMENT PANEL ASSEMBLY" . Remove side ventilator duct (right). Refer to MTC-78, "Removal of Side Ventilator Ducts" . Disconnect blower motor connector (1). Push flange holding hook (A), and then remove blower motor (2) from A/C unit assembly (3). CAUTION: When blower fan and blower motor are assembled, the balance is adjusted, so do not replace the individual parts. B C D E MJIB0440E INSTALLATION F Installation is basically the reverse order of removal. CAUTION: Correctly install blower motor flange holding hook in A/C unit assembly. G H I MTC K L M MTC-69 INTAKE DOOR INTAKE DOOR Intake Door Cable Adjustment 1. 2. 3. 4. 5. PFP:27245 BJS000E8 Remove instrument lower finisher. Refer to IP-4, "INSTRUMENT PANEL ASSEMBLY" . Remove outer cable of intake door cable (1) from clamp (A). Set intake door lever to REC position. Push intake door link (2) in the direction shown by the arrow, and then carefully pulling outer cable to controller side, and install clamp (A). Operate intake door lever to insure that inner cable moves smoothly. CAUTION: When clamping the outer cable, do not move the inner cable. MTC-70 MJIB0500E AIR MIX DOOR AIR MIX DOOR Air Mix Door Cable Adjustment 1. 2. 3. 4. 5. PFP:27180 A BJS000E9 Remove steering member. Refer to MTC-65, "A/C UNIT ASSEMBLY" . Remove outer cable of air mix door cable (1) from clamp (A). Set temperature control dial to full cold position. Push air mix door lever (2) in the direction shown by arrow, and then carefully pull outer cable toward controller side, and install clamp (A). Operate temperature control dial to insure that inner cable moves smoothly. CAUTION: When clamping the outer cable, do not move the inner cable. B C D MJIB0501E E F G H I MTC K L M MTC-71 MODE DOOR MODE DOOR Mode Door Cable Adjustment 1. 2. 3. 4. 5. PFP:27181 BJS000EA Remove glove box assembly and instrument lower cover (RH). Refer to IP-4, "INSTRUMENT PANEL ASSEMBLY" . Remove outer cable of mode door cable (1) from clamp (A). Set mode control dial to VENT position. Push main link (2) in the direction shown by the arrow, and then carefully pull outer cable to controller side, and install clamp (A). Operate mode control dial to insure that inner cable moves smoothly. CAUTION: When clamping the outer cable, do not move the inner cable. MJIB0502E MTC-72 BLOWER FAN RESISTOR BLOWER FAN RESISTOR Removal and Installation PFP:27150 A BJS000EB REMOVAL 1. 2. 3. Remove instrument panel & pad. Refer to IP-4, "INSTRUMENT PANEL ASSEMBLY" . Disconnect blower fan resistor connector. Remove mounting screws (A), and then remove blower fan resistor (1). B C D E MJIB0503E INSTALLATION Installation is basically the reverse order of removal. F G H I MTC K L M MTC-73 HEATER CORE HEATER CORE Removal and Installation PFP:27140 BJS000EC REMOVAL 1. 2. 3. 4. Remove A/C unit assembly. Refer to MTC-65, "A/C UNIT ASSEMBLY" . Remove foot duct (left). Refer to MTC-78, "Removal of Foot Ducts" . Remove mounting screws (A). Slide heater core (1) to leftward. MJIB0439E INSTALLATION Installation is basically the reverse order of removal. MTC-74 AIR CONDITIONER FILTER AIR CONDITIONER FILTER Removal and Installation PFP:27277 A BJS000ED FUNCTION Air inside passenger compartment is kept clean at either recirculation or fresh mode by installing air conditioner filter into A/C unit assembly. B C D SJIA0651E E REPLACEMENT TIMING Replace air conditioner filter. Refer to MA-55, "CHASSIS AND BODY MAINTENANCE" . Caution label is fixed inside glove box. F REPLACEMENT PROCEDURES 1. 2. 3. 4. 5. G Remove glove box assembly. Refer to IP-4, "INSTRUMENT PANEL ASSEMBLY" . Compress air conditioner filter downward while sliding it to the right side of the vehicle. Turn the bottom of air conditioner filter upward, and then remove it. Replace with new one and reinstall on A/C unit assembly. Reinstall glove box assembly. H I MTC MJIB0446E K L M MTC-75 DUCTS AND GRILLES DUCTS AND GRILLES Removal and Installation PFP:27860 BJS000EE REMOVAL MJIB0447E 1. Side defroster duct (right) 2. Defroster nozzle 3. Side defroster duct (left) 4. Side defroster grille (left) 5. Instrument side panel (left) 6. Instrument panel & pad 7. Side ventilator assembly (left) 8. Cluster lid C 9. Side ventilator assembly (right) 10. Instrument finisher E 11. Instrument side panel (right) Removal of Center Ventilator Grilles 1. 2. Remove cluster lid C. Refer to IP-4, "INSTRUMENT PANEL ASSEMBLY" . Remove center ventilator grilles (1) mounting screws (A) using a screwdriver (B), and then remove center ventilator grilles (1). MJIB0448E MTC-76 DUCTS AND GRILLES Removal of Side Ventilator Grilles 1. Remove instrument pad assembly (left). Refer to IP-4, "INSTRUMENT PANEL ASSEMBLY" . 2. Side ventilator grille (left) (1) mounting pawl ( side ventilator grille (left)(1) is pulled out. A ) is pushed, and B C D MJIB0449E 3. Remove instrument pad assembly (right). Refer to IP-4, "INSTRUMENT PANEL ASSEMBLY" . 4. Side ventilator grille (right) (1) mounting pawl ( and side ventilator grille (right)(1) is pulled out. E ) is pushed, F G H MJIB0450E Removal of Defroster Nozzle and Ducts 1. 2. Remove instrument upper finisher. Refer to IP-4, "INSTRUMENT PANEL ASSEMBLY" . Remove mounting screws (A) and then remove side defroster duct (right) (1) and side defroster duct (left) (2). I MTC K L M MJIB0451E 3. Remove mounting screws (B), and then remove defroster nozzle (3). MTC-77 DUCTS AND GRILLES Removal of Side Ventilator Ducts 1. 2. Remove instrument panel & pad. Refer to IP-4, "INSTRUMENT PANEL ASSEMBLY" . Remove mounting screws (A) and clip (B), and then remove side ventilator duct (left) (1). MJIB0475E 3. Remove mounting screw (A) and clip (B), and then remove side ventilator duct (right) (1). MJIB0476E Removal of Center Ventilator Ducts 1. 2. Remove instrument panel & pad. Refer to IP-4, "INSTRUMENT PANEL ASSEMBLY" . Remove mounting screws (A), and then remove center ventilator ducts (1). MJIB0477E Removal of Foot Ducts 1. 2. 3. Remove A/C unit assembly. Refer to MTC-65, "A/C UNIT ASSEMBLY" . Remove intake door motor (2). Refer to MTC-70, "INTAKE DOOR" . Remove mounting screws (A), and then remove foot duct (left) (1). MJIB0452E MTC-78 DUCTS AND GRILLES 4. Remove mounting screws (A), and then remove foot duct (right) (1). A B C MJIB0453E D Removal of Floor Ducts E F G H I MJIB0454E 1. 2. 1. Front floor duct 4. Rear floor duct (right) 2. Rear floor duct (left) 3. MTC Clip K Remove front seat and center console assembly. Refer to SE-8, "Removal and Installation" "INSTRUMENT PANEL ASSEMBLY" . Disengage claws (A), and then remove front floor duct (1). and IP-4, L M MJIB0455E 3. Peel back floor trim to a point where floor duct is visible. MTC-79 DUCTS AND GRILLES 4. Remove mounting clips (A), and then remove rear floor duct (left) (1) and rear floor duct (right) (2). MJIB0456E INSTALLATION Installation is basically the reverse order of removal. MTC-80 REFRIGERANT LINES REFRIGERANT LINES HFC-134a (R-134a) Service Procedure PFP:92600 A BJS000EF SETTING OF SERVICE TOOLS AND EQUIPMENT Discharging Refrigerant B WARNING: Avoid breathing A/C refrigerant and lubricant vapor or mist. Exposure may irritate eyes, nose and throat. Use only approved recovery/recycling equipment to discharge HFC-134a (R-134a) refrigerant. If accidental system discharge occurs, ventilate work area before resuming service. Additional health and safety information may be obtained from refrigerant and lubricant manufacturers. C D E F G H I SHA539DE Evacuating System and Charging Refrigerant MTC K L M SHA540DC MTC-81 REFRIGERANT LINES RJIA2143E *1 MTC-17, "LUBRICANT RETURN OPERATION" *4 MTC-53, "PERFORMANCE TEST DIAGNOSIS" *2 MTC-93, "Checking for Refrigerant Leaks" MTC-82 *3 MTC-95, "CHECKING PROCEDURE" REFRIGERANT LINES Components BJS000IQ A CR ENGINE MODELS B C D E F G H I MJIB0436E 1. High-pressure flexible hose 2. Radiator (Condenser) 3. Liquid tank 4. Compressor 5. High-pressure pipe 6. Low-pressure flexible hose MTC K L M MTC-83 REFRIGERANT LINES HR ENGINE MODELS MJIB0437E 1. High-pressure flexible hose 2. Radiator (Condenser) 3. Liquid tank 4. Compressor 5. High-pressure pipe 6. Low-pressure flexible hose 7. Service valve (High pressure) 8. Service valve (Low pressure) 9. Refrigerant pressure sensor 10. Condenser MTC-84 REFRIGERANT LINES K9K ENGINE MODELS A B C D E F G H I MTC K L MJIB0438E 1. High-pressure flexible hose 2. Refrigerant pressure sensor 3. Liquid tank 4. Radiator (Condenser) 5. Condenser 6. Compressor 7. Service valve (Low pressure) 8. Low-pressure flexible hose 9. High-pressure pipe 10. Service valve (High pressure) MTC-85 M REFRIGERANT LINES Removal and Installation of Compressor BJS000IR REMOVAL 1. 2. 3. Use a refrigerant collecting equipment (for HFC-134a) to discharge the refrigerant. Remove engine undercover, using power tools. Remove low-pressure flexible hose mounting nut and high-pressure flexible hose mounting bolt from compressor. MJIB0273E 4. 5. 6. CAUTION: Cap or wrap the joint of the pipe with suitable material such as vinyl tape to avoid the entry of air. Remove A/C compressor belt. CR: Refer to EM-14, "DRIVE BELTS" . HR: Refer to EM-114, "DRIVE BELTS" . K9K: Refer to EM-242, "DRIVE BELTS" . Disconnect compressor connector. Remove mounting bolts from compressor, using power tools. MJIB0134E 7. Remove compressor downward of the vehicle. INSTALLATION Installation is basically the reverse order of removal. CAUTION: ● Replace O-rings of low-pressure flexible hose and high-pressure flexible hose with a new ones, and then apply compressor oil to it when installing it. ● When recharging refrigerant, check for leaks. Compressor mounting bolt Tightening torque : 20.0 N·m (2.05 kg-m, 14.8 ft-lb) MTC-86 REFRIGERANT LINES CHECK DISC TO PULLEY CLEARANCE A Check clearance around entire periphery of clutch disc. Disc to pulley clearance : 0.3 - 0.6 mm (0.012 - 0.024 in) B If specified clearance is not obtained, replace compressor. C RHA087E Removal and Installation for Pipe and Hose D BJS000IS REMOVAL 1. 2. 3. 4. 5. 6. 7. E Use recovery/recycling recharging equipment [for HFC-134a (R-134a)] to discharge refrigerant. Remove the low-pressure flexible hose bracket mounting bolt and nut. Remove the high-pressure pipe and low-pressure flexible hose mounting bolts (air conditioner unit side). F CAUTION: Seal the connecting points of the pipe and hose with caps and vinyl tape, etc. to prevent them from being exposed to the atmosphere. G Remove the low-pressure flexible hose mounting bolt or nut (compressor side) and then remove the lowpressure flexible hose. CAUTION: H Seal the connecting points of the hose with caps and vinyl tape, etc. to prevent them from being exposed to the atmosphere. Remove the front bumper and air guide (RH). Refer to EI-4, "Removal and Installation" and BL-13, I "Removal and Installation" . Remove the high-pressure pipe mounting bolt (liquid tank side) and then remove the high-pressure pipe. CAUTION: MTC Seal the connecting points of the pipe with caps and vinyl tape, etc. to prevent them from being exposed to the atmosphere. Remove the high-pressure flexible hose mounting bolts and then remove the high-pressure flexible hose. K CAUTION: Seal the connecting points of the hoses with caps and vinyl tape, etc. to prevent them from being exposed to the atmosphere. L INSTALLATION CAUTION: ● Replace the O-rings on the high-pressure pipe, low-pressure flexible hose, and high-pressure flexible hose with new ones, and apply compressor lubricant to O-rings before installing. ● When charging refrigerant, check for refrigerant leaks. High-pressure pipe mounting bolt Tightening torque : 4.4 N·m (0.45 kg-m, 39.0 in-lb) Low-pressure flexible hose and high-pressure pipe mounting bolts (evaporator side) Tightening torque : 4.4 N·m (0.45 kg-m, 39.0 in-lb) Low-pressure flexible hose mounting bolt (compressor side) Tightening torque : 13.7 N·m (1.4 kg-m, 10.1 ft-lb) Low-pressure flexible hose bracket mounting bolt/nut Tightening torque : 4.2 N·m (0.43 kg-m, 37.2 in-lb) High-pressure flexible hose mounting bolt Tightening torque : 13.7 N·m (1.4 kg-m, 10.1 ft-lb) MTC-87 M REFRIGERANT LINES Removal and Installation for Refrigerant Pressure Sensor BJS000IT MJIB0457E 1. Refrigerant pressure sensor 4. Air guide 2. Condenser 3. Liquid tank REMOVAL AND INSTALLATION 1. 2. 3. Use refrigerant collecting equipment (for HFC134a) to discharge refrigerant. Remove the front bumper and air guide (RH) (4). Refer to EI-4, "Removal and Installation" and BL-13, "Removal and Installation" . Use a adjustable wrench A or other tool to hold the refrigerant pressure sensor mounting block, and then remove the refrigerant pressure sensor from the condenser (CR and HR engine models) or the high-pressure flexible hose (K9K engine models). CAUTION: ● Be careful when working so as not to damage the condenser core. ● When installing refrigerant pressure sensor, apply compressor lubricant to the O-rings. Refrigerant pressure sensor Tightening torque : 10.8 N·m (1.1 kg-m, 8.0 ft-lb) Removal and Installation for Condenser (Models without Integrated Condenser) BJS000IU REMOVAL 1. 2. 3. 4. Use refrigerant collecting equipment (for HFC134a) to discharge refrigerant. Remove the front bumper and air guide (RH). Refer to EI-4, "Removal and Installation" and BL-13, "Removal and Installation" . Disconnect the high-pressure flexible hose and high-pressure pipe from the condenser. CAUTION: Seal the connecting points of the pipes with caps and vinyl tape, etc. to prevent them from being exposed to the atmosphere. Disconnect the refrigerant pressure sensor connector, and then remove the harness clip (CR engine models). MJIA0059E MTC-88 REFRIGERANT LINES 5. 6. 7. Use cord, etc., to hold the condenser and radiator to each radiator core support upper. NOTE: To prevent the condenser and radiator from being dropped when the radiator core lower support is removed. Remove the mounting bolts, and then remove the radiator core lower support. Remove the condenser from underneath the vehicle. CAUTION: Do not damage the condenser core. A B C MJIA0060E D INSTALLATION CAUTION: ● Replace O-rings on the high-pressure pipe and high-pressure flexible hose with new ones. Apply compressor lubricant to O-rings when installing them. ● When charging refrigerant, check for refrigerant leaks. High-pressure flexible hose bolt Tightening torque : 13.7 N·m (1.4 kg-m, 10.1 ft-lb) High-pressure pipe mounting bolt Tightening torque : 4.4 N·m (0.45 kg-m, 39.0 in-lb) Radiator core lower support mounting bolts. Tightening torque : 51.1 N·m (5.3 kg-m, 37.7 ft-lb) E F G H Removal and Installation for Condenser (Models with Integrated Condenser) BJS000IV REMOVAL 1. 2. 3. 4. I Use refrigerant collecting equipment (for HFC134a) to discharge refrigerant. Remove the front bumper and air guide (RH). Refer to EI-4, "Removal and Installation" and BL-13, "Removal and Installation" . MTC Disconnect the high-pressure flexible hose from the condenser. Disconnect the high-pressure pipe from the liquid tank. CAUTION: K Seal the connecting points of the pipes with caps and vinyl tape, etc. to prevent them from being exposed to the atmosphere. L Remove the radiator assembly. CR: Refer to CO-12, "RADIATOR" . HR: Refer to CO-31, "RADIATOR" . M CAUTION: MJIA0214E Do not damage the radiator and condenser core. INSTALLATION CAUTION: ● Replace O-rings on the high-pressure pipe and high-pressure flexible hose with new ones. Apply compressor lubricant to O-rings when installing them. ● When charging refrigerant, check for refrigerant leaks. MTC-89 REFRIGERANT LINES Removal and Installation for Liquid Tank (HR Engine with A/T Models) BJS000IW REMOVAL 1. 2. 3. 4. Use refrigerant collecting equipment (for HFC134a) to discharge refrigerant. Remove condenser. Refer to MTC-88, "Removal and Installation for Condenser (Models without Integrated Condenser)" . Clean around the liquid tank to remove foreign material and corrosion. Remove the liquid tank bracket (upper/lower) mounting bolts. MJIA0061E 5. 6. Lift up the liquid tank bracket, and remove it from the condenser protruding area. Lift up the liquid tank and remove it. CAUTION: Seal the connecting points of the pipes with caps and vinyl tape, etc. to prevent them from being exposed to the atmosphere. MJIA0062E INSTALLATION Install the liquid tank, and then install liquid tank bracket to the condenser. CAUTION: ● Make sure the liquid tank bracket is correctly inserted into the condenser's protruding area (the liquid tank bracket does not move below the center of the liquid tank). ● Replace the condenser pipe O-rings with new ones. Apply a coat of compressor lubricant to the O-rings prior to installation. MJIA0063E Liquid tank bracket (upper) mounting bolt Tightening torque : 3.38 N·m (0.35 kg-m, 30.0 in-lb) Liquid tank bracket (lower) mounting bolt Tightening torque : 5.74 N·m (0.58 kg-m, 50.8 in-lb) Removal and Installation for Liquid Tank (Except HR Engine with A/T Models) BJS000IX REMOVAL 1. 2. 3. 4. 5. Use refrigerant collecting equipment (for HFC134a) to discharge refrigerant. Clean around the liquid tank to remove foreign material and corrosion. Remove the high-pressure pipe from the liquid tank. Remove the condenser pipe mounting bolt from the liquid tank, and remove pipe from the condenser protruding area. Remove the liquid tank bracket bolts and then remove the liquid tank. MJIA0215E MTC-90 REFRIGERANT LINES CAUTION: Seal the connecting points of the pipes with caps and vinyl tape, etc. to prevent them from being exposed to the atmosphere. A INSTALLATION Install the liquid tank, and then install liquid tank bracket to the condenser. CAUTION: Replace the condenser pipe O-rings with new ones. Apply a coat of compressor lubricant to the Orings prior to installation. Removal and Installation for Evaporator B C BJS000IY REMOVAL 1. Use refrigerant collecting equipment (for HFC134a) to discharge refrigerant. 2. Remove the A/C unit. Refer to MTC-65, "A/C UNIT ASSEMBLY" . CAUTION: Seal the connecting points of the pipes with caps and vinyl tape, etc. to prevent them from being exposed to the atmosphere. 3. Remove the air conditioner filter, mode door motor, and foot duct (RH). Refer to MTC-75, "AIR CONDITIONER FILTER" , MTC-72, "MODE DOOR" and MTC-78, "Removal of Foot Ducts" . 4. Remove the lower blower case and expansion valve cover. 5. Slide the evaporator (1) and lower blower case (2) downward, and remove the intake sensor (3). 6. Remove the evaporator from the lower blower case. D E F G H I MJIB0462E MTC INSTALLATION CAUTION: ● Replace low-pressure flexible hose and high-pressure pipe O-rings with new ones. Apply a coat of compressor lubricant prior to installation. ● When installing a new evaporator, install the thermistor of intake air temperature in the same position as the removed intake sensor. ● When removing and installing the intake sensor, do not rotate the thermistor insertion part. Mounting bolts for the low-pressure flexible hoses and high-pressure pipes. Tightening torque : 4.4 N·m (0.45 kg-m, 39.0 in-lb) Removal and Installation for Expansion Valve L M BJS000IZ REMOVAL 1. Use refrigerant collecting equipment (for HFC134a) to discharge refrigerant. 2. Disconnect the low-pressure flexible hose and high-pressure pipe from the evaporator. CAUTION: Seal the connecting points of the pipes with caps and vinyl tape, etc. to prevent them from being exposed to the atmosphere. 3. Remove the two bolts (A) from the expansion valve, and then remove the expansion valve (1). MJIB0460E MTC-91 K REFRIGERANT LINES INSTALLATION CAUTION: Replace the removed O-rings with new ones. Apply a coat of compressor lubricant to the O-rings prior to installation. Expansion valve mounting bolts Tightening torque : 4.0 N·m (0.41 kg-m, 35.4 in-lb) Mounting bolts for the low-pressure flexible hoses and high-pressure pipes. Tightening torque : 4.4 N·m (0.45 kg-m, 39.0 in-lb) MTC-92 REFRIGERANT LINES Checking for Refrigerant Leaks BJS000J0 Perform a visual inspection of all refrigeration parts, fittings, hoses and components for signs of A/C lubricant leakage, damage and corrosion. A/C lubricant leakage may indicate an area of refrigerant leakage. Allow extra inspection time in these areas when using either an electronic refrigerant leak detector or fluorescent dye leak detector. If dye is observed, confirm the leak with an electronic refrigerant leak detector. It is possible a prior leak was repaired and not properly cleaned. When searching for leaks, do not stop when one leak is found but continue to check for additional leaks at all system components and connections. When searching for refrigerant leaks using an electronic leak detector, move the probe along the suspected leak area at 1 to 2 inches per second and no further than 1/4 inch from the component. CAUTION: Moving the electronic leak detector probe slower and closer to the suspected leak area will improve the chances of finding a leak. Checking System for Leaks Using the Fluorescent Leak Detector A B C D E BJS000J1 1. Check A/C system for leaks using the UV lamp and safety goggles [SST: J-42220] in a low sunlight area (area without windows preferable). Illuminate all components, fittings and lines. The dye will appear as a F bright green/yellow area at the point of leakage. Fluorescent dye observed at the evaporator drain opening indicates an evaporator core assembly (tubes, core or expansion valve) leak. 2. If the suspected area is difficult to see, use an adjustable mirror or wipe the area with a clean shop rag or G cloth, with the UV lamp for dye residue. 3. After the leak is repaired, remove any residual dye using refrigerant dye cleaner [SST: J-43872] to prevent future misdiagnosis. H 4. Perform a system performance check and verify the leak repair with an approved electronic refrigerant leak detector. NOTE: I Other gases in the work area or substances on the A/C components, for example, anti-freeze, windshield washer fluid, solvents and lubricants, may falsely trigger the leak detector. Make sure the surfaces to be checked are clean. Clean with a dry cloth or blow off with shop air. MTC Do not allow the sensor tip of the detector to contact with any substance. This can also cause false readings and may damage the detector. Dye Injection BJS000J2 (This procedure is only necessary when recharging the system or when the compressor has seized and was replaced.) 1. 2. 3. 4. 5. 6. 7. Check A/C system static (at rest) pressure. Pressure must be at least 345 kPa (3.45 bar, 3.52 kg/cm2 , 50 psi). Pour one bottle (1/4 ounce / 7.4 cc) of the A/C refrigerant dye into the injector tool [SST: J-41459]. Connect the injector tool to the A/C low-pressure side service fitting. Start engine and switch A/C ON. When the A/C operating (compressor running), inject one bottle (1/4 ounce / 7.4 cc) of fluorescent dye through the low-pressure service valve using dye injector tool J-41459 (refer to the manufacture’s operating instructions). With the engine still running, disconnect the injector tool from the service fitting. CAUTION: Be careful the A/C system or replacing a component, pour the dye directly into the open system connection and proceed with the service procedures. Operate the A/C system for a minimum of 20 minutes to mix the dye with the system oil. Depending on the leak size, operating conditions and location of the leak, it may take from minutes to days for the dye to penetrate a leak and become visible. MTC-93 K L M REFRIGERANT LINES Electronic Refrigerant Leak Detector BJS000J3 PRECAUTIONS FOR HANDLING LEAK DETECTOR When performing a refrigerant leak check, use an A/C electrical leak detector (SST) or equivalent. Ensure that the instrument is calibrated and set properly per the operating instructions. The leak detector is a delicate device. In order to use the leak detector properly, read the operating instructions and perform any specified maintenance. SHA705EB 1. Position probe approximately 5 mm (3/16 in) away from point to be checked. SHA707EA 2. When testing, circle each fitting completely with probe. SHA706E 3. Move probe along component approximately 25 to 50 mm (1 to 2 in)/sec. SHA708EA MTC-94 REFRIGERANT LINES CHECKING PROCEDURE To prevent inaccurate or false readings, make sure there is no refrigerant vapor, shop chemicals, or cigarette smoke in the vicinity of the vehicle. Perform the leak test in calm area (low air/wind movement) so that the leaking refrigerant is not dispersed. 1. Turn engine OFF. 2. Connect a suitable A/C manifold gauge set to the A/C service ports. 3. 4. Check if the A/C refrigerant pressure is at least 345 kPa (3.45 bar, 3.52 kg/cm2 , 50 psi) above 16°C. If less than specification, recover/evacuate and recharge the system with the specified amount of refrigerant. NOTE: At temperatures below 16°C, leaks may not be detected since the system may not reach 345 kPa (3.45 bar, 3.52 kg/cm2 , 50 psi). Perform the leak test from the high-pressure side (compressor discharge a to evaporator inlet f) to the low-pressure side (evaporator drain hose g to shaft seal k). Refer to MTC-83, "Components" . Perform a leak check for the following areas carefully. Clean the component to be checked and move the leak detected probe completely around the connection/component. Compressor Check the fitting of high- and low-pressure flexible hoses, relief valve and shaft seal. A B C D E F Condenser Check the fitting of high-pressure flexible hose and pipe, refrigerant pressure sensor. G Liquid tank Check the refrigerant connection. H Service valves I Check all around the service valves. Ensure service valve caps are secured on the service valves (to prevent leaks). NOTE: After removing A/C manifold gauge set from service valves, wipe any residue from valves to prevent any MTC false readings by leak detector. 5. 6. 7. 8. a. b. c. d. e. 9. Cooling unit (Evaporator) With engine OFF, turn blower fan on “High” for at least 15 seconds to dissipate any refrigerant trace in the cooling unit. Wait a minimum of 10 minutes accumulation time (refer to the manufacturer’s recommended procedure for actual wait time) before inserting the leak detector probe into the drain hose. Keep the probe inserted for at least 10 seconds. Use caution not to contaminate the probe tip with water or dirt that may be in the drain hose. If a leak detector detects a leak, verify at least once by blowing compressed air into area of suspected leak, then repeat check as outlined above. Do not stop when one leak is found. Continue to check for additional leaks at all system components. If no leaks are found, perform steps 7-10. Start engine. Set the heater A/C control as follows; A/C switch: ON MODE door position: VENT (Ventilation) Intake door position: Recirculation Temperature control dial: Max. cold Fan speed: High Run engine at 1,500 rpm for at least 2 minutes. MTC-95 K L M REFRIGERANT LINES 10. Turn engine off and perform leak check again following steps 4 through 6 above. Refrigerant leaks should be checked immediately after stopping the engine. Begin with the leak detector at the compressor. The pressure on the high-pressure side will gradually drop after refrigerant circulation stops and pressure on the low-pressure side will gradually rise, as shown in the graph. Some leaks are more easily detected when pressure is high. 11. Before connecting ACR4 to vehicle, check ACR4 gauges. No refrigerant pressure should be displayed. If pressure is displayed, recover refrigerant from equipment lines. 12. Discharge A/C system using approved refrigerant recovery equipment. Repair the leaking fitting or component if necessary. 13. Evacuate and recharge A/C system and perform the leak test to confirm no refrigerant leaks. 14. Perform A/C performance test to ensure system works properly. MTC-96 SHA839E SERVICE DATA AND SPECIFICATIONS (SDS) SERVICE DATA AND SPECIFICATIONS (SDS) COMPRESSOR Model PFP:00030 A BJS000J4 CR engine models HR engine models K9K engine models ZEXEL VALEO CLIMATE CONTROL make KC59G CR-10 SANDEN make SD6V12 Type Vane rotary Displacement Max. cm3 (cu in)/rev Min. Cylinder bore × stroke mm (in) Variable volume piston 80 (4.88) Theoretical displacement 96 (5.86) Theoretical displacement 125.1 (7.63) 6.2 (0.38) 5 vanes, φ51.0 × 7.28 5 vanes, φ50.2 × 8.5 — Direction of rotation Poly V (4grooves) V-Ribbed (7 grooves) E Poly V (6 grooves) LUBRICANT BJS000J5 F CR engine models HR engine models K9K engine models ZEXEL VALEO CLIMATE CONTROL make KC59G CR-10 SANDEN make SD6V12 Name Part number Capacity m (lmp fl oz) Nissan A/C System Oil Type R Nissan A/C System Oil Type S KLH00-PAGR0 KLH00-PAGS0 Total in system — — 135 (4.75) Compressor (Service part) charging amount — — 135 (4.75) REFRIGERANT Model G H I BJS000J6 MTC CR engine models HR engine models K9K engine models ZEXEL VALEO CLIMATE CONTROL make KC59G CR-10 SANDEN make SD6V12 K 0.55 ± 0.05 (1.21 ± 0.11) L Type Capacity kg (lb) C D Clockwise (viewed from drive end) Drive belt Model B HFC-134a (R-134a) 0.475 ± 0.025 (1.04 ± 0.055) 0.475 ± 0.025 (1.04 ± 0.055) ENGINE IDLING SPEED BJS000J7 M Refer to EC-449, "SERVICE DATA AND SPECIFICATIONS (SDS)" . CR (WITH EURO−OBD). Refer to EC-801, "SERVICE DATA AND SPECIFICATIONS (SDS)" . CR (WITHOUT EURO−OBD). Refer to EC-1237, "SERVICE DATA AND SPECIFICATIONS (SDS)" . HR (WITH EURO−OBD). Refer to EC-1597, "SERVICE DATA AND SPECIFICATIONS (SDS)" . HR (WITHOUT EURO−OBD). Refer to EC-1870, "SERVICE DATA AND SPECIFICATIONS (SDS)" . K9K. BELT TENSION BJS000J8 Refer to EM-14, "Tension Adjustment" . (CR engine models). Refer to EM-114, "Tension Adjustment" . (HR engine models). Refer to EM-242, "Tension Adjustment" . (K9K engine models). MTC-97 SERVICE DATA AND SPECIFICATIONS (SDS) MTC-98 PARKING BRAKE SYSTEM F BRAKES SECTION PB PARKING BRAKE SYSTEM A B C D CONTENTS NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING ................................................ 2 NVH Troubleshooting Chart ..................................... 2 PARKING BRAKE SYSTEM ...................................... 3 On Board Inspection and Service ............................ 3 LEVER STROKE ................................................... 3 Adjustment ............................................................... 3 Components ............................................................. 4 Removal and Installation .......................................... 4 REMOVAL ............................................................. 4 INSTALLATION ..................................................... 5 SERVICE DATA AND SPECIFICATIONS (SDS) ........ 6 Parking Brake ........................................................... 6 E PB G H I J K L M PB-1 NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING NVH Troubleshooting Chart PFP:00003 BFS0008T PB-2 NVH in PS section STEERING X NVH in WT section X ROAD WHEEL — Drum rust X NVH in WT section X TYRES X NVH in RSU section X SUSPENSION Shimmy, Judder X: Applicable — BR-28 Drum runout X Drum deflection — Drum damage Shake — BR-28 Drum imbalance X Drum deformation BR-27 X NVH in RAX section BRAKE X AXLE Symptom Return spring damaged Noise — Possible cause and SUSPECTED PARTS Linings - uneven wear BR-28 Reference page Linings - damaged Use the chart below to help you find the cause of the symptom. If necessary, repair or replace these parts. X X X X X X X X X X X X X X X PARKING BRAKE SYSTEM PARKING BRAKE SYSTEM On Board Inspection and Service PFP:36010 A BFS0008U LEVER STROKE ● Operate parking brake lever with a force of 196 N (20 kg, 44.1 lb). Check if stroke is within specified number of notches. (Check it by hearing clicks of ratchet.) Lever stroke : 8 - 9 notches C Adjustment 1. 2. B BFS0008V Insert a socket wrench into opening of parking brake lever. Rotate adjusting nut (1) to fully loosen cable (2), then return parking brake lever. Depress the foot brake several times (minimum 10 times) and adjust the rear shoe clearance. NOTE: Be sure to securely depress the foot brake. D E PB MFIB9033E G 3. 4. a. b. Rotate the road wheels to make sure that there is no drag. Use the following procedure to adjust the cable. Pull the lever up to the position where a socket wrench can be inserted. Insert a socket wrench into the opening of the lever, and rotate the adjusting nut to adjust lever stroke. NOTE: Do not reuse adjusting nut after removing it. H I J MAA0182D c. d. 5. 6. 7. After operating the lever about 10 times with a force of 196 N (20 kg, 44.1 lb), make sure that the lever stroke is within the specified number of notches. With the lever completely returned, make sure that there is no drag on the rear brake. Check brake warning lamp on Combination meter comes on when parking brake is applied by 1 notch or less, and goes out again when parking brake lever returns to off position. Check if the ratchet engages and releases securely and smoothly. Check if initial free play of the lever is maximum 20 mm at the end of the release button and check operating force of release button is 4.9 N (0.50 kg, 1.10 lb) at full stroke point. PB-3 K L M PARKING BRAKE SYSTEM Components BFS0008W MFIB9034E 1. Device assembly 2. Screw 3. Warning lamp switch 4. Adjusting nut 5. Front cable 6. Rear left cable 7. Rear right cable 8. Parking brake lever grip 9. Rear cable mount 10. Back plate Removal and Installation BFS0008X REMOVAL 1. 2. 3. 4. Remove the center console. Refer to IP-4, "INSTRUMENT PANEL ASSEMBLY" . Disconnect warning lamp switch connector. Loosen adjusting nut and separate the rear left and rear right cable from front cable. Remove device assembly tightening nuts, and remove device assembly from vehicle. 5. 6. Remove tyre from vehicle. Remove rear brake shoe assembly and remove cable from the operating lever. Refer to BR-27, "Components" . Remove the center and rear heat plates. Refer to EX-3, "EXHAUST SYSTEM" . Release fuel tank clips. Refer to FL-8, "FUEL TANK" (CR), FL-19, "FUEL TANK" (HR), FL-31, "FUEL TANK" (K9K). Remove rear cable mount fixing bolts and remove rear cables from the vehicle. 7. 8. 9. PB-4 PARKING BRAKE SYSTEM INSTALLATION 1. 2. Install in the reverse order of removal. Tighten nuts and bolts to the specified torque. Adjust the parking brake. Refer to PB-3, "Adjustment" . A B C D E PB G H I J K L M PB-5 SERVICE DATA AND SPECIFICATIONS (SDS) SERVICE DATA AND SPECIFICATIONS (SDS) Parking Brake PFP:00030 BFS0008Y Control type Center lever Lever stroke [operating force 196 N (20 kg, 44.1 lb)] 8 - 9 notches Full stroke 15 notches Brake warning lamp stroke 1 notch or less PB-6 POWER SUPPLY, GROUND & CIRCUIT ELEMENTS K ELECTRICAL SECTION PG POWER SUPPLY, GROUND & CIRCUIT ELEMENTS A B C D CONTENTS PRECAUTIONS .......................................................... 3 Precautions for Supplemental Restraint System (SRS) “AIR BAG” and “SEAT BELT PRE-TENSIONER” .................................................................. 3 Maintenance Information .......................................... 3 RHD MODELS ...................................................... 3 LHD MODELS ....................................................... 3 POWER SUPPLY ROUTING CIRCUIT ...................... 4 Schematic ................................................................ 4 Wiring Diagram — POWER — ................................. 5 BATTERY POWER SUPPLY — IGNITION SW. IN ANY POSITION ................................................ 5 ACCESSORY POWER SUPPLY — IGNITION SW. IN “ACC” OR “ON” ........................................11 IGNITION POWER SUPPLY — IGNITION SW. IN “ON” AND/OR “START” .................................. 12 Fuse ....................................................................... 17 Fusible Link ............................................................ 17 Circuit Breaker ....................................................... 17 IPDM E/R (INTELLIGENT POWER DISTRIBUTION MODULE ENGINE ROOM) ...................................... 18 System Description ................................................ 18 SYSTEMS CONTROLLED BY IPDM E/R ........... 18 CAN COMMUNICATION LINE CONTROL ......... 18 IPDM E/R STATUS CONTROL ........................... 18 CAN Communication System Description .............. 19 CAN Communication Unit ...................................... 19 Function of Detecting Ignition Relay Malfunction ... 19 CONSULT-II Function (IPDM E/R) ......................... 20 CONSULT-II BASIC OPERATION ....................... 20 SELF-DIAG RESULTS ........................................ 20 DATA MONITOR ................................................. 20 CAN DIAG SUPPORT MNTR ............................. 21 ACTIVE TEST ..................................................... 21 Auto Active Test ..................................................... 22 DESCRIPTION .................................................... 22 OPERATION PROCEDURE ............................... 22 INSPECTION IN AUTO ACTIVE TEST MODE... 23 Configuration .......................................................... 25 DESCRIPTION .................................................... 25 READ CONFIGURATION PROCEDURE ............ 25 WRITE CONFIGURATION PROCEDURE .......... 27 Schematic ............................................................... 31 IPDM E/R Terminal Arrangement ........................... 32 Inspection With CONSULT-II (Self-Diagnosis) ....... 33 IPDM E/R Terminal Inspection ................................ 34 Check IPDM E/R Power Supply and Ground Circuit... 34 Diagnosis of IPDM E/R Integrated Relay ............... 36 Removal and Installation of IPDM E/R ................... 37 REMOVAL ........................................................... 37 INSTALLATION ................................................... 37 GROUND ................................................................... 38 Ground Distribution ................................................. 38 MAIN HARNESS ................................................. 38 ENGINE ROOM HARNESS ................................ 41 ENGINE CONTROL HARNESS/CR AND HR ENGINE MODELS .............................................. 45 BODY HARNESS ................................................ 46 HARNESS ................................................................. 48 Harness Layout ...................................................... 48 HOW TO READ HARNESS LAYOUT ................. 48 HARNESS OUTLINE/CR AND HR ENGINE MODELS ............................................................. 49 HARNESS OUTLINE/K9K ENGINE MODELS ... 50 MAIN HARNESS/LHD MODELS ......................... 51 MAIN HARNESS/RHD MODELS ........................ 53 ENGINE ROOM HARNESS/CR ENGINE MODELS ...................................................................... 55 ENGINE ROOM HARNESS/HR ENGINE MODELS ...................................................................... 57 ENGINE ROOM HARNESS/K9K ENGINE MODELS ...................................................................... 59 ENGINE CONTROL HARNESS/CR ENGINE MODELS ............................................................. 61 ENGINE CONTROL HARNESS/HR ENGINE MODELS ............................................................. 63 ENGINE CONTROL HARNESS/K9K ENGINE MODELS ............................................................. 65 BODY HARNESS (RH SIDE) .............................. 67 BODY HARNESS (LH SIDE) .............................. 69 PG-1 E F G H I J PG L M ROOM LAMP HARNESS .................................... 71 FRONT DOOR HARNESS LH SIDE/LHD MODELS ...................................................................... 72 FRONT DOOR HARNESS LH SIDE/RHD MODELS ...................................................................... 73 FRONT DOOR HARNESS RH SIDE/LHD MODELS ...................................................................... 74 FRONT DOOR HARNESS RH SIDE/RHD MODELS ...................................................................... 75 REAR DOOR HARNESS LH SIDE ..................... 76 REAR DOOR HARNESS RH SIDE ..................... 77 BACK DOOR HARNESS ..................................... 78 Wiring Diagram Codes (Cell Codes) ....................... 79 ELECTRICAL UNITS LOCATION ............................. 82 Electrical Units Location ......................................... 82 ENGINE COMPARTMENT .................................. 82 PASSENGER COMPARTMENT/LHD MODELS... 84 PASSENGER COMPARTMENT/RHD MODELS... 86 HARNESS CONNECTOR .........................................88 Description ..............................................................88 HARNESS CONNECTOR (TAB-LOCKING TYPE) ..................................................................88 HARNESS CONNECTOR (SLIDE-LOCKING TYPE) ..................................................................89 ELECTRICAL UNITS ................................................90 Terminal Arrangement .............................................90 SMJ (SUPER MULTIPLE JUNCTION) ......................92 Terminal Arrangement .............................................92 STANDARDIZED RELAY ..........................................93 Description ..............................................................93 NORMAL OPEN, NORMAL CLOSED AND MIXED TYPE RELAYS ........................................93 TYPE OF STANDARDIZED RELAYS ..................93 FUSE BLOCK ............................................................95 Terminal Arrangement .............................................95 FUSE, FUSIBLE LINK AND RELAY BOX ................96 Terminal Arrangement .............................................96 PG-2 PRECAUTIONS PRECAUTIONS PFP:00001 Precautions for Supplemental Restraint System (SRS) “AIR BAG” and “SEAT BELT PRE-TENSIONER” A BKS00268 The Supplemental Restraint System such as “AIR BAG” and “SEAT BELT PRE-TENSIONER”, used along with a front seat belt, helps to reduce the risk or severity of injury to the driver and front passenger for certain types of collision. Information necessary to service the system safely is included in the SRS and SB section of this Service Manual. WARNING: ● To avoid rendering the SRS inoperative, which could increase the risk of personal injury or death in the event of a collision which would result in air bag inflation, all maintenance must be performed by an authorized NISSAN/INFINITI dealer. ● Improper maintenance, including incorrect removal and installation of the SRS, can lead to personal injury caused by unintentional activation of the system. For removal of Spiral Cable and Air Bag Module, see the SRS section. ● Do not use electrical test equipment on any circuit related to the SRS unless instructed to in this Service Manual. SRS wiring harnesses can be identified by yellow and/or orange harnesses or harness connectors. Maintenance Information B C D E F BKS00269 If any of following part is replaced, always replace with new* one. If it's not (or fail to do so), the electrical system may not be operated properly. *: New one means a virgin control unit that has never been energized on-board. G RHD MODELS H ● ● ● ● ● ● BCM (Models without Intelligent Key system) Intelligent Key unit (Models with Intelligent Key system) ECM IPDM E/R Combination meter EPS control unit I J LHD MODELS ● ● ● BCM (Models without Intelligent Key system) Intelligent Key unit (Models with Intelligent Key system) ECM PG L M PG-3 POWER SUPPLY ROUTING CIRCUIT POWER SUPPLY ROUTING CIRCUIT Schematic PFP:24110 BKS0025I MKWA4392E PG-4 POWER SUPPLY ROUTING CIRCUIT Wiring Diagram — POWER — BKS0025J A BATTERY POWER SUPPLY — IGNITION SW. IN ANY POSITION B C D E F G H I J PG L M MKWA4393E PG-5 POWER SUPPLY ROUTING CIRCUIT MKWA4394E PG-6 POWER SUPPLY ROUTING CIRCUIT A B C D E F G H I J PG L M MKWA4395E PG-7 POWER SUPPLY ROUTING CIRCUIT MKWA4396E PG-8 POWER SUPPLY ROUTING CIRCUIT A B C D E F G H I J PG L M MKWA4397E PG-9 POWER SUPPLY ROUTING CIRCUIT MKWA4398E PG-10 POWER SUPPLY ROUTING CIRCUIT ACCESSORY POWER SUPPLY — IGNITION SW. IN “ACC” OR “ON” A B C D E F G H I J PG L M MKWA4399E PG-11 POWER SUPPLY ROUTING CIRCUIT IGNITION POWER SUPPLY — IGNITION SW. IN “ON” AND/OR “START” MKWA4400E PG-12 POWER SUPPLY ROUTING CIRCUIT A B C D E F G H I J PG L M MKWA4401E PG-13 POWER SUPPLY ROUTING CIRCUIT MKWA4402E PG-14 POWER SUPPLY ROUTING CIRCUIT A B C D E F G H I J PG L M MKWA4403E PG-15 POWER SUPPLY ROUTING CIRCUIT MKWA4404E PG-16 POWER SUPPLY ROUTING CIRCUIT Fuse ● ● ● ● BKS0025K A If fuse is blown, be sure to eliminate cause of malfunction before installing new fuse. Use fuse of specified rating. Never use fuse of more than specified rating. Do not partially install fuse; always insert it into fuse holder properly. Remove fuse for “ELECTRICAL PARTS (BAT)” if vehicle is not used for a long period of time. B C D CEL083 Fusible Link BKS0025L A melted fusible link can be detected either by visual inspection or by feeling with finger tip. If its condition is questionable, use circuit tester or test lamp. CAUTION: ● If fusible link should melt, it is possible that critical circuit (power supply or large current carrying circuit) is shorted. In such a case, carefully check and eliminate cause of malfunction. ● Never wrap outside of fusible link with vinyl tape. Important: Never let fusible link touch any other wiring harness, vinyl or rubber parts. Circuit Breaker E F G H CKIT0163E BKS0025M I The PTC thermistor generates heat in response to current flow. The temperature (and resistance) of the thermistor element varies with current flow. Excessive current flow will cause the element's temperature to rise. When the temperature reaches a specified level, the electrical resistance will rise sharply to control the circuit current. Reduced current flow will cause the element to cool. Resistance falls accordingly and normal circuit current flow is allowed to resume. J PG L SEL109W M PG-17 IPDM E/R (INTELLIGENT POWER DISTRIBUTION MODULE ENGINE ROOM) IPDM E/R (INTELLIGENT POWER DISTRIBUTION MODULE ENGINE ROOM) PFP:284B7 System Description BKS0025N IPDM E/R (Intelligent Power Distribution Module Engine Room) integrates the relay box and fuse block which were originally placed in engine compartment. It controls integrated relay via IPDM E/R control circuit. ● IPDM E/R-integrated control circuit performs ON-OFF operation of relay, CAN communication control and oil pressure switch signal reception, etc. ● It controls operation of each electrical part via ECM, BCM and CAN communication lines. CAUTION: None of the IPDM E/R-integrated relays can be removed. ● SYSTEMS CONTROLLED BY IPDM E/R IPDM E/R receives a request signal from each Control unit with CAN communication. It controls each system. Control system Transmit control unit Control part ● Head lamps (HI,LO) ● Tail lamps, parking and license plate lamps ● Front fog lamps BCM ● Front wipers Headlamp washer control BCM ● Headlamp washer Rear window defogger control BCM ● Rear window defogger A/C compressor control ECM ● A/C compressor Cooling fan control ECM ● Cooling fan Lamp control BCM Wiper control CAN COMMUNICATION LINE CONTROL With CAN communication, by connecting each control unit using two communication lines (CAN L-line, CAN H-line), it is possible to transmit maximum amount of information with minimum wiring. Each control unit can transmit and receive data, and reads necessary information only. Fail-safe Control ● ● When CAN communication with other control units is impossible, IPDM E/R performs fail-safe control. After CAN communication recovers normally, it also returns to normal control. Operation of control parts by IPDM E/R during fail-safe mode is as follows: Controlled system Fail-safe mode ● With the ignition switch ON, the headlamp low is ON. ● With the ignition switch OFF, the headlamp low is OFF. ● With the ignition switch ON, the tail lamp is ON. ● With the ignition switch OFF, the tail lamp is OFF. ● With the ignition switch ON, the cooling fan HI operates. ● With the ignition switch OFF, the cooling fan stops. Headlamps Tail, parking and license plate lamps Cooling fan Front wiper Until the ignition switch is turned off, the front wiper LO and HI remains in the same status it was in just before fail−safe control was initiated. Rear window defogger Rear window defogger OFF Front fog lamps Front fog lamp OFF Headlamp washer Headlamp washer is OFF A/C compressor A/C compressor OFF IPDM E/R STATUS CONTROL In order to save power, IPDM E/R switches status by itself based on each operating condition. 1. CAN communication status ● CAN communication is normally performed with other control units. ● Individual unit control by IPDM E/R is normally performed. PG-18 IPDM E/R (INTELLIGENT POWER DISTRIBUTION MODULE ENGINE ROOM) A status is changed into sleep transient status when receiving a sleep request signal from BCM while all the systems controlled by IPDM E/R are under suspension. Sleep transient status ● Process to stop CAN communication is activated. ● All systems controlled by IPDM E/R are stopped, when 3 seconds have elapsed after CAN communication with other control units is stopped, mode switches to sleep status. Sleep status ● IPDM E/R operates in low power mode. ● CAN communication is stopped. ● When a change in CAN communication line is detected, mode switches to CAN communication status. ● When a change in ignition switch signal is detected, mode switches to CAN communication status. ● 2. 3. CAN Communication System Description A B C D BKS0025O CAN (Controller Area Network) is a serial communication line for real time application. It is an on-vehicle multiplex communication line with high data communication speed and excellent error detection ability. Modern vehicles are equipped with many electronic control units and each control unit shares information and links with other control units during operation (not independent). In CAN communication, control units are connected with 2 communication lines (CAN H line, CAN L line) allowing a high rate of information transmission with less wiring. Each control unit transmits/receives data but selectively reads required data only. E CAN Communication Unit BKS0025P G BKS0027F H F Refer to LAN-27, "CAN Communication Unit" . Function of Detecting Ignition Relay Malfunction ● ● When integrated ignition relay cannot be turned OFF and ignition switch is turned OFF, IPDM E/R turns ON tail and parking lamps for 10 minutes. The lamps indicate ignition relay malfunction. When a state of ignition relay having built-in does not agree with a state of Ignition switch signal input by a CAN communication from BCM, IPDM E/R lets tail lamp relay operate. Ignition switch signal Ignition relay status Tail lamp relay ON ON — OFF OFF — ON OFF — OFF ON ON (10 minutes) NOTE: When the ignition switch is turned ON, the tail lamps are OFF. I J PG L M PG-19 IPDM E/R (INTELLIGENT POWER DISTRIBUTION MODULE ENGINE ROOM) CONSULT-II Function (IPDM E/R) BKS0025R CONSULT-II can display each diagnostic item using the diagnostic test modes shown following. Inspection Item, Diagnosis Mode Description SELF-DIAG RESULTS The IPDM E/R performs diagnosis of CAN communication and self-diagnosis. DATA MONITOR The input/output data of the IPDM E/R is displayed in real time. CAN DIAG SUPPORT MNTR The result of transmit/receive diagnosis of CAN communication can be read. ACTIVE TEST The IPDM E/R sends a drive signal to electronic components to check their operation. CONFIGURATION Performs IPDM E/R configuration read/write functions. CONSULT-II BASIC OPERATION Refer to GI-36, "CONSULT-II Start Procedure" . SELF-DIAG RESULTS Operation Procedure 1. 2. Touch “SELF-DIAG RESULTS” on “SELECT DIAG MODE” screen. Check display content in self-diagnostic results. Display Item List Display Items CONSULT-II display code Malfunction detecting condition — - NO DTC IS DETECTED.FURTHER TESTING MAY BE REQUIRED. ● CAN COMM CIRC U1000 ● If CAN communication reception/transmission data has a malfunction, or if any of the control units malfunction, data reception/transmission cannot be confirmed. TIME Possible causes CRNT PAST - - - Any of or the items below have errors. × × When the data in CAN communication is not received before the specified time ● TRANSMIT DIAG ● ECM ● BCM IGN RELAY ON B2098 Where the ignition switch is not ON position, the ignition relay in the IPDM E/R is ON. × × Ignition relay (integrated in IPDM E/R) IGN RELAY OFF B2099 Where the ignition switch is ON position, the ignition relay in the IPDM E/R is OFF. × × Ignition relay (integrated in IPDM E/R) EEPROM B2100 Malfunction is detected with the integrated EEPROM memory diagnosis. × × IPDM E/R NOTE: The details for display of the period are as follows: ● CRNT: Error currently detected with IPDM E/R. ● PAST: Error detected in the past and memorized with IPDM E/R. DATA MONITOR Operation Procedure 1. 2. Touch “DATA MONITOR” on “SELECT MONITOR ITEM ” screen. Touch “ALL SIGNALS”, “MAIN SIGNALS” or “SELECTION FROM MENU” on the “DATA MONITOR” screen. ALL SIGNALS All items will be monitored. MAIN SIGNALS Monitor the predetermined item. SELECTION FROM MENU Select any item for monitoring. 3. Touch the required monitoring item on “SELECTION FROM MENU”. In “ALL SIGNALS”, all items are monitored. In “MAIN SIGNALS”, predetermined items are monitored. PG-20 IPDM E/R (INTELLIGENT POWER DISTRIBUTION MODULE ENGINE ROOM) 4. 5. Touch “START”. Touch “RECORD” while monitoring to record the status of the item being monitored. To stop recording, touch “STOP”. All Signals, Main Signals, Selection From Menu A B Monitor item selection Item name CONSULT-II screen display Display or unit ALL SIGNALS MAIN SIGNALS SELECTION FROM MENU Description C Motor fan request MOTOR FAN REQ 1/2/3/4 × × × Signal status input from ECM A/C Compressor request AC COMP REQ ON/OFF × × × Signal status input from ECM Tail & clearance request TAIL&CLR REQ ON/OFF × × × Signal status input from BCM Headlamp LO request HL LO REQ ON/OFF × × × Signal status input from BCM Headlamp HI request HL HI REQ ON/OFF × × × Signal status input from BCM Front fog lamp request FR FOG REQ ON/OFF × × × Signal status input from BCM Headlamp washer request HL WASHER REQ ON/OFF × × This item cannot be monitored. (No change of display) Front wiper request FR WIP REQ STOP/1LOW/ LOW/HI × × × Signal status input from BCM Wiper auto stop WIP AUTO STOP ACT P/STOP P × × × Output status of IPDM E/R Wiper protection WIP PROT OFF/BLOCK × × × Control status of IPDM E/R Starter request ST RLY REQ* ON/OFF × × Signal status input from BCM Ignition relay status IGN RLY ON/OFF × × × Ignition relay status monitored with IPDM E/R Rear window defogger request RR DEF REQ ON/OFF × × × Signal status input from BCM Rear window defogger stop request DEF STOP REQ ON/OFF × × Input signal status Alternator load ALT LOAD % × × Alternator current ALT CRNT A × × Alternator number ALT NO ## × × Battery voltage BAT VOLT V × × Value measured with IPDM E/R Engine coolant temperature ENG COOL TEMP °C × × Signal status input from ECM Oil pressure switch OIL P SW OPEN/CLOSE × × Signal status input in IPDM E/R Reverse switch REV SW OPEN/CLOSE × × Signal status input in IPDM E/R E This item cannot be monitored (No change of display) NOTE: ● Perform monitoring of IPDM E/R data with the ignition switch ON. When the ignition switch is at ACC, the display may not be correct. ● *: The vehicle without Intelligent Key system displays only ON without change. CAN DIAG SUPPORT MNTR Refer to LAN-15, "CAN Diagnostic Support Monitor" . ACTIVE TEST Operation Procedure 1. 2. 3. D Touch “ACTIVE TEST” on “SELECT DIAG MODE” screen. Touch item to be tested. Touch “START”, and confirm its operation. PG-21 F G H I J PG L M IPDM E/R (INTELLIGENT POWER DISTRIBUTION MODULE ENGINE ROOM) 4. Touch “STOP” while testing to stop the operation. Test item CONSULT-II screen display Description Headlamp (HI, LO) output HEAD LAMP With a certain operation (OFF, HI ON, LO ON), the headlamp relay (Lo, Hi) can be operated. Front fog lamp output FRONT FOG LAMP With a certain ON-OFF operation, the fog lamp relay can be operated. Tail lamp output TAIL LAMP With a certain ON-OFF operation, the tail lamp relay can be operated. Rear window defogger operation REAR DEFOGGER With a certain ON-OFF operation, the rear window defogger relay can be operated. Front wiper (HI, LO) operation FRONT WIPER With a certain operation (OFF, HI ON, LO ON), the front wiper relay (Lo, Hi) can be operated. Cooling fan operation MOTOR FAN With a certain operation (1, 2, 3, 4), the cooling fan can be operated. HEAD LAMP WASHER With a certain ON-OFF operation, the headlamp washer can be operated. Headlamp washer output Auto Active Test BKS0025S DESCRIPTION In auto active test mode, operation inspection can be performed when IPDM E/R sends a drive signal to the following systems: ● Rear window defogger ● Front wiper (LO, HI) ● Tail lamps, parking lamps, license plate lamps ● Front fog lamps ● Headlamps (LO, HI) ● Headlamp washer ● A/C compressor (magnetic clutch) ● Cooling fan OPERATION PROCEDURE 1. 2. 3. 4. 5. 6. Close hood and front door (passenger side), and then lift wiper arms away from windshield (to prevent glass damage by wiper operation). NOTE: When auto active test is performed with hood opened, sprinkle water on windshield beforehand. Turn ignition switch OFF. Turn ignition switch ON, and within 20 seconds, press driver's door switch 10 times (close other doors). Then turn ignition switch OFF. Turn ignition switch ON within 10 seconds after ignition switch OFF. When auto active test mode is actuated, horn chirps once. Oil pressure warning lamp starts blinking. After a series of operations is repeated three times, auto active test is completed. NOTE: When auto active test mode has to be cancelled halfway, turn ignition switch OFF. CAUTION: Be sure to inspect BL-46, "Check Door Switch" when the auto active test cannot be performed. PG-22 IPDM E/R (INTELLIGENT POWER DISTRIBUTION MODULE ENGINE ROOM) INSPECTION IN AUTO ACTIVE TEST MODE A When auto active test mode is actuated, the following nine steps are repeated three times. B C D E F MKIB2316E G (A): Oil pressure warning lamp is blinking when the auto active test operating. Operation steps Step H Test item Operation time/ frequency 1 Rear window defogger 10 seconds 2 Front wiper LO 5 seconds → HI 5 seconds 3 Tail lamps, parking lamps, license plate lamps 10 seconds 4 Front fog lamps 10 seconds 5 Headlamp (LO) 10 seconds 6 Headlamp (HI) LO←→HI repeats every 2 seconds, 5 times 7 Headlamp washer Left 1 seconds → Right 1 second 8 A/C compressor (magnetic clutch) ON←→OFF repeat every 2 seconds, 5 times 9 Cooling fan LO 5 seconds → HI 5 seconds (Petrol engine models with air conditioner and diesel engine models) LO 10 seconds (Petrol engine models without air conditioner) Concept of Auto Active Test ● ● I J PG L M IPDM E/R actuates auto active test mode when it receives door switch signal from BCM via CAN communication line. Therefore, when auto active test mode is activated successfully, CAN communication between IPDM E/R and BCM is normal. If any of systems controlled by IPDM E/R cannot be operated, possible cause can be easily diagnosed using auto active test. PG-23 IPDM E/R (INTELLIGENT POWER DISTRIBUTION MODULE ENGINE ROOM) Diagnosis Chart in Auto Active Test Mode Symptom Inspection contents Rear window defogger does not operate. Perform auto active test. Does rear window defogger operate? Front wiper does not illuminate. Either of parking lamp, license plate lamp and tail lamp does not illuminate. Front fog lamp does not illuminate. Perform auto active test. Does rear window defogger operate? Perform auto active test. Does parking lamp, license plate lamp and tail lamp illuminate? Perform auto active test. Does the front fog lamp illuminate? Possible cause YES NO YES NO YES NO YES NO YES Headlamp (Hi, Lo) does not illuminate. Headlamp washer does not operate. Perform auto active test. Does headlamp illuminate? Perform auto active test. Does the headlamp washer operate? ● BCM signal input circuit malfunction ● Harness/connector malfunction between IPDM E/R and rear window defogger ● Open circuit of rear window defogger ● IPDM E/R (integrated relay) malfunction (Rear window defogger relay) ● BCM signal input circuit malfunction ● Wiper motor malfunction ● Front wiper motor ground. ● BCM signal input circuit malfunction ● Bulb ● Harness/connector malfunction between IPDM E/R and parking, license plate or tail lamp. ● IPDM E/R (integrated relay) malfunction ● BCM signal input circuit malfunction ● Bulb ● Harness/connector malfunction between IPDM E/R and front fog lamp ● IPDM E/R (integrated relay) malfunction ● BCM signal input circuit malfunction ● Bulb ● Headlamp ground system malfunction ● Harness/connector malfunction between IPDM E/R and headlamps ● IPDM E/R (integrated relay) malfunction (headlamp relay) ● BCM signal input circuit malfunction ● Harness/connector malfunction between IPDM E/R and headlamp washer ● Headlamp washer relay is malfunction ● CAN communication signal malfunction between ECM and IPDM E/R* ● ECM signal input circuit malfunction ● Cooling fan motor malfunction ● Harness/connector malfunction between cooling fan motor and IPDM E/R ● IPDM E/R (integrated relay) malfunction ● CAN communication signal malfunction between BCM and ECM* ● CAN communication signal malfunction between ECM and IPDM E/R* ● BCM signal input circuit malfunction ● ECM signal input circuit malfunction ● Magnetic clutch inoperative ● Harness/connector malfunction between IPDM E/R and magnetic clutch ● IPDM E/R (integrated relay) malfunction ● Harness/connector malfunction between IPDM E/R and oil pressure switch ● Oil pressure switch malfunction ● IPDM E/R malfunction ● CAN communication signal malfunction between IPDM E/R and combination meter * ● Combination meter malfunction NO YES NO YES Cooling fan does not operate. Perform auto active test. Does magnetic clutch operate? NO YES A/C compressor is inoperative. Perform auto active test. Does magnetic clutch operate? NO Oil pressure warning lamp does not operate. Perform auto active test. Does oil pressure warning lamp blink? YES NO *: Perform IPDM E/R self-diagnosis with CONSULT-II. Refer to PG-33, "Inspection With CONSULT-II (Self-Diagnosis)" . PG-24 IPDM E/R (INTELLIGENT POWER DISTRIBUTION MODULE ENGINE ROOM) Configuration BKS0026I A DESCRIPTION There are two CONFIGURATION functions, as follows. READ CONFIGURATION is a function for confirming the vehicle configuration written on IPDM E/R. WRITE CONFIGURATION is a function for writing a vehicle configuration to IPDM E/R. CAUTION: ● When replacing IPDM E/R, completely perform WRITE CONFIGURATION with CONSULT-II. ● Orderly complete the procedure of WRITE CONFIGURATION. ● If you set incorrect WRITE CONFIGURATION, vehicle operation will not be correct. ● Configuration is different by each vehicle model, confirm configuration in each case. B C D READ CONFIGURATION PROCEDURE CAUTION: If CONSULT-II is used with no connection of CONSULT CONVERTER, malfunctions might be detected in self-diagnosis depending on control unit which carry out CAN communication. 1. With the ignition switch OFF, connect CONSULT-II and CONSULT-II CONVERTER to the data link connector, then turn the ignition switch ON. E F G H PAIA0070E 2. I Touch “START(NISSAN BASED VHCL)”. J PG BCIA0029E 3. Touch “IPDM E/R” on “SELECT SYSTEM” screen. If “IPDM E/R” is not indicated, go to GI-38, "CONSULT-II Data Link Connector (DLC) Circuit" . M BCIA0030E PG-25 L IPDM E/R (INTELLIGENT POWER DISTRIBUTION MODULE ENGINE ROOM) 4. Touch “CONFIGURATION” on “SELECT DIAG MODE” screen. MKIB2361E 5. Touch “K12”, and “OK” on “VEHICLE SELECT” screen. For canceling, touch “CANCEL” on “VEHICLE SELECT” screen. NOTE: Confirm vehicle model on IDENTICATION PLATE, refer to GI section. MKIB2358E 6. Touch “READ CONFIGURATION” on “SELECT CONFIG ITEM” screen. MKIB2362E 7. Configuration of current IPDM E/R are printed out automatically. Configuration of brand-new IPDM E/R before executing “WRITE CONFIGURATION” is as follows. MANUAL SET ITEM Items Setting Value ALT TYPE TYPE 1 AUTO SET ITEM Items Setting Value STARTER MODE MODE 1 MKIB2363E PG-26 IPDM E/R (INTELLIGENT POWER DISTRIBUTION MODULE ENGINE ROOM) 8. Touch “BACK” on “ READ CONFIGURATION“screen. A B C MKIB0761E D WRITE CONFIGURATION PROCEDURE CAUTION: If CONSULT-II is used with no connection of CONSULT CONVERTER, malfunctions might be detected in self-diagnosis depending on control unit which carry out CAN communication. 1. With the ignition switch OFF, connect CONSULT-II and CONSULT-II CONVERTER to the data link connector, then turn the ignition switch ON. E F G H PAIA0070E 2. I Touch “START(NISSAN BASED VHCL)”. J PG BCIA0029E 3. Touch “IPDM E/R” on “SELECT SYSTEM” screen. If “IPDM E/R” is not indicated, go to GI-38, "CONSULT-II Data Link Connector (DLC) Circuit" . M BCIA0030E PG-27 L IPDM E/R (INTELLIGENT POWER DISTRIBUTION MODULE ENGINE ROOM) 4. Touch “CONFIGURATION” on “SELECT DIAG MODE” screen. MKIB2361E 5. Touch “K12”, and “OK” on “VEHICLE SELECT” screen. For canceling, touch “CANCEL” on “VEHICLE SELECT” screen. NOTE: Confirm vehicle model on IDENTICATION PLATE, refer to GI section. MKIB2358E 6. Touch “WRITE CONFIGURATION” on “SELECT CONFIG ITEM“screen. MKIB2362E 7. Touch “YES”. For canceling, touch “NO”. MKIB0762E PG-28 IPDM E/R (INTELLIGENT POWER DISTRIBUTION MODULE ENGINE ROOM) 8. Touch “TYPE 1”, “TYPE 2” or “TYPE 3” on “WRITE CONFIGURATION”screen based on the following ITEM LIST. A < ITEM LIST> ITEM Alternator type SET VAL NOTE B TYPE 1 Petrol engine models TYPE 2 Diesel engine models without PTC heater* TYPE 3 Diesel engine models with PTC heater* *: Models with PTC heater have PTC heater relays. Refer to Harness Layout, PG-59, "ENGINE ROOM HARNESS/K9K ENGINE MODELS" , to confirm whether PTC heater relays are equipped or not. C MKIB0763E D 9. For canceling, touch “CANCEL”. Touch “CHNG SETTING” on “WRITE CONFIGURATION“screen. CAUTION: Make sure to touch “CHNG SETTING even if the indicated configuration of brand new IPDM E/R is same as the desirable configuration. If not, configuration which is set automatically by selecting vehicle model can not be memorized. E F 10. Touch “OK” on “WRITE CONFIGURATION”screen. When touched “CANCEL”, go to previous screen. G H I MKIB0764E 11. Wait until the next screen during setting. J PG L MKIB0765E PG-29 M IPDM E/R (INTELLIGENT POWER DISTRIBUTION MODULE ENGINE ROOM) 12. WRITE CONFIGURATION results are printed out automatically. Check “WRITE CONFIGURATION” is correctly executed by comparing sheet automatically printed out with desirable configuration. MKIB2364E 13. Touch “OK” on “WRITE CONFIGURATION“screen. WRITE CONFIGURATION is completed. MKIB0767E PG-30 IPDM E/R (INTELLIGENT POWER DISTRIBUTION MODULE ENGINE ROOM) Schematic BKS0025T A B C D E F G H I J PG L M MKWA4405E PG-31 IPDM E/R (INTELLIGENT POWER DISTRIBUTION MODULE ENGINE ROOM) IPDM E/R Terminal Arrangement BKS0025U MKWA4445E PG-32 IPDM E/R (INTELLIGENT POWER DISTRIBUTION MODULE ENGINE ROOM) Inspection With CONSULT-II (Self-Diagnosis) BKS0025W 1. CHECK SELF DIAGNOSTIC RESULT A 1. 2. 3. B Connect CONSULT-II and select “IPDM E/R” on the “SELECT SYSTEM” screen. Select “SELF-DIAG RESULTS” on the “SELECT DIAG MODE” screen. Check display content in self diagnostic results. CONSULT-II display NO DTC IS DETECTED. FURTHER TESTING MAY BE REQUIRED. TIME CONSULT-II display code CRNT PAST - - - Details of diagnosis result C No malfunction D Any of or several items below have errors. CAN COM CIRC U1000 × × ● TRANSMIT ● RECEIVE (ECM) ● RECEIVE (BCM) IGN RELAY ON B2098 × × Ignition relay malfunction (integrated in IPDM E/R) IGN RELAY OFF B2099 × × Ignition relay malfunction (integrated in IPDM E/R) EEPROM B2100 × × IPDM E/R malfunction E F CAUTION: G If errors of the CAN communication system and the ignition relay ON or OFF are displayed at the same time after the self-diagnostic result, replace the IPDM E/R and perform the self-diagnosis again. H NOTE: The details for display of the period are as follows: ● CRNT: Error currently detected with IPDM E/R. I ● PAST: Error detected in the past and memorized with IPDM E/R. Contents displayed NO DTC IS DETECTED.FURTHER TESTING MAY BE REQUIRED.>>INSPECTION END J CAN COMM CIRC>>After print-out of the monitor items, refer to LAN-3, "Precautions When Using CONSULT-II" . IGN RELAY ON>>Replace IPDM E/R. PG IGN RELAY OFF>>Replace IPDM E/R. EEPROM>>Replace IPDM E/R. L M PG-33 IPDM E/R (INTELLIGENT POWER DISTRIBUTION MODULE ENGINE ROOM) IPDM E/R Terminal Inspection BKS0026O CAUTION: This is performed when the IPDM E/R is checked without removing the battery. 1. Remove the headlamp (LH). Refer to LT-32, "Removal and Installation" (Conventional type),LT-51, "Removal and Installation" (Daytime light system). 2. Remove tabs of the IPDM E/R and place the IPDM E/R with its connector facing upward. Check each terminal. SKIA2151E SKIA2152E Check IPDM E/R Power Supply and Ground Circuit BKS0025V 1. CHECK FUSE AND FUSIBLE LINK Make sure that the following fusible links or IPDM E/R fuses are not blown. Terminal No. Power source Fuse, fusible link No. 1 Battery Letter C 2 Battery Letter D 40 Ignition switch (ON) 5 OK or NG OK >> GO TO 2. NG >> Replace fuse or fusible link. PG-34 IPDM E/R (INTELLIGENT POWER DISTRIBUTION MODULE ENGINE ROOM) 2. CHECK POWER SUPPLY CIRCUIT 1. 2. A Disconnect IPDM E/R harness connector. Check voltage between IPDM E/R and ground. B Terminals Ignition switch position (+) Connector OFF ACC ON C 1 (R) Battery voltage Battery voltage Battery voltage D 2 (G) Battery voltage Battery voltage Battery voltage 0V Battery voltage Terminal (wire color) (-) E9 Ground MKIB0534E E7 40 (O) 0V E OK or NG OK >> GO TO 3. NG >> Check harness between fuse, fusible link and IPDM E/R. F 3. CHECK GROUND CIRCUIT 1. 2. G Disconnect IPDM E/R harness connectors. Check continuity between IPDM E/R harness connectors E11 terminal 3 (B), E12 terminal 54 (B) and ground. 3 (B) – Ground 54 (B) – Ground H :Continuity should exist. :Continuity should exist. I OK or NG OK >> INSPECTION END. NG >> Repair harness for ground circuit. J MKIB1920E PG L M PG-35 IPDM E/R (INTELLIGENT POWER DISTRIBUTION MODULE ENGINE ROOM) Diagnosis of IPDM E/R Integrated Relay BKS0026P 1. CHECK SYMPTOM Check the symptom of the malfunction relay. What is the symptom? No operation>>GO TO 2. No stop>> GO TO 4. 2. CHECK RELAY TYPE Which is the relay with error? Front fog lamp relay, headlamp relay (Hi, Lo), tail lamp relay, front wiper relay (main, Hi/Lo), rear window defogger relay, A/C relay, starter motor relay, cooling fan relay (Hi, Lo)>>GO TO 5. Ignition relay>> Go to PG-33, "Inspection With CONSULT-II (Self-Diagnosis)" ECM relay>>Go to EC-128, "POWER SUPPLY AND GROUND CIRCUIT" (CR engine models with EUROOBD), EC-543, "POWER SUPPLY AND GROUND CIRCUIT" (CR engine models without EUROOBD), EC-918, "POWER SUPPLY AND GROUND CIRCUIT" (HR engine models with EUROOBD), EC-1337, "POWER SUPPLY AND GROUND CIRCUIT" (HR engine models without EURO-OBD) or EC-1698, "POWER SUPPLY AND GROUND CIRCUIT" (K9K engine models). Throttle motor relay>>Go to EC-299, "DTC P1124, P1126 THROTTLE CONTROL MOTOR RELAY" (CR engine models with EURO-OBD), EC-643, "DTC P1124, P1126 THROTTLE CONTROL MOTOR RELAY" (CR engine models without EURO-OBD), EC-1090, "DTC P1124, P1126 THROTTLE CONTROL MOTOR RELAY" (HR engine models with EURO-OBD) or EC-1439, "DTC P1124, P1126 THROTTLE CONTROL MOTOR RELAY" (HR engine models without EURO-OBD). Fuel pump relay>>Go to EC-427, "FUEL PUMP" (CR engine models with EURO-OBD), EC-750, "FUEL PUMP" (CR engine models without EURO-OBD), EC-1215, "FUEL PUMP" (HR engine models with EURO-OBD) or EC-1543, "FUEL PUMP" .(HR engine models without EURO-OBD). 3. CHECK RELAY Send an operation signal to the relay using a diagnosis tool. Check the voltage at the input and output terminals of inoperative relays according to the table below or check for continuity between input and output terminals. Refer to PG-21, "ACTIVE TEST" or PG-22, "Auto Active Test" . IPDM E/R terminal number Relay name Diagnosis tool Voltage [V] Output side CONSULT-II ACTIVE TEST Auto ACTIVE TEST Front fog lamp relay 43, 44 × × Headlamp Hi relay 46, 47 × × Headlamp Lo relay 48, 50 × × 15, 16, 45, 49 × × × × × × Input side Tail lamp relay 1 Front wiper main relay 23 Front wiper HI/LO relay 24 A/C relay 41 Rear windows defogger relay Cooling fan Lo relay Cooling fan Hi relay 2 14 Battery voltage × 8 × × 10 × × 12 × × ×: Applicable OK or NG OK >> Check the control unit that controls the inoperative relay. (system) NG >> Replace the IPDM E/R. (malfunction of relay) PG-36 IPDM E/R (INTELLIGENT POWER DISTRIBUTION MODULE ENGINE ROOM) 4. CHECK RELAY TYPE A Which is the relay with error? Front fog lamp relay, headlamp relay (Hi, Lo), tail lamp relay, front wiper relay (main, Hi/Lo), rear window defogger relay, A/C relay, starter motor relay, cooling fan relay (Hi, Lo)>>GO TO 5. Ignition relay>> Go to PG-33, "Inspection With CONSULT-II (Self-Diagnosis)" ECM relay>>Go to EC-128, "POWER SUPPLY AND GROUND CIRCUIT" (CR engine models with EUROOBD), EC-543, "POWER SUPPLY AND GROUND CIRCUIT" (CR engine models without EUROOBD), EC-918, "POWER SUPPLY AND GROUND CIRCUIT" (HR engine models with EUROOBD), EC-1337, "POWER SUPPLY AND GROUND CIRCUIT" (HR engine models without EURO-OBD) or EC-1698, "POWER SUPPLY AND GROUND CIRCUIT" (K9K engine models). Throttle motor relay>>Go to EC-299, "DTC P1124, P1126 THROTTLE CONTROL MOTOR RELAY" (CR engine models with EURO-OBD), EC-643, "DTC P1124, P1126 THROTTLE CONTROL MOTOR RELAY" (CR engine models without EURO-OBD), EC-1090, "DTC P1124, P1126 THROTTLE CONTROL MOTOR RELAY" (HR engine models with EURO-OBD) or EC-1439, "DTC P1124, P1126 THROTTLE CONTROL MOTOR RELAY" (HR engine models without EURO-OBD). Fuel pump relay>>Go to EC-427, "FUEL PUMP" (CR engine models with EURO-OBD), EC-750, "FUEL PUMP" (CR engine models without EURO-OBD), EC-1215, "FUEL PUMP" (HR engine models with EURO-OBD) or EC-1543, "FUEL PUMP" .(HR engine models without EURO-OBD). 5. CHECK INPUT SIGNAL B C D E F G Check the control signal status of the relay on the IPDM E/R that receives from each control unit with the data monitor of CONSULT-II. Refer to PG-20, "DATA MONITOR" . What is the data monitor result? Other than OFF>>Check the control unit that controls the relay (system) not deactivated. OFF >> Replace the IPDM E/R. (error of relay ON) Removal and Installation of IPDM E/R H I BKS0025X : Vehicle front J REMOVAL 1. 2. Lift up the IPDM E/R while pushing and opening pawls (A) or (B), and remove the IPDM E/R while pushing and opening the other side pawls. Disconnect harness connector. PG L M PKIC0917E INSTALLATION Installation is the reverse order of removal. PG-37 GROUND GROUND Ground Distribution PFP:00011 BKS0025Y MAIN HARNESS MKWA4382E PG-38 GROUND A B C D E F G H I J PG L M MKWA4383E PG-39 GROUND MKWA4384E PG-40 GROUND ENGINE ROOM HARNESS A B C D E F G H I J PG L M MKWA4385E PG-41 GROUND MKWA4386E PG-42 GROUND A B C D E F G H I J PG L M MKWA4387E PG-43 GROUND MKWA4388E PG-44 GROUND ENGINE CONTROL HARNESS/CR AND HR ENGINE MODELS A B C D E F G H I J PG L M MKWA4389E PG-45 GROUND BODY HARNESS MKWA4390E PG-46 GROUND A B C D E F G H I J PG L M MKWA4391E PG-47 HARNESS HARNESS Harness Layout PFP:00011 BKS0025Z HOW TO READ HARNESS LAYOUT The following Harness Layouts use a map style grid to help locate connectors on the figures: ● Main Harness ● Engine Room Harness ● Engine Control Harness ● Body Harness ● Room Lamp Harness ● Front Door Harness ● Rear Door Harness ● Back Door Harness SEL252V To Use the Grid Reference 1. Find the desired connector number on the connector list. 2. Find the grid reference. 3. On the figure, find the crossing of the grid reference letter column and number row. 4. Find the connector number in the crossing zone. 5. Follow the line (if used) to the connector. CONNECTOR SYMBOL Main symbols of connector (in Harness Layout) are indicated in the below. CKIT0108E PG-48 HARNESS HARNESS OUTLINE/CR AND HR ENGINE MODELS A B C D E F G H I J PG L M MKWA4406E PG-49 HARNESS HARNESS OUTLINE/K9K ENGINE MODELS MKWA4407E PG-50 HARNESS MAIN HARNESS/LHD MODELS A B C D E F G H I J PG L M MKWA4408E PG-51 HARNESS MKWA4409E PG-52 HARNESS MAIN HARNESS/RHD MODELS A B C D E F G H I J PG L M MKWA4410E PG-53 HARNESS MKWA4411E PG-54 HARNESS ENGINE ROOM HARNESS/CR ENGINE MODELS A B C D E F G H I J PG L M MKWA4412E PG-55 HARNESS MKWA4413E PG-56 HARNESS ENGINE ROOM HARNESS/HR ENGINE MODELS A B C D E F G H I J PG L M MKWA4414E PG-57 HARNESS MKWA4415E PG-58 HARNESS ENGINE ROOM HARNESS/K9K ENGINE MODELS A B C D E F G H I J PG L M MKWA4416E PG-59 HARNESS MKWA4417E PG-60 HARNESS ENGINE CONTROL HARNESS/CR ENGINE MODELS A B C D E F G H I J PG L M MKWA4418E PG-61 HARNESS MKWA4419E PG-62 HARNESS ENGINE CONTROL HARNESS/HR ENGINE MODELS A B C D E F G H I J PG L M MKWA4420E PG-63 HARNESS MKWA4421E PG-64 HARNESS ENGINE CONTROL HARNESS/K9K ENGINE MODELS A B C D E F G H I J PG L M MKWA4422E PG-65 HARNESS MKWA4423E PG-66 HARNESS BODY HARNESS (RH SIDE) A B C D E F G H I J PG L M MKWA4424E PG-67 HARNESS MKWA4425E PG-68 HARNESS BODY HARNESS (LH SIDE) A B C D E F G H I J PG L M MKWA4426E PG-69 HARNESS MKWA4427E PG-70 HARNESS ROOM LAMP HARNESS A B C D E F G H I J PG L M MKWA4428E PG-71 HARNESS FRONT DOOR HARNESS LH SIDE/LHD MODELS MKWA4429E PG-72 HARNESS FRONT DOOR HARNESS LH SIDE/RHD MODELS A B C D E F G H I J PG L M MKWA4430E PG-73 HARNESS FRONT DOOR HARNESS RH SIDE/LHD MODELS MKWA4431E PG-74 HARNESS FRONT DOOR HARNESS RH SIDE/RHD MODELS A B C D E F G H I J PG L M MKWA4432E PG-75 HARNESS REAR DOOR HARNESS LH SIDE MKWA4433E PG-76 HARNESS REAR DOOR HARNESS RH SIDE A B C D E F G H I J PG L M MKWA4434E PG-77 HARNESS BACK DOOR HARNESS MKWA4435E PG-78 HARNESS Wiring Diagram Codes (Cell Codes) BKS0026Q Use the chart below to find out what each wiring diagram code stands for. Refer to the wiring diagram code in the alphabetical index to find the location (page number) of each wiring diagram. Code Section Wiring Diagram Name A/C ATC Air Conditioner A/C MTC Air Conditioner A/WIP WW Front Wiper and Washer System (With Rain Sensor) ABS BRC Anti-lock Brake System AP/SEN EC Absolute Pressure Sensor APPS EC Accelerator Pedal Position Sensor APPS1 EC Accelerator Pedal Position Sensor APPS2 EC Accelerator Pedal Position Sensor APPS3 EC Accelerator Pedal Position Sensor AT/IND DI A/T Indicator Lamp AUDIO AV Audio AUTO/L LT Auto Light Control BA/FTS AT A/T Fluid Temperature Sensor and TCM Power Supply BACK/L LT Back-up Lamp BRK/SW EC Brake Switch CAN AT CAN Communication Line CAN EC CAN Communication Line CAN LAN CAN System CHARGE SC Charging System CHIME DI Warning Chime CIGAR WW Cigarette Lighter CKPS EC Crankshaft Position Sensor CMPS EC Camshaft Position Sensor COMBSW LT Combination Switch COOL/F EC Cooling Fan Control CRFPS EC Common Rail Fuel Pressure Sensor D/COMP DI Drive Computer D/LOCK BL Power Door Lock DEF GW Rear Window Defogger DTRL LT Headlamp - With Daytime Light System ECMRLY EC ECM Relay ECM/PW EC ECM Power Supply For Back-up ECTS EC Engine Coolant Temperature Sensor EGRC/V EC EGR Control System ENGSS AT Engine Speed Signal EPS STC Electric Controlled Power Steering System ESP BRC Electronic Stability Program System ETC1 EC Electric Throttle Control Function ETC2 EC Throttle Control Motor Relay ETC3 EC Throttle Control Motor F/FOG LT Front Fog Lamp PG-79 A B C D E F G H I J PG L M HARNESS Code Section Wiring Diagram Name F/PUMP EC Fuel Pump FRO2 EC Front Heated Oxygen Sensor FRPS EC Fuel Rail Pressure Sensor FTS AT A/T Fluid Temperature Sensor FTS EC Fuel Temperature Sensor FUEL EC Fuel Injection System Function GLOW EC Quick Glow System H/AIM LT Headlamp Aiming Control System H/LAMP LT Headlamp H/SEAT SE Heated Seat HEATER MTC Heater System HLC WW Headlamp Washer HO2S1 EC Heated Oxygen Sensor 1 HO2S1H EC Heated Oxygen Sensor 1 Heater HO2S2 EC Rear Heated Oxygen Sensor 2 HO2S2H EC Rear Heated Oxygen Sensor 2 Heater HORN WW Horn I/KEY BL Intelligent Key System IATS EC Intake Air Temperature Sensor IATSEN EC Intake Air Temperature Sensor IGNSYS EC Ignition System ILL LT Illumination IMV/D EC Fuel Flow Actuator INJECT EC Fuel Injector INT/L LT Stop, Vanity Mirror and Trunk Room Lamps IVC EC Intake Valve Timing Control Solenoid Valve KS EC Knock Sensor LPSV AT Line Pressure Solenoid Valve MAFS EC Mass Air Flow Sensor MAIN AT Main Power Supply and Ground Circuit MAIN EC Main Power Supply and Ground Circuit METER DI Speed Meter, Tachometer, Temp, Oil and Fuel Gauge MIL/DL EC MIL & Data Link Connector MIRROR GW Door Mirror MULTI BL Multi-remote Control System NATS BL Nissan Anti-Theft System NONDTC AT NON-detective Items OVRCSV AT Overrun Clutch Solenoid Valve PGC/V EC EVAP Canister Purge Volume Control Solenoid Valve PHASE EC Camshaft Position Sensor (PHASE) PNP/SW AT Park/Neutral Position Switch PNP/SW EC Park/Neutral Position Switch POS EC Crankshaft Position Sensor (CKPS) (POS) POWER PG Power Supply Routing Circuit PG-80 HARNESS Code Section Wiring Diagram Name PRGVLV EC EVAP Canister Purge Volume Control Solenoid Valve PRWIRE BL After Market Alarm - Prewire PTC/H ATC PTC Heater PTC/H MTC PTC Heater PT/SEN AT Turbine Revolution Sensor R/FOG LT Rear Fog Lamp RP/SEN EC Refrigerant Pressure Sensor RRO2 EC Rear Heated Oxygen Sensor 2 S/LOCK BL Power Door Lock-Super Lock SEN/PW EC Sensor Power Supply SHIFT AT A/T Shift Lock System SRS SRS A B C D E Supplemental Restraint System SSV/A AT Shift Solenoid Valve A SSV/B AT Shift Solenoid Valve B START SC Starting System STOP/L LT Stop Lamp TAIL/L LT Parking, License Tail and Stop Lamps TCBST EC TC Boost Pressure Sensor TCC/V EC Turbocharger Boost Control Solenoid Valve TCV AT Torque Converter Clutch Solenoid Valve TPS1 EC Throttle Position Sensor (Sensor 1) TPS2 EC Throttle Position Sensor (Sensor 2) TPS3 EC Throttle Position Sensor TURN LT Turn Signal and Hazard Warning Lamps VSSAT AT Vehicle Speed Sensor A/T (Revolution Senor) VSSMTR AT Vehicle Speed Sensor MTR WARN DI Warning Lamps WINDOW GW Power Window WIP/R WW Rear Wiper and Washer F G H I J PG L M PG-81 ELECTRICAL UNITS LOCATION ELECTRICAL UNITS LOCATION Electrical Units Location PFP:25230 BKS00261 ENGINE COMPARTMENT MKWA4436E PG-82 ELECTRICAL UNITS LOCATION A B C D E F G H I J PG L M MKWA4437E PG-83 ELECTRICAL UNITS LOCATION PASSENGER COMPARTMENT/LHD MODELS MKWA4438E PG-84 ELECTRICAL UNITS LOCATION A B C D E F G H I J PG L M MKWA4439E PG-85 ELECTRICAL UNITS LOCATION PASSENGER COMPARTMENT/RHD MODELS MKWA4440E PG-86 ELECTRICAL UNITS LOCATION A B C D E F G H I J PG L M MKWA4441E PG-87 HARNESS CONNECTOR HARNESS CONNECTOR Description PFP:00011 BKS00262 HARNESS CONNECTOR (TAB-LOCKING TYPE) The tab-locking type connectors help prevent accidental looseness or disconnection. The tab-locking type connectors are disconnected by pushing or lifting the locking tab(s). Refer to the figure below. Refer to the next page for description of the slide-locking type connector. CAUTION: Never pull the harness or wires when disconnecting the connector. ● ● [Example] SEL769DA PG-88 HARNESS CONNECTOR HARNESS CONNECTOR (SLIDE-LOCKING TYPE) A new style slide-locking type connector is used on certain systems and components, especially those related to OBD. ● The slide-locking type connectors help prevent incomplete locking and accidental looseness or disconnection. ● The slide-locking type connectors are disconnected by pushing or pulling the slider. Refer to the figure below. CAUTION: ● Do not pull the harness or wires when disconnecting the connector. ● Be careful not to damage the connector support bracket when disconnecting the connector. ● A B C D [Example] E F G H I J PG L M SEL769V PG-89 ELECTRICAL UNITS ELECTRICAL UNITS Terminal Arrangement PFP:00011 BKS00263 MKWA4443E PG-90 ELECTRICAL UNITS A B C D E F G H I J PG L M MKWA4444E PG-91 SMJ (SUPER MULTIPLE JUNCTION) SMJ (SUPER MULTIPLE JUNCTION) Terminal Arrangement PFP:B4341 BKS00264 MKWA4442E PG-92 STANDARDIZED RELAY STANDARDIZED RELAY Description PFP:00011 A BKS00265 NORMAL OPEN, NORMAL CLOSED AND MIXED TYPE RELAYS Relays can mainly be divided into three types: normal open, normal closed and mixed type relays. B C D E F G SEL881H H TYPE OF STANDARDIZED RELAYS 1M ···················· 1 Make 2M 1T ···················· 1 Transfer 1M·1B ···················· 1 Make 1 Break ···················· 2 Make I J PG L M SEL882H PG-93 STANDARDIZED RELAY SEL188W PG-94 FUSE BLOCK FUSE BLOCK Terminal Arrangement PFP:24010 A BKS00266 B C D E F G H I J PG L M MKWA4446E PG-95 FUSE, FUSIBLE LINK AND RELAY BOX FUSE, FUSIBLE LINK AND RELAY BOX Terminal Arrangement PFP:24382 BKS00267 MKWA4447E PG-96 POWER STEERING SYSTEM G STEERING SECTION PS POWER STEERING SYSTEM A B C D CONTENTS PRECAUTIONS .......................................................... 2 Precautions for Supplemental Restraint System (SRS) “AIR BAG” and “SEAT BELT PRE-TENSIONER” .................................................................. 2 Caution: .................................................................... 2 PREPARATION ........................................................... 3 Special Service Tools ............................................... 3 NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING ................................................ 4 NVH Trouble Shooting Chart .................................... 4 STEERING WHEEL .................................................... 5 On Board Inspection and Service ............................ 5 PLAY INSPECTION .............................................. 5 NEUTRAL POSITION INSPECTION .................... 5 STEERING TORQUE INSPECTION .................... 5 STEERING ANGLE INSPECTION ........................ 5 Removal and Installation .......................................... 6 REMOVAL ............................................................. 6 INSTALLATION ..................................................... 6 STEERING COLUMN ................................................. 7 Removal and Installation .......................................... 7 REMOVAL OF STEERING COLUMN ASSEM- BLY ........................................................................ 7 INSPECTION AFTER REMOVAL OF STEERING COLUMN ASSEMBLY ................................... 8 INSTALLATION OF STEERING COLUMN ASSEMBLY ........................................................... 8 CHECK AFTER STEERING COLUMN ASSEMBLY INSTALLATION .............................................. 8 POWER STEERING GEAR AND LINKAGE .............. 9 Removal and Installation .......................................... 9 REMOVAL ............................................................. 9 INSTALLATION ..................................................... 9 Disassembly and Assembly .................................... 10 COMPONENT PARTS LOCATION (R24TTYPE)... 10 DISASSEMBLY ................................................... 10 INSPECTION AFTER DISASSEMBLY ................ 10 ASSEMBLY ......................................................... 11 SERVICE DATA AND SPECIFICATIONS (SDS) ...... 13 Wheel ..................................................................... 13 Steering Angle ........................................................ 13 Steering Column ..................................................... 13 Steering Linkage ..................................................... 13 Tightening Torque ................................................... 14 E F PS H I J K L M PS-1 PRECAUTIONS PFP:00001 PRECAUTIONS Precautions for Supplemental Restraint System (SRS) “AIR BAG” and “SEAT BELT PRE-TENSIONER” BGS0001O The Supplemental Restraint System such as “AIR BAG” and “SEAT BELT PRE-TENSIONER”, used along with a front seat belt, helps to reduce the risk or severity of injury to the driver and front passenger for certain types of collision. Information necessary to service the system safely is included in the SRS and SB section of this Service Manual. WARNING: ● To avoid rendering the SRS inoperative, which could increase the risk of personal injury or death in the event of a collision which would result in air bag inflation, all maintenance must be performed by an authorized NISSAN/INFINITI dealer. ● Improper maintenance, including incorrect removal and installation of the SRS, can lead to personal injury caused by unintentional activation of the system. For removal of Spiral Cable and Air Bag Module, see the SRS section. ● Do not use electrical test equipment on any circuit related to the SRS unless instructed to in this Service Manual. SRS wiring harnesses can be identified by yellow and/or orange harnesses or harness connectors. Caution: ● – – – – – – BGS0001P Always follow the warnings and the cautions below in disassembly procedures: Work in a clean, dust-free place. No dustproof device is necessary. Clean the outside of the unit before disassembly. Clean the parts to be disassembled. Care must be taken not to allow any dirt or other foreign materials to enter or come in contact with the parts. Assemble the disassembled parts properly, following the order shown in the manual. If work has been suspended in the middle of assembly, place a clean cover over the parts to prevent them from being contaminated. Use paper towels when removing dirt and other foreign materials. Cloth shop towels can leave lint on the cleaned parts that might affect the operation of the parts. Clean disassembled parts with kerosene (except rubber parts), and then dry them thoroughly with an air blower or paper towels. PS-2 PREPARATION PREPARATION Special Service Tools PFP:00002 A BGS0001Q Description Application B Preload gauge ST3127S000 ● Checking steering torque ● Pinion gear rotating torque measurement for steering gear C D ZZA0806D E ST27180001 Steering wheel puller Removing steering wheel F S-NT544 PS H I J K L M PS-3 Symptom STEERING PS-5 Steering wheel play × × × ×: Applicable Judder PS-4 PS-7 PS-7 PS-9 NVH in FAX, RAX, FSU, RSU section NVH in WT section NVH in WT section NVH in FAX section NVH in BR section Improper installation or looseness of steering column Steering linkage looseness AXLE AND SUSPENSION TYRES ROAD WHEEL DRIVE SHAFT BRAKES – PS-7 Steering column deformation or damage Mounting rubber deterioration Improper installation or looseness or tilt lock lever – PS-9 Tie-rod ball joint end play × Improper steering wheel PS-9 Noise Tie-rod ball joint sliding torque Possible cause and SUSPECTED PARTS PS-9 Reference page Tie-rod ball joint tensile force NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING NVH Trouble Shooting Chart Shake × × × Vibration × × × Shimmy × × × × × × × × × × × × × × × × PFP:00003 BGS0001R Use the chart below to help you find the cause of the symptom. If necessary, repair or replace these parts. × × × × × × × × × × × × × STEERING WHEEL STEERING WHEEL On Board Inspection and Service PFP:48430 A BGS0001S PLAY INSPECTION 1. Turn steering wheel to the straight-ahead position. Start engine and lightly turn steering wheel clockwise and counterclockwise until the front wheels start moving. Measure the travel to the starting point on the circumference of steering wheel. If play is outside the specified range, check steering gear assembly, front suspension, axles, and steering column for proper installation. Steering wheel play inspection standard 2. C : 0 - 35 mm (0 - 1.38 in) Check steering wheel for vertical, horizontal, or axial play. Steering wheel axial end play ● B D : 0 mm (0 in) Lift vehicle and check steering gear nuts and bolts for looseness. Tightening torque E : 94 N·m (9.6 kg-m, 69 ft-lb) NEUTRAL POSITION INSPECTION ● ● ● After wheel alignment inspection, perform neutral position inspection. Refer to FSU-6, "Wheel Alignment" F . Set vehicle to the straight-ahead position and confirm steering wheel is in the neutral position. If it is not in the neutral position, loosen lock nut on tie-rod. Then adjust until the amount of left and right PS becomes equal. STEERING TORQUE INSPECTION 1. 2. 3. Steering torque 4. H Stop vehicle on a dry flat paved road and apply parking brake. Remove air bag module. Refer to SRS-36, "DRIVER AIR BAG MODULE" . Start engine and use a preload gauge (SST) to check steering wheel torque. I : 5.9 N·m (0.60 kg-m, 52 in-lb) or less When torque is outside the standard, check steering column and steering gear. If any non-standard condition is detected, replace if necessary. J K STA0005D L STEERING ANGLE INSPECTION ● After toe-in inspection, check the steering angle. Place the front wheels on turning radius gauges and the rear wheels on stands so that the vehicle can be level. Check the maximum inner and outer wheel steering angles for LH and RH road wheels. M FAA0016D PS-5 STEERING WHEEL ● ● With the engine at idle, turn steering wheel from stop to stop and measure the steering angles. Inner wheel : 38° Outer wheel : 33° +1° -3° Steering angles are not adjustable. If any of the steering angles is different from the specified value, check steering gear, column and front suspension components for wear or damage. If any non-standard condition exists, replace if necessary. SGIA0055E Removal and Installation BGS0001T REMOVAL NOTE: When reconnecting spiral cable, fix cable with a tape so that fixing case and rotating part keep aligned. this will omit neutral position alignment procedure during spiral installation. 1. Set vehicle to the straight-ahead position. 2. Remove driver air bag module. Refer to SRS-36, "DRIVER AIR BAG MODULE" . 3. Remove steering wheel lock bolt after steering is locked. 4. Remove steering wheel using the steering wheel puller (SST: ST27180001). SRS823 INSTALLATION Reverse the removal procedure for installation attentive to the following operation. NOTE: Make sure that the spiral cable is in the neutral position. The neutral position is detected by turning left 2.6 revolutions from the right end position and ending with the locating pin (1) at the top. CAUTION: Do not run spiral cable idle needlessly. And do not turn it more than necessary (or it leads to disconnection of the cable). MGIB9046E PS-6 STEERING COLUMN STEERING COLUMN Removal and Installation PFP:48810 A BGS0001U B C D E F PS H I MGIB9047E 1. Steering wheel 2. Steering column assembly 4. EPS control unit 5. Intermediate shaft 3. Bracket plate CAUTION: ● Care must be taken not to give axial impact to the steering column assembly during removal and installation. ● When steering wheel is turned repeatedly with the vehicle stopped, care must be taken because motor and control unit may get too hot. ● Steering column assembly is heavy (approximately 10 kg). Care must be taken when removing column from vehicle. ● Steering column assembly cannot be disassembled. If any non-standard condition exists, replace column assembly as a unit. REMOVAL OF STEERING COLUMN ASSEMBLY 1. 2. 3. 4. 5. 6. 7. 8. 9. Remove driver air bag module. Refer to SRS-36, "DRIVER AIR BAG MODULE" . Remove steering wheel and spiral cable. Refer to SRS-38, "SPIRAL CABLE" . Remove column cover and instrument panel & pad. Refer to IP-4, "INSTRUMENT PANEL ASSEMBLY" . Remove front wiper and washer switch and light and turn signal lamp switch. Refer to SRS-38, "Removal and Installation" in “Light and Turn Signal Switch”, and SRS-38, "Removal and Installation" . Disconnect all the clamps and harness connectors from steering column assembly. Refer to PG-48, "Harness Layout" . Remove intermediate shaft mounting bolt on steering gear, and disconnect the shaft from steering gear. Remove harness connector of electric power steering. Refer to PG-48, "Harness Layout" . Remove nut on steering column assembly, and make sure steering column moves freely. Remove steering column assembly from vehicle. PS-7 J K L M STEERING COLUMN CAUTION: ● Be sure not to rotate column shaft by 360° or more. (Doing this causes error in steering angle value memorized in electric power steering.) ● Do not disconnect intermediate shaft and steering column. INSPECTION AFTER REMOVAL OF STEERING COLUMN ASSEMBLY ● ● Check each part of column assembly and intermediate shaft for damage or other malfunctions. If any nonstandard condition exists, replace if necessary. If vehicle has been involved in a minor collision, measure length L as shown. If outside the standard, replace steering column assembly. Length L ● : 464 mm (18.3 in) Using preload gauge, measure steering column rotating torque. If outside the standard, replace steering column assembly. Rotating torque : 0 - 2.1 N·m (0 - 0.21 kg-m, 0 - 18 in-lb) SGIA1016J INSTALLATION OF STEERING COLUMN ASSEMBLY Note the following, and install in the reverse order of removal. Tighten bolts and nuts to the specified torque. ● Connect Pinion shaft (3) to yoke of intermediate shaft (1) and Steering column (2) assembly [RHD (4); LHD (5)], and tighten bolt to the specified torque. CAUTION: ● When tightening bolts, tighten them by hand first, and make sure there is no feeling of sticking or galling before final tightening. ● Insert bolts in the proper direction. (Do not insert them from the other side.) ● Tighten bolts at connecting pinion shaft and intermediate shaft side. Make sure there is no space between pinion shaft and yoke, and between pinion shaft and cam nut. MGIB9042E CHECK AFTER STEERING COLUMN ASSEMBLY INSTALLATION ● Rotating steering wheel, check for decentered condition, binding, noise or excessive steering effort. PS-8 POWER STEERING GEAR AND LINKAGE POWER STEERING GEAR AND LINKAGE Removal and Installation PFP:49001 A BGS0001V B C D E F PS MGIB9041E 1. Steering gear assembly 2. Suspension member 3. Heat insulator REMOVAL H 1. 2. 3. 4. I 5. Lift vehicle and remove tyres. Activate key lock of steering column. Remove intermediate shaft mounting bolt on steering gear, and disconnect the shaft. Remove tie-rod from steering knuckle. If tie-rod could not be removed easily, use ball joint remover (commercial service tool). CAUTION: To avoid damage to threads and sudden disconnection of ball joint remover (commercial service tool), temporarily tighten lock nut. Remove the exhaust front tube (CR engine models). Refer to EX-3, "EXHAUST SYSTEM" . J K L SGIA0184J 6. M Remove steering gear mounting nuts and bolts, and remove the steering gear through the right side of vehicle. (Remove from left side for LHD models and from right side for RHD models.) MGIB9043E INSTALLATION Note the following, and install in the reverse order of removal. Tighten bolts and nuts to the specified torque. ● Refer to PS-7, "Removal and Installation" . PS-9 POWER STEERING GEAR AND LINKAGE Disassembly and Assembly BGS0001W COMPONENT PARTS LOCATION (R24T TYPE) MGIB9044E 1. Outer socket 2. Bulkhead sealing 3. Seal ring 4. Strap 5. Dust boot 6. Spring clip 7. Lock nut 8. Steering gear assembly 9. Heat shield DISASSEMBLY 1. 2. 3. Disengage the tab of bulkhead seal, and remove it from steering gear. Loosen lock nut of tie-rod outer socket, and remove it from steering gear. Remove spring clip and strap (cutting off), and remove dust boot and seal ring. CAUTION: When removing dust boot, be careful not to damage inner socket and gear housing assembly. MGIB9045E INSPECTION AFTER DISASSEMBLY Rack Check rack gear, and, if any damage or wear exists, replace steering gear assembly. Bulkhead Sealing In case of broken tab, or torn sealing in bulkhead seal, replace the damaged part. Tie-Rod Ball Joint 1. Tensile force ● Hook a spring balance onto the point shown in the figure and pull the balance. Make sure the balance reads the specified value when ball stud and the inner socket start to move. If it is outside the standard, replace both outer socket and steering gear assembly. MGIA0016E PS-10 POWER STEERING GEAR AND LINKAGE Measuring point of spring balance Tensile force N·m (kg-m, in-lb) Spring balance measurement N (kg, lb) 2. Outer socket Inner socket Edge of stud bolt Measuring point 0.3 - 2.9 (0.03 - 0.29, 3 -25) 0.5 - 5.0 (0.05 - 0.51, 5 - 44) 5 - 54 (0.51 - 5.5, 1.1 - 12.1) 4 - 43 (0.41 - 4.4, 0.9 - 9.7) A B C Axial end play Apply 490 N (50 kg, 110 lb) of load to the ball stud axially and use a dial gauge to measure the amount of movement the stud makes. Make sure the reading is within the range specified. If outside the standard, replace outer socket and steering assembly. D ● Outer socket No Free Play Inner socket No Free Play 3. Using preload gauge (SST), measure rotating torque of pinion gear. If the measurement is outside of the specified range, replace steering gear. Rotating torque of pinion gear Around neutral position (Within ±100°) Average A Other than the above: Maximum value C E F PS SGIA0057E H : 0.7 - 1.2 N·m (0.07 0.12 kg-m, 6 - 11 in-lb) : 1.6 N·m (0.16 kg-m, 14 in-lb) I J MGIA0017E ASSEMBLY K Note the following, and assemble in the reverse order of disassembly ● Apply multi-purpose grease to the sliding part of rack. ● Securely fix dust boot and seal ring with strap. Caulk the strap, and cut the excess of strap off. ● Engage the tab of bulkhead seal to steering gear. L M MGIA0018E PS-11 POWER STEERING GEAR AND LINKAGE ● Install lock nut and the outer socket to the inner socket and tighten lock nut until the length of the tie-rod is within the standard (length before toe-in adjustment.) Length of tie-rod (L) : 57.8 mm (2.28 in) CAUTION: Perform toe-in adjustment after this procedure. Length achieved after toe-in adjustment is not necessarily the value given here. SGIA0195J PS-12 SERVICE DATA AND SPECIFICATIONS (SDS) SERVICE DATA AND SPECIFICATIONS (SDS) Wheel PFP:00030 A BGS0001X Steering wheel axial end play 0 mm (0 in) Steering wheel free play B 0 - 35 mm (0 - 138 in) Steering Angle BGS0001Y 38° Inner wheel C +1° -3° Outer wheel 33° D Steering Column BGS0001Z Steering column length L 464 mm (18.3 in) E F PS H SGIA1016J Steering Linkage Tie-rod ball joint outer socket BGS00020 Steering gear type R24T Tensile force 0.3 - 2.9 N·m (0.03 - 0.29 kg-m, 3 - 25 in-lb) Spring balance measurement (Upper edge of stud bolt) Tie-rod ball joint inner socket J 5 - 54 N (0.51 - 5.5 kg, 1.1 - 12.1 lb) Axial end play No Free Play Tensile force I K 0.5 - 5.0 N·m (0.05 - 0.51 kg-m, 5 - 44 in-lb) Spring Balance measurement (measured at * mark) 4 - 43 N (0.41 - 4.4 kg, 0.9 - 9.7 lb) Axial end play L No Free Play Tie-rod length L 57.8 mm (2.28 in) M STC1006D PS-13 SERVICE DATA AND SPECIFICATIONS (SDS) Tightening Torque BGS00021 Unit: N·m (kg-m, ft-lb) Steering wheel bolt 34.5 (3.5, 25) Steering column to intermediate shaft to Steering gear 29.5 (3.0, 22) Steering gear to Suspension member 94 (9.6, 69) Outer socket to Steering knuckle 34.3 (3.5, 25) Tie-rod outer socket lock nut 41.7 (4.3, 31) PS-14 REAR AXLE D DRIVELINE/AXLE SECTION RAX REAR AXLE A B C RAX CONTENTS PRECAUTIONS .......................................................... 2 Caution ..................................................................... 2 Precautions for Brake System .................................. 2 PREPARATION ........................................................... 3 Special Service Tools ............................................... 3 NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING ................................................ 4 NVH Troubleshooting Chart ..................................... 4 WHEEL HUB .............................................................. 5 On-Vehicle Inspection .............................................. 5 REAR WHEEL BEARING ..................................... 5 Removal and Installation .......................................... 5 REMOVAL ............................................................. 5 INSTALLATION ..................................................... 6 Disassembly and Assembly ...................................... 6 DISASSEMBLY ..................................................... 6 INSPECTION AFTER DISASSEMBLY .................. 7 ASSEMBLY ........................................................... 7 INSPECTION AFTER ASSEMBLY ........................ 7 SERVICE DATA AND SPECIFICATIONS (SDS) ........ 8 Wheel Bearing .......................................................... 8 Tightening Torque ..................................................... 8 E F G H I J K L M RAX-1 PRECAUTIONS PRECAUTIONS Caution PFP:00001 BDS00075 Observe the following precautions when disassembling and servicing drive shaft. ● Perform work in a location which is as dust-free and dirt-free as possible. ● Before disassembling and servicing, clean the outside of parts. ● The disassembly and service location must be clean. Care must be taken to prevent parts from becoming dirty and to prevent the entry of foreign objects. ● Disassembled parts must be carefully reassembled in the correct order. If work is interrupted, a clean cover must be placed over parts. ● Paper shop cloths must be used. Fabric shop cloths must not be used because of the danger of lint adhering to parts. ● Disassembled parts (except for rubber parts) should be cleaned with kerosene which shall be removed by blowing with air or wiping with paper shop cloths. Precautions for Brake System ● ● ● ● BDS00076 When installing rubber parts, final tightening must be carried out under unladen condition* with tyres on ground. *: Fuel, radiator coolant and engine oil full. Spare tyre, jack, hand tools and mats in designated positions. Use flare nut wrench when removing or installing brake tubes. After installing removed suspension parts, check wheel alignment and adjust if necessary. Always tighten brake lines to the specified torque when installing. SBR820BA RAX-2 PREPARATION PREPARATION Special Service Tools PFP:00002 A BDS00077 Description Application B Drift ST30720000 a: 77 mm (3.03 in) dia. b: 55 mm (2.17 in) dia. Installing hub cap RAX ZZA0701D Drift ST33022000 a: 56 mm (2.20 in) dia. b: 110 mm (4.33 in) dia. C ● Installing wheel bearing ● Installing ABS sensor rotor E F ZZA0881D G Drift ST33710000 a: 30 mm (1.18 in) dia. b: 23 mm (0.91 in) dia. Removing wheel bearing H ZZA1234D I Flare nut torque wrench GG94310000 a: 10 mm (0.39 in) Removing and installing brake lines J NT406 K L M RAX-3 NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING NVH Troubleshooting Chart PFP:00003 BDS00078 Refer to RAX-5, "REAR WHEEL BEARING" NVH in FAX and FSU sections. NVH in WT section. NVH in WT section. NVH in FAX section. NVH in BR section. NVH in PS section. Wheel bearing damage FRONT AXLE AND FRONT SUSPENSION TYRES ROAD WEEL DRIVE SHAFT BRAKES STEERING × × × × Parts interference REAR AXLE × Noise × × Shake × × × × × × × × Vibration × × × × Shimmy × × × × × × × Judder × × × × × × Poor quality ride or handling × × × × Possible cause and SUSPECTED PARTS Symptom × Improper installation, looseness Reference page — Refer to RAX-5, "REAR WHEEL BEARING" Use the chart below to help you find the cause of the symptom. If necessary, repair or replace these parts. ×: Applicable RAX-4 × × × × WHEEL HUB WHEEL HUB On-Vehicle Inspection PFP:43202 A BDS00079 Check rear axle for unusual play, cracking, excessive wear, or other damage. ● Turn rear wheels (left/right) and check the play. B C RAX SMA525A E REAR WHEEL BEARING With the vehicle raised, inspect the following: ● Manually move the wheel hub in axial direction to check wheel bearing for excessive play. Axial end play ● ● F : 0.05 mm (0.0020 in) Check for unusual noise by rotating wheel. If there are any non-standard conditions, replace the wheel bearing. If outside the standard or any other non-standard condition is found, replace wheel bearing assembly. Removal and Installation BDS0007A G H I J K L M MDIB9061E 1. Back plate 2. Spindle 3. ABS sensor rotor 4. Wheel bearing 5. Snap rings 6. Brake drum 7. Hub cap REMOVAL 1. 2. 3. 4. 5. Lift up the vehicle and remove tyre from the vehicle. Release parking brake. With hub cap pliers (commercial service tool), remove hub cap from brake drum (wheel hub) Remove lock nut and separate brake drum from spindle. Remove ABS sensor rotor from back plate part. Refer to BRC-36, "WHEEL SENSORS" . Loosen self-locking nut. Refer to BR-27, "REAR DRUM BRAKE" . Separate parking brake rear cable from rear brake. Refer to PB-4, "Components" . RAX-5 WHEEL HUB 6. 7. Separate brake tube from wheel cylinder. Refer to BR-11, "Removal and Installation of Front Brake Piping and Brake Hose" . CAUTION: ● Avoid smearing brake fluid on coated surfaces while removing brake tube. ● Never depress brake pedal while removing brake tube and brake drum. Remove spindle mounting bolt. Separate back plate assembly and spindle from rear suspension trailing arm. INSTALLATION ● ● ● ● ● ● For each tightening torque, refer to RAX-5, "Removal and Installation" and tighten in the reverse order of removal. For mounting of brake tube and tightening torque, refer to BR-11, "Removal and Installation of Front Brake Piping and Brake Hose" . For mounting parking brake and tightening torque, refer to PB-3, "PARKING BRAKE SYSTEM" . For mounting ABS wheel sensor and tightening torque, refer to BRC-36, "WHEEL SENSORS" . Using a drift (SST), mount hub cap on brake drum (wheel hub). CAUTION: Do not reuse hub cap. Refill with new brake fluid and bleed air. Refer to BR-9, "BRAKE FLUID" . SDIA0766J Disassembly and Assembly BDS0007B DISASSEMBLY 1. Using snap ring pliers (commercial service tool), remove sensor rotor MDIA0062E 2. Remove snap ring. MDIA0056E RAX-6 WHEEL HUB 3. Press the wheel bearing out with a drift (SST) to remove. A B C MDIA0057E RAX INSPECTION AFTER DISASSEMBLY ● ● Check trailing arm for deformed parts, cracks, or any other damage. Replace if necessary. Check snap ring for wear or cracks. Replace if necessary. E ASSEMBLY 1. 2. Press-fit the wheel hub with a drift (SST). CAUTION: Do not press and weight on wheel bearing inner lace and sealing part. NOTE: Final press-loading guideline [50,000 N (5,100 kg, 11,240 lb)] Install snap ring. F G H MDIA0058E I 3. Press-fit the sensor rotor on the brake drum with a drift (SST). J K L MDIA0059E INSPECTION AFTER ASSEMBLY 1. Tightening torque 2. 3. M After installing brake drum on spindle, tighten lock nut to the standard torque. : 175 N·m (18 kg-m, 129 ft-lb) Rotate the wheel hub in both directions ten times each to check for smooth movement. At a rotating speed of 10 ± 2 rpm, place a spring balance on hub bolt to measure torque. Rotating torque Spring balance measurement : 0.20 - 0.95 N·m (0.02 - 0.09 kg-m) MDIA0060E : 4 - 19 N (0.41 - 1.94 kg) RAX-7 SERVICE DATA AND SPECIFICATIONS (SDS) SERVICE DATA AND SPECIFICATIONS (SDS) Wheel Bearing Axial end play 0.05 mm (0.0020 in) Rotating torque 0.20 - 0.95 N·m (0.02 - 0.09 kg-m) Spring balance measurement Installation location of spring scale PFP:00030 BDS0007C 4 - 19 N (0.41 - 1.94 kg) Hub bolt position MDIA0061E Tightening Torque Hub lock nut BDS0007D 175 N·m (18 kg-m, 129 ft-lb) RAX-8 REAR SUSPENSION E SUSPENSION SECTION RSU REAR SUSPENSION A B C D CONTENTS PRECAUTIONS .......................................................... 2 Cautions ................................................................... 2 Precautions for Brake System .................................. 2 PREPARATION ........................................................... 3 Special Service Tools ............................................... 3 NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING ................................................ 4 NVH Troubleshooting Chart ..................................... 4 REAR SUSPENSION ASSEMBLY ............................. 5 Components ............................................................. 5 On-Vehicle Inspection and Service .......................... 5 Wheel Alignment ...................................................... 6 DESCRIPTION ...................................................... 6 PRELIMINARY INSPECTION ............................... 6 CAMBER ............................................................... 6 TOE-IN .................................................................. 6 SHOCK ABSORBER .................................................. 7 Removal and Installation .......................................... 7 REMOVAL ............................................................. 7 INSPECTION AFTER REMOVAL ......................... 7 INSTALLATION ..................................................... 8 COIL SPRING ............................................................. 9 Removal and Installation .......................................... 9 REMOVAL ............................................................. 9 INSPECTION AFTER REMOVAL ......................... 9 INSTALLATION ..................................................... 9 REAR SUSPENSION BEAM .................................... 10 Removal and Installation ........................................ 10 REMOVAL ........................................................... 10 INSPECTION AFTER REMOVAL ....................... 10 INSTALLATION ................................................... 10 SERVICE DATA AND SPECIFICATIONS (SDS) ...... 11 Wheel Alignment .................................................... 11 Tightening Torque ................................................... 11 RSU F G H I J K L M RSU-1 PRECAUTIONS PRECAUTIONS Cautions ● ● ● ● PFP:00001 BES0002U Final tightening of bushings must be carried out under unladen condition with tyres on the ground. Oil will shorten life of bushings. Be sure to wipe off any spilled oil. “Unladen condition” means that fuel, coolant and lubricant are full and ready for drive. However, spare tyre, jack, and hand tools should be unloaded. After installing the removed suspension parts, always check wheel alignment and adjust if necessary. Replace the caulking nut with a new one. Install a new nut without wiping the oil off before tightening. Precautions for Brake System ● ● BES0002V Use flare nut wrench when removing or installing brake tubes. Always tighten brake lines to specified torque when installing. SBR820BA RSU-2 PREPARATION PREPARATION Special Service Tools PFP:00002 A BES0002W Tool number Tool name Description GG94310000 Flare nut torque wrench a: 10 mm (0.39 in) B Removing and installing brake lines C D NT406 RSU F G H I J K L M RSU-3 Symptom Bushing or mounting deterioration Parts interference REAR SUSPENSION Shock absorber deformation, damage or deflection Possible cause and SUSPECTED PARTS Improper installation, looseness Reference page ×: Applicable RSU-4 Noise × × × × Shake × × × × Vibration × × × × Shimmy × × × × Judder × × × Poor quality ride or handling × × × Refer to RSU-6, "Wheel Alignment" Incorrect wheel alignment FRONT AXLE AND FRONT SUSPENSION TYRES ROAD WHEEL DRIVE SHAFT BRAKES STEERING × × × × × × × × × × × × × × × × × × × × × × × × × × × × × × × × × × × NVH in PS section. NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING NVH Troubleshooting Chart NVH in BR section. NVH in FAX section. NVH in WT section. NVH in WT section. NVH in FAX and FSU sections. Refer to RSU-5, "Components" — Suspension looseness × Spring fatigue — — Refer to RSU-7, "SHOCK ABSORBER" Refer to RSU-5, "Components" NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING PFP:00003 BES0002X Use the chart below to help you find the cause of the symptom. If necessary, repair or replace these parts. × REAR SUSPENSION ASSEMBLY REAR SUSPENSION ASSEMBLY Components PFP:55020 A BES0002Y B C D RSU F G H I J MEIB9027E K 1. Bushing 2. Bushing 3. Distance tube 4. Bound bumper cover 5. Bound bumper 6. Shock absorber 7. Rear spring rubber seat 8. Coil spring 9. Rear spring rubber seat 10. Rear suspension beam L 11. Rear suspension arm bracket On-Vehicle Inspection and Service BES0002Z Check axle and suspension parts for excessive play, wear, and damage. ● Move rear wheels (RH/LH) to check for unusual free play. ● Retighten all nuts and bolts to the specified torque. ● Check shock absorber for oil leakage and damage. RSU-5 M REAR SUSPENSION ASSEMBLY Wheel Alignment BES00030 DESCRIPTION ● Measure wheel alignment under unladen conditions. “Unladen conditions” means that fuel, coolant, and lubricant are full. However, spare tyre, jack, and hand tools should be unloaded. PRELIMINARY INSPECTION 1. 2. 3. 4. 5. 6. 7. Check the tyres for improper air pressure and wear. Check road wheels for runout. Check wheel bearing axial end play. Check shock absorber operation. Check each mounting point of axle and suspension for looseness and deformation. Check each link and arm for cracks, deformation, and other damage. Check the vehicle posture. CAMBER Camber is preset at factory and cannot be adjusted. Camber ● : -1°55′- -0°25′ (-1.92°- -0.42°) If the camber is not within specification, inspect and replace any damaged or worn rear suspension parts. TOE-IN Toe-in is preset at factory and cannot be adjusted. Measure toe-in using following procedure. If out of specification, inspect and replace any damaged or worn rear suspension parts. WARNING: ● Always perform following procedure on a flat surface. ● Make sure that no person is in front of the vehicle before pushing it. 1. Bounce rear of vehicle up and down to stabilize the posture. 2. Push the vehicle straight ahead about 5 m (16 ft.). 3. Put a mark on base line of tread (rear side) of both tyres at the same height as hub center. This mark is a measuring points. AFA050 4. 5. Measure distance “A” (rear side). Push the vehicle slowly ahead to rotate the wheels 180 degrees (1/2 turn). If the wheels have rotated more than 180 degrees (1/2 turn), try the above procedure again from the beginning. Never push vehicle backward. 6. Measure distance “B” (front tyres). Total toe-in: In 0- 8 mm (0 - 0.31 in) SFA234AC RSU-6 SHOCK ABSORBER SHOCK ABSORBER Removal and Installation PFP:56210 A BES00031 REMOVAL 1. 2. 3. Raise vehicle and remove tyre. Using a flat screwdriver, remove luggage side lower finisher. CAUTION: Wrap the tip of a screwdriver with cloth to avoid damaging components. B C Remove upper nuts of the shock absorber and remove washer, bushing on the upper side of shock absorber. D RSU F SEIA0147J G 4. 5. Set a jack under trailing arm of rear suspension beam and support it. Remove lower bolts of the shock absorber. Remove shock absorber from the vehicle. H I J SEIA0146J INSPECTION AFTER REMOVAL Shock Absorber ● ● ● K Check shock absorber for deformation, cracks, and other damage. Replace if any non-standard conditions are found. Check piston rod for damage, uneven wear, and distortion, and replace shock absorber if necessary. Check welded and sealed areas for oil leakage, and replace if necessary. Bound Bumper and Bushing ● L M Check bound bumper and bushing for cracks and damage. Replace if necessary. RSU-7 SHOCK ABSORBER INSTALLATION ● ● Refer to RSU-5, "Components" for tightening torque. Install in the reverse order of removal. When installing body side bushing, install the projection to the vehicle side hole securely. MEIA0028E RSU-8 COIL SPRING COIL SPRING Removal and Installation PFP:55020 A BES00032 REMOVAL 1. 2. 3. Raise vehicle and remove tyre. Set a jack under trailing arm of rear suspension beam and support it. Remove lower side of the shock absorber. (left/right) Remove jack. Remove coil spring and spring rubber seat. B C D RSU SEIA0146J INSPECTION AFTER REMOVAL ● Check coil spring and spring rubber seat for deformation, cracks, and damage, and replace if necessary. F INSTALLATION ● ● Refer to RSU-5, "Components" for tightening torque. Tighten in the reverse order of removal. When installing spring, be sure to securely install the spring end position aligned to flush of spring rubber seat as shown in the figure. G H I J SEIA0149J K L M RSU-9 REAR SUSPENSION BEAM REAR SUSPENSION BEAM Removal and Installation PFP:55501 BES00034 REMOVAL 1. 2. 3. 4. Raise vehicle, remove tyre and replace parking lever. Install brake pedal press then open rear air bleeder. Refer to BR-10, "Bleeding Brake System" . Drain brake fluid. Refer to BR-9, "Drain and Refill" . Loosen self-locking nut, and separate parking brake rear cable from rear brake and rear suspension beam. Refer to PB-3, "PARKING BRAKE SYSTEM" . 5. Remove ABS wheel sensor. Refer to BRC-36, "WHEEL SENSORS" . 6. Separate rear brake hose from brake piping. Refer to BR-11, "BRAKE PIPING AND HOSE" . 7. Remove shock absorber lower side (left/right), coil spring (left/right). Refer to RSU-7, "SHOCK ABSORBER" , RSU-9, "COIL SPRING" 8. Set a jack under suspension beam, and remove mounting bolts of suspension arm bracket and rear suspension beam. 9. Remove suspension beam. 10. Remove brake piping from rear suspension member beam. Refer to BR-11, "BRAKE PIPING AND HOSE" . MEIA0029E 11. Remove spindle bolts and rear axle assembly. 12. Remove rear suspension arm bracket nuts and bolts. Remove rear suspension arm bracket from vehicle. SEIA0151J INSPECTION AFTER REMOVAL ● Check suspension beam and bushing for deformation, cracks, and damage. Replace if necessary. INSTALLATION ● ● ● ● ● ● Refer to RSU-5, "Components" for tightening torque. Tighten in the reverse order of removal. Refer to BR-11, "BRAKE PIPING AND HOSE" for installation of brake piping and brake hose and for tightening torque. Refer to PB-3, "PARKING BRAKE SYSTEM" for installation of parking brake and for tightening torque. Tighten rear suspension arm bracket under unladen condition. Refer to BRC-36, "WHEEL SENSORS" for installation of ABS wheel sensor and for tightening torque. Refill with new brake fluid and bleed air. Refer to BR-9, "BRAKE FLUID" . MEIA0030E RSU-10 SERVICE DATA AND SPECIFICATIONS (SDS) SERVICE DATA AND SPECIFICATIONS (SDS) Wheel Alignment Camber PFP:00030 A BES00036 -1°55′ - -0°25′ (-1.92° - -0.42°) Toe-in B In 0 - 8 mm (0 - 0.31 in) Tightening Torque BES00037 Unit: N·m (kg-m) Shock absorber piston rod lock nut C 20 (2.0, 15) Rear suspension beam to rear suspension arm bracket 160 (16, 118) Shock absorber to rear suspension beam 90 (9.2, 66) Rear suspension arm bracket to body 50 (5.1, 37) D RSU F G H I J K L M RSU-11 SERVICE DATA AND SPECIFICATIONS (SDS) RSU-12 SEAT BELTS H RESTRAINTS SECTION SB SEAT BELTS A B C D CONTENTS PRECAUTIONS .......................................................... 2 Precautions for Supplemental Restraint System (SRS) “AIR BAG” and “SEAT BELT PRE-TENSIONER” .................................................................. 2 Precaution for Seat Belt Service .............................. 2 AFTER A COLLISION ........................................... 2 SEAT BELTS .............................................................. 3 System Description .................................................. 3 SEAT BELT WARNING LAMP .............................. 3 SEAT BELT WARNING CHIME ............................ 3 Removal and Installation of Front Seat Belt ............. 3 REMOVAL ............................................................. 3 INSTALLATION ..................................................... 4 Removal and Installation of Rear Seat Belt .............. 4 REMOVAL ............................................................. 4 INSTALLATION ..................................................... 5 Inspection ................................................................. 5 POST-ACCIDENT INSPECTION .......................... 5 INSPECTION FOR SEAT BELT RETRACTOR..... 5 INSPECTION OF ELR AND SEAT BELT WITH CHILD SAFETY SEAT ANCHOR SYSTEM .......... 6 ISO FIX CHILD RESTRAINT ANCHORAGE .............. 7 Removal and Installation .......................................... 7 E F G SB I J K L M SB-1 PRECAUTIONS PFP:00001 PRECAUTIONS Precautions for Supplemental Restraint System (SRS) “AIR BAG” and “SEAT BELT PRE-TENSIONER” BHS0002L The Supplemental Restraint System such as “AIR BAG” and “SEAT BELT PRE-TENSIONER”, used along with a front seat belt, helps to reduce the risk or severity of injury to the driver and front passenger for certain types of collision. Information necessary to service the system safely is included in the SRS and SB section of this Service Manual. WARNING: ● To avoid rendering the SRS inoperative, which could increase the risk of personal injury or death in the event of a collision which would result in air bag inflation, all maintenance must be performed by an authorized NISSAN/INFINITI dealer. ● Improper maintenance, including incorrect removal and installation of the SRS, can lead to personal injury caused by unintentional activation of the system. For removal of Spiral Cable and Air Bag Module, see the SRS section. ● Do not use electrical test equipment on any circuit related to the SRS unless instructed to in this Service Manual. SRS wiring harnesses can be identified by yellow and/or orange harnesses or harness connectors. Precaution for Seat Belt Service BHS0002M CAUTION: ● Before removing the seat belt pre-tensioner assembly, turn the ignition switch off, disconnect the battery ground cable and wait at least 3 minutes. ● Do not use electrical test equipment for seat belt pre-tensioner connector. ● After replacing or reinstalling seat belt pre-tensioner assembly, or reconnecting seat belt pretensioner connector, check the system function. Refer to SRS-18, "SRS Operation Check" . ● Do not use disassemble buckle or seat belt assembly. ● Replace anchor bolts if they are deformed or worn out. ● Never oil tongue and buckle. ● If any component of seat belt assembly is questionable, do not repair. Replace the whole seat belt assembly. ● If webbing is cut, frayed, or damaged, replace seat belt assembly. ● When replacing seat belt assembly, use a genuine seat belt assembly. AFTER A COLLISION WARNING: Inspect all seat belt assemblies including retractors and attaching hardware after any collision. NISSAN recommends that all seat belt assemblies in use during a collision be replaced unless the collision was minor and the belts show no damage and continue to operate properly. Failure to do so could result in serious personal injury in an accident. Seat belt assemblies not in use during a collision should also be replaced if either damage or improper operation is noted. Seat belt pre-tensioner should be replaced even if the seat belts are not in use during a frontal collision in which the air bags are deployed. Replace any seat belt assembly (including anchor bolts) if: ● The seat belt was in use at the time of a collision (except for minor collisions and the belts, retractors and buckles show no damage and continue to operate properly). ● The seat belt was damaged in an accident. (i.e. torn webbing, bent retractor or guide, etc.) ● The seat belt attaching point was damaged in an accident. Inspect the seat belt attaching area for damage or distortion and repair as necessary before installing a new seat belt assembly. ● Anchor bolts are deformed or worn out. ● The seat belt pre-tensioner should be replaced even if the seat belts are not in use during the collision in which the air bags are deployed. SB-2 SEAT BELTS SEAT BELTS System Description PFP:86884 A BHS0004Q SEAT BELT WARNING LAMP ● ● ● Fasten driver's seat belt. The seat belt warning lamp should go out. If the seat belt warning lamp does not go out. Refer to DI-32, "WARNING LAMPS" . B C SEAT BELT WARNING CHIME ● ● ● Fasten driver's seat belt. The seat belt warning chime should not sound. If the seat belt warning chime sounds. Refer to DI-52, "WARNING CHIME" . D Removal and Installation of Front Seat Belt BHS0002N E F G SB I J PHIA1076J 1. Seat belt anchor plate (upper) 2. Seat belt anchor plate (lower) 3. Seat belt pre-tensioner 4. Seat belt adjuster cover 5. Anchor bolt 6. Seat belt pre-tensioner connector 7. Bolt 8. Seat belt adjuster CAUTION: Before servicing SRS, turn ignition switch off, disconnect the battery ground cable and wait at least 3 minutes. L M REMOVAL Seat Belt Retractor 1. 2. 3. 4. 5. 6. K Remove bolt cover. Remove shoulder anchor bolts. Remove the center pillar lower garnish. Refer to EI-26, "Removal and Installation" in EI section. Remove seat belt pre-tensioner connector on the seat belt retractor. Remove anchor plate (lower) pre-tensioner connector (driver side only). Remove pre-tensioner seat belt retractor mounting screw and floor anchor bolt. Then, remove seat belt assembly. SB-3 SEAT BELTS Seat Belt Buckle 1. 2. 3. 4. Remove front seat from vehicle body. Refer to SE-7, "FRONT SEAT" in SE section. Separate clip of buckle switch harness connector from the bottom of seat cushion. Remove seat cushion inner finisher. Refer to SE-10, "Disassembly and Assembly of Seat Cushion" in SE section. Remove anchor bolt (1) and buckle. MHIB0004E INSTALLATION ● ● Install in the reverse order of removal. Tighten anchor bolts to the specified torque. Removal and Installation of Rear Seat Belt BHS0002P MHIB9026E REMOVAL Seat Belt Retractor (side seats) 1. 2. 3. 4. Remove luggage side finisher. Refer to EI-33, "Luggage Side Finisher" . Remove shoulder anchor bolt cap. Remove shoulder and floor anchor bolt. Remove the retractor. SB-4 SEAT BELTS Seat Belt Retractor (centre seat) 1. 2. 3. 4. A Remove seat cushion trim and pad. Refer to SE-13, "Rear Seat Disassembly and Assembly" . Remove seatback trim and pad. Refer to SE-13, "Rear Seat Disassembly and Assembly" . Remove shoulder anchor bolts (2) and floor anchor bolt. Remove the retractor. B Seat Belt Buckle 1. 2. 3. Remove seat cushion trim and pad. Refer to SE-13, "Rear Seat Disassembly and Assembly" . Remove seat buckle anchor bolt. Remove seat buckle. C D INSTALLATION ● ● Install in the reverse order of removal. Tighten anchor bolts to the specified torque. E Inspection BHS0002R POST-ACCIDENT INSPECTION After a collision, inspect for damage or distortion of retractor, seat belt anchor, floor anchor, or shoulder anchor. Nissan recommends replacement of all seat belt assemblies in the following cases because these impairments may lead to personal injury. ● After a collision ● When installation point of seat belt assembly on vehicle is damaged. ● When it does not operate normally. 2. 3. 4. a. b. c. d. 5. G SB INSPECTION FOR SEAT BELT RETRACTOR 1. F Using seat belt warning lamp, make sure it works normally. Check the seat belt warning lamp/chime for proper operation as follows: Switch ignition ON. The seat belt warning lamp should illuminate. Also, the seat belt warning chime should sound for about six seconds. Fasten driver's seat belt. The seat belt warning lamp should go out and the chime (if sounding) should stop. If warning lamp stay illuminated or warning chime combine to sound. Refer to DI-52, "WARNING CHIME" . Refer to DI-32, "WARNING LAMPS" . Check whether anchor bolts on seat belt retractor and buckle are securely tightened. Confirm if the seat belt through anchor axis freely rotates, seat belt adjuster properly operates, or completely engages. Retractor operation inspection Pull out all webbing and check for twisting, cut, or other damage. Retract webbing. Check if the webbing is retracted smoothly and completely into the retractor. When webbing is not retracted smoothly due to the dust or other reasons, carry out the following procedure with “SEAT BELT, TAPE SET”. Inspection for Front Seat Belt Shoulder Anchor. 1. Pull webbing out 50 cm or more. 2. Fix webbing near the belt exit with a clip. 3. Pass the thin wire into the through part of shoulder anchor and webbing. Remove the sticking materials from the webbing by sliding the wire vertically along the surface of the webbing through part while pulling both sides of wire tightly. 4. Clean the remaining dirt by cleaning the webbing through part with a clean cloth. 5. Apply tape to the shoulder anchor belt through part where webbing touches. NOTE: Be careful to apply tape with no wrinkling or looseness. 6. Remove the seat belt fixing, and confirm webbing smoothly retracts. Insert the seat belt into the buckle and confirm seat belt is firmly secured. Remove the seat belt from buckle. Release the seat belt and confirm webbing and tongue are placed correctly. Seat belt retractor unit inspection SB-5 I J K L M SEAT BELTS a. b. Remove seat belt retractor. As shown in the figure, without twisting retractor, recline the seat belt retractor at the position retractor is mounted on the vehicle body. Slowly pull out the webbing. ● Webbing is able to pull out when reclining 15 degrees or less. ● Webbing is not able to pull out when reclining 35 degrees or more. MHIB0006E If it does not operate normally, replace seat belt assembly. INSPECTION OF ELR AND SEAT BELT WITH CHILD SAFETY SEAT ANCHOR SYSTEM ELR and Seat Belt With Child Safety Seat Anchor System ● ● ● ELR is a system which locks retractor in emergency cases such as sudden braking so that the webbing is not pulled out any further. Child safety seat anchor system is applied at the 3-point seat belt (outside seat) of back seat. Child safety seat anchor system functions when webbing is completely pulled out. Webbing is locked at certain point when retracting webbing little by little. There are 2 inspections: static and dynamic. Use the following procedures to check retractor for normal operation. ELR Static Inspection Does retractor lock and webbing stop immediately when quickly pulling webbing forward? Inspection for Child Safety Seat Anchor System 1. 2. 3. 4. Fully pull out webbing until “clicking” is heard. Is “clicking” operating sound heard when retracting webbing little by little? Is webbing locked and no longer pulled out when under tension? Is child safety seat anchor system released when webbing is completely retracted? ELR Dynamic Inspection WARNING: ● The following tests should be carried out in a safe, open place free of traffic and obstacles. ● The tests should be carried out on a dry paved road. Never attempt the tests on wet or unpaved road, open road, or highway. (This may cause an accident or personal injury.) ● Driver and passenger assume retractor will not lock and prepare themselves accordingly. 1. Tighten driver and passenger seat belts. 2. Drive at approximately 16 km/h (MPH). 3. Notify passenger of a sudden stop. Driver and passenger prepare themselves for the possibility of retractor not locking. Then, driver fully depresses the brake pedal to stop suddenly. 4. While car stops, confirm if retractor is locked and webbing is not pulled out any more. Check for only retractor part if it is not locked. SB-6 ISO FIX CHILD RESTRAINT ANCHORAGE ISO FIX CHILD RESTRAINT ANCHORAGE Removal and Installation PFP:88840 A BHS0004R B C D E F G MHIB9029E 1. Rear seat cushion frame assembly : ISO fix child restraint anchor SB : Tether strap anchor CAUTION: ISO fix child restraint anchor and Tether strap anchor are not serviceable. If damaged, replace the rear seat cushion frame assembly. I J K L M SB-7 ISO FIX CHILD RESTRAINT ANCHORAGE SB-8 STARTING & CHARGING SYSTEM K ELECTRICAL SECTION SC STARTING & CHARGING SYSTEM A B C D CONTENTS PRECAUTIONS .......................................................... 3 Precautions for Supplemental Restraint System (SRS) “AIR BAG” and “SEAT BELT PRE-TENSIONER” .................................................................. 3 PREPARATION ........................................................... 4 Special Service Tools ............................................... 4 BATTERY .................................................................... 5 How to Handle Battery ............................................. 5 METHODS OF PREVENTING OVER-DISCHARGE ............................................................... 5 CHECKING ELECTROLYTE LEVEL .................... 5 SPECIFIC GRAVITY CHECK ............................... 6 Battery Test and Charging Chart .............................. 7 CHART I ................................................................ 7 CHART II ............................................................... 8 A: SLOW CHARGE ............................................... 9 B: STANDARD CHARGE .....................................11 C: QUICK CHARGE ............................................ 12 Removal and Installation ........................................ 14 REMOVAL ........................................................... 14 INSTALLATION ................................................... 14 CHARGING SYSTEM ............................................... 15 System Description (CR Engine Models) ............... 15 System Description (HR Engine Models) ............... 15 System Description (K9K Engine Models) ............. 15 Wiring Diagram — CHARGE —/CR Engine Models... 16 Wiring Diagram — CHARGE —/HR Engine Models... 17 Wiring Diagram — CHARGE —/K9K Engine Models ........................................................................... 18 Trouble Diagnoses (CR Engine Models) ................ 20 DIAGNOSIS PROCEDURE ................................ 20 PRE-DIAGNOSIS INSPECTION ......................... 20 DIAGNOSIS CHART BY SYMPTOM .................. 20 INSPECTION FLOW BY CHARGE WARNING LAMP .................................................................. 20 CHARGE WARNING LAMP LINE INSPECTION... 21 INSPECTION OF INSUFFICIENT ALTERNATOR POWER GENERATION .............................. 22 INSPECTION OF EXCESSIVE ALTERNATOR POWER GENERATION ...................................... 23 SC-1 DARK CURRENT INSPECTION ......................... 23 OPERATION PROCEDURE OF CURRENT MEASUREMENT PROBE FOR CONSULT-II ..... 24 Trouble Diagnoses (HR Engine Models) ................ 25 DIAGNOSIS PROCEDURE ................................ 25 PRE-DIAGNOSIS INSPECTION ......................... 25 DIAGNOSIS CHART BY SYMPTOM .................. 25 INSPECTION FLOW BY CHARGE WARNING LAMP ................................................................... 25 CHARGE WARNING LAMP LINE INSPECTION... 26 VOLTAGE DETECTION LINE AND CHARGE WARNING LAMP INSPECTION ......................... 27 INSPECTION OF INSUFFICIENT ALTERNATOR POWER GENERATION .............................. 28 INSPECTION OF EXCESSIVE ALTERNATOR POWER GENERATION ...................................... 29 DARK CURRENT INSPECTION ......................... 30 OPERATION PROCEDURE OF CURRENT MEASUREMENT PROBE FOR CONSULT-II ..... 31 Trouble Diagnoses (K9K Engine Models) .............. 32 DIAGNOSIS PROCEDURE ................................ 32 PRE-DIAGNOSIS INSPECTION ......................... 32 DIAGNOSIS CHART BY SYMPTOM .................. 32 INSPECTION FLOW BY CHARGE WARNING LAMP ................................................................... 32 CHARGE WARNING LAMP LINE INSPECTION... 33 VOLTAGE DETECTION LINE AND CHARGE WARNING LAMP INSPECTION ......................... 34 INSPECTION OF INSUFFICIENT ALTERNATOR POWER GENERATION .............................. 36 INSPECTION OF EXCESSIVE ALTERNATOR POWER GENERATION ...................................... 36 DARK CURRENT INSPECTION ......................... 37 OPERATION PROCEDURE OF CURRENT MEASUREMENT PROBE FOR CONSULT-II ..... 38 Removal and Installation (CR Engine Models) ....... 39 REMOVAL ........................................................... 39 INSTALLATION ................................................... 40 Removal and Installation (HR Engine Models) ....... 40 REMOVAL ........................................................... 40 E F G H I J SC L M INSTALLATION .................................................... 41 Removal and Installation (K9K Engine Models) ..... 42 REMOVAL ........................................................... 42 INSTALLATION .................................................... 42 Disassembly ........................................................... 42 REAR COVER ..................................................... 42 REAR BEARING ................................................. 43 Inspection ............................................................... 43 ROTOR CHECK .................................................. 43 BRUSH CHECK .................................................. 43 STATOR CHECK ................................................. 43 Assembly ................................................................ 44 RING FITTING IN REAR BEARING .................... 44 REAR COVER INSTALLATION ........................... 44 STARTING SYSTEM ................................................. 45 System Description ................................................. 45 M/T MODELS ...................................................... 45 A/T MODELS ....................................................... 45 Wiring Diagram — START — /CR and HR Engine Models .................................................................... 46 Wiring Diagram — START — /K9K Engine Models... 48 Trouble Diagnoses .................................................. 50 Removal and Installation (CR Engine Models) ....... 51 REMOVAL ............................................................51 INSTALLATION ....................................................51 Removal and Installation (HR Engine Models) .......51 REMOVAL ............................................................51 INSTALLATION ....................................................52 Removal and Installation (K9K Engine Models) ......52 REMOVAL ............................................................52 INSTALLATION ....................................................52 Disassembly and Assembly ....................................52 Inspection ................................................................55 MAGNETIC SWITCH CHECK .............................55 PINION/CLUTCH CHECK ...................................55 BRUSH CHECK ...................................................55 YOKE CHECK .....................................................57 ARMATURE CHECK ...........................................57 Assembly ................................................................58 PINION PROTRUSION LENGTH ADJUSTMENT ...................................................................58 SERVICE DATA AND SPECIFICATIONS (SDS) ......60 Battery .....................................................................60 Starter .....................................................................60 Alternator ................................................................60 SC-2 PRECAUTIONS PRECAUTIONS PFP:00011 Precautions for Supplemental Restraint System (SRS) “AIR BAG” and “SEAT BELT PRE-TENSIONER” A BKS000TY The Supplemental Restraint System such as “AIR BAG” and “SEAT BELT PRE-TENSIONER”, used along with a front seat belt, helps to reduce the risk or severity of injury to the driver and front passenger for certain types of collision. Information necessary to service the system safely is included in the SRS and SB section of this Service Manual. WARNING: ● To avoid rendering the SRS inoperative, which could increase the risk of personal injury or death in the event of a collision which would result in air bag inflation, all maintenance must be performed by an authorized NISSAN/INFINITI dealer. ● Improper maintenance, including incorrect removal and installation of the SRS, can lead to personal injury caused by unintentional activation of the system. For removal of Spiral Cable and Air Bag Module, see the SRS section. ● Do not use electrical test equipment on any circuit related to the SRS unless instructed to in this Service Manual. SRS wiring harnesses can be identified by yellow and/or orange harnesses or harness connectors. B C D E F G H I J SC L M SC-3 PREPARATION PREPARATION Special Service Tools PFP:00002 BKS000TZ Tool number Tool name Description EG1187 1900 Current measurement probe for CONSULT-II System diagnose and inspection MKIA0065E SC-4 BATTERY BATTERY How to Handle Battery PFP:00011 A BKS000U0 CAUTION: ● If it becomes necessary to start the engine with a booster battery and jumper cables, use a 12-volt booster battery. ● After connecting battery cables, ensure that they are tightly clamped to battery terminals for good contact. ● Never add distilled water through the hole used to check specific gravity. B C METHODS OF PREVENTING OVER-DISCHARGE D The following precautions must be taken to prevent over-discharging a battery. ● The battery surface (particularly its top) should always be kept clean and dry. ● The terminal connections should be clean and tight. ● At every routine maintenance, check the electrolyte level. This also applies to batteries designated as “low maintenance” and “maintenance-free”. E F G MEL040F ● H When the vehicle is not going to be used over a long period of time, disconnect the negative battery terminal. (If the vehicle has an extended storage switch, turn it off.) I J SC MEL041F ● Check the charge condition of the battery. Periodically check the specific gravity of the electrolyte. Keep a close check on charge condition to prevent over-discharge. L M MEL042F CHECKING ELECTROLYTE LEVEL WARNING: Do not allow battery fluid to come in contact with skin, eyes, fabrics, or painted surfaces. After touching a battery, do not touch or rub your eyes until you have thoroughly washed your hands. If acid contacts eyes, skin or clothing, immediately flush with water for 15 minutes and seek medical attention. SC-5 BATTERY ● ● Remove the cell plug using a suitable tool. Add distilled water up to the MAX level. MEL043F Sulphation A battery will be completely discharged if it is left unattended for a long time and the specific gravity will become less than 1.100. This may result in sulphation on the cell plates. To determine if a battery has been “sulphated”, note its voltage and current when charging it. As shown in the figure, less current and higher voltage are observed in the initial stage of charging sulphated batteries. A sulphated battery may sometimes be brought back into service by means of a long, slow charge, 12 hours or more, followed by a battery capacity test. SEL709E SPECIFIC GRAVITY CHECK 1. Read hydrometer and thermometer indications at eye level. 2. Convert into specific gravity at 20°C (68°F). Example: ● When electrolyte temperature is 35°C (95°F) and specific gravity of electrolyte is 1.230, converted specific gravity at 20°C (68°F) is 1.240. ● When electrolyte temperature is 0°C (32°F) and specific gravity of electrolyte is 1.210, converted specific gravity at 20°C (68°F) is 1.196. MEL042FA SEL007Z SC-6 BATTERY Battery Test and Charging Chart BKS000U1 A CHART I B C D E F G H I J SC L M SEL754W *1. SC-6, "SPECIFIC GRAVITY CHECK" *2. SC-8, "CHART II" *4. SC-11, "B: STANDARD CHARGE" *5. SC-12, "C: QUICK CHARGE" SC-7 *3. SC-9, "A: SLOW CHARGE" BATTERY CHART II SEL755W *. ● SC-7, "CHART I" Check battery type and determine the specified current using the following table. Fig. 1 Discharging Current (Load Tester) Type Current (A) 28B19R(L) 90 34B19R(L) 99 46B24R(L) 135 55B24R(L) 135 50D23R(L) 150 55D23R(L) 180 65D26R(L) 195 80D26R(L) 195 75D31R(L) 210 063 [YUASA type code] 210 95D31R(L) 240 115D31R(L) 240 025 [YUASA type code] 240 065 [YUASA type code] 255 027 [YUASA type code] 285 075 [YUASA type code] 300 110D26R(L) 300 95E41R(L) 300 067 [YUASA type code] 325 SC-8 BATTERY Type Current (A) 130E41R(L) 330 096 [YUASA type code] 375 096 [YUASA type code] 375 010S [YUASA type code] 360 LB1 FCM 047 620 [EXIDE type code] 420 LB2 FCM 055 622 [EXIDE type code] 510 LB2 FCM 050 622 [EXIDE type code] 600 A B C A: SLOW CHARGE D E F G H I J SC L SEL756W *1. SC-6, "SPECIFIC GRAVITY CHECK" *2. SC-8, "CHART II" M SC-9 BATTERY 130E41R(L) 010S [YUASA type code] 075 [YUASA type code] 096L [YUASA type code] 11.0 (A) 14.0 (A) 10.0 (A) 065 [YUASA type code] 95E41R(L) 110D26R(L) 115D31R(L) 95D31R(L) 75D31R(L) 9.0 (A) 8.0 (A) 067 [YUASA type code] 063 [YUASA type code] 80D26R(L) 65D26R(L) 027 [YUASA type code] 025 [YUASA type code] 50D23R(L) 55D23R(L) 7.0 (A) 096 [YUASA type code] 5.0 (A) 8.5 (A) 4.0 (A) 55B24R(L) 3.0 (A) 46B24R(L) 2.75 (A) 34B19R(L) LB2 FCM 055 622 [EXIDE type code] 2.55 (A) 28B19R(L) LB2 FCM 050 622 [EXIDE type code] BATTERY TYPE LB1 FCM 047 620 [EXIDE type code] Below 1.100 CON-VERTED SPECIFIC GRAVITY Fig. 2 Initial Charging Current Setting (Slow Charge) Check battery type and determine the specified current using the table shown above. After starting charging, adjustment of charging current is not necessary. ● ● Fig. 3 Additional Charge (Slow Charge) SEL757W *. SC-8, "CHART II" CAUTION: ● Set charging current to value specified in Fig. 2. If charger is not capable of producing specified current value, set its charging current as close to that value as possible. ● Keep battery away from open flame while it is being charged. ● When connecting charger, connect leads first, then turn on charger. Do not turn on charger first, as this may cause a spark. ● If battery temperature rises above 60°C (140°F), stop charging. Always charge battery when its temperature is below 60°C (140°F). SC-10 LB1 FCM 047 620 [EXIDE type code] 4.1(A) 3.4(A) 2.0 (A) 2.8(A) 2.0 (A) 2.1(A) SC-11 4.0 (A) 8.0 (A) 5.0 (A) 6.0 (A) 13.0 (A) 7.0 (A) 11.0 (A) 9.0 (A) 9.0 (A) 3.0 (A) 8.0 (A) 7.0 (A) 5.0 (A) 8.0 (A) 4.0 (A) 10.0 (A) 7.0 (A) 6.0 (A) 9.0 (A) 6.0 (A) 5.0 (A) 130E41R(L) 010S [YUASA type code] 096L [YUASA type code] 075 [YUASA type code] 065 [YUASA type code] 95E41R(L) 110D26R(L) 115D31R(L) 95D31R(L) 75D31R(L) 096 [YUASA type code] 067 [YUASA type code] 063 [YUASA type code] 80D26R(L) 65D26R(L) 027 [YUASA type code] 025 [YUASA type code] 55D23R(L) 50D23R(L) LB2 FCM 055 622 [EXIDE type code] *1. SC-6, "SPECIFIC GRAVITY CHECK" 5.0 (A) 2.0(A) 4.2(A) 2.0 (A) 7.0 (A) 3.3(A) 3.3(A) 3.0 (A) 6.0 (A) 2.4(A) 46B24R(L) 4.0(A) 4.0 (A) 55B24R(L) LB2 FCM 050 622 [EXIDE type code] 4.8(A) 5.0 (A) 2.3(A) 34B19R(L) 28B19R(L) 1.130 - 1.160 3.0 (A) 1.160 - 1.190 CON-VERTED SPECIFIC GRAVITY 1.100 - 1.130 4.0 (A) 1.190 - 1.220 BATTERY B: STANDARD CHARGE A B C D E F *2. SC-8, "CHART II" SEL758W G Fig. 4 Initial Charging Current Setting (Standard Charge) BATTERY TYPE H I J SC L M BATTERY Check battery type and determine the specified current using the table shown above. After starting charging, adjustment of charging current is not necessary. ● ● Fig. 5 Additional Charge (Standard Charge) SEL759W *. SC-8, "CHART II" CAUTION: ● Do not use standard charge method on a battery whose specific gravity is less than 1.100. ● Set charging current to value specified in Fig. 4. If charger is not capable of producing specified current value, set its charging current as close to that value as possible. ● Keep battery away from open flame while it is being charged. ● When connecting charger, connect leads first, then turn on charger. Do not turn on charger first, as this may cause a spark. ● If battery temperature rises above 60°C (140°F), stop charging. Always charge battery when its temperature is below 60°C (140°F). C: QUICK CHARGE SEL760W *. SC-8, "CHART II" SC-12 BATTERY CONVERTED SPECIFIC GRAVITY Above 1.220 1.190 - 1.220 1.160 - 1.190 1.130 - 1.160 1.100 - 1.130 130E41R(L) 95E41R(L) 110D26R(L) 115D31R(L) 95D31R(L) B 75D31R(L) 010S [YUASA type code] 096L [YUASA type code] 075 [YUASA type code] 065 [YUASA type code] 096 [YUASA type code] 067 [YUASA type code] LB2 FCM 055 622 [EXIDE type code] LB2 FCM 050 622 [EXIDE type code] LB1 FCM 047 620 [EXIDE type code] 063 [YUASA type code] 027 [YUASA type code] 025 [YUASA type code] 80D26R(L) 65D26R(L) 55D23R(L) 50D23R(L) 55B24R(L) 46B24R(L) 34B19R(L) 28B19R(L) A C D 20 (A) 25 (A) 30 (A) 40 (A) 15 (A) 24(A) 10 (A) 23(A) E 21(A) CURRENT [A] BATTERY TYPE Fig. 6 Initial Charging Current Setting and Charging Time (Quick Charge) F 2.5 hours G H 2.0 hours I 1.5 hours J SC 1.0 hours L 0.75 hours (45 min.) Check battery type and determine the specified current using the table shown above. ● After starting charging, adjustment of charging current is not necessary. CAUTION: ● Do not use quick charge method on a battery whose specific gravity is less than 1.100. ● Set initial charging current to value specified in Fig. 6. If charger is not capable of producing specified current value, set its charging current as close to that value as possible. ● Keep battery away from open flame while it is being charged. ● When connecting charger, connect leads first, then turn on charger. Do not turn on charger first, as this may cause a spark. ● Be careful of a rise in battery temperature because a large current flow is required during quickcharge operation. If battery temperature rises above 60°C (140°F), stop charging. Always charge battery when its temperature is below 60°C (140°F). ● SC-13 M BATTERY ● Do not exceed the charging time specified in Fig. 6, because charging battery over the charging time can cause deterioration of the battery. Removal and Installation BKS000U2 REMOVAL 1. 2. 3. Loosen battery terminal nuts (A), and disconnect both battery cables from battery terminals. CAUTION: When disconnecting, disconnect the battery cable from the negative terminal fist. Loosen battery bracket mounting bolt (B), and remove battery bracket (1). Remove battery. MKIB2317E INSTALLATION Installation is the reverse order of removal. CAUTION: When connecting, connect the battery cable to the positive terminal fist. Battery bracket mounting bolt: : 14.2 N·m (1.4 kg-m, 10 ft-lb) Battery cable tightening nut: : 5.15 N·m (0.53 kg-m, 46 in-lb) SC-14 CHARGING SYSTEM CHARGING SYSTEM System Description (CR Engine Models) PFP:00011 A BKS000U3 The alternator provides DC voltage to operate the vehicle's electrical system and to keep the battery charged. The voltage output is controlled by the IC regulator. Terminal B supplies power to charge the battery and operate the vehicle's electrical system. The charging circuit is protected by the 100A link. The alternator is grounded to the body. With the ignition switch in the ON or START position, power is supplied ● 10A fuse [No. 4, located in the fuse block (J/B)] ● to combination meter terminal 28 for the charge warning lamp. Ground is supplied ● to terminal 38 of the combination meter ● through terminal 4 (L) of the alternator. The charge warning lamp will illuminate. When the alternator is providing sufficient voltage with the engine running, the ground is opened and the charge warning lamp will go off. If the charge warning lamp illuminates with the engine running, a fault is indicated. System Description (HR Engine Models) B C D E F BKS000U4 The alternator provides DC voltage to operate the vehicle's electrical system and to keep the battery charged. G The voltage output is controlled by the IC regulator. Power is supplied at all times to alternator terminal 3 through: ● 10A fuse [No. 36, located in the fuse block (J/B)]. Terminal B supplies power to charge the battery and operate the vehicle's electrical system.The charging cir- H cuit is protected by the 100A link. The alternator is grounded to the body. With the ignition switch in the ON or START position, power is supplied I ● 10A fuse [No. 4, located in the fuse block (J/B)] ● to combination meter terminal 28 for the charge warning lamp. J Ground is supplied ● to terminal 38 of the combination meter ● through terminal 2 (L) of the alternator. SC The charge warning lamp will illuminate. When the alternator is providing sufficient voltage with the engine running, the ground is opened and the charge warning lamp will go off. If the charge warning lamp illuminates with the engine running, a fault is indicated. L System Description (K9K Engine Models) BKS000U5 The alternator provides DC voltage to operate the vehicle's electrical system and to keep the battery charged. The voltage output is controlled by the IC regulator. With the ignition switch in the ON or START position, power is supplied to alternator terminal 4 (S) through: ● IPDM E/R (Intelligent Power Distribution Module Engine Room) Terminal B supplies power to charge the battery and operate the vehicle's electrical system. Output voltage is controlled by the IC regulator at terminal 4 (S) detecting the input voltage. The charging circuit is protected by the 100A link. The alternator is grounded to the body. With the ignition switch in the ON or START position, power is supplied ● 10A fuse [No. 4, located in the fuse block (J/B)] ● to combination meter terminal 28 for the charge warning lamp. Ground is supplied ● to terminal 38 of the combination meter ● through terminal 3 (L) of the alternator. The charge warning lamp will illuminate. When the alternator is providing sufficient voltage with the engine running, the ground is opened and the charge warning lamp will go off. If the charge warning lamp illuminates with the engine running, a fault is indicated. SC-15 M CHARGING SYSTEM Wiring Diagram — CHARGE —/CR Engine Models BKS000U6 MKWA4267E SC-16 CHARGING SYSTEM Wiring Diagram — CHARGE —/HR Engine Models BKS000U7 A B C D E F G H I J SC L M MKWA4268E SC-17 CHARGING SYSTEM Wiring Diagram — CHARGE —/K9K Engine Models BKS000U8 MKWA4269E SC-18 CHARGING SYSTEM A B C D E F G H I J SC L M MKWA4270E SC-19 CHARGING SYSTEM Trouble Diagnoses (CR Engine Models) BKS000U9 DIAGNOSIS PROCEDURE 1. 2. 3. 4. 5. Check malfunction symptoms or customer's remarks. Perform pre-diagnosis inspection. Refer to SC-20, "PRE-DIAGNOSIS INSPECTION" . Perform trouble diagnosis for each trouble symptom. Refer to SC-20, "DIAGNOSIS CHART BY SYMPTOM" Repair or replace parts indicated inspection flow based on the charge warning lamp. Refer to SC-20, "INSPECTION FLOW BY CHARGE WARNING LAMP" . End PRE-DIAGNOSIS INSPECTION 1. 2. 3. 4. 5. 6. Perform alternator belt inspection. Refer to EM-14, "DRIVE BELTS" . Inspect battery. Check alternator terminal B for loose or improper connection. Check alternator connector and terminals for loose connection, disconnection and bend. Check connecting condition of harness for charging system harness (fusible link terminal and battery terminal). After performing 1 to 5 above, go to trouble diagnosis for symptoms. Refer to SC-20, "DIAGNOSIS CHART BY SYMPTOM" . DIAGNOSIS CHART BY SYMPTOM Symptom Reference page Battery discharge Charge warning lamp illuminates. Refer to SC-20, "INSPECTION FLOW BY CHARGE WARNING LAMP" . Other than the above symptoms (splashing out of battery fluid, nasty smell and others) Refer to SC-23, "INSPECTION OF EXCESSIVE ALTERNATOR POWER GENERATION" . INSPECTION FLOW BY CHARGE WARNING LAMP 1. CHARGE WARNING LAMP INSPECTION 1. Turn ignition switch ON. 2. Check if charge warning lamp illuminates. Does charge warning lamp illuminate? YES >> GO TO 2. NO >> Go to SC-21, "CHARGE WARNING LAMP LINE INSPECTION" . MKIB0555E 2. CHARGE WARNING LAMP INSPECTION 1. Set engine speed at 2,500 rpm. 2. Check if charge warning lamp illuminates. Does charge warning lamp illuminate? YES >> Go to SC-23, "INSPECTION OF EXCESSIVE ALTERNATOR POWER GENERATION" . NO >> Go to SC-22, "INSPECTION OF INSUFFICIENT ALTERNATOR POWER GENERATION" . MKIB0555E SC-20 CHARGING SYSTEM CHARGE WARNING LAMP LINE INSPECTION A CAUTION: If open circuit is detected in L terminal, alternator cannot start generating. INSPECTION PROCEDURE B 1. CHARGE WARNING LAMP INSPECTION 1. 2. 3. Turn ignition switch OFF. Disconnect alternator connector Connect alternator connector terminal 4 to ground. C D E MKIB1916E 4. Turn ignition switch ON. Does charge warning lamp illuminate? YES >> GO TO 4. NO >> GO TO 2. F G H I MKIB0555E 2. CONNECTOR INSPECTION J 1. 2. Turn ignition switch OFF. Check meter and terminals (meter side, and harness side) for damage, deformation or improper connec- SC tion. OK or NG L OK >> GO TO 3. NG >> Repair terminals and connectors. 3. CONTINUITY INSPECTION 1. 2. M Disconnect combination meter connector. Check continuity between combination meter connector terminal 38 and ground, and combination meter connector terminal 38 and alternator connector terminal 4. 38 - Ground 38 - 4 : Continuity should not exist. : Continuity should exist. OK or NG OK >> Replace combination meter. (Do not replace alternator, since it is normal.) NG >> Repair the harnesses or connectors. (Do not replace alternator, since it is normal.) SC-21 CHARGING SYSTEM 4. CHARGE WARNING LAMP INSPECTION 1. Turn ignition switch OFF. 2. Connect alternator connector. 3. Turn ignition switch ON. Does charge warning lamp illuminate? YES >> Repair alternator connector. (Poor connection and intermittent problem) (Do not replace alternator, since it is normal.) NO >> Replace alternator. (circuit malfunction in alternator) MKIB0555E INSPECTION OF INSUFFICIENT ALTERNATOR POWER GENERATION CAUTION: Check them using charged battery performed battery inspection. 1. VOLTAGE INSPECTION 1. 2. Increase engine speed to 2,500 rpm. Turn electrical load to ON. (Headlamp LO turns on, blower fan motor maximum airflow amount) 3. Check battery voltage. Is the inspection result 12.8V to 15.1V? YES >> GO TO 2. NO >> Replace alternator. (Alternator power generation error.) MKIA0067E 2. CURRENT INSPECTION 1. 2. 3. Turn the ignition switch OFF. Disconnect the battery ground cable. Attach current measurement probe for CONSULT-II to the harness for alternator terminal B. (If the probe can not be attached properly, then connect the subharness between alternator terminal B and the vehicle side harness as shown in figure, and attach the probe to sub-harness.) 4. Connect battery ground cable. 5. Increase engine speed to 2,500 rpm. 6. Turn electrical load to ON. (Headlamp LO turns on, blower fan motor maximum airflow amount, rear window defogger) 7. Check alternator terminal B current. CAUTION: Be careful of rotating parts because the engine is running. MKIA0068E Is the inspection result 30A or more? YES >> GO TO dark current inspection. Refer to SC-23, "DARK CURRENT INSPECTION" . (Alternator is normal. Do not replace.) NO >> Replace alternator. (Alternator power generation error.) SC-22 CHARGING SYSTEM INSPECTION OF EXCESSIVE ALTERNATOR POWER GENERATION A 1. ALTERNATOR VOLTAGE INSPECTION 1. Increase engine speed to 2,500 rpm. 2. Check battery voltage. Is the inspection result 16V or less? YES >> Replace alternator. (Alternator power generation error.) NO >> Replace alternator. (Excessive alternator power generation.) B C D MKIA0067E E DARK CURRENT INSPECTION Dark Current: Small current while ignition switch is “OFF”. NOTE: F ● If battery ground cable is disconnected from battery terminal, a large dark current may not be reproduced. When battery discharge occurs, never disconnect battery terminal while using ammeter. ● Do not connect CONSULT-II CONVERTER to data link connector when measuring dark current. CON- G SULT-II power should be supplied using AC adapter or internal battery. 1. Attach current measurement probe for CONSULT-II to battery ground cable. Refer to SC-24, "OPERATION PROCEDURE OF H CURRENT MEASUREMENT PROBE FOR CONSULT-II" . 2. Check that all electrical equipment is turned OFF. 3. Remove key. Close and lock doors. Check that room lamp turns I off. 4. Measure dark current. Is it 50mA or less? Refer to SC-24, "OPERATION PROCEDURE OF CURRENT MEASUREMENT J PROBE FOR CONSULT-II" . NOTE: MKIA0070E Dark current stable time is different due to equipment and use of the vehicle. If it is not 50mA or less after leaving for 1 minute, measure dark current again after leaving for SC 30 minutes or more. If YES, GO TO 7. If NO, GO TO 5. 5. Remove and install fuses one by one. Search for the fuse that greatly changes dark current. L NOTE: If dark current is greatly reduced when removing the fuse, and even if dark current is not greatly increased when installing it again, the fuse circuit may be the cause. M 6. Check that dark current changes when moving the suspect circuit harness. If dark current changes, check harness for short. If dark current does not change, electronic unit in the circuit may not be entering the energy-saving mode when it turns OFF. If it does not enter the energy-saving mode, replace electronic unit. 7. No malfunction for alternator and electrical equipment. Electric load may be larger than alternator generating ability. Check the customer's usage. SC-23 CHARGING SYSTEM OPERATION PROCEDURE OF CURRENT MEASUREMENT PROBE FOR CONSULT-II For details, refer to the supplied “CONSULT-II Current Probe Operation Manual”. 1. Turn current probe power supply OFF and connect to CONSULT-II. (Red: CH1, Black: Ground) 2. Touch “SUB MODE”. 3. Touch “Extending Measurement Mode” on “SUB MODE” screen. 4. CAUTION is displayed, touch “OK”. MKIA0071E 5. 6. Set current probe range switch at the range to measure, turn current probe power supply ON. When measuring dark current, set 4A range. (Check that POWER indicator turns on. Refer to CONSULT-II Current Probe Operation Manual.) Touch the same measuring range at CONSULT-II. NOTE: If current probe measuring range is different from CONSULT-II measuring range, incorrect value is displayed. MKIA0072E 7. Adjust 0 point of current probe or CONSULT-II. (Do not clamp anything to probe.) NOTE: If 0 point is dislocated greatly, adjust at current probe side generally. MKIA0073E 8. Align current direction mark, clamp harness, and measure current. If current direction is incorrect, it is displayed negative value. NOTE: ● When current is measured, close probe joint securely. ● If multiple harnesses are clamped, measurement cannot be performed. Always clamp only one. MKIA0074E SC-24 CHARGING SYSTEM Trouble Diagnoses (HR Engine Models) BKS000UA DIAGNOSIS PROCEDURE A 1. 2. 3. B 4. 5. Check malfunction symptoms or customer's remarks. Perform pre-diagnosis inspection. Refer to SC-25, "PRE-DIAGNOSIS INSPECTION" . Perform trouble diagnosis for each trouble symptom. Refer to SC-25, "DIAGNOSIS CHART BY SYMPTOM" . Repair or replace parts indicated inspection flow based on the charge warning lamp. Refer to SC-25, "INSPECTION FLOW BY CHARGE WARNING LAMP" . End PRE-DIAGNOSIS INSPECTION 1. 2. 3. 4. 5. 6. Perform alternator belt inspection. Refer to EM-114, "DRIVE BELTS" . Inspect battery. Check alternator terminal B for loose or improper connection. Check alternator connector and terminals for loose connection, disconnection and bend. Check connecting condition of harness for charging system harness (fusible link terminal and battery terminal). After performing 1 to 5 above, go to trouble diagnosis for symptoms. Refer to SC-25, "DIAGNOSIS CHART BY SYMPTOM" . C D E F G DIAGNOSIS CHART BY SYMPTOM Symptom Reference page Battery discharge Charge warning lamp illuminates. Refer to SC-25, "INSPECTION FLOW BY CHARGE WARNING LAMP" . Other than the above symptoms (splashing out of battery fluid, nasty smell and others) Refer to SC-29, "INSPECTION OF EXCESSIVE ALTERNATOR POWER GENERATION" . H I INSPECTION FLOW BY CHARGE WARNING LAMP 1. CHARGE WARNING LAMP INSPECTION J 1. Turn ignition switch ON. 2. Check if charge warning lamp illuminates. Does charge warning lamp illuminate? YES >> GO TO 2. NO >> Go to SC-26, "CHARGE WARNING LAMP LINE INSPECTION" . SC L M MKIB0555E 2. CHARGE WARNING LAMP INSPECTION 1. Start engine. 2. Check if charge warning lamp goes off. Does charge warning lamp goes off? YES >> GO TO 3. NO >> Go to SC-27, "VOLTAGE DETECTION LINE AND CHARGE WARNING LAMP INSPECTION" . MKIB0556E SC-25 CHARGING SYSTEM 3. CHARGE WARNING LAMP INSPECTION 1. Set engine speed at 2,500 rpm. 2. Check if charge warning lamp illuminates. Does charge warning lamp illuminate? YES >> Go to SC-29, "INSPECTION OF EXCESSIVE ALTERNATOR POWER GENERATION" . NO >> Go to SC-28, "INSPECTION OF INSUFFICIENT ALTERNATOR POWER GENERATION" . MKIB0555E CHARGE WARNING LAMP LINE INSPECTION CAUTION: If open circuit is detected in L terminal, alternator cannot start generating. INSPECTION PROCEDURE 1. CHARGE WARNING LAMP INSPECTION 1. 2. 3. Turn ignition switch OFF. Disconnect alternator connector Connect alternator connector terminal 2 to ground. MKIB1917E 4. Turn ignition switch ON. Does charge warning lamp illuminate? YES >> GO TO 4. NO >> GO TO 2. MKIB0555E 2. CONNECTOR INSPECTION 1. 2. Turn ignition switch OFF. Check meter and terminals (meter side, and harness side) for damage, deformation or improper connection. OK or NG OK >> GO TO 3. NG >> Repair terminals and connectors. SC-26 CHARGING SYSTEM 3. CONTINUITY INSPECTION 1. 2. A Disconnect combination meter connector. Check continuity between combination meter connector terminal 38 and alternator connector terminal 2. 38 - 2 B : Continuity should exist. OK or NG OK >> Replace combination meter. (Do not replace alternator, since it is normal.) NG >> Repair the harnesses or connectors. (Do not replace alternator, since it is normal.) C 4. CHARGE WARNING LAMP INSPECTION D 1. Turn ignition switch OFF. 2. Connect alternator connector. 3. Turn ignition switch ON. Does charge warning lamp illuminate? YES >> Repair alternator connector. (Poor connection and intermittent problem) (Do not replace alternator, since it is normal.) NO >> Replace alternator. (circuit malfunction in alternator) E F G MKIB0555E VOLTAGE DETECTION LINE AND CHARGE WARNING LAMP INSPECTION INSPECTION PROCEDURE H 1. CHARGE WARNING LAMP INSPECTION I 1. Turn ignition switch OFF. 2. Disconnect alternator connector. 3. Turn ignition switch ON. Does charge warning lamp stay ON? YES >> GO TO 5. NO >> GO TO 2. J SC L MKIB0555E 2. VOLTAGE INSPECTION M Check voltage between alternator connector terminal 3 and ground. 3 - Ground : 12V or more Is the inspection result 12V or more? YES >> Replace alternator. NO >> GO TO 3. MKIB1918E SC-27 CHARGING SYSTEM 3. CONNECTOR INSPECTION 1. 2. Turn ignition switch OFF. Check alternator connector and terminal 3 (alternator side, and harness side) for damage, deformation or improper connection. OK or NG OK >> GO TO 4. NG >> Repair terminals and connectors. 4. CHECK FUSE Check if alternator S terminal fuse #36 (10A) is blown. OK or NG OK >> Repair harness between fuse #36 (10A) and alternator connector terminal 3. (Do not replace alternator, since it is normal.) NG >> Replace fuse. (Do not replace alternator, since it is normal.) 5. CONTINUITY INSPECTION 1. 2. 3. Turn ignition switch OFF. Disconnect combination meter connector. Check continuity between combination meter connector terminal 38 and ground, and combination meter connector terminal 38 and alternator connector terminal 2. 38 - Ground 38 - 2 : Continuity should not exist. : Continuity should exist. OK or NG OK >> Replace combination meter. (Do not replace alternator, since it is normal.) NG >> Repair the harnesses or connectors. (Do not replace alternator, since it is normal.) INSPECTION OF INSUFFICIENT ALTERNATOR POWER GENERATION CAUTION: Check them using charged battery performed battery inspection. 1. VOLTAGE INSPECTION 1. 2. Increase engine speed to 2,500 rpm. Turn electrical load to ON. (Headlamp LO turns on, blower fan motor maximum airflow amount) 3. Check battery voltage. Is the inspection result 12.8V to 15.1V? YES >> GO TO 2. NO >> Replace alternator. (Alternator power generation error.) MKIA0067E SC-28 CHARGING SYSTEM 2. CURRENT INSPECTION A 1. 2. 3. Turn the ignition switch OFF. Disconnect the battery ground cable. Attach current measurement probe for CONSULT-II to the harness for alternator terminal B. (If the probe can not be attached properly, then connect the subharness between alternator terminal B and the vehicle side harness as shown in figure, and attach the probe to sub-harness.) 4. Connect battery ground cable. 5. Increase engine speed to 2,500 rpm. 6. Turn electrical load to ON. (Headlamp LO turns on, blower fan motor maximum airflow amount, rear window defogger) 7. Check alternator terminal B current. CAUTION: Be careful of rotating parts because the engine is running. MKIA0068E Is the inspection result 30A or more? YES >> GO TO dark current inspection. Refer to SC-30, "DARK CURRENT INSPECTION" . (Alternator is normal. Do not replace.) NO >> Replace alternator. (Alternator power generation error.) B C D E F G INSPECTION OF EXCESSIVE ALTERNATOR POWER GENERATION 1. ALTERNATOR VOLTAGE INSPECTION H 1. Increase engine speed to 2,500 rpm. 2. Check battery voltage. Is the inspection result 16V or less? YES >> GO TO 2. NO >> Replace alternator. (Excessive alternator power generation.) I J SC MKIA0067E 2. BATTERY VOLTAGE INSPECTION 1. 2. 3. L Turn the ignition switch OFF. Disconnect alternator connector. Check voltage between alternator connector terminal 3 and ground. 3 - Ground M : 12V or more Is the inspection result 12V or more? YES >> Replace alternator. (Alternator power generation error) NO >> GO TO 3. MKIB1918E 3. FUSE CHECK Check if fuse #36 (10A) is blown. OK or N OK >> Repair harness between fuse #36 (10A) and alternator harness connector terminal 3. (Alternator is normal. Do not replace.) NG >> Replace fuse. (Alternator is normal. Do not replace.) SC-29 CHARGING SYSTEM DARK CURRENT INSPECTION Dark Current: Small current while ignition switch is “OFF”. NOTE: ● If battery ground cable is disconnected from battery terminal, a large dark current may not be reproduced. When battery discharge occurs, never disconnect battery terminal while using ammeter. ● Do not connect CONSULT-II CONVERTER to data link connector when measuring dark current. CONSULT-II power should be supplied using AC adapter or internal battery. 1. Attach current measurement probe for CONSULT-II to battery ground cable. Refer to SC-31, "OPERATION PROCEDURE OF CURRENT MEASUREMENT PROBE FOR CONSULT-II" . 2. Check that all electrical equipment is turned OFF. 3. Remove key. Close and lock doors. Check that room lamp turns off. 4. Measure dark current. Is it 50mA or less? Refer to SC-31, "OPERATION PROCEDURE OF CURRENT MEASUREMENT PROBE FOR CONSULT-II" . NOTE: MKIA0070E Dark current stable time is different due to equipment and use of the vehicle. If it is not 50mA or less after leaving for 1 minute, measure dark current again after leaving for 30 minutes or more. If YES, GO TO 7. If NO, GO TO 5. 5. Remove and install fuses one by one. Search for the fuse that greatly changes dark current. NOTE: If dark current is greatly reduced when removing the fuse, and even if dark current is not greatly increased when installing it again, the fuse circuit may be the cause. 6. Check that dark current changes when moving the suspect circuit harness. If dark current changes, check harness for short. If dark current does not change, electronic unit in the circuit may not be entering the energy-saving mode when it turns OFF. If it does not enter the energy-saving mode, replace electronic unit. 7. No malfunction for alternator and electrical equipment. Electric load may be larger than alternator generating ability. Check the customer's usage. SC-30 CHARGING SYSTEM OPERATION PROCEDURE OF CURRENT MEASUREMENT PROBE FOR CONSULT-II A For details, refer to the supplied “CONSULT-II Current Probe Operation Manual”. 1. Turn current probe power supply OFF and connect to CONSULT-II. (Red: CH1, Black: Ground) 2. Touch “SUB MODE”. 3. Touch “Extending Measurement Mode” on “SUB MODE” screen. 4. CAUTION is displayed, touch “OK”. B C D E MKIA0071E 5. 6. Set current probe range switch at the range to measure, turn current probe power supply ON. When measuring dark current, set 4A range. (Check that POWER indicator turns on. Refer to CONSULT-II Current Probe Operation Manual.) Touch the same measuring range at CONSULT-II. NOTE: If current probe measuring range is different from CONSULT-II measuring range, incorrect value is displayed. F G H MKIA0072E I 7. Adjust 0 point of current probe or CONSULT-II. (Do not clamp anything to probe.) NOTE: If 0 point is dislocated greatly, adjust at current probe side generally. J SC L MKIA0073E 8. Align current direction mark, clamp harness, and measure current. If current direction is incorrect, it is displayed negative value. NOTE: ● When current is measured, close probe joint securely. ● If multiple harnesses are clamped, measurement cannot be performed. Always clamp only one. M MKIA0074E SC-31 CHARGING SYSTEM Trouble Diagnoses (K9K Engine Models) BKS000UB DIAGNOSIS PROCEDURE 1. 2. 3. 4. 5. Check malfunction symptoms or customer's remarks. Perform pre-diagnosis inspection. Refer to SC-32, "PRE-DIAGNOSIS INSPECTION" . Perform trouble diagnosis for each trouble symptom. Refer to SC-32, "DIAGNOSIS CHART BY SYMPTOM" Repair or replace parts indicated inspection flow based on the charge warning lamp. Refer to SC-32, "INSPECTION FLOW BY CHARGE WARNING LAMP" . End PRE-DIAGNOSIS INSPECTION 1. 2. 3. 4. 5. 6. Perform alternator belt inspection. Refer to EM-242, "DRIVE BELTS" . Inspect battery. Check alternator terminal B for loose or improper connection. Check alternator connector and terminals for loose connection, disconnection and bend. Check connecting condition of harness for charging system harness (fusible link terminal and battery terminal). After performing 1 to 5 above, go to trouble diagnosis for symptoms. Refer to SC-32, "DIAGNOSIS CHART BY SYMPTOM" . DIAGNOSIS CHART BY SYMPTOM Symptom Reference page Battery discharge Charge warning lamp illuminates. Refer to SC-32, "INSPECTION FLOW BY CHARGE WARNING LAMP" . Other than the above symptoms (splashing out of battery fluid, nasty smell and others) Refer to SC-36, "INSPECTION OF EXCESSIVE ALTERNATOR POWER GENERATION" . INSPECTION FLOW BY CHARGE WARNING LAMP 1. CHARGE WARNING LAMP INSPECTION 1. Turn ignition switch ON. 2. Check if charge warning lamp illuminates. Does charge warning lamp illuminate? YES >> GO TO 2. NO >> Go to SC-33, "CHARGE WARNING LAMP LINE INSPECTION" . MKIB0555E 2. CHARGE WARNING LAMP INSPECTION 1. Start engine. 2. Check if charge warning lamp goes off. Does charge warning lamp goes off? YES >> GO TO 3. NO >> Go to SC-34, "VOLTAGE DETECTION LINE AND CHARGE WARNING LAMP INSPECTION" . MKIB0556E SC-32 CHARGING SYSTEM 3. CHARGE WARNING LAMP INSPECTION A 1. Set engine speed at 2,500 rpm. 2. Check if charge warning lamp illuminates. Does charge warning lamp illuminate? YES >> Go to SC-36, "INSPECTION OF EXCESSIVE ALTERNATOR POWER GENERATION" . NO >> Go to SC-36, "INSPECTION OF INSUFFICIENT ALTERNATOR POWER GENERATION" . B C D MKIB0555E CHARGE WARNING LAMP LINE INSPECTION E CAUTION: If open circuit is detected in L terminal, alternator cannot start generating. INSPECTION PROCEDURE F 1. CHARGE WARNING LAMP INSPECTION 1. 2. 3. Turn ignition switch OFF. Remove alternator connector. Connect alternator connector terminal 3 to ground. G H I MKIB1919E 4. Turn ignition switch ON. Does charge warning lamp illuminate? YES >> GO TO 4. NO >> GO TO 2. J SC L M MKIB0555E 2. CONNECTOR INSPECTION 1. 2. Turn ignition switch OFF. Check combination meter and terminals (meter side, and harness side) for damage, deformation or improper connection. OK or NG OK >> GO TO 3. NG >> Repair terminals and connectors. SC-33 CHARGING SYSTEM 3. CONTINUITY INSPECTION 1. 2. Disconnect combination meter connector. Check continuity between combination meter connector terminal 38 and alternator connector terminal 3. 38 - 3 : Continuity should exist. OK or NG OK >> Replace combination meter. (Do not replace alternator, since it is normal.) NG >> Repair the harnesses or connectors. (Do not replace alternator, since it is normal.) 4. CHARGE WARNING LAMP INSPECTION 1. Turn ignition switch OFF. 2. Connect alternator connectors. 3. Turn ignition switch ON. Does charge warning lamp illuminate? YES >> Repair alternator connector. (Poor connection and intermittent problem) (Do not replace alternator, since it is normal.) NO >> Replace alternator. (circuit malfunction in alternator) MKIB0555E VOLTAGE DETECTION LINE AND CHARGE WARNING LAMP INSPECTION INSPECTION PROCEDURE 1. CHARGE WARNING LAMP INSPECTION 1. Turn ignition switch OFF. 2. Disconnect alternator connector. 3. Turn ignition switch ON. Does charge warning lamp stay ON? YES >> GO TO 6. NO >> GO TO 2. MKIB0555E 2. VOLTAGE INSPECTION Check voltage between alternator connector terminal 4 and ground. 4 - Ground : 12V or more Is the inspection result 12V or more? YES >> Replace alternator. NO >> GO TO 3. MKIB1731E SC-34 CHARGING SYSTEM 3. CONNECTOR INSPECTION A 1. 2. Turn ignition switch OFF. Check alternator connector and terminal 4 (alternator side, and harness side) for damage, deformation or improper connection. OK or NG OK >> GO TO 4. NG >> Repair terminals and connectors. B C 4. CONNECTOR INSPECTION Check IPDM E/R and terminals (IPDM E/R side, and harness side) for damage, deformation or improper connection. OK or NG OK >> GO TO 5. NG >> Repair terminals and connectors. D E 5. CONTINUITY INSPECTION F 1. 2. G Disconnect IPDM E/R connector. Check continuity between IPDM E/R connector terminal 63 and alternator connector terminal 4. 63 - 4 : Continuity should exist. OK or NG OK >> Replace IPDM E/R. (Do not replace alternator, since it is normal.) NG >> Repair the harnesses or connectors. (Do not replace alternator, since it is normal.) H 6. CONTINUITY INSPECTION I 1. 2. 3. J Turn ignition switch OFF. Disconnect combination meter connector. Check continuity between combination meter connector terminal 38 and ground, and combination meter connector terminal 38 and alternator connector terminal 3. 38 - Ground 38 - 3 : Continuity should not exist. : Continuity should exist. OK or NG OK >> Replace combination meter. (Do not replace alternator, since it is normal.) NG >> Repair the harnesses or connectors. (Do not replace alternator, since it is normal.) SC L M SC-35 CHARGING SYSTEM INSPECTION OF INSUFFICIENT ALTERNATOR POWER GENERATION CAUTION: Check them using charged battery performed battery inspection. 1. VOLTAGE INSPECTION 1. 2. Increase engine speed to 2,500 rpm. Turn electrical load to ON. (Headlamp LO turns on, blower fan motor maximum airflow amount) 3. Check battery voltage. Is the inspection result 12.8V to 15.1V? YES >> GO TO 2. NO >> Replace alternator. (Alternator power generation error.) MKIA0067E 2. CURRENT INSPECTION 1. 2. 3. Turn ignition switch OFF. Disconnect the battery ground cable. Attach current measurement probe for CONSULT-II to the harness for alternator terminal B. (If the probe can not be attached properly, then connect the subharness between alternator terminal B and the vehicle side harness as shown in figure, and attach the probe to sub-harness.) 4. Connect battery ground cable. 5. Increase engine speed to 2,500 rpm. 6. Turn electrical load to ON. (Headlamp LO turns on, blower fan motor maximum airflow amount, rear window defogger) 7. Check alternator terminal B current. CAUTION: Be careful of rotating parts because the engine is running. MKIA0068E Is the inspection result 30A or more? YES >> GO TO dark current inspection. Refer to SC-37, "DARK CURRENT INSPECTION" . (Alternator is normal. Do not replace.) NO >> Replace alternator. (Alternator power generation error.) INSPECTION OF EXCESSIVE ALTERNATOR POWER GENERATION 1. ALTERNATOR VOLTAGE INSPECTION 1. Increase engine speed to 2,500 rpm. 2. Check battery voltage. Is the inspection result 16V or less? YES >> GO TO 2. NO >> Replace alternator. (Excessive alternator power generation.) MKIA0067E SC-36 CHARGING SYSTEM 2. BATTERY VOLTAGE INSPECTION 1. 2. 3. 4. A Turn ignition switch OFF. Disconnect alternator connector. Turn ignition switch ON. Check voltage between alternator connector terminal 4 and ground. 4 - Ground B C : 12V or more Is the inspection result 12V or more? YES >> Replace alternator. (Alternator power generation error) NO >> GO TO 3. D MKIB1731E 3. CONNECTOR INSPECTION E 1. 2. Turn ignition switch OFF. Check IPDM E/R and terminals (IPDM E/R side, and harness side) for damage, deformation or improper connection. OK or NG OK >> GO TO 4. NG >> Repair terminals and connectors. 4. CONTINUITY INSPECTION 1. 2. F G H Disconnect IPDM E/R connector. Check continuity between IPDM E/R connector terminal 63 and alternator connector terminal 4. 63 - 4 : Continuity should exist. OK or NG OK >> Replace IPDM E/R. (Do not replace alternator, since it is normal.) NG >> Repair the harnesses or connectors. (Do not replace alternator, since it is normal.) I J DARK CURRENT INSPECTION SC Dark Current: Small current while ignition switch is “OFF”. NOTE: ● If battery ground cable is disconnected from battery terminal, a large dark current may not be reproduced. L When battery discharge occurs, never disconnect battery terminal while using ammeter. ● Do not connect CONSULT-II CONVERTER to data link connector when measuring dark current. CONSULT-II power should be supplied using AC adapter or internal battery. M 1. Attach current measurement probe for CONSULT-II to battery ground cable. Refer to SC-38, "OPERATION PROCEDURE OF CURRENT MEASUREMENT PROBE FOR CONSULT-II" . 2. Check that all electrical equipment is turned OFF. 3. Remove key. Close and lock doors. Check that room lamp turns off. 4. Measure dark current. Is it 50mA or less? Refer to SC-38, "OPERATION PROCEDURE OF CURRENT MEASUREMENT PROBE FOR CONSULT-II" . NOTE: MKIA0070E Dark current stable time is different due to equipment and use of the vehicle. If it is not 50mA or less after leaving for 1 minute, measure dark current again after leaving for 30 minutes or more. If YES, GO TO 7. If NO, GO TO 5. 5. Remove and install fuses one by one. Search for the fuse that greatly changes dark current. SC-37 CHARGING SYSTEM 6. 7. NOTE: If dark current is greatly reduced when removing the fuse, and even if dark current is not greatly increased when installing it again, the fuse circuit may be the cause. Check that dark current changes when moving the suspect circuit harness. If dark current changes, check harness for short. If dark current does not change, electronic unit in the circuit may not be entering the energy-saving mode when it turns OFF. If it does not enter the energy-saving mode, replace electronic unit. No malfunction for alternator and electrical equipment. Electric load may be larger than alternator generating ability. Check the customer's usage. OPERATION PROCEDURE OF CURRENT MEASUREMENT PROBE FOR CONSULT-II For details, refer to the supplied “CONSULT-II Current Probe Operation Manual”. 1. Turn current probe power supply OFF and connect to CONSULT-II. (Red: CH1, Black: Ground) 2. Touch “SUB MODE”. 3. Touch “Extending Measurement Mode” on “SUB MODE” screen. 4. CAUTION is displayed, touch “OK”. MKIA0071E 5. 6. Set current probe range switch at the range to measure, turn current probe power supply ON. When measuring dark current, set 4A range. (Check that POWER indicator turns on. Refer to CONSULT-II Current Probe Operation Manual.) Touch the same measuring range at CONSULT-II. NOTE: If current probe measuring range is different from CONSULT-II measuring range, incorrect value is displayed. MKIA0072E 7. Adjust 0 point of current probe or CONSULT-II. (Do not clamp anything to probe.) NOTE: If 0 point is dislocated greatly, adjust at current probe side generally. MKIA0073E SC-38 CHARGING SYSTEM 8. Align current direction mark, clamp harness, and measure current. If current direction is incorrect, it is displayed negative value. NOTE: ● When current is measured, close probe joint securely. ● If multiple harnesses are clamped, measurement cannot be performed. Always clamp only one. A B C MKIA0074E Removal and Installation (CR Engine Models) D BKS000UC REMOVAL 1. 2. 3. 4. Disconnect battery ground cable. Remove fender protector from RH side. Remove alternator drive belt. Refer to EM-16, "Removal and Installation" . Remove idler pulley bracket mounting bolts, and remove idler pulley assembly. E F G MKIA0075E 5. Disconnect alternator harness connector. Terminal B mounting nut, ground wire mounting nut, and remove harness clips. H I J SC MKIA0076E 6. 7. L Remove engine mounting stay from RH side. Remove alternator upper bracket mounting bolts, and alternator upper mounting bolt. M MKIA0077E SC-39 CHARGING SYSTEM 8. 9. Loosen alternator lower mounting bolt, and pull out from U-cut portion on front cover. Remove alternator assembly from engine. MKIA0078E INSTALLATION Install in the reverse order of removal, taking care of the following point. ● Install alternator, and check tension of belt. Refer to EM-14, "Tension Adjustment" . CAUTION: Be sure to tighten B terminal mounting nut carefully. B terminal nut: : 9.32 - 10.8 N·m (0.95 - 1.1 kg-m, 82 - 95 in-lb) Ground bolt: : 2.94 - 4.9 N·m (0.30 - 0.49 kg-m, 26 - 43 in-lb) Alternator mounting bolt: : 33.3 - 46.1 N·m (3.4 - 4.7 kg-m, 24 - 34 ft-lb) Alternator upper bracket bolt: : 33.3 - 46.1 N·m (3.4 - 4.7 kg-m, 24 - 34 ft-lb) Engine mounting stay bolt: : 40.0 - 50.0 N·m (4.1 - 5.1 kg-m, 30 - 37 ft-lb) Idler pulley bracket bolt: : 16.6 - 23.5 N·m (1.7 - 2.4 kg-m, 12 - 17 ft-lb) Idler pulley nut: : 25.5 - 33.3 N·m (2.6 - 3.3 kg-m, 19 - 24 ft-lb) Removal and Installation (HR Engine Models) BKS000UD REMOVAL 1. 2. 3. 4. 5. Disconnect battery ground cable. Remove fender protector from RH side. Remove alternator drive belt. Refer to EM-115, "Removal and Installation" . Remove idler pulley assembly. Refer to EM-116, "Removal and Installation of Drive Belt Idler Pulley" . Disconnect alternator harness connector. ● B terminal mounting nut, ground wire mounting nut, and remove harness clips. MKIB1996E 6. Remove A/C compressor. Refer to ATC-140, "Removal and Installation of Compressor" (with auto A/C) or MTC-86, "Removal and Installation of Compressor" (with manual A/C). SC-40 CHARGING SYSTEM 7. Remove torque rod bolt. A B C MKIB1997E D 8. Remove alternator mounting upper bolt. E F G MKIB1998E 9. Loosen alternator mounting lower bolt. 10. Remove alternator assembly from lower side the vehicle. H I J MKIB1999E SC INSTALLATION Install in the reverse order of removal, taking care of the following point. ● Install alternator, and check tension of belt. Refer to EM-114, "Tension Adjustment" . CAUTION: Be sure to tighten B terminal mounting nut carefully. L M B terminal nut: : 9.32 - 10.8 N·m (0.95 - 1.1 kg-m, 82 - 95 in-lb) Ground bolt: : 2.94 - 4.9 N·m (0.30 - 0.49 kg-m, 26 - 43 in-lb) Alternator mounting bolt: : 21.0 - 29.0 N·m (2.2 - 2.9kg-m, 16 - 21ft-lb) Torque rod bolt: : 40.0 - 50.0 N·m (4.1 - 5.1 kg-m, 30 - 37 ft-lb) Idler pulley bolt: : 24.0 - 32.0 N·m (2.5 - 3.2kg-m, 18 - 23ft-lb) SC-41 CHARGING SYSTEM Removal and Installation (K9K Engine Models) BKS000UE REMOVAL 1. 2. 3. 4. 5. Disconnect battery ground cable. Remove under cover and RH fender protector. Remove front bumper. Refer to EI-4, "FRONT BUMPER" . Remove alternator drive belt. Refer to EM-242, "DRIVE BELTS" . Disconnect alternator harness connector and B terminal nut. MKIA0086E 6. Remove alternator upper mounting bolt. MKIA0087E 7. 8. Remove alternator lower mounting bolt. Remove alternator assembly from engine. MKIA0088E INSTALLATION Install in the reverse order of removal, taking care of the following point. ● Install alternator, and check tension of belt. Refer to EM-242, "DRIVE BELTS" . CAUTION: Be sure to tighten B terminal mounting nut carefully. Disassembly BKS000UF REAR COVER SEL032Z SC-42 CHARGING SYSTEM CAUTION: Rear cover may be hard to remove because a ring is used to lock outer race of rear bearing. To facilitate removal of rear cover, heat just bearing box section with a 200W soldering iron. Do not use a heat gun, as it can damage diode assembly. A REAR BEARING B CAUTION: ● Do not reuse rear bearing after removal. Replace with a new one. ● Do not lubricate rear bearing outer race. C Inspection BKS000UG ROTOR CHECK 1. D Resistance test Resistance : Refer to SC-60, "SERVICE DATA AND SPECIFICATIONS (SDS)" . E Not within the specified values... Replace rotor. Insulator test ● Continuity exists... Replace rotor. Check slip ring for wear. ● 2. 3. Slip ring minimum outer diameter ● : Refer to SC-60, "SERVICE DATA AND SPECIFICATIONS (SDS)" . F G SEL033Z H Not within the specified values... Replace rotor. BRUSH CHECK 1. 2. I Check smooth movement of brush. ● Not smooth... Check brush holder and clean. Check brush for wear. ● Replace brush if it is worn down to the limit line. J SC SEL631DA L STATOR CHECK 1. Continuity test ● No continuity... Replace stator. M SEL108E SC-43 CHARGING SYSTEM 2. Ground test ● Continuity exists... Replace stator. SEL109E Assembly BKS000UH RING FITTING IN REAR BEARING Fix ring into groove in rear bearing so that it is as close to the adjacent area as possible. CAUTION: Do not reuse rear bearing after removal. ● SEL044Z REAR COVER INSTALLATION 1. Fit brush assembly, diode assembly, regulator assembly and stator. SEL048Z 2. Push brushes up with fingers and install them to rotor. Take care not to damage slip ring sliding surface. SEL049Z SC-44 STARTING SYSTEM STARTING SYSTEM System Description PFP:00011 A BKS000UI M/T MODELS Power is supplied at all times ● through 30A fusible link (letter L, located in the fuse and fusible link box) ● to ignition switch terminal 1. With the ignition switch in the ON or START position, power is supplied ● through 10A fuse [No.60 located in the IPDM E/R] ● to park/neutral position switch terminal 2 ● through 10A fuse [No.5, located in fuse block (J/B)] ● through IPDM E/R terminal 21 ● to starter relay. With the shift lever in the N position (under the ignition switch ON or START position) Power is supplied ● through park/neutral position switch terminal 2 and 3 ● to IPDM E/R terminal 31 and then starter relay is energized. When ignition switch turn to START position, power is supplied ● through ignition switch terminal 1 and 5 ● through IPDM E/R terminal 9 and 11 ● to starter motor terminal 1. The starter motor plunger closes and provides a closed circuit between the battery and starter motor. The starter motor is grounded to the engine block. With power and ground supplied, cranking occurs and the engine starts. B C D E F G H I A/T MODELS Power is supplied at all times J ● through 30A fusible link (letter L, located in the fuse and fusible link box) ● to ignition switch terminal 1. With the ignition switch in the ON or START position, power is supplied SC ● through 10A fuse [No. 60 located in the IPDM E/R] ● to park/neutral position switch terminal 1. With the selector lever in the P or N position (under the ignition switch ON or START position) L Power is supplied ● through park/neutral position switch terminal 1 and 2 ● through IPDM E/R terminal 21 M ● to starter relay. ● through park/neutral position switch terminal 1 and 2 ● to IPDM E/R terminal 31. and then starter relay is energized. When ignition switch turn to START position, power is supplied ● through ignition switch terminal 1 and 5 ● through IPDM E/R terminal 9 and 11 ● to starter motor terminal 1 The starter motor plunger closes and provides a closed circuit between the battery and starter motor. The starter motor is grounded to the engine block. With power and ground supplied, cranking occurs and the engine starts. SC-45 STARTING SYSTEM Wiring Diagram — START — /CR and HR Engine Models BKS000UJ MKWA4271E SC-46 STARTING SYSTEM A B C D E F G H I J SC L M MKWA4272E SC-47 STARTING SYSTEM Wiring Diagram — START — /K9K Engine Models BKS000UK MKWA4273E SC-48 STARTING SYSTEM A B C D E F G H I J SC L M MKWA4274E SC-49 STARTING SYSTEM Trouble Diagnoses BKS000UL If any abnormality is found, immediately disconnect battery negative terminal. SEL761W SC-50 STARTING SYSTEM Removal and Installation (CR Engine Models) BKS000UM REMOVAL A 1. 2. 3. 4. 5. B Disconnect negative battery cable. Remove starter motor mounting bolt from upper side. Disconnect S terminal and B terminal from starter motor. Remove starter motor mounting bolt from lower side. Remove starter motor from lower side the vehicle. C D E F G MKIA0080E H INSTALLATION Install in the reverse order of removal. I Removal and Installation (HR Engine Models) BKS000UN J SC L M PKIC0987E 1. Cylinder block 4. Starter motor 2. B terminal harness : N·m (kg-m, ft-lb) 3. S terminal harness : N·m (kg-m, in-lb) : Engine front REMOVAL 1. 2. 3. Disconnect the battery cable from the negative terminal. Remove air duct (inlet). Refer to EM-118, "AIR CLEANER AND AIR DUCT" . Remove reservoir tank. Refer to.CO-31, "RADIATOR" . SC-51 STARTING SYSTEM 4. 5. 6. 7. Disconnect “S” terminal nut. Remove “B” terminal nut. Remove starter motor mounting bolts. Remove starter motor upward from the vehicle. INSTALLATION Installation is the reverse order of removal. CAUTION: Be sure to tighten “B” terminal nut carefully. Removal and Installation (K9K Engine Models) BKS000UO REMOVAL 1. 2. 3. 4. 5. Disconnect negative battery cable. Remove starter motor mounting bolt from upper side. Disconnect S terminal and B terminal from starter motor. Remove starter motor mounting bolt from lower side. Remove starter motor from lower side the vehicle. MKIA0089E INSTALLATION Install in the reverse order of removal. Disassembly and Assembly BKS000UP MKIB1994E 1. Gear case 2. Sleeve bearing 3. Shift lever 4. Plate 5. Packing 6. Adjusting plate 7. Magnetic switch assembly 8. Stopper clip 9. Pinion stopper SC-52 STARTING SYSTEM 10. Pinion assembly 11. Internal gear 12. Pinion shaft 13. Planetary gear 14. Ball 15. Packing 16. Yoke 17. Armature 18. Brush holder assembly 19. Rear bearing 20. Rear cover A B Through-bolt: M0T84585 C : 4.1 - 7.1 N·m (0.45 - 0.72 kg-m, 39.1 - 62.5 in-lb) D E F G H I MKIB2318E 1. Gear case 2. Shift lever 3. 4. Magnetic switch assembly 5. Packing 6. Armature 7. Yoke 8. Brush 9. Brush holder 10. Spring 11. Plate Spring J 12. Rear cover SC 13. Through-bolt L M SC-53 STARTING SYSTEM MKIB1995E 1. Gear case 2. Shift lever 3. Plate 4. Packing 5. Magnetic switch assembly 6. Ring 7. Stopper 8. Clutch gear assembly 9. Internal gear assembly 10. Shaft assembly gear 11. Gear assembly 12. Packing 13. Though-bolt 14. Yoke assembly 15. Armature 16. Brush holder assembly 17. E-ring 18. Rear cover assembly SC-54 STARTING SYSTEM Inspection BKS000UQ A MAGNETIC SWITCH CHECK ● ● 1. Before starting to check, disconnect battery ground cable. Disconnect “M” terminal of starter motor. Continuity test (between “S” terminal and switch body). ● No continuity... Replace. B C D E SEL555E 2. Continuity test (between “S” terminal and “M” terminal). ● No continuity... Replace. F G H SEL556E I PINION/CLUTCH CHECK 1. 2. 3. Inspect pinion teeth. ● Replace pinion if teeth are worn or damaged. (Also check condition of ring gear teeth.) Inspect reduction gear teeth (If equipped). ● Replace reduction gear if teeth are worn or damaged. (Also check condition of armature shaft gear teeth.) Check to see if pinion locks in one direction and rotates smoothly in the opposite direction. ● If it locks or rotates in both directions, or unusual resistance is evident.... Replace. J SC L MEL139L BRUSH CHECK Brush M Check wear of brush. Wear limit length ● : Refer to SC-60, "SERVICE DATA AND SPECIFICATIONS (SDS)" . Excessive wear... Replace. SEL014Z SC-55 STARTING SYSTEM Brush Spring Check Check brush spring pressure with brush spring detached from brush. Spring pressure (with new brush) ● : Refer to SC-60, "SERVICE DATA AND SPECIFICATIONS (SDS)" . Not within the specified values... Replace. SEL015Z Brush Holder 1. 2. Perform insulation test between brush holder (positive side) and its base (negative side). ● Continuity exists.... Replace. Check brush to see if it moves smoothly. ● If brush holder is bent, replace it; if sliding surface is dirty, clean. SEL016Z SC-56 STARTING SYSTEM YOKE CHECK A Magnet is secured to yoke by bonding agent. Check magnet to see that it is secured to yoke and for any cracks. Replace malfunctioning parts as an assembly. CAUTION: Do not clamp yoke in a vice or strike it with a hammer. B C D E F G SEL018Z H ARMATURE CHECK 1. 2. Continuity test (between two segments side by side). ● No continuity... Replace. Insulation test (between each commutator bar and shaft). ● Continuity exists.... Replace. I J SC SEL019Z 3. L Check commutator surface. ● Rough... Sand lightly with No. 500 - 600 emery paper. M SEL020Z SC-57 STARTING SYSTEM 4. Check diameter of commutator. Commutator minimum diameter : Refer to SC-60, "SERVICE DATA AND SPECIFICATIONS (SDS)" . Less than specified value... Replace. Check depth of insulating mold from commutator surface. ● 5. SEL021Z SEL022Z ● Less than 0.2 mm (0.008 in)... Undercut to 0.5 to 0.8 mm (0.020 to 0.031 in) Assembly BKS000UR Apply high-temperature grease to lubricate the bearing, gears and frictional surface when assembling the starter. Carefully observe the following instructions. PINION PROTRUSION LENGTH ADJUSTMENT Clearance With pinion driven out by magnetic switch, push pinion back to remove slack and measure clearance “ ” between the front edge of the pinion and the pinion stopper. Clearance “ ” : Refer to SC-60, "SERVICE DATA AND SPECIFICATIONS (SDS)" . SEL026Z SC-58 STARTING SYSTEM ● Not in the specified value... Adjust by adjusting plate. A B C SEL633BA D E F G H I J SC L M SC-59 SERVICE DATA AND SPECIFICATIONS (SDS) SERVICE DATA AND SPECIFICATIONS (SDS) Battery PFP:00030 BKS000US Applied model CR, HR, K9K EXIDE type code Type LB1+ (420A) LB2 (510A) LB2+ (600A) 12 - 47 12 - 55 12 - 50 Capacity V-Ah Starter BKS000UT Type M0T84585 D7E 40 M0T32171 Mitsubishi make Reduction gear type Valeo make Non reduction Mitshubishi make Reduction gear type Applied model CR System voltage V HR 12.0 Terminal voltage V 11.0 — 11.0 Less than 90 — Less than 90 More than 2,800 — More than 3,000 Minimum diameter of commutator mm (in) 28.8 — 28.8 Minimum length of brush mm (in) 5.5 — 5.5 15.0 - 20.4 — 15.0 - 20.4 Less than 0.2 — Less than 0.2 0.5 - 2.0 — 0.5 - 2.0 No-load Current A Revolution rpm Brush spring tension N (kg, lb) Clearance between bearing metal and armature shaft mm (in) Clearance “ ” between pinion front edge and pinion stopper mm (in) Alternator BKS000UU Type Applied model Nominal rating V-A 2542927 A002TJ0291ZE Valeo make Mitsubishi make CR HR 12 - 77 12 - 120 Ground polarity Negative Minimum revolutions under no-load (When 13.5V is applied) rpm 1200 1300 More than 39 / 1,800 More than 60 / 2,500 More than 76 / 5,000 More than 77 / 6,000 More than 27 / 1,300 More than 95 / 2,500 More than 116 / 5,000 14.25 - 14.85 14.1 - 14.7 Minimum length of brush mm (in) 10.5 5.00 Brush spring pressure N (g, oz.) — 4.1 - 5.3 Slip ring minimum diameter mm (in) — 22.1 Rotor coil resistance at 20° (68°F) Ω 3.01 1.8 - 2.2 Hot output current (When 13.5V is applied) A/rpm Regulated output voltage V SC-60 SEAT I BODY SECTION SE SEAT A B C D CONTENTS PRECAUTIONS .......................................................... 2 Precautions for Supplemental Restraint System (SRS) “AIR BAG” and “SEAT BELT PRE-TENSIONER” .................................................................. 2 Precautions .............................................................. 2 CLIP AND FASTENER ............................................... 3 List of Table .............................................................. 3 HEATED SEAT ........................................................... 4 Description ............................................................... 4 Wiring Diagram — H/SEAT ...................................... 5 FRONT SEAT .............................................................. 7 Component Parts Location ....................................... 7 Removal and Installation .......................................... 8 REMOVAL ............................................................. 8 INSTALLATION ..................................................... 8 Disassembly and Assembly of Seatback .................. 8 SEATBACK TRIM PAD .......................................... 8 SEATBACK FRAME .............................................. 9 Disassembly and Assembly of Seat Cushion ......... 10 SEAT CUSHION TRIM PAD ................................ 10 SEAT CUSHION FRAME .................................... 10 REAR SEAT .............................................................. 12 Removal and Installation ........................................ 12 REMOVAL ........................................................... 12 INSTALLATION ................................................... 12 Rear Seat Disassembly and Assembly .................. 13 E F G H SE J K L M SE-1 PRECAUTIONS PFP:00001 PRECAUTIONS Precautions for Supplemental Restraint System (SRS) “AIR BAG” and “SEAT BELT PRE-TENSIONER” BIS000U4 The Supplemental Restraint System such as “AIR BAG” and “SEAT BELT PRE-TENSIONER”, used along with a front seat belt, helps to reduce the risk or severity of injury to the driver and front passenger for certain types of collision. Information necessary to service the system safely is included in the SRS and SB section of this Service Manual. WARNING: ● To avoid rendering the SRS inoperative, which could increase the risk of personal injury or death in the event of a collision which would result in air bag inflation, all maintenance must be performed by an authorized NISSAN/INFINITI dealer. ● Improper maintenance, including incorrect removal and installation of the SRS, can lead to personal injury caused by unintentional activation of the system. For removal of Spiral Cable and Air Bag Module, see the SRS section. ● Do not use electrical test equipment on any circuit related to the SRS unless instructed to in this Service Manual. SRS wiring harnesses can be identified by yellow and/or orange harnesses or harness connectors. Precautions BIS000U5 When removing or disassembling any part, be careful not to damage or deform it. Protect parts, which may get in the way with cloth. ● When removing parts with a screwdriver or other tool, protect parts by wrapping them with vinyl or tape. ● Keep removed parts protected with cloth. ● If a clip is deformed or damaged, replace it. ● If an unreusable part is removed, replace it with a new one. ● Tighten bolts and nuts firmly to the specified torque. ● After re-assembly has been completed, make sure each part functions correctly. ● Remove stains in the following way. Water-soluble stains: Dip a soft cloth in warm water, and then squeeze it tightly. After wiping the stain, wipe with a soft dry cloth. Oil stain: Dissolve a synthetic detergent in warm water (density of 2 to 3% or less), dip the cloth, then clean off the stain with the cloth. Next, dip the cloth in fresh water and squeeze it tightly. Then clean off the detergent completely. Then wipe the area with a soft dry cloth. ● Do not use any organic solvent, such as thinner or benzine. ● SE-2 CLIP AND FASTENER CLIP AND FASTENER List of Table PFP:76906 A BIS000U6 B C D MIIB0032E E F G H SE J K L M SE-3 HEATED SEAT HEATED SEAT Description ● ● ● PFP:87335 BIS000U7 When handling seat, be extremely careful not to scratch heating unit. To replace heating unit, seat trim and pad should be separated. Do not use any organic solvent, such as thinner, benzene, alcohol, etc. to clean trims. SBT314 SE-4 HEATED SEAT Wiring Diagram — H/SEAT BIS000U8 A B C D E F G H SE J K L M MIWA0668E SE-5 HEATED SEAT MIWA0669E SE-6 FRONT SEAT FRONT SEAT Component Parts Location PFP:87000 A BIS000U9 CAUTION: When removing and installing seats, use shop cloths to protect the parts from damage. B C D E F G H SE J K L M MIIB9345E 1. Headrest 2. 4. Seatback trim & pad 7. Seatback frame (with active head rest) Headrest holder (free) 3. Headrest holder (locked) 5. Side air bag module* 6. Fixed inner cross rod* 8. Seatback frame (without active head rest) 9. Armrest (driver only) 10. Seat slide outer finisher 11. Back table 12. Cushion pan undercover 13. Seat slide assembly 14. Seat slide inner finisher 15. Reclining inner finisher 16. Seat lifter lever 17. Reclining dial 18. Seat cushion trim & pad 19. Seat cushion frame 20. Front leg cover (inner) 21. Front leg cover (outer) 22. Rear leg cover (inner) 23. Rear leg cover (outer) 24. Belt buckle assembly** *: Refer to SRS section (if equipped) **: Refer to SB section : Clip : Always replace after every disassembly SE-7 FRONT SEAT : Sealing point : Use recommended multi-purpose grease. : Heated seat harness connector (if equipped) Removal and Installation BIS000UA REMOVAL CAUTION: Disconnect both battery cables, and wait at least 3 minutes before beginning work. 1. Remove side air bag module connector and seatbelt buckle switch harness connector and heated seat connectors (if equipped). 2. Remove front and rear leg covers. 3. Remove bolts (4), and remove seat from vehicle. 4. Remove headrest. CAUTION: When removing and installing, use shop cloths to protect parts from damage and interference. MIIB0034E INSTALLATION ● ● Install in the reverse order of removal. Tighten front seat mounting bolts to the torque. : 46.6 N·m (4.8 kg-m, 34 ft-lb) CAUTION: When removing and installing, use shop cloths to protect parts from damage and interference. Disassembly and Assembly of Seatback BIS000UB SEATBACK TRIM PAD Disassembly 1. 2. Unfasten seatback fastener. (Vehicles with side air bags) Remove retainer. MIIB0035E 3. Turn over seatback trim, remove nuts (2), and remove fixed inner cross rod. (Vehicles with side air bags) MIIB9097E SE-8 FRONT SEAT 4. 5. Use pincers, etc., to push up hooks shown by the arrows in the figure, and remove headrest holder from seatback. Remove seatback trim and pad from seatback frame. A B C MIIB0037E D Assembly Install in the reverse order of removal. CAUTION: Before installing headrest holder, check its orientation (front/rear and right/left). E SEATBACK FRAME Disassembly F Remove seatback trim&pad. Pull out side air bag connector from back of seat cushion. Remove seat lifter lever, reclining dial, seat slide out finisher, slide inner cover, and seat slide inner fin- G isher. 4. Remove seatback frame bolts and remove seatback frame from seat slide assembly. H CAUTION: When removing or installing, use safety gloves to protect hands and seat cushion. 5. Remove seatback seat trim and pad. Refer to SE-8, "SEATBACK TRIM PAD" . SE 6. Remove side air bag module. Refer to SRS-42, "Removal and Installation" . 7. Remove seat slide inner finisher. 8. Remove fixing lockwasher from reclining shaft, then remove J reclining shaft and pulley from seatback frame. 9. Remove fixing bolts from seatback frame, then remove seatback frame. K 1. 2. 3. L M MIIB9207E SE-9 FRONT SEAT 10. Remove active headrest protector, then remove fixing bolt and active headrest (if equipped). MIIB9206E Assembly Install in the reverse order of removal. CAUTION: After assembling seatback frame, make sure reclining device operates. Disassembly and Assembly of Seat Cushion BIS000UC SEAT CUSHION TRIM PAD Disassembly 1. Mark the location of harness connectors and routing of harness before disassembly. MIIB9344E 2. 3. 4. 5. Remove seat lifter cover, seat lifter lever, reclining lever, seat slide out finisher, slide inner cover, and seat slide inner finisher. Remove seatback frame bolts, and the remove seat cushion assembly from seatback frame Remove retainer from the back of cushion. Remove seat cushion trim&pad from seat cushion frame. MIIB0038E Assembly Install in the reverse order of removal. CAUTION: When assembling seat cushion assembly in seatback assembly, make sure the reclining device operates. SEAT CUSHION FRAME Disassembly 1. 2. Remove short cushion trim&pad. Remove bolts (4), and then remove seat cushion frame from seat slide assembly. SE-10 FRONT SEAT Assembly A Install in the reverse order of removal. B C D E F G H SE J K L M SE-11 REAR SEAT REAR SEAT Removal and Installation PFP:88300 BIS000UE REMOVAL 1. 2. 3. Slide the rear seat forward. Remove seat rail cover LH and RH (1). Remove slide seat rear mountings bolts from the rear floor. MIIB9342E 4. 5. Remove leg cover LH and RH (1). Remove slide seat front mountings bolts. MIIB9341E 6. Recline the backseat and remove the slide seat assembly from rear door. NOTE: This operation requires two workers. MIIB9343E INSTALLATION ● ● Install in the reverse order of removal. Tighten mountings bolts to the specified torque SE-12 REAR SEAT Rear Seat Disassembly and Assembly BIS00161 A B C D E F G H SE J K L M MIIB9340E SE-13 REAR SEAT 1. Headrest 2. Seatback reclining cable RH 3. Reclining cable clip 4. Seatback reclining lever RH 5. Seatback frame RH 6. Headrest holder 7. Seatback reclining lever LH 8. Seat belt retractor centre 9. Rope hook 10. Seatback frame RH 11. Seatback frame LH 12. Seatback reclining cable LH 13. Seatback trim and pad RH 14. Armrest carpet 15. Armrest 16. Bolt 17. Bush 18. Armrest cap RH 19. Armrest cap LH 20. Seatback trim and pad LH 21. Seat rail cover RH 22. Seat rail cover LH 23. Carpet finisher 24. Seat belt buckle RH 25. Release bracket 26. Reclining device RH 27. Seat belt buckle centre 28. Slide seat handle 29. Release cross tube 30. Seat belt buckle LH 31. Reclining device LH 32. Hinge cover RH outer 33. Hinge cover RH inner 34. Reclining device cover RH 35. Reclining device cover LH 36. Hinge cover LH inner 37. Hinge cover LH outer 38. Cushion bracket RH 39. Pin 40. Rail assembly RH 41. Strap 42. Cushion bracket LH 43. Rail assembly LH 44. Seat cushion trim and pad 45. Cross bar 46. Leg cover RH 47. Slide seat lever 48. Leg cover LH 49. Seat cushion frame SE-14 SUPPLEMENTAL RESTRAINT SYSTEM (SRS) H RESTRAINTS SECTION SRS SUPPLEMENTAL RESTRAINT SYSTEM (SRS) A B C D CONTENTS PRECAUTIONS .......................................................... 3 Precautions for Supplemental Restraint System (SRS) “AIR BAG” and “SEAT BELT PRE-TENSIONER” .................................................................. 3 Precautions for SRS “AIR BAG” and “SEAT BELT PRE-TENSIONER” Service ..................................... 3 PREPARATION ........................................................... 4 Special Service Tools ............................................... 4 Commercial Service Tools ........................................ 4 SUPPLEMENTAL RESTRAINT SYSTEM (SRS) ....... 5 SRS Configuration ................................................... 5 Front Seat Belt Pre-tensioner with Load Limiter ..... 6 Front Side Air Bag .................................................... 6 Side Curtain Air Bag ................................................. 6 Front Passenger Air Bag Cut OFF Switch ............... 6 Front Passenger Air Bag OFF Indicator ................... 7 TROUBLE DIAGNOSIS .............................................. 8 Trouble Diagnosis Introduction ................................. 8 DIAGNOSIS FUNCTION ....................................... 8 HOW TO PERFORM TROUBLE DIAGNOSES FOR QUICK AND ACCURATE REPAIR ............... 8 WORK FLOW ........................................................ 9 Component Parts Location ..................................... 10 Schematic ...............................................................11 Wiring Diagram — SRS — ..................................... 12 CONSULT-II Function ............................................ 16 DIAGNOSIS MODE FOR CONSULT-II ............... 16 HOW TO CHANGE SELF-DIAGNOSIS MODE WITH CONSULT-II .............................................. 16 HOW TO ERASE SELF-DIAGNOSIS RESULTS... 17 Self-Diagnosis Function (Without CONSULT-II) ..... 17 HOW TO CHANGE SELF-DIAGNOSIS MODE WITHOUT CONSULT-II ...................................... 17 HOW TO ERASE SELF-DIAGNOSIS RESULTS... 17 SRS Operation Check ............................................ 18 DIAGNOSTIC PROCEDURE 1 ........................... 18 Trouble Diagnosis with CONSULT-II ...................... 20 DIAGNOSTIC PROCEDURE 2 ........................... 20 CONSULT-II DIAGNOSTIC CODE CHART (“SELF-DIAG [CURRENT]”) ................................ 21 DIAGNOSTIC PROCEDURE 3 ........................... 24 DIAGNOSTIC PROCEDURE 4 (CONTINUED FROM DIAGNOSTIC PROCEDURE 2) .............. 26 DIAGNOSTIC PROCEDURE 5 ........................... 26 Trouble Diagnosis without CONSULT-II ................. 30 DIAGNOSTIC PROCEDURE 6 ........................... 30 WARNING LAMP FLASH CODE CHART ........... 30 Trouble Diagnosis: “AIR BAG” Warning Lamp Does Not Turn OFF ......................................................... 34 DIAGNOSTIC PROCEDURE 7 ........................... 34 Trouble Diagnosis: “AIR BAG” Warning Lamp Does Not Turn ON ........................................................... 35 DIAGNOSTIC PROCEDURE 8 ........................... 35 DRIVER AIR BAG MODULE .................................... 36 Removal and Installation ........................................ 36 REMOVAL ........................................................... 36 INSTALLATION ................................................... 37 SPIRAL CABLE ........................................................ 38 Removal and Installation ........................................ 38 REMOVAL ........................................................... 38 INSTALLATION ................................................... 39 FRONT PASSENGER AIR BAG MODULE .............. 40 Removal and Installation ........................................ 40 REMOVAL ........................................................... 40 INSTALLATION ................................................... 41 FRONT SIDE AIR BAG MODULE ............................ 42 Removal and Installation ........................................ 42 REMOVAL ........................................................... 42 INSTALLATION ................................................... 43 SIDE CURTAIN AIR BAG MODULE ........................ 44 Removal and Installation ........................................ 44 REMOVAL ........................................................... 44 INSTALLATION ................................................... 44 CRASH ZONE SENSOR ........................................... 45 Removal and Installation ........................................ 45 REMOVAL ........................................................... 45 INSTALLATION ................................................... 45 SRS-1 E F G SRS I J K L M SIDE AIR BAG (SATELLITE) SENSOR ................... 46 Removal and Installation ........................................ 46 REMOVAL ........................................................... 46 INSTALLATION .................................................... 46 SEAT BELT PRE-TENSIONER ................................. 47 Removal and Installation ........................................ 47 DIAGNOSIS SENSOR UNIT ..................................... 48 Removal and Installation ........................................ 48 REMOVAL ........................................................... 48 INSTALLATION .................................................... 48 ECU DISCRIMINATED NO. ................................. 48 DISPOSALOFAIRBAGMODULEANDSEATBELT PRE-TENSIONER ..................................................... 49 Caution for Air Bag Module and Seat Belt Pretensioner ................................................................. 49 CHECKING DEPLOYMENT TOOL ..................... 49 DEPLOYMENT PROCEDURES FOR AIR BAG MODULE .................. 50 DEPLOYMENT PROCEDURES FOR SEAT BELT PRE-TENSIONER ....................................................................54 DEPLOYMENT PROCEDURES FOR FRONT SEAT BELT PRE-TENSIONER 2 (OUTSIDE OF VEHICLE) ............................................................55 DEPLOYMENT OF AIR BAG MODULE AND SEAT BELT PRE-TENSIONER WHILE MOUNTED IN VEHICLE ......................................57 DISPOSING OF AIR BAG MODULE AND SEAT BELT PRE-TENSIONER ......................................57 COLLISION DIAGNOSIS ..........................................58 For Frontal Collision ................................................58 SRS INSPECTION (FOR FRONTAL COLLISION) ...................................................................58 For Side Collision ....................................................60 WHEN THE SIDE AIR BAG IS ACTIVATED IN THE SIDE COLLISION: .......................................60 WHEN SRS IS NOT ACTIVATED IN THE SIDE COLLISION: .........................................................60 SRS INSPECTION (FOR SIDE COLLISION) ......60 SRS-2 PRECAUTIONS PRECAUTIONS PFP:00001 Precautions for Supplemental Restraint System (SRS) “AIR BAG” and “SEAT BELT PRE-TENSIONER” A BHS0002S The Supplemental Restraint System such as “AIR BAG” and “SEAT BELT PRE-TENSIONER”, used along with a front seat belt, helps to reduce the risk or severity of injury to the driver and front passenger for certain types of collision. Information necessary to service the system safely is included in the SRS and SB section of this Service Manual. WARNING: ● To avoid rendering the SRS inoperative, which could increase the risk of personal injury or death in the event of a collision which would result in air bag inflation, all maintenance must be performed by an authorized NISSAN/INFINITI dealer. ● Improper maintenance, including incorrect removal and installation of the SRS, can lead to personal injury caused by unintentional activation of the system. For removal of Spiral Cable and Air Bag Module, see the SRS section. ● Do not use electrical test equipment on any circuit related to the SRS unless instructed to in this Service Manual. SRS wiring harnesses can be identified by yellow and/or orange harnesses or harness connectors. B C D E F Precautions for SRS “AIR BAG” and “SEAT BELT PRE-TENSIONER” Service BHS0002T ● ● ● ● ● ● ● G Do not use electrical test equipment to check SRS circuits unless instructed to in this Service Manual. Before servicing the SRS, turn ignition switch “OFF”, disconnect battery ground cable and wait at least 3 minutes. For approximately 3 minutes after the cables is removed, it is still possible for the air bag and seat belt SRS pre-tensioner to deploy. Therefore, do not work on any SRS connectors or wires until at least 3 minutes have passed. Diagnosis sensor unit must always be installed with their arrow marks “⇐” pointing towards the front of the I vehicle for proper operation. Also check diagnosis sensor unit for cracks, deformities or rust before installation and replace as required. The spiral cable must be aligned with the neutral position since its rotations are limited. Do not attempt to J turn steering wheel or column after removal of steering gear. Handle air bag module carefully. Always place driver and front passenger air bag modules with the pad side facing upward and place front side air bag module standing with stud bolt side setting bottom. K Conduct self-diagnosis to check entire SRS for proper function after replacing any components. After air bag inflates, the front instrument panel assembly should be replaced if damaged. L M SRS-3 PREPARATION PREPARATION Special Service Tools PFP:00002 BHS0002U Tool number Tool name Application KV99105300 Air bag module bracket Anchoring air bag module S-NT354 KV99106400 Deployment tool Disposing of air bag module S-NT357 KV99109700 Deployment tool adapter for front passenger air bag module Connection between the deployment tool and front passenger air bag module SHIA0038J KV99110500 ● Deployment tool adapter for pretensioner seat belt module ● Deployment tool adapter for driver air bag mmodule ● Deployment tool adapter for side curtain air bag module ● Connection between the deployment tool and pre-tensioner seat belt ● Connection between the deployment tool and driver air bag module ● Connection between the deployment tool and side curtain air bag module PHIA0184E KV99108300 Deployment tool adapter for front side air bag module Connection between the deployment tool and front side air bag module ZZA1166D Commercial Service Tools BHS0002V Tool name Application Tamper resistant TORX bit Size: T30 S-NT757 SRS-4 SUPPLEMENTAL RESTRAINT SYSTEM (SRS) SUPPLEMENTAL RESTRAINT SYSTEM (SRS) SRS Configuration PFP:28556 A BHS0002W B C D E F G SRS I MHIB0115E J The air bag deploys if the diagnosis sensor unit activates while the ignition switch is in the ON or START position. The collision modes for which supplemental restraint systems are activated are different among the SRS systems. For example, the driver air bag module and front passenger air bag module are activated in a frontal collision but not in a side collision. SRS configurations which are activated for some collision modes are as follows; SRS configuration Frontal collision Left side collision Right side collision Driver air bag module × — — Front passenger air bag module × — — Front LH seat belt pre-tensioner × — — Front RH seat belt pre-tensioner × — — Front LH side air bag module — × — Front RH side air bag module — — × LH side curtain air bag module — × — RH side curtain air bag module — — × SRS-5 K L M SUPPLEMENTAL RESTRAINT SYSTEM (SRS) Front Seat Belt Pre-tensioner with Load Limiter The seat belt pre-tensioner system with load limiter is installed for both the driver's seat and the front passenger's seat. It operates simultaneously with the SRS air bag system in the event of a frontal collision with an impact exceeding a specified level. When the frontal collision with an impact exceeding a specified level occurs, seat belt slack resulting from clothing or other factors is immediately taken up by the pre-tensioner. Vehicle passengers are securely restrained. When passengers in a vehicle are thrown forward in a collision and the restraining force of the seat belt exceeds a specified level, the load limiter permits the specified extension of the seat belt by the twisting of the ELR shaft, and a relaxation of the chest-area seat belt web tension while maintaining force. Front Side Air Bag BHS0002X SRS444 BHS0002Y Front side air bag is built-in type. The front seatbacks with built-in type side air bag have the labels as shown. SHIA0170E Side Curtain Air Bag BHS0002Z The side curtain air bags have the labels as shown. PHIA0850J Front Passenger Air Bag Cut OFF Switch BHS00030 Operating the front passenger air bag cut OFF switch to ON or OFF position will switch the front air bag to armed or disarmed state. The front passenger air bag cut OFF switch is located in right hand side of the instrument side mask for LHD model. (And oppositely for the RHD model) MHIB0118E SRS-6 SUPPLEMENTAL RESTRAINT SYSTEM (SRS) Front Passenger Air Bag OFF Indicator BHS00031 A The front passenger air bag OFF indicator is arranged in the A/C control panel. Air bag OFF indicator - (1) B C D MHIB0132E E F G SRS I J K L M SRS-7 TROUBLE DIAGNOSIS TROUBLE DIAGNOSIS Trouble Diagnosis Introduction PFP:00004 BHS00032 CAUTION: ● Do not use electrical test equipment on any circuit related to the SRS unless instructed in this Service Manual. SRS wiring harnesses can be identified by yellow and/or orange harnesses or harness connectors. ● Do not attempt to repair, splice or modify the SRS wiring harness. If the harness is damaged, replace it with a new one. ● Keep ground portion clean. DIAGNOSIS FUNCTION The SRS self-diagnosis results can be read by using “AIR BAG” warning lamp and/or CONSULT-II. The User mode is exclusively prepared for the customer (driver). This mode warns the driver of a system malfunction through the operation of the “AIR BAG” warning lamp. The Diagnosis mode allows the technician to locate and inspect the malfunctioning part. The mode applications for the “AIR BAG” warning lamp and CONSULT-II are as follows: User mode Diagnosis mode Display type “AIR BAG” warning lamp X X ON-OFF operation CONSULT-II — X Monitoring HOW TO PERFORM TROUBLE DIAGNOSES FOR QUICK AND ACCURATE REPAIR A good understanding of the malfunction conditions can make troubleshooting faster and more accurate. In general, each customer feels differently about a malfunction. It is important to fully understand the symptoms or conditions for a customer complaint. Information from Customer WHAT..... Vehicle model WHEN..... Date, Frequencies WHERE..... Road conditions HOW..... Operating conditions, Symptoms Preliminary Check Check that the following parts are in good order. ● Battery (Refer to SC-5, "How to Handle Battery" .) ● Fuse (Refer to SRS-12, "Wiring Diagram — SRS —" .) ● System component-to-harness connections SRS-8 TROUBLE DIAGNOSIS WORK FLOW A B C D E F G SRS I J K L PHIA0710E *1: SRS-8, "Preliminary Check" *2: SRS-18, "SRS Operation Check" *3: SRS-20, "DIAGNOSTIC PROCEDURE 2" *4: SRS-30, "DIAGNOSTIC PROCEDURE 6" *5 *6 SRS-24, "DIAGNOSTIC PROCEDURE 3" SRS-9 SRS-30, "DIAGNOSTIC PROCEDURE 6" M TROUBLE DIAGNOSIS Component Parts Location BHS00033 MHIB0125E 1. Driver air bag module 2. Spiral cable 3. Diagnosis sensor unit 4. Side air bag (satellite) sensors 5. Seat belt Pre-tensioners 6. Front side air bag modules 7. Front passenger air bag module 8. Crash zone sensor 9. Curtain air bag module SRS-10 TROUBLE DIAGNOSIS Schematic BHS00034 A B C D E F G SRS I J K L M MHWA0060E SRS-11 TROUBLE DIAGNOSIS Wiring Diagram — SRS — BHS00035 MHWA0061E SRS-12 TROUBLE DIAGNOSIS A B C D E F G SRS I J K L M MHWA0062E SRS-13 TROUBLE DIAGNOSIS MHWA0063E SRS-14 TROUBLE DIAGNOSIS A B C D E F G SRS I J K L M MHWA0064E SRS-15 TROUBLE DIAGNOSIS CONSULT-II Function BHS00036 DIAGNOSIS MODE FOR CONSULT-II ● ● ● ● “SELF-DIAG [CURRENT]” A current Self-diagnosis result (also indicated by the number of warning lamp flashes in the Diagnosis mode) is displayed on the CONSULT-II screen in real time. This refers to a malfunctioning part requiring repairs. “SELF-DIAG [PAST]” Diagnosis results previously stored in the memory are displayed on the CONSULT-II screen. The stored results are not erased until memory erasing is executed. “TROUBLE DIAG RECORD” With TROUBLE DIAG RECORD, diagnosis results previously erased by a reset operation can be displayed on the CONSULT-II screen. “ECU DISCRIMINATED NO.” The diagnosis sensor unit for each vehicle model is assigned with its own, individual classification number. This number will be displayed on the CONSULT-II screen, as shown. When replacing the diagnosis sensor unit, refer to the part number for the compatibility. After installation, replacement with a correct unit can be checked by confirming this classification number on the CONSULT-II screen. After repair, make sure the discriminated number of diagnosis sensor unit installed to vehicle are same. Refer to SRS-48, "ECU DISCRIMINATED NO." . PHIA0218E HOW TO CHANGE SELF-DIAGNOSIS MODE WITH CONSULT-II From User Mode to Diagnosis Mode After selecting “AIR BAG” on the “SELECT SYSTEM” screen, User mode automatically changes to Diagnosis mode. SRS803 From Diagnosis Mode to User Mode To return to User mode from Diagnosis mode, touch “BACK” key of CONSULT-II until “SELECT SYSTEM” appears, Diagnosis mode automatically changes to User mode. SRS804 SRS-16 TROUBLE DIAGNOSIS HOW TO ERASE SELF-DIAGNOSIS RESULTS ● ● ● “SELF-DIAG [CURRENT]” A current Self-diagnosis result is displayed on the CONSULT-II screen in real time. After the malfunction is repaired completely, no malfunction is detected on “SELF-DIAG [CURRENT]”. “SELF-DIAG [PAST]” Return to the “SELF-DIAG [CURRENT]” CONSULT-II screen by touching “BACK” key of CONSULT-II and select “SELF-DIAG [CURRENT]” in SELECT DIAG MODE. Touch “ERASE” in “SELF-DIAG [CURRENT]” mode. NOTE: If the memory of the malfunction in “SELF-DIAG [PAST]” is not erased, the User mode shows the system malfunction by the operation of the warning lamp even if the malfunction is repaired completely. “TROUBLE DIAG RECORD” The memory of “TROUBLE DIAG RECORD” cannot be erased. A B C D E F G SRS701 Self-Diagnosis Function (Without CONSULT-II) ● ● BHS00037 The reading of these results is accomplished “User mode” and “Diagnosis mode”. After a malfunction is repaired, turn ignition switch ON. Diagnosis mode returns to the User mode. At that time, the self-diagnostic result is cleared. HOW TO CHANGE SELF-DIAGNOSIS MODE WITHOUT CONSULT-II SRS I J K L M PHIA0709E HOW TO ERASE SELF-DIAGNOSIS RESULTS After a malfunction is repaired, turn the ignition switch OFF for at least one second, then back ON. Diagnosis mode returns to the User mode. At that time, the self-diagnostic result is cleared. SRS-17 TROUBLE DIAGNOSIS SRS Operation Check BHS00038 DIAGNOSTIC PROCEDURE 1 Checking Air Bag Operation by Using “AIR BAG” Warning Lamp — User Mode 1. 2. Turn the ignition switch from OFF to ON, and check that the air bag warning lamp blinks. Compare the SRS air bag warning lamp blinking pattern with the examples. BF-1845D SRS-18 TROUBLE DIAGNOSIS Warning lamp examples “AIR BAG” warning lamp operation-User mode- SRS condition Reference item A B ● No malfunction is detected. ● No further action is necessary. — C D SHIA0011E E F ● The system is malfunctioning and need to be repaired as indicated. Go to SRS-20, "DIAGNOSTIC PROCEDURE 2" or SRS-30, "DIAGNOSTIC PROCEDURE 6" . G SRS SHIA0012E ● Air bag is deployed. ● Seat belt pre-tensioner is deployed. Go to SRS-58, "COLLISION DIAGNOSIS" . I ● Diagnosis sensor unit is malfunctioning. ● Air bag power supply circuit is malfunctioning. ● SRS air bag warning lamp circuit is malfunctioning. Go to SRS-34, "Trouble Diagnosis: “AIR BAG” Warning Lamp Does Not Turn OFF" . J K SHIA0013E L ● ● Diagnosis sensor unit is malfunctioning. Air bag warning lamp circuit is malfunctioning. SHIA0014E SRS-19 Go to SRS-35, "Trouble Diagnosis: “AIR BAG” Warning Lamp Does Not Turn ON" . M TROUBLE DIAGNOSIS Trouble Diagnosis with CONSULT-II BHS00039 DIAGNOSTIC PROCEDURE 2 CAUTION: If CONSULT-II is used with no connection of CONSULT-II CONVERTER, malfunctions might be detected in self-diagnosis depending on control unit which carry out CAN communication. Refer to GI-36, "CONSULT-II Start Procedure" . 1. Touch “SELF-DIAG [CURRENT]”. SRS697 2. Diagnostic code is displayed on “SELF-DIAG [CURRENT]”. SHIA0203E a. If no malfunction is detected on “SELF-DIAG [CURRENT]” even though malfunction is detected in “SRS Operation Check”, check the battery voltage. If the battery voltage is less than 9 V, charge or replace the battery. SRS-24, "DIAGNOSTIC PROCEDURE 3" . If the battery voltage is OK, go to SRS-26, "DIAGNOSTIC PROCEDURE 4 (CONTINUED FROM DIAGNOSTIC PROCEDURE 2)" diagnose the following cases: ● Self-diagnostic result “SELF-DIAG [PAST]” (previously stored in the memory) might not be erased after repair. ● The SRS system malfunctions intermittently. SRS701 SRS-20 TROUBLE DIAGNOSIS CONSULT-II DIAGNOSTIC CODE CHART (“SELF-DIAG [CURRENT]”) Diagnostic item NO DTC IS DETECTED. Repair order “Recheck SRS at each replacement” Explanation When malfunction is indicated by the “AIR BAG” warning lamp in User mode. ● ● ● Low battery voltage (Less than 9V) Self-diagnostic result “SELF-DIAG [PAST]” (previously stored in the memory) might not be erased after repair. Intermittent malfunction has been detected in the past. ● No malfunction is detected. DRIVER AIRBAG MODULE [OPEN] ● Driver air bag module circuit is open (including the spiral cable). DRIVER AIRBAG MODULE [VB-SHORT] ● DRIVER AIRBAG MODULE [GND-SHORT] ● Go to SRS-24, "DIAGNOSTIC PROCEDURE 3" after charging the battery. B ● Go to SRS-26, "DIAGNOSTIC PROCEDURE 4 (CONTINUED FROM DIAGNOSTIC PROCEDURE 2)" . C ● Go to SRS-26, "DIAGNOSTIC PROCEDURE 5" . ● D — Driver air bag module circuit is shorted to a power supply circuit (including the spiral cable). Driver air bag module circuit is shorted to ground (including the spiral cable). Driver air bag module circuit is shorted between lines. 1. Visually check the wiring harness connection. E 2. Replace the harness if it has visible damage. 3. Replace driver air bag module. (Before disposal, it must be deployed.) F 4. Replace the spiral cable. 5. Replace the diagnosis sensor unit. G 6. Replace the related harness. DRIVER AIRBAG MODULE [SHORT] ● ASSIST A/B MODULE [OPEN] ● Front passenger air bag module circuit is open. 1. Visually check the wiring harness connection. ASSIST A/B MODULE [VB-SHORT] ● Front passenger air bag module circuit is shorted to a power supply circuit. 2. Replace the harness if it has visible damage. ASSIST A/B MODULE [GND-SHORT] ● Front passenger air bag module circuit is shorted to ground. ASSIST A/B MODULE [SHORT] ● Front passenger air bag module circuit is shorted between lines. 3. Replace front passenger air bag module. (Before disposal, it must be deployed.) SRS ● Crash zone sensor I J 4. Replace the diagnosis sensor unit. 5. Replace the related harness. CRASH ZONE SEN [UNIT FAIL] CRASH ZONE SEN [COMM FAIL] CRASH ZONE SEN [UNMATCH] A K 1. Visually check the wiring harness connection. 2. Replace the harness if it has visible damage. L 3. Replace the crash zone sensor. 4. Replace the diagnosis sensor unit. 5. Replace the related harness. SIDE MODULE LH [OPEN] ● Front LH side air bag module circuit is open. 1. Visually check the wiring harness connection. SIDE MODULE LH [VB-SHORT] ● Front LH side air bag module circuit is shorted to a power supply circuit. 2. Replace the harness if it has visible damage. SIDE MODULE LH [GND-SHORT] ● Front LH side air bag module circuit is shorted to ground. SIDE MODULE LH [SHORT] ● Front LH side air bag module circuit is shorted between lines. 3. Replace front LH setback assembly (front LH side air bag module). (Before disposal, it must be deployed.) 4. Replace the diagnosis sensor unit. 5. Replace the related harness. SRS-21 M TROUBLE DIAGNOSIS Diagnostic item Explanation Repair order “Recheck SRS at each replacement” SIDE MODULE RH [OPEN] ● Front RH side air bag module circuit is open. 1. Visually check the wiring harness connection. SIDE MODULE RH [VB-SHORT] ● Front RH side air bag module circuit is shorted to some power supply circuit. 2. Replace the harness if it has visible damage. SIDE MODULE RH [GND-SHORT] ● Front RH side air bag module circuit is shorted to ground. SIDE MODULE RH [SHORT] ● Front RH side air bag module circuit is shorted between lines. 3. Replace front RH setback assembly (front RH side air bag module). (Before disposal, it must be deployed.) 4. Replace the diagnosis sensor unit. 5. Replace the related harness. SATELLITE SENS LH [UNIT FAIL] SATELLITE SENS LH [COMM FAIL] ● LH side air bag (Satellite) sensor 1. Visually check the wiring harness connection. 2. Replace the harness if it has visible damage. 3. Replace the LH side air bag (Satellite) sensor. 4. Replace the diagnosis sensor unit. 5. Replace the related harness. SATELLITE SENS RH [UNIT FAIL] SATELLITE SENS RH [COMM FAIL] ● RH side air bag (Satellite) sensor 1. Visually check the wiring harness connection. 2. Replace the harness if it has visible damage. 3. Replace the RH side air bag (Satellite) sensor. 4. Replace the diagnosis sensor unit. 5. Replace the related harness. PRE-TEN FRONT LH [OPEN] ● Front LH pre-tensioner circuit is open. 1. Visually check the wiring harness connections. PRE-TEN FRONT LH [VB-SHORT] ● Front LH pre-tensioner circuit is shorted to a power supply circuit. 2. Replace the harness if it has visible damage. PRE-TEN FRONT LH [GND-SHORT] ● Front LH pre-tensioner circuit is shorted to ground. 3. Replace front LH seat belt. (Before disposal, it must be activated.) PRE-TEN FRONT LH [SHORT] ● Front LH pre-tensioner circuit is shorted between lines. 4. Replace the diagnosis sensor unit. PRE-TEN FRONT RH [OPEN] ● Front RH pre-tensioner circuit is shorted to a power supply circuit. 1. Visually check the wiring harness connections. PRE-TEN FRONT RH [VB-SHORT] ● Front RH pre-tensioner circuit is shorted to a power supply circuit. 2. Replace the harness if it has visible damage. PRE-TEN FRONT RH [GND-SHORT] ● Front RH pre-tensioner circuit is shorted to ground. 3. Replace front RH seat belt. (Before disposal, it must be activated.) PRE-TEN FRONT RH [SHORT] ● Front RH pre-tensioner circuit is shorted between lines. 4. Replace the diagnosis sensor unit. CURTAIN MODULE LH [OPEN] ● LH side curtain air bag module circuit is open. 1. Visually check the wiring harness connection. CURTAIN MODULE LH [VB-SHORT] ● LH side curtain air bag module circuit is shorted to some power supply circuits. 2. Replace the harness if it has visible damage. CURTAIN MODULE LH [GND-SHORT] ● LH side curtain air bag module circuit is shorted to ground. CURTAIN MODULE LH [SHORT] ● LH side curtain air bag module circuit is shorted between lines. 3. Replace LH side curtain air bag module. (Before disposal, it must be deployed.) 5. Replace the related harness. 5. Replace the related harness. 4. Replace the diagnosis sensor unit. 5. Replace the related harness. SRS-22 TROUBLE DIAGNOSIS Diagnostic item Explanation Repair order “Recheck SRS at each replacement” CURTAIN MODULE RH [OPEN] ● RH side curtain air bag module circuit is open. 1. Visually check the wiring harness connection. CURTAIN MODULE RH [VB-SHORT] ● RH side curtain air bag module circuit is shorted to a power supply circuit. 2. Replace the harness if it has visible damage. CURTAIN MODULE RH [GND-SHORT] ● RH side curtain air bag module circuit is shorted to ground. CURTAIN MODULE RH [SHORT] ● RH side curtain air bag module circuit is shorted between lines. 3. Replace RH side curtain air bag module. (Before disposal, it must be deployed.) ● Diagnosis sensor unit is malfunctioning. B C 4. Replace the diagnosis sensor unit. 5. Replace the related harness. CONTROL UNIT A D 1. Visually check the wiring harness connection. 2. Replace the harness if it has visible damage. E 3. Replace the diagnosis sensor unit. PASS AIR BAG DEACT SW ● Front passenger air bag cut OFF switch unit is malfunctioning. 1. Visually check the wiring harness connection. 2. Replace the harness if it has visible damage. F G 3. Replace the cut OFF switch. 4. Replace the diagnosis sensor unit. PASS AIR BAG INDICATOR CKT ● Front passenger air bag OFF indicator circuit is open, or shorted each other or to ground. 1. Visually check the wiring harness connection. 2. Replace the harness if it has visible damage. SRS I 3. Replace the cut OFF indicator. 4. Replace the diagnosis sensor unit. NOTE: Follow the procedures in numerical order when repairing malfunctioning parts. Confirm whether malfunction is eliminated using air bag warning lamp or CONSULT-II each time repair is finished. If malfunction is still observed, proceed to the next step. When malfunction is eliminated, further repair work is not required. J K L M SRS-23 TROUBLE DIAGNOSIS DIAGNOSTIC PROCEDURE 3 Final checking after repairing SRS by using CONSULT-II — Diagnosis mode CAUTION: If CONSULT-II is used with no connection of CONSULT-II CONVERTER, malfunctions might be detected in self-diagnosis depending on control unit which carry out CAN communication. 1. Touch “SELF-DIAG [CURRENT]”. SRS697 a. If no malfunction is detected on “SELF-DIAG [CURRENT]”, repair of SRS is completed. Go to step 2. If any malfunction is detected on “SELF-DIAG [CURRENT]”, the malfunctioning part is not repaired completely or another malfunctioning part is detected. Go to SRS-20, "DIAGNOSTIC PROCEDURE 2" , and repair malfunctioning part completely. SRS701 2. Touch “ERASE”. NOTE: Touch “ERASE” to clear the memory of the malfunction (“SELFDIAG [PAST]”). If the memory of the malfunction in “SELF-DIAG [PAST]” is not erased, the User mode shows the system malfunction by the operation of the warning lamp even if the malfunction is repaired completely. SRS773 3. Touch “BACK” key of CONSULT-II to “SELECT DIAG MODE” screen. Touch “SELF-DIAG [PAST]”. SRS697 SRS-24 TROUBLE DIAGNOSIS 4. 5. 6. Check that no malfunction is detected on “SELF-DIAG [PAST]”. Touch “BACK” key of CONSULT-II until “SELECT SYSTEM” appears in order to return to User mode from Diagnosis mode. Turn ignition switch OFF then turn off and disconnect CONSULT-II. Go to SRS-18, "Checking Air Bag Operation by Using “AIR BAG” Warning Lamp — User Mode" . A B C SRS702 D E F G SRS I J K L M SRS-25 TROUBLE DIAGNOSIS DIAGNOSTIC PROCEDURE 4 (CONTINUED FROM DIAGNOSTIC PROCEDURE 2) Inspecting SRS malfunctioning record 1. CONSIDER POSSIBILITY OF NOT ERASING SELF-DIAGNOSTIC RESULT AFTER REPAIRING Is it the first time for maintenance of SRS? YES or NO YES >> Go to SRS-20, "DIAGNOSTIC PROCEDURE 2" . NO >> Self-diagnostic result “SELF-DIAG [PAST]” (previously stored in the memory) might not be erased after repair. Go to SRS-24, "DIAGNOSTIC PROCEDURE 3" . DIAGNOSTIC PROCEDURE 5 Inspecting SRS intermittent malfunction by using CONSULT-II — Diagnosis mode CAUTION: If CONSULT-II is used with no connection of CONSULT-II CONVERTER, malfunction might be detected in self-diagnosis depending on control unit which carry out CAN communication. 1. Touch “SELF-DIAG [PAST]”. SRS697 a. If diagnostic codes are displayed on “SELF-DIAG [PAST]”, go to step 5. SRS700 2. If no malfunction is detected on “SELF-DIAG [PAST]”, touch “BACK” and go back to “SELECT DIAG MODE”. SRS702 SRS-26 TROUBLE DIAGNOSIS 3. Touch “TROUBLE DIAG RECORD”. NOTE: With “TROUBLE DIAG RECORD”, diagnosis results previously erased by a reset operation can be displayed. A B C SRS697 D Diagnostic code is displayed on “TROUBLE DIAG RECORD”. Touch “PRINT”. E Compare diagnostic codes to SRS-27, "CONSULT-II Diagnostic Code Chart (“SELF-DIAG [PAST]” or “TROUBLE DIAG RECORD”)" . 7. Touch “BACK” key of CONSULT-II until “SELECT SYSTEM” F appears. 8. Turn ignition switch OFF, then turn off and disconnect CONSULT-II, and both battery cables. G 9. Repair the system as outlined by the “Repair order” in “IntermitSHIA0182E tent Malfunction Diagnostic Code Chart”, that corresponds to the self-diagnostic result. For replacement procedure of component parts, refer to the Removal and InstallaSRS tion procedure for the appropriate component. 10. Go to SRS-24, "DIAGNOSTIC PROCEDURE 3" , for final checking. 4. 5. 6. CONSULT-II Diagnostic Code Chart (“SELF-DIAG [PAST]” or “TROUBLE DIAG RECORD”) Diagnostic item NO DTC IS DETECTED. Explanation When malfunction is indicated by the “AIR BAG” warning lamp in User mode. ● Low battery voltage (Less than 9V) Repair order “Recheck SRS at each replacement” ● Go to SRS-24, "DIAGNOSTIC PROCEDURE 3" . Go to SRS-24, "DIAGNOSTIC PROCEDURE 3" . ● No malfunction is detected. ● DRIVER AIRBAG MODULE [OPEN] ● Driver air bag module circuit is open (including the spiral cable). 1. Visually check the wiring harness connection. DRIVER AIRBAG MODULE [VB-SHORT] ● Driver air bag module circuit is shorted to a power supply circuit (including the spiral cable). DRIVER AIRBAG MODULE [GND-SHORT] ● Driver air bag module circuit is shorted to ground (including the spiral cable). DRIVER AIRBAG MODULE [SHORT] ● Driver air bag module circuit is shorted between lines. ASSIST A/B MODULE [OPEN] ● Front passenger air bag module circuit is open. 1. Visually check the wiring harness connection. ASSIST A/B MODULE [VB-SHORT] ● Front passenger air bag module circuit is shorted to a power supply circuit. 2. Replace the harness if it has visible damage. ASSIST A/B MODULE [GND-SHORT] ● Front passenger air bag module circuit is shorted to ground. ASSIST A/B MODULE [SHORT] ● Front passenger air bag module circuit is shorted between lines. 3. If the harness check result is OK, replace the diagnosis sensor unit and front passenger air bag module (Before disposal, it must be deployed.). SRS-27 I 2. Replace the harness if it has visible damage. 3. If the harness check result is OK, replace driver air bag module (Before disposal, it must be deployed.), diagnosis sensor unit and spiral cable. J K L M TROUBLE DIAGNOSIS Diagnostic item CRASH ZONE SEN [UNIT FAIL] CRASH ZONE SEN [COMM FAIL] Explanation ● Crash zone sensor Repair order “Recheck SRS at each replacement” 1. Visually check the wiring harness connection. 2. Replace the harness if it has visible damage. 3. If the harness check result is OK, replace crash zone sensor and diagnosis sensor unit. SIDE MODULE LH [OPEN] ● Front LH side air bag module circuit is open. 1. Visually check the wiring harness connection. SIDE MODULE LH [VB-SHORT] ● Front LH side air bag module circuit is shorted to a power supply circuit. 2. Replace the harness if it has visible damage. SIDE MODULE LH [GND-SHORT] ● Front LH side air bag module circuit is shorted to ground. SIDE MODULE LH [SHORT] ● Front LH side air bag module circuit is shorted between lines. 3. If the harness check result is OK, replace the diagnosis sensor unit and LH side air bag module. (Before disposal, it must be deployed.). SIDE MODULE RH [OPEN] ● Front RH side air bag module circuit is open. 1. Visually check the wiring harness connection. SIDE MODULE RH [VB-SHORT] ● Front RH side air bag module circuit is shorted to a power supply circuit. 2. Replace the harness if it has visible damage. SIDE MODULE RH [GND-SHORT] ● Front RH side air bag module circuit is shorted to ground. SIDE MODULE RH [SHORT] ● Front RH side air bag module circuit is shorted between lines. 3. If the harness check result is OK, replace the diagnosis sensor unit and RH side air bag module (Before disposal, it must be deployed.) SATELLITE SENS LH [UNIT FAIL] SATELLITE SENS LH [COMM FAIL] ● LH side air bag (Satellite) sensor 1. Visually check the wiring harness connection. 2. Replace the harness if it has visible damage. 3. If the harness check result is OK, replace the diagnosis sensor unit and LH side air bag (Satellite) sensor. SATELLITE SENS RH [UNIT FAIL] SATELLITE SENS RH [COMM FAIL] ● RH side air bag (Satellite) sensor 1. Visually check the wiring harness connection. 2. Replace the harness if it has visible damage. 3. If the harness check result is OK, replace the diagnosis sensor unit and RH side air bag (Satellite) sensor. PRE-TEN FRONT LH [OPEN] ● Front LH pre-tensioner circuit is open. 1. Visually check the wiring harness connections. PRE-TEN FRONT LH [VB-SHORT] ● Front LH pre-tensioner circuit is shorted to a power supply circuit. 2. Replace the harness if it has visible damage. PRE-TEN FRONT LH [GND-SHORT] ● Front LH pre-tensioner circuit is shorted to ground. PRE-TEN FRONT LH [SHORT] ● Front LH pre-tensioner circuit is shorted between lines. 3. If the harness check result is OK, replace the diagnosis sensor unit and front LH seat belt (Before disposal, it must be activated.) SRS-28 TROUBLE DIAGNOSIS Diagnostic item Explanation Repair order “Recheck SRS at each replacement” A PRE-TEN FRONT RH [OPEN] ● Front RH pre-tensioner circuit is open. 1. Visually check the wiring harness connections. PRE-TEN FRONT RH [VB-SHORT] ● Front RH pre-tensioner circuit is shorted to a power supply circuit. 2. Replace the harness if it has visible damage. PRE-TEN FRONT RH [GND-SHORT] ● Front RH pre-tensioner circuit is shorted to ground. PRE-TEN FRONT RH [SHORT] ● Front RH pre-tensioner circuit is shorted between lines. 3. If the harness check result is OK, replace the diagnosis sensor unit and front RH seat belt (Before disposal, it must be activated.) CURTAIN MODULE LH [OPEN] ● LH side curtain air bag module circuit is open. 1. Visually check the wiring harness connection. CURTAIN MODULE LH [VB-SHORT] ● LH side curtain air bag module circuit is shorted to a power supply circuits. 2. Replace the harness if it has visible damage. E CURTAIN MODULE LH [GND-SHORT] ● LH side curtain air bag module circuit is shorted to ground. 3. If the harness check result is OK, replace the diagnosis sensor unit and LH side curtain air bag module. (Before disposal, it must be deployed.) F G CURTAIN MODULE RH [OPEN] ● RH side curtain air bag module circuit is open. 1. Visually check the wiring harness connection. CURTAIN MODULE RH [VB-SHORT] ● RH side curtain air bag module circuit is shorted to a power supply circuit. 2. Replace the harness if it has visible damage. CURTAIN MODULE RH [GND-SHORT] ● RH side curtain air bag module circuit is shorted to ground. CURTAIN MODULE RH [SHORT] ● RH side curtain air bag module circuit is shorted between lines. 3. If the harness check result is OK, replace the diagnosis sensor unit and RH side curtain air bag module. (Before disposal, it must be deployed.) CONTROL UNIT ● Diagnosis sensor unit is malfunctioning. 1. Visually check the wiring harness connection. B C D SRS I J 2. Replace the harness if it has visible damage. 3. Replace the diagnosis sensor unit. PASS A/B DEACT SW ● Front passenger air bag cut OFF switch unit is malfunctioning. K 1. Visually check the wiring harness connection. 2. Replace the harness if it has visible damage. L 3. Replace the cut OFF switch. 4. Replace diagnosis sensor unit. PASS A/B INDCTR CKT ● Front passenger air bag OFF indicator circuit is open, or shorted each other or to ground. 1. Visually check the wiring harness connection. 2. Replace the harness if it has visible damage. 3. Replace the cut OFF indicator. 4. Replace diagnosis sensor unit. SRS-29 M TROUBLE DIAGNOSIS Trouble Diagnosis without CONSULT-II BHS0003A DIAGNOSTIC PROCEDURE 6 Inspecting SRS Malfunctioning Parts by Using “AIR BAG” Warning Lamp—Diagnosis Mode NOTE: SRS will not enter Diagnosis mode if no malfunction is detected in User mode. 1. Turn ignition switch ON. 2. After “AIR BAG” warning lamp lights for 7 seconds, turn ignition switch OFF within 1 second. 3. Wait more than 3 seconds. 4. Repeat the steps 1 to 3 two times. 5. Turn ignition switch ON. SRS is now in Diagnosis mode. “AIR BAG” warning lamp operates in Diagnosis mode as follows: WARNING LAMP FLASH CODE CHART SHIA0026E PHIA0185E SHIA0028E SRS-30 TROUBLE DIAGNOSIS A B C SHIA0029E D E F G SHIA0083E SRS I J K SHIA0030E L M SHIA0031E SRS-31 TROUBLE DIAGNOSIS SHIA0032E SHIA0033E SHIA0034E SHIA0035E SRS-32 TROUBLE DIAGNOSIS A B C SHIA0084E D E F G SHIA0086E SRS I J K L M SRS-33 TROUBLE DIAGNOSIS Trouble Diagnosis: “AIR BAG” Warning Lamp Does Not Turn OFF BHS0003B DIAGNOSTIC PROCEDURE 7 1. CHECK THE DEPLOYMENT OF AIR BAG MODULE Is air bag module deployed? YES or NO YES >> Refer to SRS-58, "COLLISION DIAGNOSIS" . NO >> GO TO 2. 2. CHECK THE AIR BAG FUSE Check 10A fuse [No.3, located in fuse block (J/B)]. Refer to PG-4, "POWER SUPPLY ROUTING CIRCUIT" . OK or NG OK >> GO TO 4. NG >> GO TO 3 3. CHECK AIR BAG FUSE AGAIN Replace “AIR BAG” fuse and turn ignition switch ON. Does the “AIR BAG” fuse blow again? YES >> Repair or replace main harness. NO >> INSPECTION END 4. CHECK DIAGNOSIS SENSOR UNIT Connect CONSULT-II and touch “START”. Is “AIR BAG” displayed on CONSULT-II? YES or NO YES >> GO TO 5. NO >> Visually check the wiring harness connection of diagnosis sensor unit. If the harness connection check result is OK, replace diagnosis sensor unit. BCIA0030E 5. CHECK HARNESS CONNECTION Is harness connection between warning lamp and diagnosis sensor unit OK? OK or NG OK >> Replace diagnosis sensor unit. NG >> Connect “AIR BAG” warning lamp and diagnosis sensor unit connector properly. If “AIR BAG” warning lamp still does not go off, replace harness. SRS-34 TROUBLE DIAGNOSIS Trouble Diagnosis: “AIR BAG” Warning Lamp Does Not Turn ON BHS0003C A DIAGNOSTIC PROCEDURE 8 1. CHECK “METER” FUSE Check 10A fuse [No.2, located in fuse block (J/B)]. Refer to PG-4, "POWER SUPPLY ROUTING CIRCUIT" . OK or NG OK >> GO TO 3. NG >> GO TO 2. B C 2. CHECK “METER” FUSE AGAIN D Replace 10A fuse [No.2, located in fuse block (J/B)] and turn ignition switch ON. Does the meter fuse blow again? YES >> Repair or replace the related harness. NO >> INSPECTION END E 3. CHECK HARNESS CONNECTION BETWEEN DIAGNOSIS SENSOR UNIT AND COMBINATION F METER Disconnect diagnosis sensor unit connector and turn ignition switch ON. Does “AIR BAG” warning lamp turn ON? YES or NO YES >> Replace diagnosis sensor unit. NO >> Replace combination meter assembly. G SRS I J K L M SRS-35 DRIVER AIR BAG MODULE DRIVER AIR BAG MODULE Removal and Installation PFP:K8510 BHS0003D PHIA1081J 1. Side lid 2. Driver air bag module REMOVAL CAUTION: ● Before servicing SRS, turn the ignition switch OFF, disconnect both battery cables and wait at least 3 minutes. ● Always work from the side of driver air bag module. ● Do not use air tools or electric tools for servicing. 1. Remove the side lids. 2. Remove the right and left side special bolts. Special bolt (TORX T30) : 9.3 N·m (0.95 kg-m, 82.5 in-ib) MIIB0243E 3. 4. Disconnect the steering wheel switch sub-harness connector. Disconnect the air bag harness connector, and remove the driver air bag module. CAUTION: ● For removing and installing air bag harness connector, insert a flat-bladed screwdriver wrapped with a tape into lock, and raise lock to remove connector. ● Install connector with lock raised, and push lock into connector. ● Confirm the lock is fully pushed in after mounting connector. MIIB0244E SRS-36 DRIVER AIR BAG MODULE CAUTION: ● Always place driver air bag module with pad side facing upward. ● Do not insert any foreign objects (screwdriver, etc.) into driver air bag module. ● Do not attempt to disassemble driver air bag module. ● Do not use old bolts after removal; replace with new ones. ● Do not expose the driver air bag module to temperatures exceeding 90°C (194°F). A B C MIIB0245E ● ● Replace driver air bag module if it has been dropped or sustained an impact. Do not allow oil, grease or water to come in contact with the front passenger air bag module. D E F G SBF814E SRS INSTALLATION Install in the reverse order of removal. CAUTION: ● Always work from the side of driver air bag module. ● Do not use air tools or electric tools for servicing. ● After the work is completed, perform self-diagnosis to check that no malfunction is detected. Refer to SRS-18, "SRS Operation Check" . I J K L M SRS-37 SPIRAL CABLE SPIRAL CABLE Removal and Installation PFP:25554 BHS0003E PHIA1083J 1. Steering wheel 2. Steering key cylinder escutcheon 3. Steering column cover (lower/upper) 4. Wiper and Washer switch 5. Lighting and turn signal switch 6. Spiral cable REMOVAL CAUTION: ● Before servicing SRS, turn the ignition switch OFF, disconnect both battery cables and wait at least 3 minutes. ● Do not use air tools or electric tools for servicing. 1. Remove driver air bag module. Refer to SRS-36, "DRIVER AIR BAG MODULE" . 2. Set the steering wheel in the neutral position. 3. Remove horn switch connector. MIIB0249E 4. 5. 6. 7. Remove steering wheel. Refer to PS-5, "STEERING WHEEL" . Remove steering column cover. Refer to IP-7, "F. Steering Column Cover Upper" . Remove wiper and washer switch, lighting and turn signal switch. Loosen screws. While pushing upper plastic tab, remove spiral cable. CAUTION: ● Do not attempt to disassemble spiral cable. ● Do not apply lubricant to the spiral cable. SRS-38 SPIRAL CABLE 8. Remove horn switch connector, and then spiral cable connector. A B C SHIA0193E D INSTALLATION Install in the reverse order of removal. CAUTION: ● Do not use air tools or electric tools for servicing. ● The spiral cable may snap due to steering operation if the cable is installed in an improper position. ● Also, with the steering linkage disconnected the cable may snap by turning the steering wheel beyond the limited number of turns. The spiral cable can be turned counterclockwise about 2.5 turns from the right end position. ● After the work is completed, perform self-diagnosis to check that no malfunction is detected. Refer to SRS-18, "SRS Operation Check" . E F G PHIA0275E SRS I J K L M SRS-39 FRONT PASSENGER AIR BAG MODULE FRONT PASSENGER AIR BAG MODULE Removal and Installation PFP:K8515 BHS0003F REMOVAL CAUTION: ● Before servicing SRS, turn ignition switch OFF, disconnect both battery cables and wait at least 3 minutes. ● Always work from the side of or under front passenger air bag module. ● Do not use air tools or electric tools for servicing. 1. Remove glove box assembly. Refer to IP-5, "Removal and Installation" . 2. Remove air bag module mounting bolt. Mounting bolt - (1) : 24.5 N·m (2.5 kg-m, 18 ft-lb) MHIB0126E 3. 4. 5. Disconnect harness connector from the passenger air bag module. Remove instrument assist upper panel. Refer to IP-4, "INSTRUMENT PANEL ASSEMBLY" . Remove air bag module mounting screws. Mounting screw - (1) Air bag module - (2) MHIB0127E 6. Remove air bag module from the instrument assist upper panel. NOTE: Pull out and remove air bag module front tab and rear tab. Front tab - (1) Rear tab - (2) MHIB0131E SRS-40 FRONT PASSENGER AIR BAG MODULE CAUTION: ● Always place front passenger air bag module with warning label side facing upward. ● Do not insert any foreign objects (screwdriver, etc.) into front passenger air bag module. ● Do not attempt to disassemble front passenger air bag module. ● Do not use old bolts after removal; replace with new ones. A B C PHIA0167E ● ● ● ● Replace front passenger air bag module if it has been dropped or sustained an impact. Do not expose the front passenger air bag module to temperature exceeding 90°C (194°F). Do not allow oil, grease or water to come in contact with the front passenger air bag module. After front passenger air bag module inflates, the instrument panel assembly should be replaced. D E F G SBF814E SRS INSTALLATION Install in the reverse order of removal. CAUTION: ● Always work from the side of or under front passenger air bag module. ● Do not use air tools or electric tools for servicing. ● After the work is completed, perform self-diagnosis to check that no malfunction is detected. Refer to SRS-18, "SRS Operation Check" . I J K L M SRS-41 FRONT SIDE AIR BAG MODULE FRONT SIDE AIR BAG MODULE Removal and Installation PFP:K8EH0 BHS0003G MIIB0255E REMOVAL CAUTION: ● Before servicing SRS, turn the ignition switch OFF, disconnect both battery cables and wait at least 3 minutes. ● Always work from the rear of the front side air bag module. ● Do not use air tools or electric tools for servicing. 1. Remove the driver and/or passenger seat. Refer to SE-10, "Disassembly and Assembly of Seat Cushion" . 2. Remove the seatback trim and pad. Refer to SE-8, "Disassembly and Assembly of Seatback" . 3. Remove the air bag module harness clips. 4. Remove the special nuts coated with bonding agent from the front side air bag module, and remove the front side air bag module. CAUTION: ● Always place the front side air bag module standing with the stud bolts side facing down. ● Do not insert any foreign objects (screwdriver, etc.) into front side air bag module. ● Do not attempt to disassemble front side air bag module. ● Do not use old bolts after removal; replace with new ones. PHIA0169E ● ● ● ● Replace front seatback assembly (side air bag module) if it has been dropped or sustained an impact. Do not expose front seatback assembly (side air bag module) to temperature exceeding 90°C (194°F). Do not allow oil, grease or water to come in contact with the front side air bag module. After front side air bag module inflates, front seatback assembly must be replaced. SBF814E SRS-42 FRONT SIDE AIR BAG MODULE INSTALLATION Install in the reverse order of removal. CAUTION: ● Always work from the side of or under front side air bag module. ● Do not use air tools or electric tools for servicing. ● After the work is completed, perform self-diagnosis to make sure that no malfunction is detected. Refer to SRS-18, "SRS Operation Check" . A B C D E F G SRS I J K L M SRS-43 SIDE CURTAIN AIR BAG MODULE SIDE CURTAIN AIR BAG MODULE Removal and Installation PFP:985P0 BHS0003H PHIA1075J 1. Curtain air bag module REMOVAL CAUTION: ● Before servicing SRS, turn the ignition switch OFF, disconnect both battery cables and wait at least 3 minutes. ● Always work from the side of the side curtain air bag module. ● Do not use air tools or electric tools for servicing. 1. Remove headliner. Refer to EI-30, "HEADLINER" . 2. Disconnect curtain air bag module connector. 3. Remove the side curtain air bag module mounting bolts. Mounting bolt : 10.8 N·m (1.1 kg-m, 8 ft-lb) 4. Remove the side curtain air bag module. CAUTION: ● Always place the side curtain air bag module with the warning label facing upward. ● Do not attempt to disassemble side curtain air bag module. ● Do not insert any foreign objects (screw driver, etc.) into air bag module connector. ● Replace side curtain air bag module if it has been dropped or sustained an impact. ● Do not expose the air bag module to temperatures exceeding 90°C (194°F). ● Do not allow oil, grease or water to come in contact with the side curtain air bag module. SBF814E INSTALLATION Install in the reverse order of removal. CAUTION: ● Always work from the side of the side curtain air bag module. ● Do not use air tools or electric tools for servicing. ● After replacement of side curtain air bag module, perform self-diagnosis to check that no malfunction is detected. Refer to SRS-18, "SRS Operation Check" . SRS-44 CRASH ZONE SENSOR CRASH ZONE SENSOR Removal and Installation PFP:98582 A BHS0003I REMOVAL CAUTION: ● Before servicing SRS, turn ignition switch OFF, disconnect both battery cables and wait at least 3 minutes. ● Do not use air tools or electric tools for servicing. 1. Disconnect crash zone sensor connector. 2. Remove mounting nuts, and then crush zone sensor. Mounting nut - (1) : B C D 10.8 N·m (1.1 kg-m, 8 ft-lb) Crash zone sensor - (2) E F MHIB0128E CAUTION: Replace crash zone sensor if it has been dropped or sustained an impact. ● Do not attempt to disassemble crash zone sensor. ● Do not use old bolts after removal; replace with new ones. ● G SRS INSTALLATION Install in the reverse order of removal. CAUTION: ● Check crash zone sensor for proper installation. ● Do not use air tools or electric tools for servicing. ● After the work is complete, perform self-diagnosis to check that no malfunction is detected. Refer to SRS-18, "SRS Operation Check" . I J K L M SRS-45 SIDE AIR BAG (SATELLITE) SENSOR SIDE AIR BAG (SATELLITE) SENSOR Removal and Installation PFP:98830 BHS0003J REMOVAL CAUTION: ● Before servicing SRS, turn ignition switch OFF, disconnect both battery cables and wait at least 3 minutes. ● Do not use air tools or electric tools for servicing. 1. Remove front seat belt. Refer to SB-3, "Removal and Installation of Front Seat Belt" . 2. Remove side air bag (Satellite) sensor connector. 3. Remove mounting nuts, then remove side air bag (Satellite) sensor. Mounting nut - (1) : 10.8 N·m (1.1 kg-m, 8 ft-lb) Satellite sensor - (2) Satellite sensor connector - (3) MHIB0130E CAUTION: ● Check side air bag (Satellite) sensor to ensure it is free of deformities, dents, cracks or rust. If it shows any visible signs of damage, replace it with new one. ● Do not attempt to disassemble side air bag (Satellite) sensor if it has been dropped or sustained an impact. ● Do not use old nuts after removal; replace with new ones. INSTALLATION Install in the reverse order of removal. CAUTION: ● Check side air bag (Satellite) sensor for proper installation. ● Do not use air tools or electric tools for servicing. ● After replacement of side air bag (Satellite) sensor, perform self-diagnosis to check that no malfunction is detected. Refer to SRS-18, "SRS Operation Check" . SRS-46 SEAT BELT PRE-TENSIONER SEAT BELT PRE-TENSIONER Removal and Installation PFP:86884 A BHS0003K For removal and installation procedures, refer to SB-3, "Removal and Installation of Front Seat Belt" . B C D E F G SRS I J K L M SRS-47 DIAGNOSIS SENSOR UNIT DIAGNOSIS SENSOR UNIT Removal and Installation PFP:28556 BHS0003L REMOVAL CAUTION: ● Before servicing SRS, turn ignition switch OFF, disconnect both battery cables and wait at least 3 minutes. ● Do not use air tools or electric tools for servicing. 1. Disconnect each harness connector for air bag module and seat belt pre-tensioner. 2. Remove console box. Refer to IP-4, "INSTRUMENT PANEL ASSEMBLY" . 3. Remove the diagnosis sensor unit connector. 4. Remove mounting bolts and ground bolt, then remove diagnosis sensor unit. Mounting bolt - (1) : 24.5 N·m (2.5 kg-m, 18 ft-lb) Ground bolt - (2) : 6.9 N·m (0.7 kg-m, 61 in-lb) MHIB0129E CAUTION: Do not use old bolts after removal; replace with new ones. ● Check diagnosis sensor unit brackets to ensure it is free of deformities, dents, cracks or rust. if it shows any visible signs of damage, replace it with new one. ● Replace diagnosis sensor unit if it has been dropped or sustained an impact. ● INSTALLATION Install in the reverse order of removal. CAUTION: ● Do not use air tools or electric tools for servicing. ● Check the diagnosis sensor unit for proper installation. ● After replacement of diagnosis sensor unit, perform self-diagnosis to check that no malfunction is detected. Refer to SRS-18, "SRS Operation Check" . ECU DISCRIMINATED NO. After replacing the diagnosis sensor unit, make sure that the diagnosis unit identification is correct for the vehicle as equipped. Specification Discriminated No. 2WD/LHD Driver air bag module and Passenger air bag module, Seat belt pre-tensioner/pre-tensioner 2 A911 2WD/RHD Driver air bag module and Passenger air bag module, Seat belt pre-tensioner/pre-tensioner 2 A912 2WD/LHD Driver air bag module and Passenger air bag module, Seat belt pre-tensioner/pre-tensioner 2, and front side air bag module A913 2WD/RHD Driver air bag module and Passenger air bag module, Seat belt pre-tensioner/pre-tensioner 2, and front side air bag module A914 2WD/LHD Driver air bag module and Passenger air bag module, Seat belt pre-tensioner/pre-tensioner 2, front side air bag module and side curtain air bag module A915 2WD/RHD Driver air bag module and Passenger air bag module, Seat belt pre-tensioner/pre-tensioner 2, front side air bag module and side curtain air bag module A916 SRS-48 DISPOSAL OF AIR BAG MODULE AND SEAT BELT PRE-TENSIONER DISPOSAL OF AIR BAG MODULE AND SEAT BELT PRE-TENSIONER Caution for Air Bag Module and Seat Belt Pre-tensioner ● ● ● ● ● ● ● ● ● ● ● ● PFP:00014 A BHS0003M Before disposing of air bag module and seat belt pre-tensioner, or vehicles equipped with such systems, deploy the systems. If such systems have already been deployed due to an accident, dispose of them as B indicated inSRS-49, "DISPOSAL OF AIR BAG MODULE AND SEAT BELT PRE-TENSIONER" . When deploying the air bag module and seat belt pre-tensioner, always use the Special Service Tool; Deployment tool (KV99106400). C When deploying the air bag module and seat belt pre-tensioner, stand at least 5 m (16 ft) away from the deployment component. When deploying air bag module and seat belt pre-tensioner, a fairly loud noise is made, followed by D smoke being released. The smoke is not poisonous, however, be careful not to inhale smoke since it irritates the throat and can cause choking. Always activate one air bag module at a time. E Due to heat, leave air bag module unattended for more than 30 minutes after deployment. Also leave seat belt pre-tensioner unattended for more than 10 minutes after deployment. Be sure to wear gloves when handling a deployed air bag module and seat belt pre-tensioner. F Never apply water to the deployed air bag module and seat belt pre-tensioner. Wash your hands clean after finishing work. Place the vehicle outdoors with an open space of at least 6 m (20 ft) on all sides when deploying air bag G module and seat belt pre-tensioner while mounted in vehicle. Use a voltmeter to make sure the vehicle battery is fully charged. Do not dispose of the air bag module and seat belt pre-tensioner un-deployed. SRS CHECKING DEPLOYMENT TOOL Connecting to Battery CAUTION: The battery must show voltage of 9.6 V or more. Remove the battery from the vehicle and place it on dry wood blocks approximately 5 m (16 ft) away from the vehicle. ● Wait 3 minutes after the vehicle battery is disconnected before proceeding. ● Connect red clip of deployment tool to battery positive terminal and black clip to negative terminal. Make sure the polarity is correct. The right side lamp in the tool, marked “deployment tool power”, should glow with a green light. If the right side lamp glows red, reverse the connections to the battery. I J K L PHIA0003E M Deployment Tool Check Press the deployment tool switch to the ON position. The left side lamp in the tool, marked “air bag connector voltage” should illuminate. If it does not illuminate, replace the tool. SBF266H SRS-49 DISPOSAL OF AIR BAG MODULE AND SEAT BELT PRE-TENSIONER Air Bag Deployment Tool Lamp Illumination Chart (Battery Connected) Switch operation Left side lamp, green* “AIR BAG CONNECTOR VOLTAGE” Right side lamp, green* “DEPLOYMENT TOOL POWER” OFF OFF ON ON ON ON *: If this lamp glows red, the tool is connected to the battery incorrectly. Reverse the connections and make sure the lamp glows green. DEPLOYMENT PROCEDURES FOR AIR BAG MODULE Unless the vehicle is being scrapped, deploying the air bag in the vehicle is not recommended. This may cause damage to the vehicle interior. Anchor air bag module bracket (SST: KV99105300) in a vise secured to a firm foundation during deployment. SRS232-E Deployment of Driver Air Bag Module 1. Make an 8.5 mm (0.335 in) diameter hole in air bag module bracket (SST: KV99105300) at the position shown in figure at right. MIIB0263E 2. 3. Using wire, secure air bag module to air bag module bracket at two places. CAUTION: Use wire of at least 1 mm (0.041 in) diameter. Firmly secure air bag module bracket with air bag module attached in a vise. PHIA0551E 4. Connect deployment tool adapter (SST: KV99110500) to deployment tool (SST: KV99106400) to air bag module connector. PHIA0552E SRS-50 DISPOSAL OF AIR BAG MODULE AND SEAT BELT PRE-TENSIONER 5. Connect red clip of deployment tool to battery positive terminal and black clip to negative terminal. 6. The lamp on the right side of the tool, marked “deployment tool power”, should glow green, not red. 7. Press the button on the deployment tool. The left side lamp on the tool, marked “air bag connector voltage”, will illuminate and the air bag module will deploy. CAUTION: When deploying the driver air bag module, stand at least 5 m (16 ft) away from the air bag module. A B C SRS020-A D Deployment of Front Passenger Air Bag Module 1. Make an 8.5 mm (0.335 in) diameter hole in air bag module bracket (SST: KV99105300) at the position shown in figure at right. E F G SHIA0064J 2. SRS Firmly secure air bag module bracket (SST: KV99105300) in a vise. I J SRS232-E 3. Match a hole in air bag module bracket (held in vise) and front passenger air bag module and fix them with a bolt [M8 × 25 - 30 mm (0.98 - 1.18 in)] and wire. CAUTION: If a gap exists between front passenger air bag module and air bag module bracket, use a piece of wood inserted in the gap to stabilize the air bag module. L M MIIB0266E SRS-51 K DISPOSAL OF AIR BAG MODULE AND SEAT BELT PRE-TENSIONER 4. 5. 6. Connect deployment tool adapter (SST: KV99109700) to deployment tool (SST: KV99106400) connector and front passenger air bag module connector. Connect red clip of deployment tool to battery positive terminal and black clip to negative terminal. The lamp on the right side of the tool, marked “deployment tool power”, should glow green, not red. MIIB0267E 7. Press the button on the deployment tool. The left side lamp on the tool, marked “air bag connector voltage”, will illuminate and the air bag module will deploy. CAUTION: ● When deploying the front passenger air bag module, do not stand on the deploying side. ● Stand at least 5 m (16 ft) away from the air bag module. SRS020-A Deployment of Front Side Air Bag Module 1. Make 6.5 mm (0.256 in) diameter holes in air bag module bracket (SST: KV99105300) at the position shown in figure at right. MIIB0268E 2. 3. Firmly secure air bag module bracket (SST: KV99105300) in a vise. Insert the stud bolts of side air bag module into the two holes in air bag module bracket (held in vise) and fix them with two M6 nuts. CAUTION: Side air bag module should be secured to air bag module bracket (SST: KV99105300) in a vise with stud bolt side setting bottom. MIIB0269E SRS-52 DISPOSAL OF AIR BAG MODULE AND SEAT BELT PRE-TENSIONER 4. Connect deployment tool adapter (SST: KV99108300) and deployment tool (SST: KV99106400) on side air bag module. A B C PHIA0008E D 5. Connect red clip of deployment tool to battery positive terminal and black clip to negative terminal. 6. The lamp on the right side of the tool, marked “deployment tool power”, should glow green, not red. 7. Press the button on the deployment tool. The left side lamp on the tool, marked “air bag connector voltage”, will illuminate and the air bag module will deploy. CAUTION: When deploying the front side air bag module, stand at least 5 m (16 ft) away from the air bag module. E F G PHIA0567E Deployment of Side Curtain Air Bag Module·· 1. SRS Cut the inflator from side curtain air bag module. I J PHIA1311J 2. Connect deployment tool (SST: KV99106400) connector to deployment tool adapter (SST: KV99110500) the inflator. K L M PHIA1312J SRS-53 DISPOSAL OF AIR BAG MODULE AND SEAT BELT PRE-TENSIONER 3. Put the inflator connected with the deployment tool adaptor (SST: KV99110500) into a tire without wheel. Inflator - (1) PHIA1284J 4. Put the tyre with the inflator onto another tyre without wheel. Add an additional tyre without wheel and then a tyre mounted on a wheel on top. CAUTION: Tie all tyres together with a strap in order keep them standing. 5. Connect red clip of deployment tool to battery positive terminal and black clip to negative terminal. 6. The lamp on the right side of the tool, marked “deployment tool power”, should glow green, not red. MIIB0273E 7. Press the button on the deployment tool. The left side lamp on the tool, marked “air bag connector voltage”, will illuminate and the air bag module will deploy. CAUTION: When deploying the side curtain air bag module, stand at least 5 m (16 ft) away from the side curtain air bag module. DEPLOYMENT PROCEDURES FOR SEAT BELT PRE-TENSIONER 1. Firmly grip pre-tensioner in a vise. PHIA0034E 2. Cut the webbing off. PHIA0035E SRS-54 DISPOSAL OF AIR BAG MODULE AND SEAT BELT PRE-TENSIONER 3. Connect deployment tool adapter (SST: KV99110500) to deployment tool (SST: KV99106400) connector and front seat belt pretensioner connector. A B C PHIA0556E D 4. Connect red clip of deployment tool to battery positive terminal and black clip to negative terminal. 5. The lamp on the right side of the tool, marked “deployment tool power”, should glow green, not red. 6. Press the button on the deployment tool. The left side lamp on the tool, marked “seat belt pre-tensioner connector voltage”, will illuminate and the seat belt pre-tensioner will deploy. CAUTION: When deploying the front seat belt pre-tensioner, stand at least 5 m (16 ft) away from the seat belt pre-tensioner. E F G SRS242-D DEPLOYMENT PROCEDURES FOR FRONT SEAT BELT PRE-TENSIONER 2 (OUTSIDE OF VEHICLE) 1. SRS Cut off the webbing. Seat belt - (1) Inflator - (2) I J K PHIA1167E 2. Connect deployment tool and deployment tool adapter yellow connector to front seat belt pre-tensioner. Deployment tool - A Deployment tool adapter - C Yellow connector - (c) L : KV99106400 : KV99110500 M PHIA1168E SRS-55 DISPOSAL OF AIR BAG MODULE AND SEAT BELT PRE-TENSIONER 3. Put the pre-tensioner connected with the deployment tool into a tire without a wheel. Inflator - (1) PHIA1288J 4. 5. 6. Connected red clip of deployment tool to battery positive terminal and back clip to negative terminal. The lamp on the right side of the tool, marked "deployment tool power" , should glow green, not red. Press the button on the deployment tool. The left side lamp on the tool, marked "seat beltpre-tensioner connector voltage" , will illuminate and the seat belt pre-tensioner will deploy. Inflator - (1) Deployment tool - A : KV99106400 PHIA1173E CAUTION: When deploying the front seat belt pre-tensioner, stand at least 5 m (16 ft) away from the seat belt pretensioner. SRS-56 DISPOSAL OF AIR BAG MODULE AND SEAT BELT PRE-TENSIONER DEPLOYMENT OF AIR BAG MODULE AND SEAT BELT PRE-TENSIONER WHILE MOUNTED IN VEHICLE A When disposing of a vehicle, deploy air bag module and seat belt pre-tensioners while they are mounted in vehicle. B CAUTION: When deploying air bag module or seat belt pre-tensioner, ensure vehicle is empty. 1. Disconnect both the vehicle battery cables and wait 3 minutes. C 2. Disconnect air bag module and seat belt pre-tensioner connector. 3. Connect deployment tool (SST: KV99106400 ) to air bag module. For driver air bag module, attach deployment tool adapter (SST: KV99110500) to the tool connector. For front passenger air bag module, attach deployment tool adapter (SST: KV99109700) to the tool con- D nector. For front side air bag module, attach deployment tool adapter (SST: KV99108300) to the tool connector. For seat belt pre-tensioner, attach deployment tool adapter (SST: KV99110500) to the tool connector. E For side curtain air bag module, attach deployment tool adapter (SST: KV99110500) to the tool connector. 4. Connect red clip of deployment tool to battery positive terminal and black clip to negative terminal. F 5. The lamp on the right side of the tool, marked “deployment tool power”, should glow green, not red. 6. Press the button on the deployment tool. The left side lamp on G the tool, marked “air bag connector voltage”, will illuminate and the air bag module or seat belt pre-tensioner will deploy. CAUTION: SRS Activate only one air bag module or seat belt pre-tensioner at a time. SRS006 DISPOSING OF AIR BAG MODULE AND SEAT BELT PRE-TENSIONER Deployed air bag module and seat belt pre-tensioner are very hot. Before disposing of air bag module, and seat belt pre-tensioner wait at least 30 minutes, and 10 minutes, respectively. Seal them in a plastic bag before disposal. CAUTION: ● Never apply water to a deployed air bag module and seat belt pre-tensioner. ● Be sure to wear gloves when handling a deployed air bag module and seat belt pre-tensioner. ● No poisonous gas is produced upon air bag module deployment. However, be careful not to inhale gas since it irritates throat and can cause choking. ● Do not attempt to disassemble air bag module and seat belt pre-tensioner. ● Air bag module and seat belt pre-tensioner cannot be SBF276H reused. ● Wash your hands clean after finishing work. SRS-57 I J K L M COLLISION DIAGNOSIS COLLISION DIAGNOSIS For Frontal Collision PFP:00015 BHS0003N To repair the SRS, perform the following steps. When SRS (except the front side air bag and side curtain air bag modules) is activated in a collision: 1. Replace the diagnosis sensor unit. 2. Remove the air bag modules (except the front side air bag modules and side curtain air bag modules), crash zone sensor assembly, bracket and seat belt pre-tensioner assemblies. 3. Check the SRS components using the table below: – Replace any SRS components showing visible signs of damage (dents, cracks and deformation). 4. Install new air bag modules (except the front side air bag modules and side curtain air bag modules) crash zone sensor assembly, bracket and seat belt pre-tensioner assemblies. 5. Conduct self-diagnosis using CONSULT-II or “AIR BAG” warning lamp. Refer to SRS-18, "SRS Operation Check" for details. Ensure entire SRS operates properly. When SRS is not activated in a collision: 1. Check the SRS components using the table below: – Replace any SRS components showing visible signs of damage (dents, cracks and deformation). 2. Conduct self-diagnosis using CONSULT-II or “AIR BAG” warning lamp. Refer to SRS-18, "SRS Operation Check" for details. Ensure entire SRS operates properly. SRS INSPECTION (FOR FRONTAL COLLISION) Part SRS is activated SRS is NOT activated Air bag module (driver and front passenger air bag module) REPLACE Install with new bolts. 1. Remove air bag module. Check harness cover and connectors for damage, terminals for deformities, and harness for binding. 2. – Install driver air bag module into the steering wheel to check fit and alignment with the wheel. – Install passenger air bag module into the instrument panel to check fit with the instrument panel. 3. No damage found, reinstall with new bolts. 4. If damaged—REPLACE air bag modules with new special bolts. Air bag must be deployed before disposal. Crash zone sensor REPLACE the crash zone sensor and bracket with new nuts. 1. Remove the crash zone sensor. Check harness connectors for damage, terminals for deformities, and harness for binding. 2. Check for visible signs of damage (dents, cracks, deformation) of the crash zone sensor and bracket. 3. Install the crash zone sensor to check fit. 4. No damage found, reinstall with new bolts. 5. If damaged—REPLACE the crash zone sensor and bracket with new nuts. Seat belt pretensioner assemblies REPLACE Install seat belt pretensioner with new bolts. 1. Remove seat belt pre-tensioners. Check harness cover and connectors for damage, terminals for deformities, and harness for binding. 2. Check belts for damage and anchors for loose mounting. 3. Check retractor for smooth operation. 4. Check seat belt adjuster for damage. 5. If no damage is found, reinstall seat belt pre-tensioner assembly with new bolts. 6. If damaged—REPLACE seat belt pre-tensioners with new bolts. Seat belt pre-tensioners must be deployed before disposal. Diagnosis sensor unit REPLACE Install with new bolts. 1. Check case for dents, cracks or deformities. 2. Check connectors for damage, and terminals for deformities. 3. If no damage is found, reinstall with new bolts and ground bolt. 4. If damaged—REPLACE diagnosis sensor unit with new bolts and ground bolt. SRS-58 COLLISION DIAGNOSIS Part Steering wheel SRS is activated SRS is NOT activated 1. Visually check steering wheel for deformities. A 2. Check harness (built into steering wheel) and connectors for damage, and terminals for deformities. 3. Install air bag module to check fit or alignment with steering wheel. 4. Check steering wheel for excessive free play. B 5. If no damage is found, reinstall with nut. 6. If damaged—REPLACE. Spiral cable C 1. Visually check spiral cable and combination switch for damage. 2. Check connectors and protective tape for damage. 3. Check steering wheel for noise, binding or heavy operation. D 4. If no damage is found, reinstall with screws. 5. If damaged—REPLACE. Harness and connectors 1. Check connectors for poor connection, damage, and terminals for deformities. 2. Check harness for binding, chafing, cuts, or deformities. 3. If no damage is found, reinstall the harness and connectors. 4. If damaged—REPLACE damaged section of harness. Do not attempt to repair, splice or modify any SRS harness. Instrument panel E 1. Visually check instrument panel for damage. 2. If no damage is found, reinstall the instrument panel. F G 3. If damaged—REPLACE the instrument panel with bolts. SRS I J K L M SRS-59 COLLISION DIAGNOSIS For Side Collision BHS0003O WHEN THE SIDE AIR BAG IS ACTIVATED IN THE SIDE COLLISION: 1. – – – – 2. – 3. Replace the following components: All parts of front seatback (including front seatback frame) with front side air bag module (on the side on which front side air bag is activated) Curtain air bag module (on the side on which side curtain air bag is activated) Diagnosis sensor unit Satellite sensor (on the side on which side air bag and side curtain air bag is activated) Check the SRS components and the related parts using the following table. Replace any SRS components and the related parts showing visible signs of damage (dents, cracks, deformation). Conduct self-diagnosis using CONSULT-II or “AIR BAG” warning lamp. Refer to SRS-18, "SRS Operation Check" . Ensure entire SRS operates properly. WHEN SRS IS NOT ACTIVATED IN THE SIDE COLLISION: 1. – 2. Check the SRS components and the related parts using the following table. Replace any SRS components and the related parts showing visible signs of damage (dents, cracks, deformation). Conduct self-diagnosis using CONSULT-II or “AIR BAG” warning lamp. Refer to SRS-18, "SRS Operation Check" . Ensure entire SRS operates properly. SRS INSPECTION (FOR SIDE COLLISION) Part (LH or RH) side curtain air bag module Front (LH or RH) side air bag module (LH or RH) side air bag (Satellite) sensor Diagnosis sensor unit Front side air bag and side curtain air bag is activated REPLACE the side curtain air bag module. (Repair the center pillar inner, etc. before installing new one if damaged.) Front side air bag and side curtain air bag is NOT activated 1. Check for visible signs of damage (dents, tears, deformation) of the center pillar on the collision side. 2. If damaged— Remove the side curtain air bag module. 3. Check for visible signs of damaged (tears etc.) of the side curtain air bag module. 4. Check harness and connectors for damage, and terminals for deformities. 5. If no damage is found, reinstall the side curtain air bag module with new bolts. 6. If damaged—REPLACE the side curtain air bag module with new bolts. Air bag must be deployed before disposal. REPLACE all parts of seatback with deployed front side air bag module. 1. Check for visible signs of damage (dents, tears, deformation) of the seatback on the collision side. REPLACE the side air bag (Satellite) sensor on the collision side with new nuts. (Repair the center pillar inner, etc. before installing new one if damaged.) 1. Remove the side air bag (Satellite) sensor on the collision side. Check harness connectors for damage, terminals for deformities, and harness for binding. REPLACE the diagnosis sensor unit with the new bolts. 1. Check case and bracket for dents, cracks or deformities. 2. Check harness and connectors for damage, and terminals for deformities. 3. If damaged—REPLACE the front seatback assembly. Air bag must be deployed before disposal. 2. Check for visible signs of damage (dents, cracks, deformation) of the side air bag (Satellite) sensor. 3. Install the side air bag (Satellite) sensor to check fit. 4. If no damage is found, reinstall the side sir bag (Satellite) sensor with new nuts. 5. If damaged—REPLACE the side air bag (Satellite) sensor with new nuts. 2. Check connectors for damage, and terminals for deformities. 3. If no damage is found, reinstall the diagnosis sensor unit with new bolts and ground bolt. 4. If damaged—REPLACE the diagnosis sensor unit with new bolts and ground bolt. SRS-60 COLLISION DIAGNOSIS Part Seat belt pretensioner assembly Front side air bag and side curtain air bag is activated Front side air bag and side curtain air bag is NOT activated 1. Check if the seat belt can be extended smoothly. If the seat belt cannot be extended smoothly, – Check for deformities of the center pillar inner. – If the center pillar inner has no damage, Replace the seat belt pre-tensioner assembly. 2. Remove the seat belt pre-tensioner assembly on the collision side. Check harness cover and connectors for damage, terminals for deformities, and harness for binding. A B C 3. Check for visible signs of damage (dents, cracks, deformation) of the seat belt pre-tensioner assembly. 4. Check seat belt adjuster for damage. D 5. If no damage is found, reinstall the seat belt pre-tensioner assembly. 6. If damaged—REPLACE the seat belt pre-tensioner assembly with new bolts. The seat belt pre-tensioner assembly must be deployed before disposal. Seat with front side air bag REPLACE all parts of front seatback (including front seatback frame) E 1. Visually check the seat on the collision side. 2. Remove the seat on the collision side and check the following for damage and deformities. – Harness, connectors and terminals – Frame and recliner (for front and rear seat), and also adjuster and slides (for front seat) F G 3. If no damage is found, reinstall the seat. 4. If damaged—REPLACE the damaged seat parts using new bolts. Center inner pillar 1. Check the center inner pillar on the collision side for damage (dents, cracks, deformation). SRS 2. If damaged—REPAIR the center inner pillar. Trim/headlining 1. Check for visible signs of damage (dents, cracks, deformation) of the interior trim on the collision side. 2. If damaged—REPLACE the damaged trim parts. I J K L M SRS-61 COLLISION DIAGNOSIS SRS-62 STEERING CONTROL SYSTEM G STEERING SECTION STC STEERING CONTROL SYSTEM A B C D CONTENTS EPS PRECAUTIONS .......................................................... 2 Maintenance Information .......................................... 2 RHD MODELS ...................................................... 2 LHD MODELS ....................................................... 2 SYSTEM DESCRIPTION ............................................ 3 Components ............................................................. 3 Electric Power Steering Function ............................. 3 Fail-Safe Function .................................................... 3 TROUBLE DIAGNOSIS .............................................. 4 How to Perform Trouble Diagnosis .......................... 4 BASIC CONCEPT ................................................. 4 Component Parts Location ....................................... 5 Schematic ................................................................ 6 Wiring Diagram — EPS — ....................................... 7 Control Unit Input/Output Signal Standard ............. 10 CIRCUIT TESTER REFERENCE VALUE ........... 10 STANDARD BY CONSULT-II .............................. 10 CONSULT-II Function (EPS) ...................................11 CONSULT-II MAIN FUNCTION ............................11 CONSULT-II START PROCEDURE .....................11 SELF-DIAGNOSIS ...............................................11 DATA MONITOR ................................................. 12 ECU PART NUMBER .......................................... 13 CAN COMMUNICATION ..................................... 13 For Fast and Accurate Trouble Diagnosis .............. 13 Basic Inspection ..................................................... 13 BASIC INSPECTION 1: POWER SUPPLY CIRCUIT TERMINAL LOOSENESS AND BATTERY... 13 BASIC INSPECTION 2: EPS WARNING LAMP INSPECTION ...................................................... 13 BASIC INSPECTION 3: EPS CONTROL UNIT POWER SUPPLY CIRCUIT AND GROUND CIRCUIT INSPECTION ............................................. 14 Inspection 1: Battery Voltage Malfunction .............. 15 Inspection 2: Torque Sensor Malfunction ............... 16 Inspection 3: Motor Malfunction .............................. 17 Inspection 4: EEPROM Malfunction ....................... 18 Inspection 5: Control unit malfunction .................... 18 Inspection 6: Vehicle Speed Signal Malfunction ..... 19 Inspection 7: Engine Signal Malfunction ................. 19 Inspection 8: CAN Communication Circuit ............. 20 Symptom 1: Steering is Heavy or Light .................. 20 Symptom 2: There is a Difference in the Steering Turning/Returning Force of Left and Right (Biased to One Side) ........................................................... 21 Symptom 3: Steering Wheel Turning Force is Uneven (Torque Variation) ...................................... 21 Symptom 4: EPS Warning Lamp Stays ON ............ 22 STC-1 E F STC H I J K L M PRECAUTIONS [EPS] PRECAUTIONS Maintenance Information [EPS] PFP:00001 BGS0004A If any of following part is replaced, always replace with new* one. If it's not (or fail to do so), the electrical system may not be operated properly. *: New one means a virgin control unit that has never been energized on-board. RHD MODELS ● ● ● ● ● ● BCM (Models without Intelligent Key system) Intelligent Key unit (Models with Intelligent Key system) ECM IPDM E/R Combination meter EPS control unit LHD MODELS ● ● ● BCM (Models without Intelligent Key system) Intelligent Key unit (Models with Intelligent Key system) ECM STC-2 SYSTEM DESCRIPTION [EPS] SYSTEM DESCRIPTION Components PFP:00000 A BGS0002W B C D E F STC SGIA1304E 1. Steering wheel 2. Motor 3. EPS control unit 4. Steering gear assembly 5. Torque sensor 6. Reduction gear A. Sensor processing signal B. Sensor signal C. Assist torque signal (motor drive) F. CAN (L) D. Ignition power E. CAN (H) G. Power supply H. Ground I Electric Power Steering Function BGS0002X Parts name Electric power steering (EPS) control unit Motor Torque sensor Reduction gear EPS warning lamp H Function J ● Outputs optimum assist torque signal to motor by steering wheel turning force (sensor signal) from torque sensor and vehicle speed signal from CAN communication. ● Reduces output signals to motor and protects motor and EPS control unit when using power steering continuously and excessively. ● Under unusual conditions of electric system, fail-safe function starts, output signal to motor is turned off, and then changes to manual steering. EPS warning lamp turns on to indicate system error. ● Controls communication with other control units by using CAN communication. ● Allows system diagnosis with CONSULT-II ● Produces assist torque by control signal from EPS control unit. ● Detects steering wheel turning force and outputs sensor signal to EPS control unit. ● Increases motor-produced assist torque by worm gear and transmits it to column shaft. ● Turns on when fail-safe function operates, and indicates manual steering state. ● Turns on when key switch is turned on to check value, and turns off after engine starts Fail-Safe Function L M BGS0002Y In case an unusual condition is encountered in the system, fail-safe function stops EPS control and the system enters a fail-safe state. EPS warning lamp turns on to indicate unusual state, and enters a manual steering state. (Control turning force of steering wheel becomes heavy.) STC-3 K TROUBLE DIAGNOSIS [EPS] TROUBLE DIAGNOSIS How to Perform Trouble Diagnosis PFP:00004 BGS0002Z BASIC CONCEPT ● ● The most important point to perform trouble diagnosis is to understand systems (control and mechanism) in vehicle thoroughly. It is also important to clarify customer complaints before inspection. First of all, reproduce symptom, and understand it fully. Ask customer about his/her complaints carefully. In some cases, it will be necessary to check symptom by driving vehicle with customer. CAUTION: Customers are not professionals. Do not assume “maybe customer means...” or “maybe customer mentioned this symptom”. SEF234G ● ● ● It is essential to check symptoms right from beginning in order to repair a malfunction completely. For an intermittent malfunction, it is important to reproduce symptom based on interview with customer and past examples. Do not perform inspection on ad hoc basis. Most intermittent malfunctions are caused by poor contacts. In this case, it will be effective to shake suspected harness or connector by hand. When repairs are performed without any symptom check, no one can judge if malfunction has actually been eliminated. After diagnosis, make sure to perform “ERASE MEMORY”. Refer to STC-11, "Erase Memory" . Always read “GI General Information” to confirm general precautions. Refer to GI-4, "General Precautions" . STC-4 SEF233G TROUBLE DIAGNOSIS [EPS] Component Parts Location BGS00030 A B C D E F STC H I J K L M MGIB0003E 1. Motor 2. EPS control unit 3. 4. Reduction gear (built-in) 5. EPS warning lamp A. Sensor processing signal B. Sensor signal C. Assist torque signal (motor drive) D. Ignition power E. CAN (H) F. G. Power supply H. Ground CAN (L) STC-5 Torque sensor (built-in) TROUBLE DIAGNOSIS [EPS] Schematic BGS00031 MGWA0006E STC-6 TROUBLE DIAGNOSIS [EPS] Wiring Diagram — EPS — BGS00032 A B C D E F STC H I J K L M MGWA0005E STC-7 TROUBLE DIAGNOSIS [EPS] MGWA0007E STC-8 TROUBLE DIAGNOSIS [EPS] A B C D E F STC H I J K L M MGWA0008E STC-9 TROUBLE DIAGNOSIS [EPS] Control Unit Input/Output Signal Standard BGS00033 CIRCUIT TESTER REFERENCE VALUE CAUTION: When checked using a circuit tester for voltage measurement, connector terminals should not be forcefully extended. Terminal Measuring point Measuring condition Standard Torque sensor (sub) Ignition switch ON, steering wheel in neutral position Approx. 2.5 V Torque sensor power supply Ignition switch ON Approx. 8 V 6 (G) Torque sensor (main) Ignition switch ON, steering wheel in neutral position Approx. 2.5 V 7 (Y) Torque sensor ground – Continuity exit – – Ignition switch ON Battery voltage (Approx. 12 V) Ignition switch OFF Approx. 0 V + (wire color) – 4 (V) 5 (BR) Ground 9 (L) – CAN H 10 (O) Ground Ignition power 16 (Y) – CAN L – – 17 (R) Ground Battery power supply Ignition switch ON or OFF Battery voltage (Approx. 12 V) 18 (B) Ground Ground – Continuity exit Motor (+) – – Motor (–) – – 19 (–) – 20 (–) STANDARD BY CONSULT-II CAUTION: The output signal indicates the EPS control unit calculation date. The normal values will be displayed even in the event that the output circuit (harness) is open. DATA MONITOR Monitor item Condition Ignition switch ON or engine running Malfunction inspection checklist Reference values for normal operation Battery voltage (Approx. 12 V) STC-15, "Inspection 1: Battery Voltage Malfunction" Neutral (Steering force is zero): Approx. 0 N·m. The value is changed according to steering left or right. STC-16, "Inspection 2: Torque Sensor Malfunction" Neutral (Steering force is zero and in vehicle is in straight-ahead position): Approx. 0 A. The value is changed according to steering left or right. STC-16, "Inspection 2: Torque Sensor Malfunction", STC-17, "Inspection 3: Motor Malfunction" , STC-18, "Inspection 5: Control unit malfunction" Almost in accordance with the speedometer display. It is not a malfunction, though it might not be corresponding just after ignition switch is turned ON. STC-19, "Inspection 6: Vehicle Speed Signal Malfunction" EPS warning lamp ON: ON EPS warning lamp OFF: OFF Warning lamp circuit inspection DERATING STAT (ON/OFF) Usually OFF. Turn ON when the stationary steering is performed excessively. Return to OFF when leaving it for a while. This is normal. ENGINE STATUS (stop, stall, run, and crank) Displays engine status. STC-19, "Inspection 7: Engine Signal Malfunction" MOTOR VOL (V) TORQUE SENSOR (Nm) MOTOR SIG (A) MOTOR CURRENT (A) Turning steering wheel clockwise or counter clockwise at ignition switch ON or running engine VEHICLE SPEED (km/h) WARNING LAMP (ON/OFF) Ignition switch ON or engine running STC-10 TROUBLE DIAGNOSIS [EPS] CONSULT-II Function (EPS) BGS00034 A CONSULT-II MAIN FUNCTION CONSULT-II can display each diagnostic item using the diagnostic test modes shown following. Mode Function Reference SELF-DIAG RESULTS Receives self-diagnosis results from EPS control unit and indicates DTCs. STC-11, "SELF-DIAGNOSIS" DATA MONITOR Receives input/output signals from EPS control unit and indicates and stores them to facilitate locating cause of malfunctions. STC-12, "DATA MONITOR" ECU PART NUMBER Displays EPS control unit part number. STC-13, "ECU PART NUMBER" CAN DIAG SUPPORT MNTR Monitors transmitting/receiving status of CAN communication. STC-13, "CAN COMMUNICATION" CONSULT-II START PROCEDURE B C D E Refer to GI-36, "CONSULT-II Start Procedure" . SELF-DIAGNOSIS Operation Procedure 1. 2. 3. 4. 5. 6. F Turn ignition switch OFF. Connect CONSULT-II and CONSULT-II CONVERTER to data link connector. STC Turn ignition switch ON. Touch “START (NISSAN BASED VHCL)” “EPS” “SELF-DIAG RESULTS”. ● If EPS is not displayed, print the “SELECT SYSTEM” screen. Then refer to LAN-3, "Precautions When H Using CONSULT-II" . NOTE: Just after starting engine, or turning ignition switch ON, it may not be displayed even if “START (NISI SAN BASED VHCL)” is touched. In this case, reconnect CONSULT-II and CONSULT-II CONVERTER. The self-diagnostic results are displayed. (Touch “PRINT” to print out the self-diagnostic results if necessary.) Check EPS warning lamp if “NO FAILURE” is displayed. J Perform the appropriate inspection from the display item list, and repair or replace the malfunctioning component. Refer to STC-12, "Display Item List" . Erase Memory 1. 2. 3. K Turn ignition switch OFF. Start engine, and touch “START (NISSAN BASED VHCL)” “EPS” “SELF-DIAG RESULTS” and “ERASE” in this order to erase the diagnostic memory. CAUTION: If memory cannot be erased, repeat step 1, 2. Perform self-diagnosis again, and make sure that DTC memory is erased. STC-11 L M TROUBLE DIAGNOSIS [EPS] Display Item List CAUTION: When malfunctions are detected in several system, including the “CAN COMM [U1000]”, inspect the CAN communication system. DTC code Diagnostic item Diagnostic item is detected when.... Check items C1601 BATTERY_VOLT Power supply malfunction supplied to EPS. STC-15 C1604 TORQUE_SENSOR Torque sensor malfunction assembled in column assembly. STC-16 C1606 EPS_MOTOR Motor driver malfunction of motor or EPS control unit. STC-17 C1607 EEPROM EEPROM malfunction of EPS control unit. STC-18 C1608 CONTROL_UNIT EPS control unit internal malfunction. STC-18 C1609 CAN_VHCL_SPEED Vehicle speed signal malfunction received via CAN communication. STC-19 C1610 CAN_ENG_PRM Engine signal malfunction received via CAN communication. STC-19 U1000 CAN_COMM_CIRCUIT Malfunction is detected in CAN communication circuit. STC-20 DATA MONITOR Operation Procedure 1. 2. 3. 4. Touch “START (NISSAN BASED VHCL)” “EPS” “DATA MONITOR”. ● If EPS is not displayed, print the “SELECT SYSTEM” screen. Then refer to LAN-3, "Precautions When Using CONSULT-II" . NOTE: Just after starting engine, or turning ignition switch ON, it may not be displayed even if “START (NISSAN BASED VHCL)” is touched. In this case, reconnect CONSULT-II and CONSULT-II CONVERTER. Return to the monitor item selection screen, and touch any of “ALL SIGNALS”, “SELECTION FROM MENU”. Touch “START”. “DATA MONITOR” screen is displayed. Display Item List Item (Display or Unit) Remarks MOTOR VOL (V) Displays power supply voltage supplied EPS control unit TORQUE SENSOR (Nm) Displays steering wheel turning force detected by torque sensor MOTOR SIG (A) Displays command value of a current sent to motor Displays current value used by EPS. MOTOR CURRENT (A) NOTE: Quick steering may cause mismatch with a command value. This is not a malfunction. VEHICLE SPEED (km/h) In close agreement with a vehicle speed read by speedometer. It may not agree immediately after ignition key switch ON, however, this is not a malfunction. WARNING LAMP (ON/OFF) EPS warning lamp operation condition is displayed DERATING STAT (ON/OFF) Under normal conditions OFF. It turns on if the steering wheel is turned excessively. When left standing, it recovers to OFF. ENGINE STATUS (stop, stall, run, and crank) Displays engine status STC-12 TROUBLE DIAGNOSIS [EPS] ECU PART NUMBER Operation Procedure 1. 2. A Touch “START (NISSAN BASED VHCL)” “EPS” “ECU PART NUMBER”. ● If EPS is not displayed, print the “SELECT SYSTEM” screen. Then refer to LAN-3, "Precautions When Using CONSULT-II" . NOTE: Just after starting engine, or turning ignition switch ON, it may not be displayed even if “START (NISSAN BASED VHCL)” is touched. In this case, reconnect CONSULT-II and CONSULT-II CONVERTER. The part number described on EPS control unit sticker is displayed. CAN COMMUNICATION System Description For Fast and Accurate Trouble Diagnosis BGS00035 Check the following items with the vehicle stopped ● Is air pressure and size of tires proper? ● Is the specified part used for the steering wheel? ● Is control unit a genuine part? ● Is the conditions (looseness of mounting bolts, damage on rod of main body, damage on boot or fire wall seal and leakage of grease) of installation for steering column assembly and steering gear assembly are normal? ● Is the wheel alignment adjusted properly? Refer to FSU-6, "Wheel Alignment" . ● Are there any damage or modification to suspension or body resulting in increased weight or altered ground clearance? ● Check each link installation condition of suspension and axle. ● Is the battery voltage proper? ● Check each connector connection condition. Check the following items while driving the vehicle ● Conditions when the error occurred (5W 1H). ● Is the engine is normal? Basic Inspection BGS00036 BASIC INSPECTION 1: POWER SUPPLY CIRCUIT TERMINAL LOOSENESS AND BATTERY Check battery terminals for looseness on both positive and negative ones and ground connection. Also make sure that battery voltage does not drop. BASIC INSPECTION 2: EPS WARNING LAMP INSPECTION 2. 3. C D CAN (Controller Area Network) is a serial communication line for real time application. It is an on-vehicle multiplex communication line with high data communication speed and excellent error detection ability. Many electronic control units are equipped onto a vehicle, and each control unit shares information and links with other control units during operation (not independent). In CAN communication, control units are connected with 2 communication lines (CAN H line, CAN L line) allowing a high rate of information transmission with less wiring. Each control unit transmits/receives data but selectively reads required data only. Refer to LAN-21, "CAN COMMUNICATION" . 1. B Make sure EPS warning lamp turns on when ignition switch is turned ON. ● If it does not turn on, refer to STC-20, "Inspection 8: CAN Communication Circuit" . ● Check combination meter if CAN communication is normal. Refer to DI-4, "COMBINATION METERS" . Make sure that EPS warning lamp turns off when the engine is started after ignition switch is turned ON. If it does not turn off, perform self-diagnosis. Refer to STC-11, "SELF-DIAGNOSIS" . Always erase DTC memory after completing self-diagnosis. Refer to STC-11, "Erase Memory" . STC-13 E F STC H I J K L M TROUBLE DIAGNOSIS [EPS] BASIC INSPECTION 3: EPS CONTROL UNIT POWER SUPPLY CIRCUIT AND GROUND CIRCUIT INSPECTION 1. CHECK EPS CONTROL UNIT CONNECTOR Turn ignition switch OFF, disconnect EPS control unit harness connector, and check terminal for deformation, disconnection, looseness, etc. OK or NG OK >> GO TO 2. NG >> Connector terminal connection is loose, damaged, open, or shorted. Repair or replace the terminal. 2. CHECK EPS CONTROL UNIT GROUND CIRCUIT Disconnect EPS control unit harness connector M24, and then check continuity between EPS control unit harness connector M24 and ground. 18 – Ground : Continuity exist. OK or NG OK >> GO TO 3. NG >> Ground circuit open or shorted. Repair or replace any inoperative parts. SGIA1306E 3. CHECK EPS CONTROL UNIT POWER SUPPLY CIRCUIT 1. 2. Turn ignition switch on. Check voltage between EPS control unit harness connector M24, M25 and ground. 10, 17 – Ground : Battery voltage (Approx. 12 V) OK or NG OK >> Power supply and ground circuit are normal. NG >> Power supply circuit open or shorted. Repair or replace any inoperative parts. SGIA1307E STC-14 TROUBLE DIAGNOSIS [EPS] Inspection 1: Battery Voltage Malfunction BGS00037 1. CHECK EPS CONTROL UNIT CONNECTOR A 1. Turn ignition switch OFF, disconnect EPS control unit harness connector, and check terminal for deformation, disconnection, looseness, etc. 2. Reconnect harness connector securely, and perform self-diagnosis. Is “BATTERY_VOLT” indicated in self-diagnosis display? YES >> GO TO 2. NO >> Connector terminal connection is loose, damaged, open, or shorted. Repair or replace the terminal. Turn ignition switch OFF. Disconnect EPS control unit harness connector M24, and then check continuity between EPS control unit harness connector M24 and ground. 18 – Ground C D 2. CHECK EPS CONTROL UNIT GROUND CIRCUIT 1. 2. B E F : Continuity exist. OK or NG OK >> GO TO 3. NG >> Ground circuit open or shorted. Repair or replace any inoperative parts. STC H SGIA1306E 3. CHECK EPS CONTROL UNIT POWER SUPPLY CIRCUIT I 1. 2. Turn ignition switch ON. Check voltage between EPS control unit harness connector M24, M25 and ground. 10, 17 – Ground J : Battery voltage (Approx. 12 V) OK or NG OK >> GO TO 4. NG >> Connector terminal connection is loose, damaged, open, or shorted. Repair or replace any inoperative parts. K L SGIA1307E M 4. CHECK EPS CONTROL UNIT 1. 2. Turn ignition switch OFF, disconnect EPS control unit harness connector. Start engine. Check “MOTOR VOL” in CONSULT-II data monitor. Voltage : 10 – 16 V OK or NG OK >> GO TO 5. NG >> EPS control unit malfunction. (Replace EPS control unit) STC-15 TROUBLE DIAGNOSIS [EPS] 5. CHECK POWER SUPPLY CIRCUIT Turn head lamp, A/C, blower fan and rear window defogger OFF. Turn steering wheel until it stops. At that time, check “MOTOR VOL” in CONSULT-II data monitor. Voltage : 10 – 16 V OK or NG OK >> INSPECTION END NG >> Power supply circuit open or shorted. Repair or replace any inoperative pars. Inspection 2: Torque Sensor Malfunction BGS00038 1. CHECK EPS CONTROL UNIT CONNECTOR 1. Turn ignition switch OFF, disconnect EPS control unit harness connector, and check terminal for deformation, disconnection, looseness, etc. 2. Reconnect harness connector securely, and perform self-diagnosis. Is “TORQUE SENSOR” indicated in self-diagnosis display? YES >> GO TO 2. NO >> Connector terminal connection is loose, damaged, open, or shorted. Repair or replace the terminal. 2. CHECK TORQUE SENSOR CONNECTOR 1. Turn ignition switch OFF, disconnect torque sensor harness connector, and check terminal for deformation, looseness, etc. 2. Reconnect harness connector securely, and perform self-diagnosis. Is “TORQUE SENSOR” indicated in self-diagnosis display? YES >> GO TO 3. NO >> Connector terminal connection is loose, damaged, open, or shorted. Repair or replace the terminal. 3. CHECK TORQUE SENSOR HARNESS 1. 2. Turn ignition switch OFF, disconnect the harness connectors of EPS control unit and torque sensor. Check continuity between EPS control unit harness connector and torque sensor harness connector. A Connector B Terminal Connector 4 EPS control unit: M25 5 Continuity Terminal 3 Torque sensor: M26 2 6 1 7 4 Yes MGIB0002E OK or NG OK >> GO TO 4. NG >> Open or short in harness between EPS control unit and torque sensor. Repair applicable harness. STC-16 TROUBLE DIAGNOSIS [EPS] 4. CHECK TORQUE SENSOR POWER SUPPLY 1. 2. A Connect the harness connectors of EPS control unit and torque sensor. Turn ignition switch ON. Turn steering to the neutral position (steering force: zero), and then check voltage EPS control unit harness connector M25. B Torque sensor power supply 5–7 : Approx. 8 V C OK or NG OK >> GO TO 5. NG >> EPS control unit malfunction. (Replace EPS control unit) D SGIA1309E E 5. CHECK TORQUE SENSOR SIGNAL Turn steering to the neutral position (steering force: zero), and then check voltage EPS control unit harness connector M25. F Torque sensor (sub) 4–7 : Approx. 2.5 V Torque sensor (main) 6–7 : Approx. 2.5 V STC OK or NG OK >> EPS control unit malfunction. (Replace EPS control unit) NG >> Torque sensor malfunction. (Replace steering column assembly [with motor, reduction gear, sensor]) Inspection 3: Motor Malfunction H SGIA1310E I BGS00039 1. CHECK EPS CONTROL UNIT CONNECTOR J 1. Turn ignition switch OFF, disconnect EPS control unit harness connector, and check terminal for deformation, disconnection, looseness, etc. 2. Reconnect harness connector securely, and perform self-diagnosis. Is “EPS MOTOR” indicated in self-diagnosis display? YES >> GO TO 2. NO >> Connector terminal connection is loose, damaged, open, or shorted. Repair or replace the terminal. 2. CHECK MOTOR RESISTANCE 1. 2. L M Turn ignition switch OFF, disconnect motor harness connector M 351 from EPS control unit. Check resistance between motor harness connector M351. 19 – 20 K : Approx. 0.1 Ω or less OK or NG OK >> EPS control unit malfunction. (Replace EPS control unit) NG >> Motor malfunction. (Replace steering column assembly [with motor, reduction gear, sensor]) SGIA1311E STC-17 TROUBLE DIAGNOSIS [EPS] Inspection 4: EEPROM Malfunction BGS0003A 1. CHECK EPS CONTROL UNIT CONNECTOR 1. Turn ignition switch OFF, disconnect EPS control unit harness connector, and check terminal for deformation, disconnection, looseness, etc. 2. Reconnect harness connector securely, and perform self-diagnosis. Is “EEPROM” indicated in self-diagnosis display? YES >> EPS control unit malfunction. (Replace EPS control unit) NO >> Connector terminal connection is loose, damaged, open, or shorted. Repair or replace the terminal. Inspection 5: Control unit malfunction BGS0003B 1. CHECK EPS CONTROL UNIT CONNECTOR Turn ignition switch OFF, disconnect EPS control unit harness connector, and check terminal for deformation, disconnection, looseness, etc. OK or NG OK >> GO TO 2. NG >> Connector terminal connection is loose, damaged, open, or shorted. Repair or replace the terminal. 2. CHECK EPS CONTROL UNIT GROUND CIRCUIT Disconnect EPS control unit harness connector M24, and then check continuity between EPS control unit harness connector M24 and ground. 18 – Ground : Continuity exist. OK or NG OK >> GO TO 3. NG >> Ground circuit open or shorted. Repair or replace any inoperative parts. SGIA1306E 3. CHECK EPS CONTROL UNIT POWER SUPPLY CIRCUIT 1. 2. Turn ignition switch turned ON. Check voltage between EPS control unit harness connector M24, M25 and ground. 10, 17 – Ground : Battery voltage (Approx. 12 V) OK or NG OK >> GO TO 4. NG >> Power supply circuit open or shorted. Repair or replace any inoperative parts. SGIA1307E 4. CHECK EPS CONTROL UNIT Connect EPS control unit harness connector securely, and perform self-diagnosis. Is “CONTROL UNIT” indicated in self-diagnosis display? YES >> EPS control unit malfunction. (Replace EPS control unit) NO >> INSPECTION END. STC-18 TROUBLE DIAGNOSIS [EPS] Inspection 6: Vehicle Speed Signal Malfunction BGS0003C 1. CHECK ABS ACTUATOR AND ELECTRIC UNIT (CONTROL UNIT) CIRCUIT A Perform self-diagnosis of ABS actuator and electric unit (control unit). OK or NG OK >> GO TO 2. NG >> Repair or replace the affect part. B C 2. CHECK SPEEDOMETER Perform combination meter (speedometer) self-diagnosis. OK or NG OK >> GO TO 3. NG >> Repair or replace the affect part. D E 3. CHECK EPS CONTROL UNIT CONNECTOR 1. 2. Turn ignition switch OFF, disconnect EPS control unit harness connector, and check terminal for deformation, disconnection, looseness, etc. Reconnect harness connector securely, and perform self-diagnosis. F STC SELF-DIAG RESULTS CAN_VHCL_SPEED H CAN_COMM_CIRCUIT Is above displayed on self-diagnosis display? YES >> ● EPS control unit malfunction. (Replace EPS control unit) ● If “CAN_COMM_CIRCUIT” is displayed, refer to STC-20, "Inspection 8: CAN Communication Circuit" . NO >> Connector terminal connection is loose, damaged, open, or shorted. Repair or replace the terminal. Inspection 7: Engine Signal Malfunction K Make sure that the engine speed signal in CONSULT II data monitor is the almost same as the tachometer. OK or NG OK >> GO TO 2. NG >> Check tachometer and circuit. Refer to DI-4, "COMBINATION METERS" . 2. CHECK EPS CONTROL UNIT CONNECTOR 2. J BGS0003D 1. CHECK ENGINE SPEED SIGNAL 1. I Turn ignition switch OFF, disconnect EPS control unit harness connector, and check terminal for deformation, disconnection, looseness, etc. Reconnect harness connector securely, and perform self-diagnosis. SELF-DIAG RESULTS CAN_ENG_RPM CAN_COMM_CIRCUIT Is above displayed on self-diagnosis display? YES >> ● EPS control unit malfunction. (Replace EPS control unit) ● If “CAN_COMM_CIRCUIT” is displayed, refer to STC-20, "Inspection 8: CAN Communication Circuit" . NO >> Connector terminal connection is loose, damaged, open, or shorted. Repair or replace the terminal. STC-19 L M TROUBLE DIAGNOSIS [EPS] Inspection 8: CAN Communication Circuit BGS0003E 1. CHECK EPS CONTROL UNIT CONNECTOR 1. Turn ignition switch OFF, disconnect EPS control unit harness connector, and check terminal for deformation, disconnection, looseness, etc. 2. Reconnect harness connector securely, and perform self-diagnosis. Is “CAN COMM CIRCUIT” displayed on self-diagnosis display? YES >> Print out the self-diagnosis results and refer to STC-20, "Inspection 8: CAN Communication Circuit" . NO >> Connector terminal connection is loose, damaged, open, or shorted. Repair or replace the terminal. Symptom 1: Steering is Heavy or Light BGS0003F 1. CHECK SELF-DIAGNOSIS RESULTS Check self-diagnosis results. Are there malfunctioning systems in self-diagnosis results? YES >> GO TO 2. NO >> GO TO 4. 2. CHECK EPS CONTROL UNIT CONNECTOR 1. Turn ignition switch OFF, disconnect EPS control unit harness connector, and check terminal for deformation, disconnection, looseness, etc. 2. Reconnect harness connector securely, and perform self-diagnosis. Are there malfunctioning systems in self-diagnosis results? YES >> Repair malfunctioning circuit, and GO TO 3. NO >> GO TO 3. 3. CHECK SYMPTOM Make sure that the steering does not have the symptoms of “Heavy” or “Light”. OK or NG OK >> INSPECTION END. NG >> GO TO 4. 4. CHECK CAN COMMUNICATION CIRCUIT AGAIN Check CAN communication circuit. Refer to STC-20, "Inspection 8: CAN Communication Circuit" . OK or NG OK >> GO TO 5. NG >> Repair malfunctioning circuit. 5. CHECK EPS CONTROL UNIT POWER SUPPLY CIRCUIT Check EPS control unit power supply circuit. Refer to STC-15, "Inspection 1: Battery Voltage Malfunction" . OK or NG OK >> Check steering wheel turning force. Refer to PS-5, "STEERING TORQUE INSPECTION" . NG >> Repair power supply circuit. STC-20 TROUBLE DIAGNOSIS [EPS] Symptom 2: There is a Difference in the Steering Turning/Returning Force of Left and Right (Biased to One Side) BGS0003G A 1. CHECK SELF-DIAGNOSIS RESULTS B Check self-diagnosis results. Are there malfunctioning systems in self-diagnosis results? YES >> GO TO 2. NO >> GO TO 4. C 2. CHECK EPS CONTROL UNIT CONNECTOR 1. Turn ignition switch OFF, disconnect EPS control unit harness connector, and check terminal for deformation, disconnection, looseness, etc. 2. Reconnect harness connector securely, and perform self-diagnosis. Are there malfunctioning systems in self-diagnosis results? YES >> Repair malfunctioning circuit, and GO TO3. NO >> GO TO 3. D E F 3. CHECK SYMPTOM Make sure that the steering does not have the symptoms of “Heavy” or “Light”. OK or NG OK >> INSPECTION END. NG >> GO TO 4. STC H 4. WHEEL ALIGNMENT INSPECTION I Check wheel alignment. Refer to FSU-6, "Wheel Alignment" . OK or NG OK >> Check steering wheel turning force. Refer to PS-5, "STEERING TORQUE INSPECTION" . NG >> Adjust wheel alignment. Refer to FSU-6, "Wheel Alignment" . Symptom 3: Steering Wheel Turning Force is Uneven (Torque Variation) J BGS0003H 1. CHECK SELF-DIAGNOSIS RESULTS K Check self-diagnosis results. Are there malfunctioning systems in self-diagnosis results? YES >> GO TO 2. NO >> GO TO 4. L 2. CHECK EPS CONTROL UNIT CONNECTOR M 1. Turn ignition switch OFF, disconnect EPS control unit harness connector, and check terminal for deformation, disconnection, looseness, etc. 2. Reconnect harness connector securely, and perform self-diagnosis. Are there malfunctioning systems in self-diagnosis results? YES >> Repair malfunctioning circuit, and GO TO 3. NO >> GO TO 3. 3. CHECK SYMPTOM Make sure that the steering does not have the symptoms of “Heavy” or “Light”. OK or NG OK >> INSPECTION END. NG >> GO TO 4. STC-21 TROUBLE DIAGNOSIS [EPS] 4. CHECK EPS CONTROL UNIT POWER SUPPLY CIRCUIT Check EPS control unit power supply circuit. Refer to STC-15, "Inspection 1: Battery Voltage Malfunction" . OK or NG OK >> GO TO 5. NG >> Repair malfunctioning circuit. 5. CHECK STEERING COLUMN INTERMEDIATE SHAFT 1. Check the connection between the intermediate shaft and the mounting part of steering column assembly and steering gear assembly. Refer to PS-7, "STEERING COLUMN" . 2. Make sure that steering wheel turning force is uneven (torque variation). OK or NG OK >> INSPECTION END. NG >> Check steering wheel turning force. Refer to PS-5, "STEERING TORQUE INSPECTION" . Symptom 4: EPS Warning Lamp Stays ON BGS0003I 1. CHECK SELF-DIAGNOSIS RESULTS Check self-diagnosis results. Are there malfunctioning systems in self-diagnosis results? YES >> GO TO 2. NO >> GO TO 4. 2. CHECK EPS CONTROL UNIT CONNECTOR 1. Turn ignition switch OFF, disconnect EPS control unit harness connector, and check terminal for deformation, disconnection, looseness, etc. 2. Reconnect harness connector securely, and perform self-diagnosis. Are there malfunctioning systems in self-diagnosis results? YES >> Repair malfunctioning circuit, and GO TO 3. NO >> GO TO 3. 3. CHECK SYMPTOM Make sure that the steering does not have the symptoms of “Heavy” or “Light”. OK or NG OK >> INSPECTION END. NG >> GO TO 4. 4. CHECK EPS CONTROL UNIT POWER SUPPLY CIRCUIT Check EPS control unit power supply circuit. Refer to STC-15, "Inspection 1: Battery Voltage Malfunction" . OK or NG OK >> GO TO 5. NG >> Repair malfunctioning circuit. 5. CHECK STEERING WHEEL TURNING FORCE Check the EPS assist force when the steering is operated. Refer to PS-5, "STEERING TORQUE INSPECTION" . OK or NG OK >> Check CAN communication circuit. Refer to STC-20, "Inspection 8: CAN Communication Circuit" . NG >> EPS control unit malfunction. STC-22 ROAD WHEELS & TYRES E SUSPENSION SECTION WT ROAD WHEELS & TYRES A B C D CONTENTS PRECAUTIONS .......................................................... 2 Precautions for Supplemental Restraint System (SRS) “AIR BAG” and “SEAT BELT PRE-TENSIONER” .................................................................. 2 NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING ................................................ 3 NVH Troubleshooting Chart ..................................... 3 ROAD WHEEL ............................................................ 4 Inspection ................................................................. 4 ALUMINUM WHEEL ............................................. 4 STEEL WHEEL ..................................................... 4 ROAD WHEEL AND TYRE ASSEMBLY .................... 5 Balancing Wheels (Bonding Weight Type) ............... 5 REMOVAL ............................................................. 5 WHEEL BALANCE ADJUSTMENT ....................... 5 Balancing Wheels (Drive-in Weight Type) ................ 6 WHEEL BALANCE ADJUSTMENT ....................... 6 Rotation .................................................................... 7 SERVICE DATA .......................................................... 8 Road Wheel .............................................................. 8 Tyre ........................................................................... 8 WT F G H I J K L M WT-1 PRECAUTIONS PFP:00011 PRECAUTIONS Precautions for Supplemental Restraint System (SRS) “AIR BAG” and “SEAT BELT PRE-TENSIONER” BES00038 The Supplemental Restraint System such as “AIR BAG” and “SEAT BELT PRE-TENSIONER”, used along with a front seat belt, helps to reduce the risk or severity of injury to the driver and front passenger for certain types of collision. Information necessary to service the system safely is included in the SRS and SB section of this Service Manual. WARNING: ● To avoid rendering the SRS inoperative, which could increase the risk of personal injury or death in the event of a collision which would result in air bag inflation, all maintenance must be performed by an authorized NISSAN/INFINITI dealer. ● Improper maintenance, including incorrect removal and installation of the SRS, can lead to personal injury caused by unintentional activation of the system. For removal of Spiral Cable and Air Bag Module, see the SRS section. ● Do not use electrical test equipment on any circuit related to the SRS unless instructed to in this Service Manual. SRS wiring harnesses can be identified by yellow and/or orange harnesses or harness connectors. WT-2 NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING NOISE, VIBRATION AND HARSHNESS (NVH) TROUBLESHOOTING NVH Troubleshooting Chart PFP:00003 A BES00039 × Shimmy × × × × × Judder × × × × Poor quality ride or handling × × × × Noise × × × Shake × × Shimmy, judder × Poor quality ride or handling × × × × × × × × × × × × × Refer to ROAD WHEEL in this chart. × NVH in PS section. NVH in BR section. NVH in FAX section. Refer to TYRES in this chart. × NVH in RAX and RSU sections. — STEERING × BRAKE × DRIVE SHAFT × ROAD WHEEL × × C H × × × × × × × × × × × × × × × × × × × × × × × × × × × × × × × × × × × × × × × × × × × × × ×: Applicable WT-3 × WT G × × D F TYRES Shake REAR AXLE AND REAR SUSPENSION × NVH in FAX and FSU sections. × FRONT AXLE AND FRONT SUSPENSION × NVH in MT, AT and CVT section. × B DIFFERENTIAL Non-uniformity × Incorrect tyre size Deformation or damage — Uneven tyre wear ROAD WHEEL — Incorrect tyre pressure × Vibration Symptom — Imbalance Noise Possible cause and SUSPECTED PARTS TYRES — Out-of-round Reference page — Refer to WT-4, "ROAD WHEEL" Use the chart below to help you find the cause of the symptom. If necessary, repair or replace these parts. × × I J K L M ROAD WHEEL ROAD WHEEL Inspection PFP:40300 BES0003A ALUMINUM WHEEL 1. 2. a. b. Check tyres for wear and improper inflation. Check wheels for deformation, cracks and other damage. If deformed, remove wheel and check wheel runout. Remove tyre from aluminum wheel and mount on a tyre balance machine. Set dial indicator as shown in the illustration. Wheel runout (Dial indicator value): Refer to WT-8, "SERVICE DATA" SFA975B STEEL WHEEL 1. 2. a. b. c. d. e. Check tyres for wear and improper inflation. Check wheels for deformation, cracks and other damage. If deformed, remove wheel and check wheel runout. Remove tyre from steel wheel and mount wheel on a tyre balance machine. Set two dial indicators as shown in the illustration. Set each dial indicator to 0. Rotate wheel and check dial indicators at several points around the circumference of the wheel. Calculate runout at each point as shown below. Radial runout = (A + B)/2 Lateral runout = (C + D)/2 f. : 0.5 mm (0.020 in) : 0.8 mm (0.031 in) Select maximum positive runout value and the maximum negative value. Add the two values to determine total runout. In case a positive or negative value is not available, use the maximum value (negative or positive) for total runout. If the total runout value exceeds the limit, replace steel wheel. Wheel runout: Refer to WT-8, "SERVICE DATA" WT-4 MDIA0001E ROAD WHEEL AND TYRE ASSEMBLY ROAD WHEEL AND TYRE ASSEMBLY Balancing Wheels (Bonding Weight Type) PFP:40312 A BES0003B REMOVAL 1. 2. Remove inner and outer balance weights from the road wheel. CAUTION: Be careful not to scratch the road wheel during removal procedures. Using releasing agent, remove double-faced adhesive tape from the road wheel. CAUTION: Be careful not to scratch the road wheel during removal. ● After removing double-faced adhesive tape, wipe clean traces of releasing agent from the road wheel. B C D WHEEL BALANCE ADJUSTMENT If a tyre balance machine has adhesion balance weight mode settings and drive-in weight mode setting, WT select and adjust a drive-in weight mode suitable for road wheels. 1. Set road wheel on wheel balancer using the center hole as a guide. Start the tyre balance machine. 2. When inner and outer unbalance values are shown on the wheel balancer indicator, multiply outer unbalance value by 5/3 to determine balance weight that should be used. Select the outer balance weight with F a value closest to the calculated value above and install it to the designated outer position of, or at the designated angle in relation to the road wheel. CAUTION: G ● Do not install the inner balance weight before installing the outer balance weight. ● Before installing the balance weight, be sure to clean the mating surface of the road wheel. Indicated unbalance value × 5/3 = balance weight to be installed H Calculation example: 23 g (0.81 oz) × 5/3 = 38.33 g (1.35 oz) = 40 g (1.41 oz) balance weight (closer to calculated balance weight value) I Note that balance weight value must be closer to the calculated balance weight value. Example: J 37.4 = 35 g (1.23 oz) 37.5 = 40 g (1.41 oz) ● SMA054D ● ● ● Attach weight as shown in figure. When attaching weight to road wheel, align it with step on rear surface of wheel, as shown in figure. Attach so that center of weight and position (angle) of wheel balancer indicator are aligned. Do not attach more than 2 adhesive weights. L M MDIA0002E WT-5 K ROAD WHEEL AND TYRE ASSEMBLY If calculated value exceeds 50 g (1.76 oz), attach two weights side by side, as shown in figure. CAUTION: When attaching two weights, do not attach them one on top of the other. 3. Start the wheel balancer again. 4. As before, attach drive-in weight to inner side of road wheel, according to amount and position (angle) of imbalance indicated by wheel balancer. 5. Start wheel balancer. Check that residual imbalance amount is 10 g (0.35 oz) or less for both outer and inner sides. ● If residual imbalance exceeds 10 g (0.35 oz), then repeat procedure from start. ● MDIA0003E Permissible amount of residual imbalance Dynamic (at lug) : 10 g (0.35 oz) or less (one side) Static (at lug) : 20 g (0.71 oz) or less Maximum balance weight correction : 100 g (3.53 oz) Balancing Wheels (Drive-in Weight Type) BES0003C WHEEL BALANCE ADJUSTMENT 1. 2. ● ● ● ● Remove wheel from vehicle. Set road wheel on wheel balancer and start balancer machine. Set with top/bottom reversed from vehicle installation position. After setting wheel on wheel balancer, make mark on top surface of wheel. Adjust wheel balance using a wheel balancer with straight cone attachment. Be sure cone contacts reverse side of wheel. If a general-purpose taper cone must be used to adjust wheel balance, place cone against reverse side of wheel and support it. Resin hammer must be used to drive in balance weights. CAUTION: Do not reuse balance weights after they are removed. Be sure to use new Nissan genuine weights designed for use with steel wheels. Permissible amount of residual imbalance Dynamic (at lug) : 10 g (0.35 oz) or less (one side) Static (at lug) : 20 g (0.71 oz) or less Maximum balance weight correction : 60 g (2.12 oz) 3. 4. Remove wheel from wheel balancer. Install wheel to vehicle, with mark on lower side. ● Minimize imbalance by keeping same relative positions between hub-wheel contact points when installing to vehicle as when adjusting wheel balance. CAUTION: So as not to deform wheel, install by tightening at opposite angles, in 2 - 3 steps. Tightening torque of wheel nut : 105 N·m (11 kg-m, 77 ft-lb) WT-6 ROAD WHEEL AND TYRE ASSEMBLY Rotation ● ● ● BES0003D A After rotating the tyres, adjust the tyre pressure. Retighten the wheel nuts when the vehicle has been driven for 1,000 km (600 miles) (also in cases of a flat tyre, etc). Do not include the T-type spare tyre when rotating the tyres. CAUTION: When installing wheels, tighten them diagonally by dividing the work two to three times in order to prevent the wheels from developing any distortion. Tightening torque of wheel nut B C : 105 N·m (11 kg-m, 77 ft-lb) D SMA829C WT F G H I J K L M WT-7 SERVICE DATA SERVICE DATA Road Wheel PFP:00030 BES0003E Kind of wheel Aluminum Steel Lateral deflection Less than 0.3 mm (0.012 in) Less than 0.5 mm (0.020 in) Vertical deflection Less than 0.3 mm (0.012 in) Less than 0.8 mm (0.031 in) Deflection limit Allowable quantity of residual unbalance Dynamic (On the ear part) Less than 10 g (0.35 oz) (per side) Static (On the ear part) Less than 20 g (0.70 oz) Tyre BES0003F Unit: kPa (kg/cm2 , psi) Air pressure Tyre size Front wheel Normal condition Rear wheel Full load Normal condition Full load 216 (2.2, 31) 275 (2.8, 40) 175/65R15 226 (2.3, 33) 185/65R15 226 (2.3, 33) 206 (2.1, 30) 185/55R16 (Acenta grade with CR engine) 235 (2.4, 34) 216 (2.2, 31) 185/55R16 (except Acenta grade with CR engine) 245 (2.5, 36) 216 (2.2, 31) T125/70D14 T125/70D15 412 (4.2, 60) WT-8 WIPER, WASHER & HORN K ELECTRICAL SECTION WW WIPER, WASHER & HORN A B C D CONTENTS PRECAUTIONS .......................................................... 3 Precautions for Supplemental Restraint System (SRS) “AIR BAG” and “SEAT BELT PRE-TENSIONER” .................................................................. 3 Maintenance Information .......................................... 3 RHD MODELS ...................................................... 3 LHD MODELS ....................................................... 3 PrecautionsforProcedureswithoutCowlTopCover..... 3 FRONT WIPER AND WASHER SYSTEM .................. 4 Components Parts and Harness Connector Location ........................................................................... 4 System Description .................................................. 4 OUTLINE ............................................................... 4 LOW SPEED WIPER OPERATION ...................... 5 HIGH SPEED WIPER OPERATION ..................... 5 INTERMITTENT OPERATION .............................. 5 AUTO WIPER OPERATION (MODELS WITH LIGHT AND RAIN SENSOR) ................................ 6 AUTO STOP OPERATION .................................... 6 MIST OPERATION ................................................ 6 WASHER OPERATION ......................................... 7 FAIL-SAFE FUNCTION ......................................... 7 COMBINATIONSWITCHREADING FUNCTION..... 8 CAN Communication ...............................................11 SYSTEM DESCRIPTION .....................................11 CAN Communication Unit .......................................11 Schematic .............................................................. 12 Wiring Diagram — WIPER — ................................ 13 Terminals and Reference Values for BCM ............. 16 Reference Values for BCM (Input) ......................... 20 Terminals and Reference Values for IPDM E/R ..... 23 CONSULT-II Function (BCM) ................................. 24 CONSULT-II BASIC OPERATION ....................... 24 WORK SUPPORT ............................................... 24 DATA MONITOR ................................................. 24 ACTIVE TEST ..................................................... 24 CONSULT-II Function (IPDM E/R) ......................... 25 CONSULT-II BASIC OPERATION ....................... 25 DATA MONITOR ................................................. 25 ACTIVE TEST ..................................................... 25 Diagnosis Chart by Symptom ................................. 26 Front Wiper Does Not Operate ............................... 28 Front Wiper Does Not Return to Stop Position (After Front Wiper Operate for 10 Seconds, They Stop for 20 Seconds, and After Repeating the Operations Five Times, They Become Inoperative) .................. 31 Only Front Wiper Low Does Not Operate ............... 33 Only Front Wiper Hi Does Not Operate .................. 35 Only Front Wiper Intermittent Does Not Operate ... 37 Only Front Wiper Auto Dose Not Operate .............. 38 Front Wiper Interval Time Is Not Controlled by Vehicle Speed ................................................................ 40 Front Wiper Intermittent Operation Switch Position Cannot Be Adjusted ................................................ 40 WiperDoesNotWipeWhenFrontWasherOperates ... 41 Front Wiper Does Not Stop ..................................... 41 Removal and Installation of Front Wiper Arms, Adjustment of Wiper Arms Stop Location ............... 42 REMOVAL ........................................................... 42 INSTALLATION ................................................... 42 ADJUSTMENT .................................................... 42 Removal and Installation of Front Wiper Drive Assembly ................................................................ 43 REMOVAL ........................................................... 43 INSTALLATION ................................................... 44 Washer Nozzle Adjustment .................................... 44 Washer Tube Routing ............................................. 45 Removal and Installation of Front Washer Nozzle... 45 REMOVAL ........................................................... 45 INSTALLATION ................................................... 45 Inspection for Washer Nozzle ................................. 46 CHECK VALVE INSPECTION ............................. 46 InspectionofFrontWiperandWasherSwitchCircuit... 46 RemovalandInstallationofFrontWiperandWasher Switch ..................................................................... 46 REMOVAL ........................................................... 46 INSTALLATION ................................................... 46 Removal and Installation of Washer Tank .............. 46 REMOVAL ........................................................... 46 WW-1 E F G H I J WW L M INSTALLATION .................................................... 47 Removal and Installation of Front Washer Motor ... 47 REMOVAL ........................................................... 47 INSTALLATION .................................................... 47 Removal and Installation of Light and Rain Sensor... 47 REMOVAL ........................................................... 47 INSTALLATION OF RAIN SENSOR .................... 47 INSTALLATION OF LIGHT AND RAIN SENSOR HOUSING ............................................................ 48 REAR WIPER AND WASHER SYSTEM .................. 49 Components Parts and Harness Connector Location .......................................................................... 49 System Description ................................................. 49 OUTLINE ............................................................. 49 REAR WIPER OPERATION ................................ 49 INTERMITTENT OPERATION ............................ 50 AUTO STOP OPERATION .................................. 50 WASHER OPERATION ....................................... 50 REAR WIPER REVERSE RANGE OPERATION (IF AUTO WIPER IS EQUIPPED) ....................... 50 COMBINATIONSWITCHREADING FUNCTION... 50 CAN Communication .............................................. 50 SYSTEM DESCRIPTION .................................... 50 CAN Communication Unit ....................................... 50 Wiring Diagram — WIP/R — .................................. 51 WITHOUT RAIN SENSOR .................................. 51 Schematic ............................................................... 53 WITH RAIN SENSOR .......................................... 53 Wiring Diagram — WIP/R — .................................. 54 WITH RAIN SENSOR .......................................... 54 Terminals and Reference Values for BCM .............. 57 Reference Values for BCM (Input) .......................... 60 Terminals and Reference Values for IPDM E/R ...... 62 CONSULT-II Function (BCM) .................................. 63 Diagnosis Chart by Symptom ................................. 64 Rear Wiper Does Not Operate ............................... 65 Rear Wiper Does Not Return to Stop Position ........ 67 Only Rear Wiper ON Does Not Operate ................. 68 Only Rear Wiper Intermittent Does Not Operate ... 69 Wiper Does Not Wipe WhenRear Washer Operates... 69 Removal andInstallationofRear WiperArm,Adjustment of Wiper Arm Stop Location ........................... 69 REMOVAL ........................................................... 69 INSTALLATION .................................................... 69 Removal and Installation of Rear Wiper Motor ....... 70 REMOVAL ........................................................... 70 INSTALLATION .................................................... 70 Rear Washer Nozzle Adjustment ............................ 71 Rear Washer Tube Layout ...................................... 71 Removal and Installation of Rear Washer Nozzle... 71 REMOVAL ........................................................... 71 INSTALLATION ....................................................71 CHECK VALVE INSPECTION .............................72 Inspection of Rear Wiper and Washer Switch Circuit...72 Removaland Installation of Rear Wiper and Washer Switch .....................................................................72 Removaland Installation of Rear Wiper and Washer Tank ........................................................................72 Removaland Installation of Rear Wiper and Washer Pump .......................................................................72 HEADLAMP WASHER ..............................................73 Components Parts and Harness Connector Location ..........................................................................73 System Description .................................................73 OUTLINE .............................................................73 HEADLAMP WASHER OPERATION ...................74 CAN Communication ..............................................74 CAN Communication Unit .......................................74 Wiring Diagram —HLC— ........................................75 Terminals and Reference Values for BCM ..............77 Reference Values for BCM (Input) ..........................80 Terminals and Reference Values for IPDM E/R ......82 CONSULT-II Function (BCM) ..................................83 CONSULT-II Function (IPDM E/R) ..........................83 Diagnosis Chart by Symptom .................................83 Headlamp Washer Does Not Operate ....................84 Removal and Installation for Headlamp Washer Nozzle .....................................................................88 REMOVAL ............................................................88 INSTALLATION ....................................................88 Removal and Installation for Washer Tank ..............88 Removal and Installation for Headlamp Washer Motor .......................................................................88 Headlamp Washer Tube Layout .............................88 HORN ........................................................................89 Wiring Diagram —HORN— ....................................89 Removal and Installation .........................................90 REMOVAL ............................................................90 INSTALLATION ....................................................90 POWER SOCKET .....................................................91 Wiring Diagram —P/SCKT— ..................................91 Removal and Installation .........................................92 REMOVAL ............................................................92 INSTALLATION ....................................................92 Removal and Installation of Console Power Socket...92 REMOVAL ............................................................92 INSTALLATION ....................................................92 Removal and Installation of Luggage Room Power Socket .....................................................................92 REMOVAL ............................................................92 INSTALLATION ....................................................92 WW-2 PRECAUTIONS PRECAUTIONS PFP:00001 Precautions for Supplemental Restraint System (SRS) “AIR BAG” and “SEAT BELT PRE-TENSIONER” A BKS0010Y The Supplemental Restraint System such as “AIR BAG” and “SEAT BELT PRE-TENSIONER”, used along with a front seat belt, helps to reduce the risk or severity of injury to the driver and front passenger for certain types of collision. Information necessary to service the system safely is included in the SRS and SB section of this Service Manual. WARNING: ● To avoid rendering the SRS inoperative, which could increase the risk of personal injury or death in the event of a collision which would result in air bag inflation, all maintenance must be performed by an authorized NISSAN/INFINITI dealer. ● Improper maintenance, including incorrect removal and installation of the SRS, can lead to personal injury caused by unintentional activation of the system. For removal of Spiral Cable and Air Bag Module, see the SRS section. ● Do not use electrical test equipment on any circuit related to the SRS unless instructed to in this Service Manual. SRS wiring harnesses can be identified by yellow and/or orange harnesses or harness connectors. Maintenance Information B C D E F BKS0028L If any of following part is replaced, always replace with new* one. If it's not (or fail to do so), the electrical system may not be operated properly. *: New one means a virgin control unit that has never been energized on-board. G RHD MODELS H ● ● ● ● ● ● BCM (Models without Intelligent Key system) Intelligent Key unit (Models with Intelligent Key system) ECM IPDM E/R Combination meter EPS control unit I J LHD MODELS ● ● ● BCM (Models without Intelligent Key system) Intelligent Key unit (Models with Intelligent Key system) ECM Precautions for Procedures without Cowl Top Cover WW L BKS0010Z When performing the procedure after removing cowl top cover, cover the lower end of windshield with urethane, etc. M PIIB3706J WW-3 FRONT WIPER AND WASHER SYSTEM FRONT WIPER AND WASHER SYSTEM Components Parts and Harness Connector Location PFP:28810 BKS00111 MKIB2263E : Vehicle front 1. IPDM E/R E10, E11, E12 [Engine room (left)] 2. BCM M57, M58, M59 (View with instrument panel removed) 3. Data link connector 4. Front wiper motor E39 5. Front and rear washer motor E24 (View with front bumper removed) 6. Combination switch (Wiper switch) M38 7. Sun-visor 8. Light and rain sensor R2 System Description ● ● ● ● BKS00112 Front wiper HI/LO relay and front wiper main relay are built into IPDM E/R. Wiper switch (combination switch) is composed of a combination of 5 output terminals and 5 input terminals. Terminal combination status is read by BCM when switch is turned ON. BCM controls front wiper LO, HI, and INT (intermittent) operation. IPDM E/R operates wiper motor according to CAN communication signals from BCM. OUTLINE Power is supplied at all times ● through 20A fuse (No.48, located in the IPDM E/R) ● to front wiper main relay. ● through 20A fuse (No.61 and 62, located in the IPDM E/R) ● to IPDM E/R (CPU). ● through 40A fusible link (letter J, located in fuse and fusible link box) ● to BCM terminals 74 and 79. WW-4 FRONT WIPER AND WASHER SYSTEM When ignition switch ON or START position, power is supplied ● through 10A fuse [No.5, located in fuse block (J/B)] ● to BCM terminal 24, ● through 10A fuse [No.3, located in fuse block (J/B)] ● to combination switch terminal 14, and ● to front wiper HI/LO relay, front wiper main relay and IPDM E/R (CPU) Ground is supplied ● to front wiper motor terminal 2 and, ● to IPDM E/R terminals 3 and 54 ● through body grounds E28, E44 and E45, and ● to combination switch terminal 12 and ● to BCM terminals 2 and 70 ● through body grounds M21 and M66. A B C D E LOW SPEED WIPER OPERATION When front wiper switch is placed in LO position, BCM reads combination switch condition (Refer to WW-8, "COMBINATION SWITCH READING FUNCTION" ). And BCM sends front wiper request signal (LO) to IPDM E/R with CAN communication line. When IPDM E/R receives front wiper request signal (LO), it turns ON front wiper main relay (built into IPDM E/R). Power is supplied ● through front wiper main relay and front wiper HI/LO relay and ● through IPDM E/R terminal 23 ● to front wiper motor terminal 1. Ground is supplied ● to front wiper motor terminal 2, ● through body grounds E28, E44 and E45. With power and ground are supplied, the front wiper motor operates at low speed. F G H I J HIGH SPEED WIPER OPERATION When front wiper switch is placed in HI position, BCM reads combination switch condition (Refer toWW-8, "COMBINATION SWITCH READING FUNCTION" ). And BCM sends front wiper request signal (HI) to IPDM E/R with CAN communication line. When IPDM E/R receives front wiper request signal (HI), it turns ON front WW wiper HI/LO relay and front wiper main relay (built into IPDM E/R). Power is supplied ● through front wiper main relay and front wiper HI/LO relay and, L ● through IPDM E/R terminal 24 ● to front wiper motor terminal 4. M Ground is supplied ● to front wiper motor terminal 2 ● through body grounds E28, E44 and E45. With power and ground are supplied, the front wiper motor operates at high speed. INTERMITTENT OPERATION Front wiper intermittent operation delay interval is determined by a combination of 3 switches (intermittent operation dial position 1, 2, and 3) and by vehicle speed signal. After each intermittent operation delay interval, BCM sends front wiper request signal to IPDM E/R. WW-5 FRONT WIPER AND WASHER SYSTEM Wiper Intermittent Dial Position Setting Combination switch Wiper intermittent dial position Intermittent operation interval 1 Short Intermittent operation dial position 1 Intermittent operation dial position 2 Intermittent operation dial position 3 ON ON ON ON ON OFF ON OFF OFF OFF OFF OFF 5 OFF OFF ON 6 OFF ON ON OFF ON OFF 2 3 4 7 ↑ ↓ Long Example: For wiper intermittent dial position 1 Using combination switch reading function, BCM detects ON/OFF status of intermittent operation dial positions 1, 2, and 3. When combination switch status is as listed below, BCM determines that it is wiper intermittent dial position 1. ● Intermittent operation dial position 1: ON (Continuity exists between combination switch output 3 and input 1.) ● Intermittent operation dial position 2: ON (Continuity exists between combination switch output 5 and input 1.) ● Intermittent operation dial position 3: ON (Continuity exists between combination switch output 4 and input 2.) BCM determines front wiper intermittent operation delay interval from wiper intermittent dial position 1 and vehicle speed, and sends wiper request signal (INT) to IPDM E/R. AUTO WIPER OPERATION (MODELS WITH LIGHT AND RAIN SENSOR) When front auto wiper switch is toggled to AUTO position (light and rain sensor equipped), BCM reads the current combination switch condition/position (refer to WW-8, "COMBINATION SWITCH READING FUNCTION" ) and change light and rain sensor into 4stages of wiper sensitivity level. When light and rain sensor detect rain with ignition switch ON and auto wiper switch in AUTO position the front wiper will wipe the screen. (Light and rain sensor will not react, if no raindrop is detected.) ● from light and rain sensor terminal 2 ● to BCM terminal 63. BCM send wiper request signal to IPDM E/R with CAN communication line. IPDM E/R operate front wiper. Change the wiper speed by rainfall. The light and rain sensor sensitivity is controlled by the wiper volume switch combined with front wiper and washer switch and BCM. AUTO STOP OPERATION With wiper switch turned OFF, wiper motor will continue to operate until wiper arms reach stop position. When wiper arms are not located at stop position with wiper switch OFF, power is supplied ● from terminal 23 of the IPDM E/R ● to front wiper motor terminal 1, in order to continue wiper motor operation at low speed. Ground is supplied ● to front wiper motor terminal 2 ● through body grounds E28 and E44. When wiper arms reach stop position, front wiper motor terminals 2 and 5 are connected. Then the IPDM E/R sends auto stop operation signal to BCM with CAN communication line. When BCM receives auto-stop operation signal, BCM sends wiper stop signal to IPDM E/R with CAN communication line. IPDM E/R stops wiper motor. Wiper motor will then stop wiper arms at the STOP position. MIST OPERATION When the front wiper switch is in mist position, low speed wiper operation cycles once and then stops. WW-6 FRONT WIPER AND WASHER SYSTEM For additional information about wiper operation under this condition, refer to WW-5, "LOW SPEED WIPER OPERATION" . If the front wiper switch is held in the mist position, low speed wiper operation continues. A WASHER OPERATION When front wiper switch is pulled to washer position, power is supplied ● through combination switch terminal 13 ● to washer motor terminal 1. Ground is supplied ● to washer motor terminal 2 ● through combination switch terminals 11 and 12, and ● through body grounds M21 and M66. With power and ground supplied, the washer motor operates, and at the same time, When the wiper switch is pulled to the WASH position for 1 second or more. BCM sends front wiper request signal (low) to IPDM E/R with CAN communication line. And the front wiper motor operates in low speed for 3 times to clean wind shield and then an additional wiping action will occur after 3 seconds to remove the moisture appear on the glass shortly after the wash/wipe action. FAIL-SAFE FUNCTION If CAN communication is malfunctioning, IPDM E/R maintains the condition of just before the fail-safe status until ignition switch is turned OFF. (If wipers operate in LO just before the fail-safe status, operating in LO continues until ignition switch turns OFF.) Refer to PG-18, "Fail-safe Control" . B C D E F G H I J WW L M WW-7 FRONT WIPER AND WASHER SYSTEM COMBINATION SWITCH READING FUNCTION Description ● ● BCM reads combination switch (wiper) status, and controls related systems such as headlamps and wipers, according to the results. BCM reads information for a maximum of 20 switches by combining 5 output terminals (OUTPUT 1-5) and 5 input terminals (INPUT 1-5). Operation Description ● ● ● BCM activates transistors of output terminals (OUTPUT 1-5) periodically, and allows current to flow in turn. If any (1 or more) switches are turned ON, the circuit of output terminals (OUTPUT 1-5) and input terminals (INPUT 1-5) becomes active. At this time, transistors of output terminals (OUTPUT 1-5) are activated to allow current to flow. When voltage of the input terminal (INPUT 1-5) corresponding to that switch changes, the interface in the BCM detects a voltage change, and the BCM determines that the switch is ON. MKIB2223E BCM - Operation Table of Combination Switches ● BCM reads operation status of the combination switch using combinations shown in the table below. PKIC0420E WW-8 FRONT WIPER AND WASHER SYSTEM Sample Operation: (When Wiper Switch is Turned to LOW Position) ● ● ● When wiper switch is turned to LOW position, front wiper LOW contact in combination switch turns ON. At this time if OUTPUT 1 transistor is activated, BCM detects that voltage changes in INPUT 3. When BCM detects that voltage changes in INPUT 3 while OUTPUT 1 transistor is ON, it judges that front wiper switch is in LOW position. Then BCM sends front wiper request signal (LO) to IPDM E/R using CAN communication. If BCM detects that voltage changes in INPUT 3 when OUTPUT 1 transistor is activated again, it recognizes that wiper switch is still in LOW position. A B C D E F G H MKIB2225E NOTE: Each OUTPUT terminal transistor is activated at 10 ms intervals. Therefore after switch is turned ON, electrical loads are activated with time delay. But this time delay is so short that it cannot be detected by human senses. I J Operation Mode Combination switch reading function has operation modes shown below. 1. Normal status ● When BCM is not in sleep status, output terminals (OUTPUT 1-5) send out ON signal every 10 ms. 2. Sleep status WW L M WW-9 FRONT WIPER AND WASHER SYSTEM ● When BCM is in sleep status, BCM enters low power mode. Mean while out put terminals (OUTPUT 15) send out ON signal every 60ms, and accept only input from light switch system. PKIC0832E Intermittent Operation Wiper intermittent operation delay interval is determined from a combination of 3 switches (intermittent operation dial position 1, intermittent operation dial position 2, and intermittent operation dial position 3) and vehicle speed signal. During each intermittent operation delay interval, BCM sends front wiper request signal to IPDM E/R. WW-10 FRONT WIPER AND WASHER SYSTEM CAN Communication BKS00113 SYSTEM DESCRIPTION A CAN (Controller Area Network) is a serial communication line for real time application. It is an on-vehicle multiplex communication line with high data communication speed and excellent error detection ability. Many electronic control units are equipped onto a vehicle, and each control unit shares information and links with other control units during operation (not independent). In CAN communication, control units are connected with 2 communication lines (CAN H line, CAN L line) allowing a high rate of information transmission with less wiring. Each control unit transmits/receives data but selectively reads required data only. B CAN Communication Unit C BKS00114 Refer to LAN-27, "CAN Communication Unit" . D E F G H I J WW L M WW-11 FRONT WIPER AND WASHER SYSTEM Schematic BKS00115 MKWA4279E WW-12 FRONT WIPER AND WASHER SYSTEM Wiring Diagram — WIPER — BKS00116 A B C D E F G H I J WW L M MKWA4280E WW-13 FRONT WIPER AND WASHER SYSTEM MKWA4281E WW-14 FRONT WIPER AND WASHER SYSTEM A B C D E F G H I J WW L M MKWA4282E WW-15 FRONT WIPER AND WASHER SYSTEM Terminals and Reference Values for BCM BKS00117 Measuring condition Terminal No. Wire color 2 B Signal name Ground Signal input/ output — Ignition switch Operation or condition ON — Reference value [V] 0 OFF (Wiper intermittent dial position 4) PKIB8643J Approx. 1.2V Any of several conditions below 7 BR Combination switch output 5 Output ON ● Front fog lamp switch (Operates only front fog lamp switch) (Wiper intermittent dial position 4) ● Rear fog lamp switch (Wiper intermittent dial position 4) ● Rear wiper ON (Wiper intermittent dial position 4) ● Wiper intermittent dial position 1 ● Wiper intermittent dial position 2 ● Wiper intermittent dial position 6 ● Wiper intermittent dial position 7 PKIB4956J Approx. 1.0V OFF (Wiper intermittent dial position 4) PKIB4958J Approx. 1.2V 8 L Combination switch output 3 Output ON Any of several conditions below ● Lighting switch 2ND (Wiper intermittent dial position 4) ● Lighting switch HI beam (Operates only HI beam switch) (Wiper intermittent dial position 4) ● Wiper intermittent dial position 1 ● Wiper intermittent dial position 2 ● 9 V Combination switch output 1 Output ON Wiper intermittent dial position 3 PKIB4959J Approx. 1.0V OFF (Wiper intermittent dial position 4) PKIB4958J Approx. 1.2V WW-16 FRONT WIPER AND WASHER SYSTEM Measuring condition Terminal No. Wire color Signal name Signal input/ output A Ignition switch Reference value [V] Operation or condition B Any of several conditions below ● Turn signal switch to right ● Turn signal switch to left ● Front wiper switch MIST ● Front wiper switch LO ● Front washer switch C PKIB4959J D Approx. 1.0V 13 14 15 19 24 GB P W Combination switch input 1 Combination switch input 3 Combination switch input 5 L CAN H O Ignition power supply Input Input Input ON ● OFF ● Front wiper switch HI (Wiper intermittent dial position 4) ● Rear wiper switch INT (Wiper intermittent dial position 4) ● Wiper intermittent dial position 1 ● Wiper intermittent dial position 2 ● Wiper intermittent dial position 3 ● Wiper intermittent dial position 6 ● Wiper intermittent dial position 7 ● OFF ● Lighting switch AUTO ● Rear fog lamp switch ● Front wiper switch MIST ● Front wiper switch INT ● Front wiper switch LO ● OFF ● Lighting switch 1ST ● Lighting switch 2ND ● Lighting switch HIGH beam (Operates only HIGH beam switch) ● Turn signal switch to right ON ON Input/ output — Input ON E WW-20, "Reference Values for BCM (Input)" F G H — WW-20, "Reference Values for BCM (Input)" I J WW-20, "Reference Values for BCM (Input)" WW L — M — WW-17 Battery voltage FRONT WIPER AND WASHER SYSTEM Measuring condition Terminal No. Wire color Signal name Signal input/ output Ignition switch Reference value [V] Operation or condition OFF (Wiper intermittent dial position 4) PKIB4958J Approx. 1.2V 27 GR Combination switch output 4 Output ON Any of several conditions below ● Lighting switch AUTO (Wiper intermittent dial position 4) ● Lighting switch 1ST (The same result with lighting switch 2ND) (Wiper intermittent dial position 4) ● Wiper intermittent dial position 1 ● Wiper intermittent dial position 5 ● Wiper intermittent dial position 6 PKIB4959J Approx. 1.0V OFF (Wiper intermittent dial position 4) PKIB4958J 28 G Combination switch output 2 Output Approx. 1.2V ON Any of several conditions below ● Lighting switch 2ND ● Lighting switch PASSING (Operates only PASSING switch) ● Front wiper switch INT ● Front wiper switch HI PKIB4959J Approx. 1.0V 33 R Combination switch input 2 Input ON ● OFF ● Front washer switch (Wiper intermittent dial position 4) ● Rear wiper switch ON (Wiper intermittent dial position 4) WW-20, "Reference Values for BCM (Input)" Rear washer switch ON (Wiper intermittent dial position 4) ● ● Wiper intermittent dial position 1 ● Wiper intermittent dial position 5 ● Wiper intermittent dial position 6 WW-18 FRONT WIPER AND WASHER SYSTEM Measuring condition Terminal No. 34 39 Wire color Y Y Signal name Combination switch input 4 CAN L Signal input/ output Input Input/ output A Ignition switch ON Reference value [V] Operation or condition B ● OFF ● Front fog lamp switch ON ● Lighting switch 2ND ● Lighting switch PASSING (Operates only PASSING switch) ● Turn signal switch to left WW-20, "Reference Values for BCM (Input)" C D — — — E 63 BR Light and rain sensor signal Input ON — F MKIB2017E Approx. 8.9V 70 B Ground — ON — 0 73 V Room lamp power supply Output — — Battery voltage 74 Y Power source (Fusible link) Input OFF — Battery voltage 79 Y Power source (Fusible link) Input OFF — Battery voltage G H I J WW L M WW-19 FRONT WIPER AND WASHER SYSTEM Reference Values for BCM (Input) BKS001KE CAUTION: ● Check combination switch system terminal waveform under the loaded condition with lighting switch, turn signal switch and wiper switch OFF not to be fluctuated by overloaded. ● Turn wiper dial position to 4 except when checking waveform or voltage of wiper dial position. Wiper dial position can be confirmed on CONSULT-II. Refer to WW-24, "DATA MONITOR" . INPUT Condition and reference value OFF Lighting switch 1ST PKIB4956J INPUT 5 (Wiper intermittent dial position 4) Lighting switch 2ND PKIB8624J Approx. 0.9V Approx. 1.5 - 2.0V Lighting switch HI beam (Operates only HI beam switch) Turn signal switch to right PKIB8639J Approx. 2.5 - 3.0V — PKIB8625J PKIB8644J Approx. 1.5 - 2.0V Approx. 1.5 - 2.0V Lighting switch 2ND OFF PKIB4958J INPUT 4 (Wiper intermittent dial position 4) Turn signal switch to left PKIB8628J Approx. 1.0V Approx. 1.5 - 2.0V Front fog lamp switch (Operates only front fog lamp switch) Lighting switch PASSING (Operates only PASSING switch) PKIB8630J Approx. 2.0V — PKIB8629J PKIB8627J Approx. 1.5 - 2.0V Approx. 2.0V WW-20 FRONT WIPER AND WASHER SYSTEM INPUT Condition and reference value OFF Lighting switch AUTO Front wiper switch INT A B PKIB4958J PKIB8631J Approx. 1.0V INPUT 3 (Wiper intermittent dial position 4) Approx. 2.0V PKIB8632J Approx. 2.0V Any of several conditions below ● Front ● Front wiper switch LO C D Rear fog lamp switch wiper switch MIST E — F PKIC1030E Approx. 1.5V PKIB8629J Approx. 2.0V OFF (Wiper intermittent dial position 4) Front washer switch (Wiper intermittent dial position 4) Rear washer switch (Wiper intermittent dial position 4) G H I PKIB4958J PKIB8632J Approx. 1.0V Approx. 2.0V PKIB8631J Approx. 2.0V J Any of the conditions below INPUT 2 Rear wiper switch ON (Wiper intermittent dial position 4) ● Wiper intermittent dial position 1 ● Wiper intermittent dial position 5 ● Wiper intermittent dial position 6 WW — L PKIB8634J Approx. 1.5 - 2.0V PKIB8633J Approx. 2.0V WW-21 M FRONT WIPER AND WASHER SYSTEM INPUT Condition and reference value Any of the conditions below OFF (Wiper intermittent dial position 4) Front wiper switch HI (Wiper intermittent dial position 4) ● Rear wiper switch INT (Wiper intermittent dial position 4) ● Wiper PKIB4958J intermittent dial position 3 PKIB8635J Approx. 1.0V Approx. 2.0V PKIB8636J Approx. 2.0V INPUT 1 Any of the conditions below Any of the conditions below ● Wiper intermittent dial position 1 ● Wiper intermittent dial position 6 ● Wiper intermittent dial position 2 ● Wiper intermittent dial position 7 — PKIB8637J Approx. 2.5 - 3.0V PKIB8638J Approx. 2.0V WW-22 FRONT WIPER AND WASHER SYSTEM Terminals and Reference Values for IPDM E/R BKS00118 A Terminal No. Wire color 3 B Ground 23 Y 24 LG Measuring condition Signal input/ output Ignition switch Operation or condition — ON — Low speed power source Output ON High speed power source Output Signal name ON Reference value [V] B Wiper switch Wiper switch 0 OFF 0 LO Battery voltage OFF 0 HI Battery voltage 52 L CAN H Input/ output — — — 54 B Ground — — — 0 Wiper operating Battery voltage Wiper stopped 0 — — 55 OR Wiper auto stop signal Input ON 58 W CAN L Input/ output — C D E F G H I J WW L M WW-23 FRONT WIPER AND WASHER SYSTEM CONSULT-II Function (BCM) BKS0011B CONSULT-II can display each diagnostic item using the diagnostic modes shown following. BCM diagnosis position Diagnosis mode Changes the setting for each function. DATA MONITOR Displays BCM input data in real time. WIPER ACTIVE TEST SELF-DIAG RESULTS BCM Description WORK SUPPORT CAN DIAG SUPPORT MNTR Device operation can be checked by applying a drive signal to device. BCM performs self-diagnosis of CAN communication. The result of transmit/receive diagnosis of CAN communication can be read. CONSULT-II BASIC OPERATION Refer to GI-36, "CONSULT-II Start Procedure" . WORK SUPPORT Supported item Description RR WIP RVRS SET Rear wiper reverse range operation setting can be changed. DATA MONITOR Monitor item “UNIT” Contents IGN ON SW [ON/OFF] Displays “ignition switch ON (ON)/Other OFF or ACC (OFF)” status as judged from ignition switch signal. FR WIPER HI [ON/OFF] Displays “Front Wiper HI (ON)/Others (OFF)” status as judged from wiper switch signal. FR WIPER LOW [ON/OFF] Displays “Front Wiper LOW (ON)/Others (OFF)” status as judged from wiper switch signal. FR WIPER INT [ON/OFF] Displays “Front Wiper INT (ON)/Others (OFF)” status as judged from wiper switch signal. FR WASHER SW [ON/OFF] Displays “Front Washer Switch (ON)/Others (OFF)” status as judged from wiper switch signal. [1 - 7] Displays intermittent operation dial position setting (1 - 7) as judged from wiper switch signal. FR WIPER STOP [ON/OFF] Displays “Stopped (ON)/Operating (OFF)” status as judged from the auto-stop signal. VEHICLE SPEED [km/h] INT VOLUME Displays vehicle speed status as judged from vehicle speed signal. H/L WASH SW [ON/OFF] Displays (Headlamp washer switch: ON/Others: OFF) as judged from headlamp washer switch signal H/L SW POS [ON/OFF] Displays (Headlamp switch: ON/Others: OFF) as judged from lighting switch signal RR WIPER ON [ON/OFF] Displays “Rear Wiper ON (ON)/Others (OFF)” status as judged from wiper switch signal. RR WIPER INT [ON/OFF] Displays “Rear Wiper INT (ON)/Others (OFF)” status as judged from wiper switch signal. RR WASHER SW [ON/OFF] Displays “Rear Washer Switch (ON)/Others (OFF)” status as judged from wiper switch signal. RR WIPER STOP [ON/OFF] Displays “Rear Wiper Stop (ON)/Others (OFF)” status as judged from wiper switch signal. REVERSE SW CAN [ON/OFF] Displays “Reverse position (ON)/Others (OFF)” status as judged from reverse signal. R/WIP MTR SIG [ON/OFF] Displays “Rear wiper motor signal (ON)/Others (OFF)” status as judged to rear wiper motor output signal. ACTIVE TEST Test item Indication CONSULT-II display Description Front wiper output (HI, LOW) FR WIPER Front wiper can be operated by ON (HI, LO)–OFF operation. Rear wiper output RR WIPER Rear wiper can be operated by any ON-OFF operation. Head lamp washer output HEAD LAMP WASHER Head lamp washer can be operated by any ON-OFF operation. WW-24 FRONT WIPER AND WASHER SYSTEM CONSULT-II Function (IPDM E/R) BKS0011C CONSULT-II can display each diagnostic item using the diagnostic modes shown following. Diagnosis Mode A Description SELF−DIAG RESULTS Refer to PG-20, "SELF-DIAG RESULTS" . DATA MONITOR The input/output data of IPDM E/R is displayed in real time. CAN DIAG SUPPORT MNTR The result of transmit/receive diagnosis of CAN communication can be read. ACTIVE TEST IPDM E/R sends a drive signal to electronic components to check their operation. B CONSULT-II BASIC OPERATION C D Refer to GI-36, "CONSULT-II Start Procedure" . DATA MONITOR E Monitor item selection Item name Display or unit All signals HEADLAMP WASHER REQUEST ON/OFF × FR WIPER REQUEST OFF/LO/HI × WIPER AUTO STOP ON/OFF × WIPER PROTECTION OFF/LS/HS/Block Main signal Sele ct from men u Description F × Signal status input from BCM × × Signal status input from BCM × × IPDM E/R output status × IPDM E/R control status (LS: low speed operation/ HS: high speed operation/ BLOCK: wiper arm is locked) × NOTE: Perform monitoring of IPDM E/R data with ignition switch ON. When ignition switch is at ACC, the display may not be correct. G H I J ACTIVE TEST Test item Indication on CONSULT-II display Description Front wiper (HI, LO) FRONT WIPER With a certain operation (HI, LO, OFF) front wiper relay can be operated. Headlamp washer HEADLAMP WASHER Headlamp washer relay can be operated by switching (ON and OFF) optionally. WW L M WW-25 FRONT WIPER AND WASHER SYSTEM Diagnosis Chart by Symptom Symptom Possible causes BKS001HD Possible malfunctioning system and part Inspection procedure Reference page BCM OUTPUT 2 - INPUT 1, BCM OUTPUT 1 - INPUT 3 and BCM OUTPUT 2 - INPUT 3 system Combination switch reading function malfunction Front wiper does ● 10A (M7) fuse ● 40A fusible link CONSULT-II ● Combination switch (Front wiper HI, LOW, and INT systems malfunction) ● ● Harness and connector between combination switch and BCM ● BCM CONSULT-II not operateCAUTION 1 Front wiper request signal malfunction (CAN) BCM - IPDM E/R system ● BCM (Transmission malfunction) ● IPDM E/R (Receiving malfunction) IPDM E/R - front wiper motor system Front wiper HI/LO output malfunction Front wiper does not return to stop position (after front wiper operate for 10 seconds, they stop for 20 seconds, and after repeating the operations five times, they become inoperative) DATA MONITOR (BCM) ● 20A (#48, #62) fuse ● Front wiper motor ● Harness and connector between IPDM E/R and front wiper motor ● IPDM E/R ● SELF-DIAGNOSIS (BCM) ● ACTIVE TEST (BCM) ● DATA MONITOR (IPDM E/R) CONSULT-II ● ACTIVE TEST (IPDM E/R) Other than CONSULT-II ● Front wiper motor output inspection CONSULT-II IPDM E/R - front wiper motor system Auto-stop signal malfunction ● Front wiper motor ● Harness and connector between IPDM E/R and front wiper motor ● ● DATA MONITOR (IPDM E/R) Other than CONSULT-II ● IPDM E/R Auto-stop signal malfunction Auto-stop signal system inspection CAUTION 2 IPDM E/R - front wiper motor system Only front wiper LOW does not operate Front wiper LO output malfunction ● Front wiper motor ● Harness and connector between IPDM E/R and front wiper motor ● IPDM E/R Only front wiper HI does not operate Front wiper HI output malfunction ● Front wiper motor ● Harness and connector between IPDM E/R and front wiper motor ● IPDM E/R ● ACTIVE TEST (IPDM E/R) Other than CONSULT-II Front wiper motor LO output inspection WW-33, "Only Front Wiper Low Does Not Operate" CONSULT-II ● ACTIVE TEST (IPDM E/R) Other than CONSULT-II ● WW-26 WW-31, "Front Wiper Does Not Return to Stop Position (After Front Wiper Operate for 10 Seconds, They Stop for 20 Seconds, and After Repeating the Operations Five Times, They Become Inoperative)" CONSULT-II ● IPDM E/R - Front wiper motor system WW-28, "Front Wiper Does Not Operate" Front wiper motor HI output inspection WW-35, "Only Front Wiper Hi Does Not Operate" FRONT WIPER AND WASHER SYSTEM Symptom Possible causes Possible malfunctioning system and part Inspection procedure BCM OUTPUT 1 - INPUT 3 or BCM OUTPUT 2 - INPUT 3 system Only front wiper INT does not operate Combination switch reading function malfunction ● Combination switch (Front wiper INT systems malfunction) ● Harness and connector between combination switch and BCM ● BCM CONSULT-II ● DATA MONITOR (BCM) Reference page WW-37, "Only Front Wiper Intermittent Does Not Operate" A B C BCM - light and rain sensor Only front wiper AUTO does not operate Front wiper interval time is not controlled by vehicle speed Light and rain sensor signal malfunction Vehicle speed signal (meter) malfunction (CAN) ● BCM Other than CONSULT-II ● Harness and connector between BCM and light and rain sensor ● ● Light and rain sensor Combination meter - BCM (CAN communication) system ● ● Front wiper intermittent operation switch position cannot be adjusted Combination meter (Transmission malfunction) Light and rain sensor circuit inspection ● CONSULT-II ● SELF-DIAGNOSIS (METER, BCM) ● DATA MONITOR (METER, BCM) BCM (Receiving malfunction) ● ● Combination switch (Intermittent control 1, 2, and 3 systems malfunction) WW-40, "Front Wiper Interval Time Is Not Controlled by Vehicle Speed" Combination switch reading function malfunction CONSULT-II ● DATA MONITOR (BCM) Harness and connector between combination switch and BCM WW-40, "Front Wiper Intermittent Operation Switch Position Cannot Be Adjusted" Combination switch (Front washer system malfunction) ● Harness and connector between combination switch and BCM CONSULT-II ● DATA MONITOR (BCM) WW-41, "Wiper Does Not Wipe When Front Washer Operates" Front wiper does not stop ● Combination switch (Front wiper HI, LOW, and INT systems malfunction) ● Harness and connector between combination switch and BCM ● BCM IPDM E/R - Front wiper motor system Front wiper HI/LO output malfunction ● ● I J WW BCM BCM OUTPUT 2 - INPUT 1, BCM OUTPUT 1 - INPUT 3 and BCM OUTPUT 2 - INPUT 3 system Combination switch reading function malfunction H BCM ● ● F G BCM OUTPUT 1 - INPUT 2 system Wiper does not wipe when front washer operates D E BCM OUTPUT 3 - INPUT 1, BCM OUTPUT 5 - INPUT 1 and BCM OUTPUT 4 - INPUT 2 system Combination switch reading function malfunction WW-38, "Only Front Wiper Auto Dose Not Operate" Harness and connector between IPDM E/R and front wiper motor IPDM E/R L CONSULT-II ● DATA MONITOR (BCM) M WW-41, "Front Wiper Does Not Stop" Other than CONSULT-II ● Front wiper motor output inspection CAUTION: 1. When the IPDM E/R is performing the fail-safe control, the front wiper may not be operated. Check if the system is not in the fail-safe condition. 2. This phenomenon occurs when IPDM E/R judges that front wiper is locked. It stops wiper output while IPDM E/R is operating front wiper and auto stop signal does not change for at least 10 seconds. In this state, use IPDM E/R data monitor to check if “wiper protection” item is “BLOCK”. WW-27 FRONT WIPER AND WASHER SYSTEM Front Wiper Does Not Operate BKS001HL CAUTION: ● During IPDM E/R fail-safe control, front wipers may not operate. Refer to PG-18, "CAN COMMUNICATION LINE CONTROL" in “PG IPDM E/R” to make sure that it is not in fail-safe status. 1. CHECK FUSE Check fuse and fusible link for blown-out. ● Unit Power source Fuse No. Ignition ON or START 3 Front wiper main relay Battery 48 IPDM E/R Battery 61, 62 Battery J Ignition switch ON or START position 5 Front and rear washer motor BCM Refer to WW-13, "Wiring Diagram — WIPER —" . OK or NG OK >> GO TO 2. NG >> If fuse is blown, be sure to eliminate cause of problem before installing new fuse Refer to PG-4, "POWER SUPPLY ROUTING CIRCUIT" . 2. CHECK BCM POWER SUPPLY CIRCUIT 1. 2. 3. Turn ignition switch OFF. Disconnect BCM connector. Check voltage between BCM harness connector and ground. Terminal Ignition switch position (+) Connector (–) 74 M59 79 M57 OFF ACC ON Battery voltage Battery voltage Battery voltage Battery voltage Battery voltage Battery voltage 0V Battery voltage Terminal Ground 24 0V MKIB0352E OK or NG OK >> GO TO 3. NG >> Check harness for open or short between fuse, fusible link and BCM. 3. CHECK IPDM E/R GROUND CIRCUIT 1. 2. Disconnect IPDN E/R harness connector. Check continuity between IPDM E/R harness connector and ground. Connector Terminal E11 3 E12 54 Continuity Ground Yes OK or NG OK >> GO TO 4. NG >> Harness for open ground circuit. MKIB2004E WW-28 FRONT WIPER AND WASHER SYSTEM 4. CHECK BCM GROUND CIRCUIT A Check continuity between BCM harness connector and ground. Connector Terminal M57 2 M59 70 Continuity Ground B Yes C OK or NG OK >> GO TO 5. NG >> Check harness ground circuit. D MKIB0353E 5. ACTIVE TEST E With CONSULT-ll Turn ignition switch ON. Select “IPDM E/R” on CONSULT-II, and select “ACTIVE TEST” on “SELECT DIAG MODE” screen. 3. Select “FRONT WIPER” on “SELECT TEST ITEM” screen. 4. Touch “LO” or “HI” screen. 1. 2. F G Without CONSULT-ll Start up auto active test. Refer to PG-22, "Auto Active Test" . Does front wiper operate normally? YES >> GO TO 6. NO >> GO TO 8. H I SKIA3486E 6. CHECK CIRCUIT BETWEEN COMBINATION SWITCH AND BCM J With CONSULT-ll Select “BCM” on CONSULT-II, and select “WIPER” on “SELECT TEST ITEM” screen. 2. Select “DATA MONITOR” on “SELECT DIAG MODE” screen. Make sure that “FR WIPER INT”, “FR WIPER LOW”, and “FR WIPER HI” turn ON-OFF according to wiper switch operation. 1. Without CONSULT-ll Refer to LT-125, "Combination Switch Inspection" . OK or NG OK >> GO TO 7. NG >> Check combination switch (wiper switch). Refer to LT125, "Combination Switch Inspection" . WW L M PKIB0110E 7. CHECK CIRCUIT BETWEEN IPDM E/R AND BCM Select “BCM” on CONSULT-II, and perform self-diagnosis for “BCM”. Displayed self-diagnosis results NO DTC>>Replace BCM. Refer to BCS-17, "Removal and Installation of BCM" . CAN COMM CIRCUIT>>Check CAN communication line of BCM. Refer to BCS-17, "CAN Communication Inspection With CONSULT-II (Self-Diagnosis)" . PKIA7627E WW-29 FRONT WIPER AND WASHER SYSTEM 8. CHECK GROUND CIRCUIT 1. 2. 3. Turn ignition switch OFF. Disconnect front wiper motor connector. Check continuity between front wiper motor harness connector [A (LHD models) or B (RHD models)] and ground. LHD models (A) Front wiper motor connector Terminal E39 5 Continuity Ground Yes RHD models (B) Front wiper motor connector Terminal E66 2 Continuity Ground Yes MKIB2303E OK or NG OK >> GO TO 9. NG >> Repair harness or connector. 9. CHECK FRONT WIPER CIRCUIT 1. 2. Disconnect IPDM E/R connector. Check continuity between IPDM E/R harness connector (A) and front wiper motor harness connector [B (LHD models) or C (RHD models)]. LHD models A Connector B Terminal Connector Terminal 23 E10 Continuity 2 E39 24 Yes 1 RHD models A Connector C Terminal Connector 23 E10 3. Terminal Continuity 1 E66 24 Yes 4 Check continuity between IPDM E/R harness connector (A) and Ground. A Connector 23 E10 Continuity Terminal Ground No 24 OK or NG OK >> GO TO 10. NG >> Repair harness or connector. WW-30 MKIB2226E FRONT WIPER AND WASHER SYSTEM 10. CHECK IPDM E/R 1. 2. 3. 4. 5. 6. A With CONSULT-ll Connect IPDM E/R connector. Turn ignition switch ON. Select “IPDM E/R” by CONSULT-II, and select “ACTIVE TEST” on “SELECT DIAG MODE” screen. Select “FRONT WIPER” on “SELECT TEST ITEM” screen. Touch “LO” or “HI” screen. Check voltage between IPDM E/R harness connector and ground while front wiper (HI, LO) is operating. B C D Terminal (+) (-) IPDM E/R connector Voltage Stopped Approx. 0V LO operation Battery voltage Stopped Approx. 0V HI operation Battery voltage E Terminal 23 E10 Ground 24 1. 2. 3. 4. Condition F SKIA2170E G Without CONSULT-ll Connect IPDM E/R connector. Turn ignition switch ON. Start up auto active test. Refer to PG-22, "Auto Active Test" . Check voltage between IPDM E/R harness connector and ground while front wiper (HI, LO) is operating. H I Terminal (+) IPDM E/R connector (-) Condition Voltage Stopped Approx. 0V LO operation Battery voltage Stopped Approx. 0V HI operation Battery voltage J Terminal 23 E10 Ground 24 WW L OK or NG OK >> Replace front wiper drive assembly. Refer to WW-43, "Removal and Installation of Front Wiper Drive Assembly" . NG >> Replace IPDM E/R. Refer to PG-37, "Removal and Installation of IPDM E/R" . Front Wiper Does Not Return to Stop Position (After Front Wiper Operate for 10 Seconds, They Stop for 20 Seconds, and After Repeating the Operations Five Times, They Become Inoperative) BKS001HM CAUTION: ● When auto-stop signal has not varied for 10 seconds or longer while IPDM E/R is operating front wipers, IPDM E/R considers that front wipers are locked, and stops wiper output. That causes this symptom. ● This status can be checked by “DATA MONITOR” of “IPDM E/R” on which “WIPER PROT” item shows “BLOCK”. WW-31 M FRONT WIPER AND WASHER SYSTEM 1. CHECK FRONT WIPER STOP SIGNAL With CONSULT-ll Select “IPDM E/R” on CONSULT-II. With “DATA MONITOR”, make sure that “WIP AUTO STOP” turns “ACT P” - “STOP P” linked with wiper operation. Without CONSULT-ll GO TO 2. OK or NG OK >> Replace IPDM E/R. Refer to PG-37, "Removal and Installation of IPDM E/R" . NG >> GO TO 2. PKIA7614E 2. CHECK IPDM E/R Check voltage between IPDM E/R harness connector and ground while front wiper motor is stopped and while it is operating. Terminal (+) IPDM E/R connector Terminal E12 55 Condition Voltage Wiper stopped Approx. 0V Wiper operating Battery voltage (-) Ground OK or NG OK >> Replace IPDM E/R. Refer to PG-37, "Removal and Installation of IPDM E/R" . NG >> GO TO 3. WW-32 SKIA2172E FRONT WIPER AND WASHER SYSTEM 3. CHECK FRONT WIPER AUTO STOP CIRCUIT 1. 2. 3. A Turn ignition switch OFF. Disconnect IPDM E/R connector and wiper motor connector. Check continuity between IPDM E/R harness connector (A) and front wiper motor harness connector [B (LHD models) or C (RHD models)]. B LHD models C A B Connector Terminal Connector Terminal E12 55 E39 4 Continuity D Yes RHD models A 4. E C Connector Terminal Connector Terminal E12 55 E66 5 Continuity Yes F Check continuity between IPDM E/R harness connector (A) and Ground. A Connector Terminal E12 55 Ground G Continuity No OK or NG OK >> Replace front wiper drive assembly. Refer to WW-43, "Removal and Installation of Front Wiper Drive Assembly" . NG >> Repair harness or connector. Only Front Wiper Low Does Not Operate H MKIB2227E I BKS001HN 1. ACTIVE TEST With CONSULT-ll 1. Select “IPDM E/R” on CONSULT-II, and select “ACTIVE TEST” on “SELECT DIAG MODE” screen. 2. Select “FRONT WIPER” on “SELECT TEST ITEM” screen. 3. Touch “LO” screen. WW L Without CONSULT-ll Start up auto active test. Refer to PG-22, "Auto Active Test" . Does front wiper operate normally? YES >> Refer to LT-125, "Combination Switch Inspection" . NO >> GO TO 2. M SKIA3486E WW-33 J FRONT WIPER AND WASHER SYSTEM 2. CHECK FRONT WIPER MOTOR CIRCUIT 1. 2. 3. Turn ignition switch OFF. Disconnect IPDM E/R connector and front wiper motor connector. Check continuity between IPDM E/R harness connector (A) and front wiper motor harness [B (LHD models) or C (RHD models)]. LHD models A B Connector Terminal Connector Terminal E10 23 E39 2 Continuity Yes RHD models A 4. C Connector Terminal Connector Terminal E10 23 E66 1 Continuity Yes Check continuity between IPDM E/R harness connector (A) and ground. A Connector Terminal E10 23 Ground Continuity No OK or NG OK >> GO TO 3. NG >> Repair harness or connector. MKIB2228E WW-34 FRONT WIPER AND WASHER SYSTEM 3. CHECK IPDM E/R 1. 2. 3. 4. 5. 6. A With CONSULT-ll Connect IPDM E/R connector. Turn ignition ON. Select “IPDM E/R” on CONSULT-II, and select “ACTIVE TEST” on “SELECT DIAG MODE” screen. Select “FRONT WIPER” on “SELECT TEST ITEM” screen. Touch “LO” screen. Check voltage between IPDM E/R harness connector terminal and ground while front wiper LO is operating. B C D Terminal (+) Continuity (-) IPDM E/R connector Terminal E10 23 Ground E Battery voltage F Without CONSULT-ll MKIB0490E 1. Connect IPDM E/R connector. 2. Turn ignition ON. 3. Start up auto active test. Refer to PG-22, "Auto Active Test" . 4. Check voltage between IPDM E/R harness connector terminal and ground while front wiper LO is operating. G H Terminal (+) Continuity I Battery voltage J (-) IPDM E/R connector Terminal E10 23 Ground OK or NG OK >> Replace front wiper drive assembly. Refer to WW-43, "Removal and Installation of Front Wiper WW Drive Assembly" . NG >> Replace IPDM E/R. Refer to PG-37, "Removal and Installation of IPDM E/R" . Only Front Wiper Hi Does Not Operate BKS001HO 1. ACTIVE TEST With CONSULT-ll 1. Select “IPDM E/R” on CONSULT-II, and select “ACTIVE TEST” on “SELECT DIAG MODE” screen. 2. Select “FRONT WIPER” on “SELECT TEST ITEM” screen. 3. Touch “HI” screen. M Without CONSULT-ll Start up auto active test. Refer to PG-22, "Auto Active Test" . Does front wiper operate normally? YES >> Refer to LT-125, "Combination Switch Inspection" . NO >> GO TO 2. WW-35 L SKIA3486E FRONT WIPER AND WASHER SYSTEM 2. CHECK FRONT WIPER MOTOR CIRCUIT 1. 2. 3. Turn ignition switch OFF. Disconnect IPDM E/R connector and front wiper motor connector. Check continuity between IPDM E/R harness connector (A) and front wiper motor harness connector [B (LHD models) or C (RHD models)]. LHD models A B Connector Terminal Connector Terminal E10 24 E39 1 Continuity Yes RHD models A 4. C Connector Terminal Connector Terminal E10 24 E66 4 Continuity Yes Check continuity between IPDM E/R harness connector (A) and ground. A Connector Terminal E10 24 Ground Continuity No OK or NG OK >> GO TO 3. NG >> Repair harness or connector. MKIB2229E WW-36 FRONT WIPER AND WASHER SYSTEM 3. CHECK IPDM E/R 1. 2. 3. 4. 5. 6. A With CONSULT-ll Connect IPDM E/R connector. Turn ignition ON. Select “IPDM E/R” on CONSULT-II, and select “ACTIVE TEST” on “SELECT DIAG MODE” screen. Select “FRONT WIPER” on “SELECT TEST ITEM” screen. Touch “HI” screen. Check voltage between IPDM E/R harness connector terminal and ground while front wiper HI is operating. B C D Terminal (+) (-) IPDM E/R connector Terminal E10 24 Ground Continuity E Battery voltage F Without CONSULT-ll SKIA2174E 1. Connect IPDM E/R connector. 2. Turn ignition ON. 3. Start up auto active test. Refer to PG-22, "Auto Active Test" . 4. Check voltage between IPDM E/R harness connector terminal and ground while front wiper HI is operating. G H Terminal (+) (-) IPDM E/R connector Terminal E10 24 Ground Continuity I Battery voltage J OK or NG OK >> Replace front wiper drive assembly. Refer to WW-43, "Removal and Installation of Front Wiper WW Drive Assembly" . NG >> Replace IPDM E/R. Refer to PG-37, "Removal and Installation of IPDM E/R" . Only Front Wiper Intermittent Does Not Operate BKS001HP 1. CHECK COMBINATION SWITCH With CONSULT-ll 1. Select “BCM” on CONSULT-II, and select “WIPER” on “SELECT TEST ITEM” screen. 2. Select “DATA MONITOR” on “SELECT DIAG MODE” screen. Make sure that “FR WIPER INT”, turn ON-OFF according to wiper switch operation. Without CONSULT-ll Refer to LT-125, "Combination Switch Inspection" . OK or NG OK >> Replace BCM. Refer to BCS-17, "Removal and Installation of BCM" . NG >> Check combination switch (wiper switch) Refer to LT125, "Combination Switch Inspection" . WW-37 L M PKIB0110E FRONT WIPER AND WASHER SYSTEM Only Front Wiper Auto Dose Not Operate BKS001KR 1. CHECK CONDITIONS OF WINDSHIELD (LIGHT AND RAIN SENSOR DETECTION AREA) Check “light and rain sensor” detection area of windshield for dirt such as greases. OK or NG OK >> GO TO 2. NG >> Clean “light and rain sensor” detection area of windshield fully. 2. CHECK LIGHT AND RAIN SENSOR SIGNAL 1. 2. Turn ignition switch ON. Check signal between BCM harness connector and ground with oscilloscope. (+) Connector Terminals (Wire color) (-) Condition M58 63 Ground IGN ON Signal (Reference value.) MKIB0664E MKIB2017E Approx. 8.9V OK or NG OK >> Replace light and rain sensor. Refer to WW-47, "Removal and Installation of Light and Rain Sensor" . If front wiper does not operate, replace BCM. Refer to BCS-17, "Removal and Installation of BCM" . NG >> GO TO 3. 3. CHECK LIGHT AND RAIN SENSOR POWER SUPPLY CIRCUIT 1. Check continuity between BCM harness connector and “light and rain sensor” harness connector. BCM 2. Light and rain sensor Connector Terminal Connector Terminal M59 73 R2 1 Continuity Yes Check continuity between BCM harness connector and ground. BCM Continuity Connector Terminal M59 73 Ground MKIB1979E No OK or NG OK >> GO TO 4. NG >> Repair harness or connector. WW-38 FRONT WIPER AND WASHER SYSTEM 4. CHECK LIGHT AND RAIN SENSOR POWER SUPPLY 1. 2. 3. 4. A Turn ignition switch OFF. Disconnect “light and rain sensor” harness connector. Turn ignition switch ON. Check voltage between “light and rain sensor” harness connector and ground. B C Terminal (+) Voltage (-) Light and rain sensor connector Terminal R2 1 Ground D Battery voltage OK or NG OK >> GO TO 5. NG >> Replace BCM. Refer to BCS-17, "Removal and Installation of BCM" . E MKIB2262E F 5. CHECK LIGHT AND RAIN SENSOR GROUND CIRCUIT 1. 2. G Turn ignition switch OFF. Check continuity between “light and rain sensor” harness connector and ground. Light and rain sensor connector Terminal R2 3 H Continuity Ground I Yes OK or NG OK >> GO TO 6. NG >> Repair or replace harness. J MKIB2027E 6. CHECK LIGHT AND RAIN SENSOR SIGNAL CIRCUIT 1. 2. Disconnect BCM connector. Check continuity between BCM harness connector and “light and rain sensor” harness connector. BCM 3. WW L Light and rain sensor Connector Terminal Connector Terminal M58 63 R2 2 M Continuity Yes Check continuity between BCM harness connector and ground. BCM Continuity Connector Terminal M58 63 Ground MKIB1978E No OK or NG OK >> Replace light and rain sensor. Refer to WW-47, "Removal and Installation of Light and Rain Sensor" . NG >> Repair or replace harness. WW-39 FRONT WIPER AND WASHER SYSTEM Front Wiper Interval Time Is Not Controlled by Vehicle Speed BKS001HQ 1. CHECK WIPER SPEED SETTING 1. Select “BCM” on CONSULT-II screen. Select “WIPER” on “SELECT TEST ITEM” screen. 2. Select “WORK SUPPORT” on “SELECT DIAG MODE”. Select “WIPER SPEED SETTING” on “SELECT WORK ITEM” screen. Touch “START”. 3. Confirm “CURRENT SETTING” is “ON”. OK or NG OK >> GO TO 2. NG >> Change “CURRENT SETTING” to “ON”. SKIB6431E 2. CHECK FUNCTION OF COMBINATION METER Confirm that speedometer operates normally. Does front wiper operate normally? YES >> GO TO 2. NO >> Combination meter vehicle speed system is malfunction. Refer to DI-16, "Check Vehicle Speed Signal" . 3. CHECK CAN COMMUNICATION BETWEEN BCM AND COMBINATION METER Select “BCM” on CONSULT-II, and perform self-diagnosis for “BCM”. Displayed self-diagnosis results NO DTC>>Replace BCM. Refer to BCS-17, "Removal and Installation of BCM" . CAN COMM CIRCUIT>>Check CAN communication line of BCM. Refer to BCS-17, "CAN Communication Inspection With CONSULT-II (Self-Diagnosis)" . PKIA7627E Front Wiper Intermittent Operation Switch Position Cannot Be Adjusted BKS001HR 1. CHECK CIRCUIT BETWEEN COMBINATION SWITCH AND BCM With CONSULT-ll Select “BCM” on CONSULT-II, and select “WIPER” on “SELECT TEST ITEM” screen. 2. Select “DATA MONITOR” on “SELECT DIAG MODE” screen. Make sure that “INT VOLUME”, changes in order from 1 to 7 according to wiper switch operation. 1. Without CONSULT-ll Refer to LT-125, "Combination Switch Inspection" . OK or NG OK >> Replace BCM. Refer to BCS-17, "Removal and Installation of BCM" . NG >> Check combination switch (wiper switch). Refer to LT125, "Combination Switch Inspection" . WW-40 PKIB0110E FRONT WIPER AND WASHER SYSTEM Wiper Does Not Wipe When Front Washer Operates BKS001HS 1. CHECK CIRCUIT BETWEEN COMBINATION SWITCH AND BCM A With CONSULT-ll 1. Select “BCM” on CONSULT-II, and select “WIPER” on “SELECT TEST ITEM” screen. 2. Select “DATA MONITOR” on “SELECT DIAG MODE” screen. Make sure that “FR WASHER SW” turns ON-OFF according to front wiper switch operation. Without CONSULT-ll Refer to LT-125, "Combination Switch Inspection" . OK or NG OK >> Replace BCM Refer to BCS-17, "Removal and Installation of BCM" . NG >> Check front wiper switch. Refer to LT-125, "Combination Switch Inspection" . Front Wiper Does Not Stop B C D E PKIB0110E BKS001HT F 1. CHECK CIRCUIT BETWEEN COMBINATION SWITCH AND BCM With CONSULT-ll 1. Select “BCM” on CONSULT-II, and select “WIPER” on “SELECT TEST ITEM” screen. 2. Select “DATA MONITOR” on “SELECT DIAG MODE” screen. Make sure that “FR WIPER INT”, “FR WIPER LOW”, “FR WIPER HI”, and “FR WASHER SW” turns ON-OFF according to front wiper switch operation. Without CONSULT-ll Refer to LT-125, "Combination Switch Inspection" . OK or NG OK >> Replace IPDM E/R. Refer to PG-37, "Removal and PKIB0110E Installation of IPDM E/R" . NG >> Check combination switch (wiper switch). Refer to LT-125, "Combination Switch Inspection" . G H I J WW L M WW-41 FRONT WIPER AND WASHER SYSTEM Removal and Installation of Front Wiper Arms, Adjustment of Wiper Arms Stop Location BKS0011L REMOVAL 1. 2. 3. Turn wiper switch ON to operate wiper motor, and then turn wiper switch OFF (auto stop). Open hood, remove arm caps, and remove wiper arm nuts. Raise wiper arm, and remove wiper arm from the vehicle. INSTALLATION 1. 2. 3. Clean up the pivot area as shown in the figure. This will reduce possibility of wiper arm looseness. Prior to wiper arm installation, turn on wiper switch to operate wiper motor and then turn it “OFF” (auto stop). Push wiper arm onto pivot shaft, paying attention to blind spline. SEL024J 4. 5. 6. Lift the blade up and then set it down onto glass surface to set the blade center to clearance “L1” & “L2” immediately before tightening nuts. NOTE: This illustration is for LHD models. The layout for RHD models is symmetrically opposite. Spray washer fluid. Turn on wiper switch to operate wiper motor and then turn it “OFF”. Make sure that wiper blades stop within clearance “L1” & “L2”. Clearance “L1” RHD LHD Clearance “L2” ● 48.0 ± 7.5 mm (1.890 ± 0.295 in) RHD 46.0 ± 7.5 mm (1.811 ± 0.295 in) LHD 43.0 ± 7.5 mm (1.693 ± 0.295 in) Tighten wiper arm nuts to specified torque. Front wiper arm nuts 7. : 23.5 N·m (2.4 kg-m, 17 ft-lb) Attach wiper arm caps. ADJUSTMENT Refer to WW-42, "INSTALLATION" . WW-42 PKIA9951E FRONT WIPER AND WASHER SYSTEM Removal and Installation of Front Wiper Drive Assembly BKS0011N A LHD models B C D E F MKIB2230E 1. Wiper arm and blade assembly (RH) 2. Wiper drive assembly mounting bolts 3. Wiper drive assembly 4. Wiper arm and blade assembly (LH) 5. Wiper arm mounting nuts 6. Wiper arm caps : N·m (kg-m, ft-lb) : N·m (kg-m, in-lb) : Should be lubricated with grease. G H I RHD models J WW L M MKIB2231E 1. Wiper arm caps 2. Wiper arm mounting nuts 3. Wiper arm and blade assembly (RH) 4. Wiper drive assembly mounting bolts 5. Wiper drive assembly 6. Wiper arm and blade assembly (LH) : N·m (kg-m, ft-lb) : N·m (kg-m, in-lb) REMOVAL 1. 2. 3. Operate front wiper motor, and stop at the auto stop position. Remove wiper arms. Refer to WW-42, "REMOVAL" . Remove cowl top cover. Refer to EI-12, "COWL TOP" . WW-43 : Should be lubricated with grease. FRONT WIPER AND WASHER SYSTEM 4. 5. Disconnect wiper motor connector and remove connector clips. Remove front wiper drive assembly mounting bolts (A), and remove front wiper drive assembly (1) from the vehicle. MKIB2237E INSTALLATION 1. Install front wiper drive assembly to the vehicle. Front wiper drive assembly mounting bolts 2. 3. 4. 5. 6. : 4.5 N- m (0.46kg-m, 40 in-lb) Connect wiper motor connector. Turn wiper switch ON to operate wiper motor, then turn wiper switch OFF (auto stop). Install connector clips to the wiper frame, and install cowl top cover. Refer to EI-12, "COWL TOP" . Attach wiper arms. Refer to WW-42, "INSTALLATION" . Adjustment of wiper arm stop location. Install arm caps. Washer Nozzle Adjustment ● ● BKS0011O In this model, the washer nozzle has a non-adjustment nozzle and requires no adjusting. If necessary, ensure that washer fluid spray covers at least the area as shown in the figure. h1: h2: h3: h4: 320 mm (12.60 in) 115 mm (4.53 in) 160 mm (6.30 in) 315 mm (12.40 in) NOTE: This illustration is for LHD models. The layout for RHD models is symmetrically opposite. MKIB2217E ● If the above is not satisfied, confirm that the washer nozzle is installed correctly on the cowl top cover and/or cowl top cover is installed correctly on the body. ● If they are installed correctly, and the fluid is still spraying out of the shooting target areas, replace them with new washer nozzle and/or cowl top cover. CAUTION: Never adjust the washer nozzle (1) with needle pin. If attempts are made to adjust the washer nozzle with needle pin, the nozzle may be damaged. MKIB2216E WW-44 FRONT WIPER AND WASHER SYSTEM Washer Tube Routing BKS0011P A B C D E F G H I J MKIB2300E 1. Front washer tube 2. Clip 3. Front and rear washer tank 4. Front washer nozzle (LH) 5. Front washer nozzle (RH) 6. Check valve 7. Joint washer tube 8. Rear washer nozzle 9. Rear washer tube Removal and Installation of Front Washer Nozzle WW BKS001C5 REMOVAL 1. 2. 3. Remove cowl top cover. Refer to EI-12, "COWL TOP" . Remove washer tube. While pressing pawl (A) on the reverse side of front washer nozzle (1), remove front washer nozzle from cowl top cover. M MKIB2224E INSTALLATION Note the following, and installation is the reverse order of removal. CAUTION: Install left and right nozzle correctly. Incorrect side nozzle can be installed, but spray points wrong. WW-45 L FRONT WIPER AND WASHER SYSTEM Inspection for Washer Nozzle BKS001C6 CHECK VALVE INSPECTION A check valve is provided in the washer fluid line. Be careful not to connect check valve to washer tube in the wrong direction. MKIB2218E Inspection of Front Wiper and Washer Switch Circuit BKS001C7 Refer to LT-125, "Combination Switch Inspection" . Removal and Installation of Front Wiper and Washer Switch BKS001C8 REMOVAL 1. 2. 3. Remove steering column cover. Refer to IP-4, "INSTRUMENT PANEL ASSEMBLY" . Disconnect the wiper and washer switch connector. Pull wiper and washer switch (1) toward the passenger door while pressing pawls (A) in direction shown by the arrow ( ) in the figure, and remove it from the base. SKIB5666E INSTALLATION Installation is the reverse order of removal. Removal and Installation of Washer Tank BKS001C9 REMOVAL 1. Remove clip (A) and pull washer tank inlet (1) out of washer tank. – : Vehicle front Remove front bumper. Refer to EI-4, "FRONT BUMPER" . Disconnect washer motor connector. 2. 3. SKIB3755J WW-46 FRONT WIPER AND WASHER SYSTEM 4. Remove screws (A) and nut (B). – : Vehicle front Remove washer tube (2), and remove washer tank (1) from vehicle. 5. A B C MKIB2239E D INSTALLATION Note the following, and installation is the reverse order of removal. CAUTION: After installation, add water up to the upper level of washer tank inlet, and check for water leaks. Washer tank mounting nut : 4.5 N·m (0.46 kg-m, 40 in-lb) Washer tank mounting screws : 4.5 N·m (0.46 kg-m, 40 in-lb) Removal and Installation of Front Washer Motor E F BKS001CA G REMOVAL 1. 2. Remove fender protector (front) RH. Refer to EI-14, "FENDER PROTECTOR" . Disconnect washer motor (1) connector and remove washer tube. 3. Pull out front washer motor in direction shown by the arrow ( in the figure. Remove front washer motor from washer tank. H ) I J MKIB2261E INSTALLATION Note the following, and installation is the reverse order of removal. CAUTION: When installing washer motor, there should be no packing twists, etc. Removal and Installation of Light and Rain Sensor L BKS001KS M REMOVAL 1. Remove inside mirror. Refer to GW-104, "INSIDE MIRROR" . 2. Remove clip and pawl. 3. Pull out the light and rain sensor. 4. Remove light and rain sensor harness connector. CAUTION: Do not touch the electronic circuit board on rain sensor. MKIB2028E INSTALLATION OF RAIN SENSOR Install in the reverse order of removal. WW-47 WW FRONT WIPER AND WASHER SYSTEM INSTALLATION OF LIGHT AND RAIN SENSOR HOUSING CAUTION: When windshield is replaced, always replace rain sensor housing. 1. Clean the surface of bonded area on the windshield. 2. Fix rain sensor housing against light and rain sensor bracket from the top, then press it in a downward motion until it is completely attach together. CAUTION: Do not touch the adhesive. MKIB2029E WW-48 REAR WIPER AND WASHER SYSTEM REAR WIPER AND WASHER SYSTEM Components Parts and Harness Connector Location PFP:28710 A BKS0012O B C D E F G MKIB2264E : Vehicle front 1. BCM M57, M58, M59 (View with instrument panel removed) 2. Data link connector 4. Rear wiper motor B45 5. Front and rear washer motor E24 (View with front bumper removed) System Description ● ● 3. Combination switch (Wiper switch) M38 H I BKS0012P Wiper switch (combination switch) is composed of a combination of 5 output terminals and 5 input terminals. Terminal combination status is read by BCM when switch is turned ON. BCM controls rear wiper and INT (intermittent) operation. OUTLINE J WW Power is supplied at all times ● through 40A fusible link (letter J, located in fuse and fusible link box) ● to BCM terminals 74 and 79. When ignition switch turned ON or START position, power is supplied ● through 10A fuse [No. 5 located in the fuse block (J/B)] ● to BCM terminal 24. ● through 10A fuse [No. 3 located in the fuse block (J/B)] ● to combination switch terminal 14. Ground is supplied ● to BCM terminals 2 and 70, ● to combination switch terminal 12. ● through body grounds M21 and M66, ● to rear wiper motor terminal 3. ● through body ground B13, B28, B38 and B48 REAR WIPER OPERATION When wiper switch is in the rear wiper ON position, BCM detect rear wiper ON signal by BCM wiper switch reading function. BCM operate rear wiper motor, power is supplied ● through BCM terminal 71 ● to rear wiper motor terminal 1. WW-49 L M REAR WIPER AND WASHER SYSTEM Ground is supplied ● to rear wiper motor terminal 3 ● through body grounds B13, B28, B38 and B48. With power and ground supplied, the rear wiper motor operates. INTERMITTENT OPERATION The rear wiper motor operates the wiper arms at low speed approximately every 7 seconds. When wiper switch is in the rear wiper INT position, BCM detect rear wiper INT signal by BCM wiper switch reading function (Refer to WW-8, "COMBINATION SWITCH READING FUNCTION" ). BCM operate rear wiper motor, power supplied ● through BCM terminal 71. ● to rear wiper motor terminal 1 Ground is supplied. ● to rear wiper motor terminal 3 ● through body ground B13, B28, B38 and B48. The wiper motor operates at intermittent. AUTO STOP OPERATION With rear wiper switch turned OFF, rear wiper motor will continue to operate until wiper arm reaches rear wiper stopper. WASHER OPERATION When rear wiper switch is pushed to WASH position, Power is supplied. ● through combination switch terminal 11 ● to washer motor terminal 2. Ground is supplied ● to washer motor terminal 1 ● to combination switch terminals 12 and 13, and ● through body grounds M21 and M66. With power and ground supplied, the rear washer motor is operated, and at the same time, When the wiper switch is pushed to the WASH position for 1 second or more, BCM reads combination switch condition (Refer to WW-8, "COMBINATION SWITCH READING FUNCTION" ), rear wiper motor is operated by BCM, and the rear wiper motor operates approximately 3 times after wiper switch is released. REAR WIPER REVERSE RANGE OPERATION (IF AUTO WIPER IS EQUIPPED) ● ● ● When front wiper is active in auto operation with shift in reverse position, front and rear wiping action is synchronous. If front wiper becomes continuous, the rear wiper will intermittent, wiping every 7 seconds. When shift is in reverse position then front wiper switch toggle from OFF to AUTO, rear wiping action will occur once. When front wiper switch is in auto position with shift is in reverse position, if front washer pull more than 0.4second, front wiper and rear wiper once. COMBINATION SWITCH READING FUNCTION Refer to WW-8, "COMBINATION SWITCH READING FUNCTION" . CAN Communication BKS0012Q SYSTEM DESCRIPTION CAN (Controller Area Network) is a serial communication line for real time application. It is an on-vehicle multiplex communication line with high data communication speed and excellent error detection ability. Many electronic control units are equipped onto a vehicle, and each control unit shares information and links with other control units during operation (not independent). In CAN communication, control units are connected with 2 communication lines (CAN H line, CAN L line) allowing a high rate of information transmission with less wiring. Each control unit transmits/receives data but selectively reads required data only. CAN Communication Unit BKS0012R Refer to LAN-27, "CAN Communication Unit" . WW-50 REAR WIPER AND WASHER SYSTEM Wiring Diagram — WIP/R — BKS0012S A WITHOUT RAIN SENSOR B C D E F G H I J WW L M MKWA4283E WW-51 REAR WIPER AND WASHER SYSTEM MKWA4284E WW-52 REAR WIPER AND WASHER SYSTEM Schematic BKS0012T A WITH RAIN SENSOR B C D E F G H I J WW L M MKWA4285E WW-53 REAR WIPER AND WASHER SYSTEM Wiring Diagram — WIP/R — BKS0012U WITH RAIN SENSOR MKWA4286E WW-54 REAR WIPER AND WASHER SYSTEM A B C D E F G H I J WW L M MKWA4287E WW-55 REAR WIPER AND WASHER SYSTEM MKWA4288E WW-56 REAR WIPER AND WASHER SYSTEM Terminals and Reference Values for BCM BKS0012V A Terminal No. Wire color 2 B Signal name Ground Measuring condition Signal input/ output Ignition switch Operation or condition Reference value [V] (Approx.) — ON — 0 B C OFF (Wiper intermittent dial position 4) D PKIB8643J Approx. 1.2V E Any of several conditions below 7 BR Combination switch output 5 Output ON ● Front fog lamp switch (Operates only front fog lamp switch) (Wiper intermittent dial position 4) ● Rear fog lamp switch (Wiper intermittent dial position 4) ● Rear wiper ON (Wiper intermittent dial position 4) ● Wiper intermittent dial position 1 ● Wiper intermittent dial position 2 ● Wiper intermittent dial position 6 ● Wiper intermittent dial position 7 F G PKIB4956J H Approx. 1.0V I J OFF (Wiper intermittent dial position 4) WW PKIB4958J Approx. 1.2V 8 L Combination switch output 3 Output ON Any of several conditions below ● Lighting switch 2ND (Wiper intermittent dial position 4) ● Lighting switch HI beam (Operates only HI beam switch) (Wiper intermittent dial position 4) ● Wiper intermittent dial position 1 ● Wiper intermittent dial position 2 ● 9 V Combination switch output 1 Output ON Wiper intermittent dial position 3 L M PKIB4959J Approx. 1.0V OFF (Wiper intermittent dial position 4) PKIB4958J Approx. 1.2V WW-57 REAR WIPER AND WASHER SYSTEM Terminal No. Wire color Signal name Signal input/ output Measuring condition Ignition switch Operation or condition Reference value [V] (Approx.) Any of several conditions below ● Turn signal switch to right ● Turn signal switch to left ● Front wiper switch MIST ● Front wiper switch LO ● Front washer switch PKIB4959J Approx. 1.0V 13 14 15 GB P W Combination switch input 1 Combination switch input 3 Combination switch input 5 Input Input Input 19 L CAN-H Input/ output 23 P Rear wiper position detection signal Input Ignition power supply Input 24 O ON ● OFF ● Front wiper switch HI (Wiper intermittent dial position 4) ● Rear wiper switch INT (Wiper intermittent dial position 4) ● Wiper intermittent dial position 1 ● Wiper intermittent dial position 2 ● Wiper intermittent dial position 3 ● Wiper intermittent dial position 6 ● Wiper intermittent dial position 7 ● OFF ● Lighting switch AUTO ● Rear fog lamp switch ● Front wiper switch MIST ● Front wiper switch INT ● Front wiper switch LO ● OFF ● Lighting switch 1ST ● Lighting switch 2ND ● Lighting switch HIGH beam (Operates only HIGH beam switch) ● Turn signal switch to right ON ON — WW-60, "Reference Values for BCM (Input)" WW-60, "Reference Values for BCM (Input)" WW-60, "Reference Values for BCM (Input)" — Rear wiper operating 0 Rear wiper not operating Battery voltage — Battery voltage ON ON WW-58 REAR WIPER AND WASHER SYSTEM Terminal No. Wire color Signal name Signal input/ output Measuring condition Ignition switch Operation or condition Reference value [V] (Approx.) A B OFF (Wiper intermittent dial position 4) C PKIB4958J Approx. 1.2V 27 GR Combination switch output 4 Output ON D Any of several conditions below ● ● Lighting switch AUTO (Wiper intermittent dial position 4) E Lighting switch 1ST (The same result with lighting switch 2ND) (Wiper intermittent dial position 4) ● Wiper intermittent dial position 1 ● Wiper intermittent dial position 5 ● Wiper intermittent dial position 6 F PKIB4959J G Approx. 1.0V H OFF (Wiper intermittent dial position 4) I PKIB4958J 28 G Combination switch output 2 Approx. 1.2V Output J ON Any of several conditions below ● Lighting switch 2ND ● Lighting switch PASSING (Operates only PASSING switch) ● Front wiper switch INT ● Front wiper switch HI WW L PKIB4959J Approx. 1.0V 33 34 R Y Combination switch input 2 Combination switch input 4 Input Input ON ON ● OFF ● Front washer switch (Wiper intermittent dial position 4) ● Rear wiper switch ON (Wiper intermittent dial position 4) ● Rear washer switch ON (Wiper intermittent dial position 4) ● Wiper intermittent dial position 1 ● Wiper intermittent dial position 5 ● Wiper intermittent dial position 6 ● OFF ● Front fog lamp switch ON ● Lighting switch 2ND ● Lighting switch PASSING (Operates only PASSING switch) ● Turn signal switch to left WW-59 M WW-60, "Reference Values for BCM (Input)" WW-60, "Reference Values for BCM (Input)" REAR WIPER AND WASHER SYSTEM Measuring condition Terminal No. Wire color Signal input/ output 39 Y CAN-L Input/ output 70 B Ground — ON 71 BR Output ON Signal name Rear wiper operation signal Ignition switch Operation or condition — Reference value [V] (Approx.) — — 0 Rear wiper operating Battery voltage Rear wiper not operating 0 74 Y Power source (Fusible link) Input OFF — Battery voltage 79 Y Power source (Fusible link) Input OFF — Battery voltage Reference Values for BCM (Input) BKS001KP CAUTION: ● Check combination switch system terminal waveform under the loaded condition with lighting switch, turn signal switch and wiper switch OFF not to be fluctuated by overloaded. ● Turn wiper dial position to 4 except when checking waveform or voltage of wiper dial position. Wiper dial position can be confirmed on CONSULT-II. Refer to WW-24, "DATA MONITOR" . INPUT Condition and reference value OFF Lighting switch 1ST PKIB4956J INPUT 5 (Wiper intermittent dial position 4) Lighting switch 2ND PKIB8624J Approx. 0.9V Approx. 1.5 - 2.0V Lighting switch HI beam (Operates only HI beam switch) Turn signal switch to right PKIB8639J Approx. 2.5 - 3.0V — PKIB8625J PKIB8644J Approx. 1.5 - 2.0V Approx. 1.5 - 2.0V WW-60 REAR WIPER AND WASHER SYSTEM INPUT Condition and reference value OFF Lighting switch 2ND Turn signal switch to left A B PKIB4958J INPUT 4 (Wiper intermittent dial position 4) PKIB8628J Approx. 1.0V Approx. 1.5 - 2.0V Front fog lamp switch (Operates only front fog lamp switch) Lighting switch PASSING (Operates only PASSING switch) PKIB8630J C Approx. 2.0V D E — F PKIB8629J PKIB8627J Approx. 1.5 - 2.0V OFF Approx. 2.0V Lighting switch AUTO Front wiper switch INT G H PKIB4958J Approx. 1.0V INPUT 3 (Wiper intermittent dial position 4) PKIB8631J Approx. 2.0V PKIB8632J I Approx. 2.0V Any of several conditions below ● Front ● Front wiper switch LO J Rear fog lamp switch wiper switch MIST — PKIC1030E PKIB8629J WW L Approx. 1.5V Approx. 2.0V M WW-61 REAR WIPER AND WASHER SYSTEM INPUT Condition and reference value OFF (Wiper intermittent dial position 4) Front washer switch (Wiper intermittent dial position 4) PKIB4958J Rear washer switch (Wiper intermittent dial position 4) PKIB8632J PKIB8631J Approx. 2.0V Approx. 2.0V Approx. 1.0V Any of the conditions below INPUT 2 Rear wiper switch ON (Wiper intermittent dial position 4) ● Wiper intermittent dial position 1 ● Wiper intermittent dial position 5 ● Wiper intermittent dial position 6 — PKIB8634J Approx. 1.5 - 2.0V PKIB8633J Approx. 2.0V Any of the conditions below OFF (Wiper intermittent dial position 4) Front wiper switch HI (Wiper intermittent dial position 4) ● Rear wiper switch INT (Wiper intermittent dial position 4) ● Wiper PKIB4958J intermittent dial position 3 PKIB8635J Approx. 1.0V Approx. 2.0V PKIB8636J Approx. 2.0V INPUT 1 Any of the conditions below Any of the conditions below ● Wiper intermittent dial position 1 ● Wiper intermittent dial position 6 ● Wiper intermittent dial position 2 ● Wiper intermittent dial position 7 — PKIB8637J PKIB8638J Approx. 2.5 - 3.0V Approx. 2.0V Terminals and Reference Values for IPDM E/R Ignition switch Operation or condition Reference value [V] (Approx.) — ON — 0 Reverse switch signal Input ON CAN H Input/ output Wire color 3 B Ground 18 30 L R L Measuring condition Signal Input/ Output Terminal No. 52 BKS0012W Signal designation Shift knob — WW-62 Reverse Battery voltage Other than above 0 — — REAR WIPER AND WASHER SYSTEM Terminal No. Wire color 54 B 58 Y Measuring condition Signal Input/ Output Ignition switch Operation or condition Reference value [V] (Approx.) Ground — — — 0 CAN L Input/ output — — — Signal designation CONSULT-II Function (BCM) A B BKS0012Z C Refer to WW-24, "CONSULT-II Function (BCM)" . D E F G H I J WW L M WW-63 REAR WIPER AND WASHER SYSTEM Diagnosis Chart by Symptom Symptom Possible causes BKS001HE Possible malfunctioning system and part Inspection procedure Reference page BCM OUTPUT 5 - INPUT 2 and BCM OUTPUT 4 - INPUT 1 system ● Combination switch reading function malfunction Rear wiper does not operate Combination switch (Rear wiper ON and INT systems malfunction) ● Harness and connector between combination switch and BCM ● BCM BCM - Rear wiper motor system Rear wiper motor output malfunction ● 40A fusible link ● 10A fuse ● Rear wiper motor ● Harness and connector between BCM and rear wiper motor ● Harness and connector between rear wiper motor and ground ● BCM CONSULT-II ● DATA MONITOR (BCM) CONSULT-II ● ACTIVE TEST (BCM) WW-65, "Rear Wiper Does Not Operate" Other than CONSULT-II ● Rear wiper motor output inspection BCM - Rear wiper motor system Rear wiper motor CONSULT-II ● Harness and connector between BCM and rear wiper motor ● ● Harness and connector between rear wiper motor and ground ● BCM ● Rear wiper does not return to stop position Auto-stop signal malfunction DATA MONITOR (BCM) Other than CONSULT-II ● Auto-stop signal system inspection WW-67, "Rear Wiper Does Not Return to Stop Position" BCM OUTPUT 5 - INPUT 2 system ● Only rear wiper ON does not operate Combination switch reading function malfunction Combination switch (Rear wiper ON system malfunction) ● Harness and connector between combination switch and BCM ● BCM CONSULT-II ● DATA MONITOR (BCM) BCM OUTPUT 4 - INPUT 1 system Only rear wiper INT does not operate Combination switch reading function malfunction ● Combination switch (Rear wiper INT system malfunction) ● Harness and connector between combination switch and BCM ● BCM CONSULT-II ● DATA MONITOR (BCM) BCM OUTPUT 3 - INPUT 2 system Wiper does not wipe when rear washer operates Combination switch reading function malfunction ● Combination switch (Rear washer system malfunction) ● Harness and connector between combination switch and BCM ● BCM WW-64 CONSULT-II ● DATA MONITOR (BCM) WW-68, "Only Rear Wiper ON Does Not Operate" WW-69, "Only Rear Wiper Intermittent Does Not Operate" WW-69, "Wiper Does Not Wipe When Rear Washer Operates" REAR WIPER AND WASHER SYSTEM Rear Wiper Does Not Operate BKS001HG 1. CHECK FUSES A Check fuse and fusible link for blown-out. ● UNIT POWER SOURCE FUSE No. IPDM E/R Battery 61, 62 Battery J Ignition switch ON or START position 5 Ignition switch (ON) 3 BCM Combination switch B C D Refer to WW-51, "Wiring Diagram — WIP/R —" (without light and rain sensor), WW-54, "Wiring Diagram — WIP/R —" (with light and rain sensor). OK or NG OK >> GO TO 2. NG >> If fuse is blown, be sure to eliminate cause of malfunction before installing new fuse or fusible link. Refer to PG-4, "POWER SUPPLY ROUTING CIRCUIT" . E F 2. CHECK BCM POWER SUPPLY CIRCUIT 1. 2. 3. Turn ignition switch OFF. Disconnect BCM connector. Check voltage between BCM harness connector and ground. G H Terminals Ignition switch position (+) Connector (–) 74 M59 79 M57 OFF ACC ON Battery voltage Battery voltage Battery voltage Battery voltage Battery voltage Battery voltage 0V 0V Battery voltage I Terminal Ground 24 J MKIB0352E WW OK or NG OK >> GO TO 3. NG >> Check harness for open or short between fuse, fusible link and BCM. L 3. CHECK BCM GROUND CIRCUIT M Check continuity between BCM harness connector and ground. Connector Terminal M57 2 M59 70 Continuity Ground Yes OK or NG OK >> GO TO 4. NG >> Check harness ground circuit. MKIB0353E WW-65 REAR WIPER AND WASHER SYSTEM 4. CHECK CIRCUIT BETWEEN COMBINATION SWITCH AND BCM With CONSULT-ll Select “BCM” on CONSULT-II. Select “WIPER” on “SELECT TEST ITEM” screen. 2. Select “DATA MONITOR” on “SELECT DIAG MODE” screen. 3. Make sure that “RR WIPER ON”, turn ON-OFF according to combination switch (wiper switch) operation. 1. Without CONSULT-ll Refer to LT-125, "Combination Switch Inspection" . OK or NG OK >> GO TO 5. NG >> Check combination switch (wiper switch). Refer to LT125, "Combination Switch Inspection" . SKIA5322E 5. ACTIVE TEST With CONSULT-ll Select “BCM” on CONSULT-II. Select “WIPER” on “SELECT SYSTEM” screen. 2. Select “ACTIVE TEST” on “SELECT DIAG MODE” screen. 3. Select “REAR WIPER” on “SELECT TEST ITEM” screen. 4. Touch “ON” screen. 1. Without CONSULT-ll GO TO 6. Does rear wiper operate normally? YES >> Replace BCM. Refer to BCS-17, "Removal and Installation of BCM" . NO >> GO TO 6. SKIA3503E 6. CHECK REAR WIPER MOTOR GROUND CIRCUIT 1. 2. 3. Turn ignition switch OFF. Disconnect rear wiper motor harness connector. Check continuity between rear wiper motor harness connector and ground. Rear wiper motor connector Terminal B45 4 Ground Continuity Yes OK or NG OK >> GO TO 7. NG >> Repair harness or connector. MKIB2232E WW-66 REAR WIPER AND WASHER SYSTEM 7. CHECK CIRCUIT BETWEEN BCM AND REAR WIPER MOTOR 1. 2. A 3. A Disconnect BCM harness connector. Check continuity between BCM harness connector (A) and rear wiper motor harness connector (B). B B Continuity Connector Terminal Connector Terminal M59 71 B45 2 C Yes Check continuity between BCM harness connector (A) and ground. A Continuity Connector Terminal M59 71 Ground D MKIB2233E E No OK or NG OK >> GO TO 8. NG >> Repair harness or connector. F 8. CHECK REAR WIPER MOTOR POWER SUPPLY G 1. 2. 3. Connect BCM harness connector. Turn ignition switch ON. Check voltage between rear wiper motor harness connector and ground. H I Terminal (+) Rear wiper motor connector Terminal B45 2 (-) Ground Condition Voltage J Wiper stopped Approx. 0V Wiper operating Battery voltage WW MKIB2234E OK or NG OK >> Replace rear wiper motor. Refer to WW-70, "Removal and Installation of Rear Wiper Motor" . NG >> Replace BCM. Refer to BCS-17, "Removal and Installation of BCM" . Rear Wiper Does Not Return to Stop Position L BKS001HH 1. CHECK REAR WIPER MOTOR CIRCUIT M With CONSULT-ll Select “BCM” on CONSULT-II. Select “WIPER” on “SELECT TEST ITEM” screen. 2. Select “DATA MONITOR” on “SELECT DIAG MODE” screen. 3. Make sure that “RR WIPER STOP”, turn ON-OFF linked with rear wiper operation. 1. Without CONSULT-ll GO TO 2. OK or NG OK >> Replace BCM. Refer to BCS-17, "Removal and Installation of BCM" . NG >> GO TO 2. WW-67 SKIB6434E REAR WIPER AND WASHER SYSTEM 2. CHECK REAR WIPER MOTOR AUTO STOP SIGNAL Check voltage between BCM harness connector terminal and ground while rear wiper motor is stopped and while it is operating. Terminal (+) BCM connector Terminal M57 23 Condition Voltage Wiper stopped Battery voltage Wiper operating Approx. 0V (-) Ground OK or NG OK >> Replace BCM. Refer to BCS-17, "Removal and Installation of BCM" . NG >> GO TO 3. MKIB2235E 3. CHECK REAR WIPER AUTO STOP CIRCUIT 1. 2. 3. Turn ignition switch OFF. Disconnect BCM connector and rear wiper motor connector. Check continuity between BCM harness connector (A) and rear wiper motor harness connector (B). A 4. B Continuity Connector Terminal Connector Terminal M57 23 B45 3 Yes Check continuity between BCM harness connector (A) and ground. A MKIB2236E Continuity Connector Terminal M57 23 Ground No OK or NG OK >> Replace rear wiper motor. Refer to WW-70, "Removal and Installation of Rear Wiper Motor" . NG >> Repair harness or connector. Only Rear Wiper ON Does Not Operate BKS001HI 1. CHECK COMBINATION SWITCH INPUT SIGNAL 1. 2. 3. Select “BCM” on CONSULT-II. Select “WIPER” on “SELECT TEST ITEM” screen. Then select “DATA MONITOR” on “SELECT DIAG MODE” screen. Make sure “RR WIPER ON” turns ON-OFF according to operation of combination switch (wiper switch). When rear wiper switch is in ON position : RR WIPER ON OK or NG OK >> Replace BCM. Refer to BCS-17, "Removal and InstallaSKIB6435E tion of BCM" . NG >> Check combination switch (wiper switch). Refer to WW-8, "COMBINATION SWITCH READING FUNCTION" . WW-68 REAR WIPER AND WASHER SYSTEM Only Rear Wiper Intermittent Does Not Operate BKS001HJ 1. CHECK COMBINATION SWITCH INPUT SIGNAL 1. 2. 3. A Select “BCM” on CONSULT-II. Select “WIPER” on “SELECT TEST ITEM” screen. Then select “DATA MONITOR” on “SELECT DIAG MODE” screen. Make sure “RR WIPER INT” turns ON-OFF according to operation of combination switch (wiper switch). When rear wiper switch is in INT position B C : RR WIPER INT ON D OK or NG OK >> Replace BCM. Refer to BCS-17, "Removal and InstallaSKIB6436E tion of BCM" . NG >> Check combination switch (wiper switch). Refer to WW-8, "COMBINATION SWITCH READING FUNCTION" . Wiper Does Not Wipe When Rear Washer Operates BKS001HK 1. CHECK COMBINATION SWITCH INPUT SIGNAL 1. 2. 3. Select “BCM” on CONSULT-II. Select “WIPER” on “SELECT TEST ITEM” screen. Then select “DATA MONITOR” on “SELECT DIAG MODE” screen. Make sure “RR WASHER SW” turns ON-OFF according to operation of rear washer switch. When rear wiper switch is in WASHER position H : RR WASHER SW ON I Removal and Installation of Rear Wiper Arm, Adjustment of Wiper Arm Stop Location BKS00134 Turn rear wiper switch ON to operate wiper motor, and then turn rear wiper switch OFF (auto stop). Remove rear wiper arm cap, and remove rear wiper arm nut. Raise rear wiper arm, and remove rear wiper arm from the vehicle. INSTALLATION 2. Clean up the pivot area as shown in the figure. This will reduce possibility of rear wiper arm nut looseness. Prior to rear wiper arm installation, turn rear wiper switch ON to operate wiper motor, and then turn rear wiper switch OFF (auto stop). SKIA0082J WW-69 J WW REMOVAL 1. F G OK or NG OK >> Replace BCM. Refer to BCS-17, "Removal and InstallaSKIB6437E tion of BCM" . NG >> Check combination switch (wiper switch). Refer to WW-8, "COMBINATION SWITCH READING FUNCTION" . 1. 2. 3. E L M REAR WIPER AND WASHER SYSTEM 3. 4. Lift the blade up and then set it down onto glass surface to set the blade center to lowest heat wire immediately. Tighten rear wiper arm nut to specified torque. Rear wiper arm nut 5. 6. 7. :7.0 N·m (0.71 kg-m, 62 in-lb) Spray washer fluid. Turn rear wiper switch ON to operate wiper motor, and then turn rear wiper switch OFF (auto stop). Make sure that wiper blade stop within lowest heat wire. Install rear wiper arm cap. MKIB2219E Removal and Installation of Rear Wiper Motor BKS00136 MKIB2220E 1. Rear wiper arm cap 2. Rear wiper arm 3. Rear wiper blade 4. Rear wiper motor mounting bolt 5. Rear wiper motor 6. Pivot seal 7. Rear wiper arm nut REMOVAL 1. 2. 3. 4. 5. Remove rear wiper arm. Refer to WW-69, "Removal and Installation of Rear Wiper Arm, Adjustment of Wiper Arm Stop Location" . Remove pivot seal. Remove back door finisher. Refer to EI-22, "Removal and Installation" . Disconnect rear wiper motor connector. Remove rear wiper motor mounting bolts (A), and remove rear wiper motor (1) from the vehicle. SKIB3770J INSTALLATION CAUTION: Never drop the rear wiper motor or cause it to interfere with other parts. 1. Install pivot seal. WW-70 REAR WIPER AND WASHER SYSTEM 2. Install rear wiper motor to the vehicle. Rear wiper motor mounting bolts 3. 4. 5. A : 5.0 N·m (0.50 kg-m, 43 in-lb) Connect rear wiper motor connector. Turn rear wiper switch ON to operate wiper motor, and then turn rear wiper switch OFF (auto stop). Install back door finisher. Refer to EI-22, "Removal and Installation" . Install rear wiper arm and arm cap. B C Rear Washer Nozzle Adjustment BKS00137 Adjust spray position as shown in the figure. Unit: mm (in) Spray position h (hight) I (width) φ (spray point area) A 140 (5.51) 38 (1.50) 60 (2.36) D E F MKIB2221E Insert a needle or suitable tool into the nozzle hole and move it to adjust the spray position. G H I J MKIB0509E Rear Washer Tube Layout BKS00139 WW Refer to WW-45, "Washer Tube Routing" . Removal and Installation of Rear Washer Nozzle BKS0013A L REMOVAL 1. 2. 3. 4. Remove high-mounted stop lamp. Refer to LT-130, "Removal and Installation of High-Mounted Stop Lamp" . Disconnect washer tube (2) at the joint. NOTE: Washer tube can be accessed through the opening where the high-mounted stop lamp was located. While pressing pawl (B) on the reverse side of rear washer nozzle (1), remove rear washer nozzle from back door. NOTE: Rear washer nozzle can be accessed through the opening of the back door inner panel (A). Remove washer hose from washer nozzle. SKIB3773J INSTALLATION Installation is the reverse order of removal. Adjust nozzle spray location. Refer to WW-71, "Rear Washer Nozzle Adjustment" . WW-71 M REAR WIPER AND WASHER SYSTEM CHECK VALVE INSPECTION Make sure air can pass through the hose by blowing forward (toward the nozzle) and air cannot pass through by suction. MKIB1984E Inspection of Rear Wiper and Washer Switch Circuit BKS0013B Refer to LT-125, "Combination Switch Inspection" . Removal and Installation of Rear Wiper and Washer Switch BKS0013C Refer to LT-128, "Removal and Installation" . Removal and Installation of Rear Wiper and Washer Tank BKS0013D Refer to.WW-46, "Removal and Installation of Washer Tank" . Removal and Installation of Rear Wiper and Washer Pump Refer to WW-47, "Removal and Installation of Front Washer Motor" . WW-72 BKS0013E HEADLAMP WASHER HEADLAMP WASHER Components Parts and Harness Connector Location PFP:28620 A BKS001M3 B C D E F G MKIB2265E : Vehicle front 1. IPDM E/R E10, E11, E12 [Engine room (left)] 2. BCM M57, M58, M59 (View with instrument panel removed) 4. Headlamp washer switch M18 (RHD models) 5. Headlamp washer motor E25 (View with front bumper removed) System Description H 3. Data link connector I BKS0013F Headlamp washer operates under the following conditions. J ● When lighting switch is in 1ST position ● When daytime light system is operating ● When auto light system is operating (low beam is ON) WW When the headlamp washer switch is ON position the BCM (body control module) receives input signal requesting the headlamp washer operates. The CPU (central processing unit) of the IPDM E/R (intelligent power distribution module engine room) controls the headlamp washer relay coil. When activated this relay L directs power headlamp washer motor. OUTLINE Power is supplied at all times ● through 30A fusible link (letter L, located in fuse and fusible link box). ● to headlamp washer relay terminals 1 and 3. ● through 40A fusible link (letter J, located in fuse and fusible link box). ● to BCM terminals 74 and 79. ● through 20A fuse (No.61, 62, located in IPDM E/R). ● to IPDM E/R (CPU). When ignition switch ON or START position, power is supplied ● to IPDM E/R (CPU), and ● through 10A fuse [No.5, located in fuse block (J/B)] ● to BCM terminal 24. Ground is supplied ● to IPDM E/R terminals 3 and 54, and ● to head lamp washer motor terminal 1, ● through body grounds E28, E44 and E45. WW-73 M HEADLAMP WASHER ● ● ● to BCM terminals 2 and 70, and to head lamp washer switch terminal 2, through body grounds M21 and M66. HEADLAMP WASHER OPERATION When lighting switch is placed in 2nd position, BCM read combination switch condition (Refer to WW-8, "COMBINATION SWITCH READING FUNCTION" ). And headlamp washer switch ON, ground is supplied. ● to BCM terminal 62, and ● through headlamp washer switch terminal 1 and 2. ● through body grounds M21 and M66. BCM sends headlamp washer request signal to IPDM E/R with CAN communication line. And IPDM E/R is grounded to headlamp washer relay terminal 2 through IPDM E/R terminal 56. Then headlamp washer relay is energized, power is supplied. ● through headlamp washer relay terminal 5 ● to headlamp washer motor terminal 2. Ground is supplied. ● to terminal 1 of headlamp washer motor ● through body grounds E28, E44 and E45. With power and ground supplied, the headlamp washer operates. CAN Communication BKS0013G CAN (Controller Area Network) is a serial communication line for real time application. It is an on-vehicle multiplex communication line with high data communication speed and excellent error detection ability. Many electronic control units are equipped onto a vehicle, and each control unit shares information and links with other control units during operation (not independent). In CAN communication, control units are connected with 2 communication lines (CAN H line, CAN L line) allowing a high rate of information transmission with less wiring. Each control unit transmits/receives data but selectively reads required data only. CAN Communication Unit BKS0013H Refer to LAN-27, "CAN Communication Unit" . WW-74 HEADLAMP WASHER Wiring Diagram —HLC— BKS0013I A B C D E F G H I J WW L M MKWA4289E WW-75 HEADLAMP WASHER MKWA4290E WW-76 HEADLAMP WASHER Terminals and Reference Values for BCM BKS0013J A Measuring condition Terminal No. Wire color 2 B Signal name Ground Signal input/ output — Ignition switch Operation or condition ON — Reference value [V] B 0 C OFF (Wiper intermittent dial position 4) D PKIB8643J Approx. 1.2V E Any of several conditions below 7 BR Combination switch output 5 Output ON ● Front fog lamp switch (Operates only front fog lamp switch) (Wiper intermittent dial position 4) ● Rear fog lamp switch (Wiper intermittent dial position 4) ● Rear wiper ON (Wiper intermittent dial position 4) ● Wiper intermittent dial position 1 F G H PKIB4956J ● Wiper intermittent dial position 2 ● Wiper intermittent dial position 6 ● Wiper intermittent dial position 7 Approx. 1.0V I J OFF (Wiper intermittent dial position 4) WW PKIB4958J Approx. 1.2V 8 L Combination switch output 3 Output ON L Any of several conditions below ● Lighting switch 2ND (Wiper intermittent dial position 4) ● Lighting switch HI beam (Operates only HI beam switch) (Wiper intermittent dial position 4) ● Wiper intermittent dial position 1 ● Wiper intermittent dial position 2 ● Wiper intermittent dial position 3 WW-77 M PKIB4959J Approx. 1.0V HEADLAMP WASHER Measuring condition Terminal No. Wire color Signal name Signal input/ output Ignition switch Reference value [V] Operation or condition OFF (Wiper intermittent dial position 4) PKIB4958J 9 V Combination switch output 1 Output Approx. 1.2V ON Any of several conditions below ● Turn signal switch to right ● Turn signal switch to left ● Front wiper switch MIST ● Front wiper switch LO ● Front washer switch PKIB4959J Approx. 1.0V 13 14 15 GB P W Combination switch input 1 Combination switch input 3 Combination switch input 5 Input Input Input ON ● OFF ● Front wiper switch HI (Wiper intermittent dial position 4) ● Rear wiper switch INT (Wiper intermittent dial position 4) ● Wiper intermittent dial position 1 ● Wiper intermittent dial position 2 ● Wiper intermittent dial position 3 ● Wiper intermittent dial position 6 ● Wiper intermittent dial position 7 ● OFF ● Lighting switch AUTO ● Rear fog lamp switch ● Front wiper switch MIST ● Front wiper switch INT ● Front wiper switch LO ● OFF ● Lighting switch 1ST ● Lighting switch 2ND ● Lighting switch HIGH beam (Operates only HIGH beam switch) ● Turn signal switch to right ON ON WW-80, "Reference Values for BCM (Input)" WW-80, "Reference Values for BCM (Input)" WW-80, "Reference Values for BCM (Input)" 19 L CAN H Input/ output — — — 24 O Ignition power supply Input ON — Battery voltage WW-78 HEADLAMP WASHER Measuring condition Terminal No. Wire color Signal name Signal input/ output A Ignition switch Reference value [V] Operation or condition B C OFF (Wiper intermittent dial position 4) PKIB4958J D Approx. 1.2V 27 GR Combination switch output 4 Output ON Any of several conditions below ● Lighting switch AUTO (Wiper intermittent dial position 4) ● Lighting switch 1ST (The same result with lighting switch 2ND) (Wiper intermittent dial position 4) ● Wiper intermittent dial position 1 ● Wiper intermittent dial position 5 ● Wiper intermittent dial position 6 E F PKIB4959J G Approx. 1.0V H OFF (Wiper intermittent dial position 4) I PKIB4958J 28 G Combination switch output 2 Output ON Any of several conditions below ● Lighting switch 2ND ● Lighting switch PASSING (Operates only PASSING switch) ● Front wiper switch INT ● Front wiper switch HI WW L PKIB4959J Approx. 1.0V 33 R Combination switch input 2 Input ON J Approx. 1.2V ● OFF ● Front washer switch (Wiper intermittent dial position 4) ● Rear wiper switch ON (Wiper intermittent dial position 4) ● Rear washer switch ON (Wiper intermittent dial position 4) ● Wiper intermittent dial position 1 ● Wiper intermittent dial position 5 ● Wiper intermittent dial position 6 WW-79 WW-80, "Reference Values for BCM (Input)" M HEADLAMP WASHER Measuring condition Terminal No. 34 Wire color Y Signal input/ output Signal name Combination switch input 4 Ignition switch Input ON 39 Y CAN L Input/ output — 62 G Headlamp washer switch Input ON 70 B Ground 74 Y 79 Y Reference value [V] Operation or condition ● OFF ● Front fog lamp switch ON ● Lighting switch 2ND ● Lighting switch PASSING (Operates only PASSING switch) ● Turn signal switch to left — — Operated Headlamp washer switch WW-80, "Reference Values for BCM (Input)" Other than above 0 Battery voltage — ON — 0 Power source (Fusible link) Input OFF — Battery voltage Power source (Fusible link) Input OFF — Battery voltage Reference Values for BCM (Input) BKS001KQ CAUTION: ● Check combination switch system terminal waveform under the loaded condition with lighting switch, turn signal switch and wiper switch OFF not to be fluctuated by overloaded. ● Turn wiper dial position to 4 except when checking waveform or voltage of wiper dial position. Wiper dial position can be confirmed on CONSULT-II. Refer to WW-24, "DATA MONITOR" . INPUT Condition and reference value OFF Lighting switch 1ST PKIB4956J INPUT 5 (Wiper intermittent dial position 4) Lighting switch 2ND PKIB8624J Approx. 0.9V Approx. 1.5 - 2.0V Lighting switch HI beam (Operates only HI beam switch) Turn signal switch to right PKIB8639J Approx. 2.5 - 3.0V — PKIB8625J PKIB8644J Approx. 1.5 - 2.0V Approx. 1.5 - 2.0V WW-80 HEADLAMP WASHER INPUT Condition and reference value OFF Lighting switch 2ND Turn signal switch to left A B PKIB4958J INPUT 4 (Wiper intermittent dial position 4) PKIB8628J Approx. 1.0V Approx. 1.5 - 2.0V Front fog lamp switch (Operates only front fog lamp switch) Lighting switch PASSING (Operates only PASSING switch) PKIB8630J C Approx. 2.0V D E — F PKIB8629J PKIB8627J Approx. 1.5 - 2.0V OFF Approx. 2.0V Lighting switch AUTO Front wiper switch INT G H PKIB4958J INPUT 3 (Wiper intermittent dial position 4) Approx. 1.0V PKIB8631J Approx. 2.0V PKIB8632J I Approx. 2.0V Any of several conditions below ● Front ● Front wiper switch LO J Rear fog lamp switch wiper switch MIST — PKIC1030E PKIB8629J WW L Approx. 1.5V Approx. 2.0V M WW-81 HEADLAMP WASHER INPUT Condition and reference value Front washer switch (Wiper intermittent dial position 4) OFF (Wiper intermittent dial position 4) PKIB4958J Rear washer switch (Wiper intermittent dial position 4) PKIB8632J PKIB8631J Approx. 2.0V Approx. 2.0V Approx. 1.0V Any of the conditions below INPUT 2 Rear wiper switch ON (Wiper intermittent dial position 4) ● Wiper intermittent dial position 1 ● Wiper intermittent dial position 5 ● Wiper intermittent dial position 6 — PKIB8634J Approx. 1.5 - 2.0V PKIB8633J Approx. 2.0V Any of the conditions below OFF (Wiper intermittent dial position 4) Front wiper switch HI (Wiper intermittent dial position 4) ● Rear wiper switch INT (Wiper intermittent dial position 4) ● Wiper PKIB4958J intermittent dial position 3 PKIB8635J Approx. 1.0V Approx. 2.0V PKIB8636J Approx. 2.0V INPUT 1 Any of the conditions below Any of the conditions below ● Wiper intermittent dial position 1 ● Wiper intermittent dial position 6 ● Wiper intermittent dial position 2 ● Wiper intermittent dial position 7 — PKIB8637J PKIB8638J Approx. 2.5 - 3.0V Approx. 2.0V Terminals and Reference Values for IPDM E/R BKS0013K Measuring condition Signal Input/ output Ignition switch Operation or condition Ground — ON — 0 L CAN H Input/ output — — — B Ground — — — 0 Terminal No. Wire color 3 B 52 54 Signal name Reference value [V] WW-82 HEADLAMP WASHER Terminal No. Wire color 56 LG 58 Y Measuring condition Signal Input/ output Ignition switch Headlamp washer signal Output ON CAN L Input/ output — Signal name Reference value [V] Headlamp washer : Operating Battery voltage : Other than above 0 — B — CONSULT-II Function (BCM) C BKS0013M D Refer to WW-24, "CONSULT-II Function (BCM)" . CONSULT-II Function (IPDM E/R) BKS0013N Refer to WW-25, "CONSULT-II Function (IPDM E/R)" . E Diagnosis Chart by Symptom Symptom Possible causes BKS001HF Possible malfunctioning system and part BCM - headlamp washer switch system Headlamp washer switch signal malfunction ● 40A fusible link ● 10A fuse ● Headlamp washer switch ● Harness and connector between headlamp washer switch and BCM ● Harness and connector between headlamp washer switch and ground ● Headlamp washer motor output malfunction ● 30A fusible link ● 20A fuse ● Headlamp washer motor ● Headlamp washer relay ● Harness and connector between IPDM E/R and headlamp washer relay ● Harness and connector between headlamp washer relay and headlamp washer motor ● Harness and connector between headlamp washer motor and ground ● Inspection procedure IPDM E/R WW-83 Reference page F CONSULT-II ● G ACTIVE TEST (BCM) H Other than CONSULT-II ● Headlamp washer switch output inspection BCM IPDM E/R - Headlamp washer motor system Headlamp washer does not operate A Operation or condition CONSULT-II ● ACTIVE TEST (IPDM E/R) I WW-84, "Headlamp Washer Does Not Operate" J WW Other than CONSULT-II ● Headlamp washer motor output inspection L M HEADLAMP WASHER Headlamp Washer Does Not Operate BKS0013O 1. CHECK FUSE Check fuse and fusible link for blown-out. ● Unit Power source Fuse No. Headlamp washer relay Battery L IPDM E/R Battery 61, 62 Battery J Ignition switch ON or START position 5 BCM Refer to WW-75, "Wiring Diagram —HLC—" . OK or NG OK >> GO TO 2. NG >> If fuse is blown, be sure to eliminate cause of problem before installing new fuse or fusible link, Refer to PG-4, "POWER SUPPLY ROUTING CIRCUIT" . 2. CHECK BCM POWER SUPPLY CIRCUIT 1. 2. 3. Turn ignition switch OFF. Disconnect BCM connector. Check voltage between BCM harness connector and ground. Terminals Ignition switch position (+) Connector Terminal (Wire color) M59 74 M59 79 M57 24 (–) Ground OFF ACC ON Battery voltage Battery voltage Battery voltage Battery voltage Battery voltage Battery voltage 0V 0V Battery voltage MKIB0352E OK or NG OK >> GO TO 3. NG >> Check harness for open or short between fuse, fusible link and BCM. 3. CHECK IPDM E/R GROUND CIRCUIT 1. 2. Disconnect IPDM E/R harness connector. Check continuity between IPDM E/R harness connector and ground. Connector Terminal (Wire color) E11 3 E12 54 Continuity Ground Yes OK or NG OK >> GO TO 4. NG >> Harness for open ground circuit. MKIB2004E WW-84 HEADLAMP WASHER 4. CHECK BCM GROUND CIRCUIT A Check continuity between BCM harness connector and ground. Terminals B Continuity Connector Terminal (Wire color) M57 2 Ground Yes M59 70 Ground Yes OK or NG OK >> GO TO 5. NG >> Check harness ground circuit. C D MKIB0353E 5. ACTIVE TEST E 1. Select “BCM” on CONSULT-II. Select “ACTIVE TEST” on “SELECT DIAG MODE” screen. 2. Select “HEAD LAMP WASHER” on “SELECT TEST ITEM” screen. 3. Touch “ON” screen. Does headlamp washer operate normally? YES >> GO TO 12. NO >> GO TO 6. F G H SKIB6240E 6. CHECK POWER SUPPLY CIRCUIT TO HEADLAMP WASHER RELAY I 1. 2. 3. J Turn ignition switch OFF. Remove headlamp washer relay. Check voltage between headlamp washer relay harness connector and ground. WW Terminal (+) Headlamp washer relay connector M19 (-) Voltage L Terminal 1 Ground Battery voltage M 5 OK or NG OK >> GO TO 7. NG >> Repair harness or connector. MKIB2304E 7. CHECK HEADLAMP WASHER RELAY 1. 2. Apply battery voltage to between headlamp washer relay terminal 1 and 2. Check continuity between terminal 3 and 5. 3–5 : Continuity should exist. OK or NG OK >> GO TO 8. NG >> Replace headlamp washer relay. MKIB2007E WW-85 HEADLAMP WASHER 8. CHECK IPDM E/R 1. 2. 3. 4. Turn ignition switch OFF. Install headlamp washer relay. Turn ignition switch ON. Select “IPDM E/R” on CONSULT-II. Select “HEAD LAMP WASHER” active test. Refer to WW-25, "ACTIVE TEST" . When headlamp washer operating, check voltage between IPDM E/R harness connector and ground. Terminals (+) Headlamp washer condition (-) Connector Terminal E12 56 Ground Voltage [V] (Approx.) OFF Battery voltage ON 0 MKIB2008E OK or NG OK >> GO TO 10. NG >> GO TO 9. 9. CHECK CONTINUITY BETWEEN IPDM E/R AND HEADLAMP WASHER RELAY 1. 2. 3. Turn ignition switch OFF. Disconnect IPDM E/R harness connector and remove headlamp washer relay. Check continuity between IPDM E/R harness connector and headlamp washer relay harness connector. IPDM E/R Headlamp washer relay Connector Terminal Connector Terminal E12 56 M19 2 Continuity Yes >> Replace IPDM E/R. Refer to PG-37, "Removal and Installation of IPDM E/R" . >> Repair harness or connector. OK NG MKIB2009E 10. CHECK HEADLAMP WASHER MOTOR CIRCUIT 1. 2. Disconnect headlamp washer motor connector. Check continuity between headlamp washer relay harness connector (A) and headlamp washer motor harness connector (B). A B Continuity Connector Terminal Connector Terminal M19 3 E25 2 Yes OK or NO OK >> GO TO 11. NO >> Repair harness or connector. MKIB2305E WW-86 HEADLAMP WASHER 11. CHECK HEADLAMP WASHER MOTOR GROUND CIRCUIT A Check continuity between headlamp washer motor harness connector and ground. B Headlamp washer motor connector Terminal E25 1 Continuity Ground Yes OK or NG OK >> Replace headlamp washer motor. Refer to WW-88, "Removal and Installation for Headlamp Washer Motor" . NG >> Repair harness or connector. C D MKIB2011E 12. CHECK HEADLAMP WASHER SWITCH CIRCUIT E 1. 2. F 3. Turn ignition switch OFF. Disconnect BCM connector and headlamp washer switch connector. Check continuity between BCM harness connector and headlamp washer switch harness connector. BCM Headlamp washer switch Connector Terminal Connector Terminal M58 62 M18 1 G Continuity H Yes OK or NO OK >> GO TO 13. NO >> Repair harness or connector. MKIB2012E I 13. CHECK HEADLAMP WASHER SWITCH J Check continuity between headlamp washer switch terminals 1 and 2. Headlamp washer switch terminal 1 2 Switch condition Continuity OFF No ON Yes WW L OK or NG OK >> GO TO 14. NG >> Replace headlamp washer switch. M MKIB2013E 14. CHECK HEADLAMP WASHER SWITCH GROUND CIRCUIT Check continuity between headlamp washer switch harness connector and ground. Headlamp washer switch connector Terminal M18 2 Ground Continuity Yes OK or NG OK >> Replace BCM. Refer to BCS-17, "Removal and Installation of BCM" . NG >> Repair harness or connector. MKIB2014E WW-87 HEADLAMP WASHER Removal and Installation for Headlamp Washer Nozzle BKS0013P REMOVAL 1. 2. 3. Remove front bumper. Refer to EI-4, "FRONT BUMPER" Remove headlamp washer tube. Remove headlamp washer nozzle from front bumper. INSTALLATION Install in the reverse order of removal. Removal and Installation for Washer Tank BKS0013Q Refer to WW-46, "Removal and Installation of Washer Tank" , Removal and Installation for Headlamp Washer Motor BKS0013R 1. 2. 3. Remove front bumper. Refer to EI-4, "FRONT BUMPER" Remove headlamp washer motor (1) connector and hose. Pull out headlamp washer motor in the direction of the arrow ( ) in the figure, and remove the washer pump from the washer tank. CAUTION: When installing headlamp washer motor, there should be no packing twist, etc. MKIB2240E Headlamp Washer Tube Layout BKS0013S MKIB2222E 1. Headlamp cleaner RH 2. Washer tank WW-88 3. Headlamp cleaner LH HORN HORN Wiring Diagram —HORN— PFP:25610 A BKS0013T B C D E F G H I J WW L M MKWA4291E WW-89 HORN Removal and Installation BKS0013U REMOVAL 1. 2. 3. Remove front grille. Refer to EI-10, "Removal and Installation" . Disconnect horn connector. Remove horn mounting nut (A) and remove horn (1) from vehicle. MKIB2238E INSTALLATION Installation is the reverse order of removal. ● Tighten horn bolt to specified torque. Horn mounting bolt : 17.1 N·m (1.74 kg-m, 12.6 in-lb) WW-90 POWER SOCKET POWER SOCKET Wiring Diagram —P/SCKT— PFP:253A2 A BKS0013V B C D E F G H I J WW L M MKWA4292E WW-91 POWER SOCKET Removal and Installation BKS0013W REMOVAL 1. 2. 3. 4. – Remove center console assembly. Refer to IP-13, "CENTER CONSOLE ASSEMBLY" . Remove instrument panel stay cover. Refer to IP-9, "M. Instrument Pad (Driver Side)" . Disconnect the power socket connector. Remove inner socket (1) from the ring (2), while pressing the hook (B) on the ring out from square hole (A). Cut out (C) SKIB3767J INSTALLATION Note the following, and install in the reverse order of the removal. NOTE: Install the inner socket with its cut out aligned with that on the ring. Removal and Installation of Console Power Socket BKS001HA REMOVAL 1. 2. 3. Remove center console assembly. Refer to IP-13, "CENTER CONSOLE ASSEMBLY" . Disconnect power socket connector. Remove inner socket (2) from the ring (1), while pressing the hook (B) on the ring out from square hole (A). MKIB2301E INSTALLATION Note the following, and install in the reverse order of the removal. NOTE: Install the inner socket with its cut out aligned with that on the ring. Removal and Installation of Luggage Room Power Socket BKS001HB REMOVAL 1. 2. 3. Remove luggage side finisher lower (left). Refer to EI-32, "LUGGAGE FLOOR TRIM" . Disconnect power socket connector. Remove inner socket (2) from the ring (1), while pressing the hook (B) on the ring out from square hole (A). MKIB2302E INSTALLATION Note the following, and install in the reverse order of the removal. NOTE: Install the inner socket with its cut out aligned with that on the ring. WW-92